D902 3-Cyl PFR-KD Zexel Injection Pump Troubleshooting

[Bjoxee]

Greetings all,

First time poster here on OTT. I have a 2006 BX2350D with a D902 power plant. I took it upon myself to perform a rebuild of the injection pump to try to mitigate excessive smoking while the engine was under load. Nothing serious - just more of an annoyance for an otherwise flawless running engine. All cylinders fired and the engine ran smoothly (as smooth as one of these can anyway). The only thing that was the smoke which was nothing more than a mild haze.

Anyway, I bought a cheap rebuild kit off eBay and needless to say I got what I paid for. Nothing fit properly and ended up just cleaning up the original pump components and putting everything back together until the proper rebuild kit arrived. I got the pump back on the tractor and got it running however it is now not firing on one cylinder. I'm not sure how the D902 number's it's cylinders but it's the rear most cylinder from the front of the tractor. The pump is pushing fuel to this cylinder but I'm assuming it's not at a high enough pressure to make the injector fire. During re-assembly of the pump, I unfortunately got the chamfered tappet plates (they resemble coin-cell batteries) mixed up. They're numbered 12, 17 and 20. I'm looking for some direction as to how to best address this. Is there a way to determine which cylinder gets the proper plate? I have a feeling that the ones in cylinder 2 and this rear cylinder are mixed up. Is this even a potential cause for a cylinder not to fire?

Would it be best to first determine the correct location(s) of these plates and then proceed with a full rebuild with the "higher quality" kit that I now have? I scoured this site for any similar issues but a cursory search did not yield anything of substance. Any feedback would be greatly appreciated.

Kindly,
Brian

 

[JimNC1]

Greetings all,

First time poster here on OTT. I have a 2006 BX2350D with a D902 power plant. I took it upon myself to perform a rebuild of the injection pump to try to mitigate excessive smoking while the engine was under load. Nothing serious - just more of an annoyance for an otherwise flawless running engine. All cylinders fired and the engine ran smoothly (as smooth as one of these can anyway). The only thing that was the smoke which was nothing more than a mild haze.

Anyway, I bought a cheap rebuild kit off eBay and needless to say I got what I paid for. Nothing fit properly and ended up just cleaning up the original pump components and putting everything back together until the proper rebuild kit arrived. I got the pump back on the tractor and got it running however it is now not firing on one cylinder. I'm not sure how the D902 number's it's cylinders but it's the rear most cylinder from the front of the tractor. The pump is pushing fuel to this cylinder but I'm assuming it's not at a high enough pressure to make the injector fire. During re-assembly of the pump, I unfortunately got the chamfered tappet plates (they resemble coin-cell batteries) mixed up. They're numbered 12, 17 and 20. I'm looking for some direction as to how to best address this. Is there a way to determine which cylinder gets the proper plate? I have a feeling that the ones in cylinder 2 and this rear cylinder are mixed up. Is this even a potential cause for a cylinder not to fire?

Would it be best to first determine the correct location(s) of these plates and then proceed with a full rebuild with the "higher quality" kit that I now have? I scoured this site for any similar issues but a cursory search did not yield anything of substance. Any feedback would be greatly appreciated.

Kindly,
Brian

Hi.

I just wanted to chime in that maybe the plates are not your problem. Normally it will put the plunger too high or too low, which will affect timing and not fuel delivery. It should still run on all cylinders.
I'm still riding the struggle bus with my d600 that I rebuit. After rebuilding, I ended up with a cold cylinder and one that is erratic. I blame the cheap kit as well.

I can offer some advice:
Before reassembly, hook up the fuel lines and turn the key on - MAKE sure it's not peeing fuel into the oil! Mine is dumping more than it is returning. I think the cheap kit is to blame.
Can I ask where you purchased the "proper" one? I only find individual parts on the Kubota site, no kit. And you have to sell a kidney to afford them.
Make absolute sure you put the plungers back in and they are not 180 degrees out. When you drop the housing in, make sure the helix on the plunger will line up with the fuel opening. I took mine back apart to double check. The opening on the housing and the helix should point toward the fuel input side and not necessarily always toward the rack!

I'm going to proceed to put the old parts back in mine and try to see if I can get it back to running at least. My reason for rebuild was it was putting fuel in the oil, but not this bad!

 

[Russell King]

I would call Oregon Fuel Injection in both of your cases. They may be willing to provide information but they can probably do a better job of repairing your pumps than you will ever be able to do. They have the knowledge and proper tools to do the pump repair.

Home

Oregon Fuel Injection specializes in the repair of diesel fuel injection systems, replacement diesel parts, performance parts, drive-in service, repairs and diagnostics.

oregonfuelinjection.com

 

[North Idaho Wolfman]

Well let me add some bad news to your plate.
The "haze" you were getting had nothing to do with the fuel injection pump.
If there is any culprit it would have been the injectors, rings or the valve seals.

And even more, you have botched the rebuild, and below is the only reasonable repair method.

Now for the "repair", Pull the pump, remove all of the shims off the bottom of the pump and save them.
Remove any fuel inlet parts.
Remove the Injectors.
Put the pump in a Ziplock bag, put the injectors in a ziplock bag, put them in a flat rate box with proper packing and send them to Oregon Fuel Injection.

You do not have the timing and test equipment to rebuild it properly!

 

[Bjoxee]

LOL! Glad to see online forum culture is alive and well here just as it is anywhere else.

Appreciate the feedback both useful and insulting.

