Troubleshooting and Maintenance of Diesel Injection Pumps

The fuel injection pump is a core component of the engine, making daily maintenance critical. When the fuel injection pump malfunctions, how should it be repaired? 

In the following, I will explain common fault cases and troubleshooting methods for excavator fuel injection pumps.

Fault 1: Diesel mixing with engine oil. This issue is typically caused by wear of the injection pump, manifested by an increase in oil volume with a strong diesel odor. It may be due to excessive wear of the pump plunger assembly causing internal leakage in the pump, or excessive clearance in the fuel pump allowing diesel to enter the engine oil. Check the wear of injection pump components; if there is an oil leak issue, further examine the clearance of the fuel pump and replace parts as needed.

Fault 2: Oil leakage at the fuel pump oil pipe joint. The leak at the high-pressure oil pipe joint connected to the oil outlet of the fuel pump may be due to poor sealing. Inspect the joint for wear or loose screws and replace worn components. When there is oil leakage at the connection between the injector and the high-pressure oil pipe, adding gaskets will improve the seal.

Fault 3: Misalignment and fracture of the fuel injection pump with the drive shaft. If the fuel injection pump shaft fractures, this is a serious fault requiring the replacement of the connecting shaft. Loose screws can cause the injection pump to loosen, increase friction gaps, and eventually lead to the fracture of the connecting shaft. Use copper shims to fill gaps, clean threaded holes, tighten bolts, ensure alignment between the injection pump shaft and drive shaft, eliminate gaps, and ensure gap-free installation.

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