DF-354 Feul Injection Pump Problem

[rahl]

Hi all, new member here. I have a DF-354 with the TY395I engine with just under 150 hours on it.

A couple of weeks ago I lost throttle control and the revs slowly dropped until the engine stopped. I was able to restart the engine and idle about 50 feet to a better spot for working on the engine. The engine stopped again and I couldn't restart it. I checked the basics like fuel, air filter, throttle linkages, etc. but couldn't see an obvious problem.

I got a local mechanic in to have a look. He cracked the fuel lines and found that injectors 1 and 3 were not pumping fuel. After speaking to the dealer's mechanic, he opened the fuel pump's cover plate for a look (BTW The plate appears to have been removed previously, the screws were scored and the gasket was missing. I've never removed the plate, only the filler/drain bolts when changing the oil). He found that the first and third clips were loose.



He also thought that the (return?) springs behind the first and third clips looked loose or broken. The pistons inside the springs were also not aligned the same way, as though the first and third pistons were rotated to the "stop" position so no fuel was getting through. He couldn't do much more that day so we closed the pump up again.

The mechanic came back yesterday. He tried realigning the pistons manually, without luck, so pulled the top of the pump off for a better look. He found the first and third springs broken and some scoring on the small lever off the side of those pistons.




We're thinking that the problem is the broken springs I'm going into town tomorrow to see if I can get replacement springs (we're trying to avoid removing the entire pump at this stage). Would anyone here know the part number for the fuel injection pump or the springs themselves?

The pump is the same as dougw's

[rayh]

This pump sure looks a mess for 150 hrs. Did you buy this machine new? That curd on top by the springs should not be there ever. Were you faithful in changing the oil in the pump? The scoring on the BTM lever is not serious. The top is the working end. The clamps being loose-This will change the fuel delivery to each cylinder...must be carefully adjusted. Must be set on test stand, or on engine with engine running very slowly. Good luck.

[GuglioLS]

Hope you find the parts local. That poor thing looks like it's been pumping sludge, surprising it worked at all. What's the condition of the filter, fuel lines, fuel tank, Fuel bowl screen, Oh and the little filter embedded into the banjo bolt where it connects to the pump? As far as I know there are no individual parts for these injector pumps available from any of the Chinese tractor and parts suppliers. They only stock the complete pump, which in your case you might seriously consider.

Have you thought about draining the fuel tank then flushing out the entire fuel system with fresh diesel? Might be a good idea. If it were mine I would do that and replace all the hoses and filter. As bad as that thing is, I believe the injectors and high pressure lines feeding them would be clogged or contaminated as well.

Good luck with it

Larry

[rahl]

I've had the tractor from new. I changed the injector pump oil at the first recommended 30 hour service but haven't changed it since.

I haven't checked the condition of the fuel lines,etc. and won't get the chance for a few days. I have thought about flushing the fuel system but haven't yet. All the fuel that has gone into the tank has gone through an additional filter.

I would have thought that the parts we're looking at sit in oil though, not fuel. The top of the piston and the helical groove are free of crud.

[GuglioLS]

The top of the piston and the helical groove are free of crud

Thats good news, you just might get away with the springs and cleaning it up real good. Did you have any luck finding anything close? Adjusting the metering pistons using a pressure / volume Gauge designed to do that would be best. Getting the fuel delivery equal on all three injectors is crucial and the adjustments pretty touchy. You mentioned a gasket was missing, do you think because of that it took on allot of dust and caused the failure? I'm curious what the oil looked like when you drained it to take it apart? If I remember correctly Doug's was somewhat gummed up on the governor side. I think he fixed his by cleaning out the insides, fortunately none of his springs were broken. Maybe contact some of the dealers, perhaps one of them has an injector for parts. Whatever you do I hope you get it running soon, having a broken tractor sucks. Again good luck, and keep the information and updates coming, we all want to see you back in the saddle again.

Larry

[rahl]

Hi all.

I was able to source identical springs at the local diesel injector specialists. They will have 3 new springs in stock for me on Thursday. I have a mechanic helping me with this so I'll pass on your setup information Larry.

You mentioned a gasket was missing, do you think because of that it took on allot of dust and caused the failure?

Although the gasket was missing, there was no oil leaking around the cover plate. If there was no oil leaking out I cannot imagine dust getting in. There was a layer of crud caked to the inside surface of the cover plate, maybe that was creating a bit of a seal? I'm honestly not sure.

I'm curious what the oil looked like when you drained it to take it apart?

The oil was dark and syrupy. I didn't feel it so cannot comment on its texture.

Maybe contact some of the dealers, perhaps one of them has an injector for parts.

I have contacted a couple of US dealers who have been very helpful. I now have a possible part number for the pump and an offer to send some springs pulled from a donor pump.

Whatever you do I hope you get it running soon, having a broken tractor sucks.

So do I. The tractor's like 10 extra pairs of hands. I need the FEL to move some building materials and the backhoe to dig my shed's footings. Oh well, I hope it's going soon.

[rayh]

Be sure when you assemble this pump, that each plunger is put back in the same barrel as it was originally in...they are matched sets,,very important.. The crud in the spring area is dirt that has gotten into the pump from outside...this is not from diesel fuel. Diesel is on the top section, which has no connection to the spring area.....dirt in fuel will not affect this spring area. The bearing and governer will have suffered some damage, but probaly will still work.
Good luck

[rahl]

We got the pump back together on Saturday. FWIW, the replacement springs and gasket were from a Sims injection pump; the spring part number was 25883. The engine fired at the first attempt and is running well. I changed the injection pump oil again after we got it running to try to remove any remaining crud.

Thanks for the advice everyone.

[3RRL]

Glad to read you got it back together and that it fired right up. That's great!
Have you figured out what caused the return springs to fail in the first place? The oil being dark and syrupy leads me to believe it was getting contaminated somehow, possibly letting tiny particles score the pistons and seize them up ... possibly leading to this failure. What did your mechanic say about that?
In any case, it's great you got parts to fix it like that.
Rob-