I’ll call Oregon and chat with them about what is going on and have them walk me through some troubleshooting methods.

 

[North Idaho Wolfman]

LOL! Glad to see online forum culture is alive and well here just as it is anywhere else.

Appreciate the feedback both useful and insulting.

I’ll call Oregon and chat with them about what is going on and have them walk me through some troubleshooting methods.

What insults?
Oregon Fuel injection is not going to " walk you threw troubleshooting it"
You have messed up and got in over your head, simple as that.
You now need a professional to get you out of the situation.

 

[North Idaho Wolfman]

Hi.

I just wanted to chime in that maybe the plates are not your problem. Normally it will put the plunger too high or too low, which will affect timing and not fuel delivery. It should still run on all cylinders.
I'm still riding the struggle bus with my d600 that I rebuit. After rebuilding, I ended up with a cold cylinder and one that is erratic. I blame the cheap kit as well.

I can offer some advice:
Before reassembly, hook up the fuel lines and turn the key on - MAKE sure it's not peeing fuel into the oil! Mine is dumping more than it is returning. I think the cheap kit is to blame.
Can I ask where you purchased the "proper" one? I only find individual parts on the Kubota site, no kit. And you have to sell a kidney to afford them.
Make absolute sure you put the plungers back in and they are not 180 degrees out. When you drop the housing in, make sure the helix on the plunger will line up with the fuel opening. I took mine back apart to double check. The opening on the housing and the helix should point toward the fuel input side and not necessarily always toward the rack!

I'm going to proceed to put the old parts back in mine and try to see if I can get it back to running at least. My reason for rebuild was it was putting fuel in the oil, but not this bad!

The chamfered tapered plates are to set spring pressure, not timing.

Fuel in the oil will not be fixed with any "kit", you have a worn out pump that has too much tolerance on the pumps and will need a professional rebuild.

 

[Russell King]

LOL! Glad to see online forum culture is alive and well here just as it is anywhere else.

Appreciate the feedback both useful and insulting.

I’ll call Oregon and chat with them about what is going on and have them walk me through some troubleshooting methods.

I am sorry that you feel insulated by any of the posts in reply to your question. Would you please be so kind as to state what information insulted you so we can avoid such things in the future?

 

[Bjoxee]

I am sorry that you feel insulated by any of the posts in reply to your question. Would you please be so kind as to state what information insulted you so we can avoid such things in the future?

Certainly. Bottom line is I posed a technical question here having not found what I was looking for elsewhere on the web. I am a mechanical engineer by trade and am more than mechanically inclined. Wolfman took it upon himself to cynically assume as if I was some mechanically incompetent imbecile having no insight into my background or abilities. I understand what he was getting at but if I wanted to take the path of least resistance and “just give it to an expert” I wouldn’t have posted here in the first place.

BTW - I swapped the tappet plates around and now the engine runs perfectly. Hope this helps someone else in my position who doesn’t have time for boomer-laden pontification.

 

[GreensvilleJay]

This post is a great example as to why it's IMPORTANT to take 'before' pictures when disassembling ANYTHING and taking the time to layout the 'bits and pieces' on a clean,tidy work table.

While the pump isn't a complicated device, it does need verything put back where it came from.

Happily it came to a 'running again' conclusion !!

 

[North Idaho Wolfman]

Certainly. Bottom line is I posed a technical question here having not found what I was looking for elsewhere on the web. I am a mechanical engineer by trade and am more than mechanically inclined. Wolfman took it upon himself to cynically assume as if I was some mechanically incompetent imbecile having no insight into my background or abilities. I understand what he was getting at but if I wanted to take the path of least resistance and “just give it to an expert” I wouldn’t have posted here in the first place.

BTW - I swapped the tappet plates around and now the engine runs perfectly. Hope this helps someone else in my position who doesn’t have time for boomer-laden pontification.

Sorry you got your feeling hurt.
And I'll 100% guarantee you it's not running Perfectly, but I guess it's perfect enough for a mechanical engineer.

FYI: I'm not a boomer

 

[Bjoxee]

Sorry you got your feeling hurt.
And I'll 100% guarantee you it's not running Perfectly, but I guess it's perfect enough for a mechanical engineer.

FYI: I'm not a boomer

LOL! Ok boomer. Keep telling yourself what you want to believe. Meanwhile my tractor runs perfect and I was able to do it myself much to your dismay. Sucks to suck doesn’t it? PSA for those who are mechanically inclined- these pumps are simple and can be rebuilt properly by those who have a willing mindset despite what puppyman thinks.

Appreciate the worthwhile feedback from those with the right mindset. Here’s hoping I can inspire another who aren’t afraid to get their hands dirty and learn.

Best,
B

 

[North Idaho Wolfman]

LOL! Ok boomer. Keep telling yourself what you want to believe. Meanwhile my tractor runs perfect and I was able to do it myself much to your dismay. Sucks to suck doesn’t it? PSA for those who are mechanically inclined- these pumps are simple and can be rebuilt properly by those who have a willing mindset despite what puppyman thinks.

Appreciate the worthwhile feedback from those with the right mindset. Here’s hoping I can inspire another who aren’t afraid to get their hands dirty and learn.

Best,
B

Ok, You just continue on thinking you're all high and mighty and I'm a complete doof.
Doesn't bother me in the least.
PSA: You didn't rebuild the pump, you threw some parts in it and got lucky, Way to use that engineering degree!