Author Topic: How to remove fuel injection pump in 295d engine ?  (Read 321 times)

Halfwalker

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How to remove fuel injection pump in 295d engine ?
« on: November 10, 2019, 08:33:36 PM »
I have an old 295/2100 ChinaDiesel generator, about 15 years old or so.  In general, it has run pretty well, lots of oomph, and always started up fine after a few seconds of churning.  About 5 years ago we had a run of good weather, or the power company kept their lines well, because we didn't have any outages that required the generator (I have an inverter with big batteries).  Power would come back, batteries would charge back up and all was well.

So a couple of years ago I did some improvements ...  Ran a 3/8" copper line through conduit down from the heating oil tank - no more refilling that silly tank on top of the genset.  I removed that tank and the associated "instrument panel" of useless gauges, wired up my own set of gauges, etc.  All looked OK.

Except that the damn thing wouldn't start.  No matter what I did.  Frustrated, I gave it up for a while, but have now come back to get it running again.

I've heard that the fuel injection pump can sometimes go bad, and I have a sneaking suspicion that may be the culprit here.  I mean, it's a diesel - give it fuel and air and it runs, right ?  So I though to pull it off, take it apart and see what I could see.  BTW, overall the engine is crappy design - hidden/blocked bolts means you have to remove other stuff first.

I have the 3 bolts that hold the main injection assembly to the engine out, and the assembly is loose, can be rotated.  That required removing the front plunger assembly since it blocked one of the bolts.  But the assembly wouldn't come off.  So I removed the oil-filler neck, which required removing the damn water pump feed because one of THOSE bolts was blocked.

Removed the big nut inside there, but the assembly is still stuck.  It rotates fine, but won't come out.  I'm loathe to put too much force on it ...  Sooo, after that long ramble, I guess these are the questions :

How is that injection pump assembly removed ?
Any tips for disassembly and possibly repair ?
A source for parts ?  Millions of these were made, must be easy(ish) to get once found.

(Hmm, can't seem to attach images.  It says "uploading" then just refreshes to a new "New Topic" page" and nothing happens.  Maybe I can edit the post or do a reply to include the images ?)

(Ah-ha.  Images were too big.  Resized down now)
« Last Edit: November 10, 2019, 08:47:37 PM by Halfwalker »

Johndoh

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Re: How to remove fuel injection pump in 295d engine ?
« Reply #1 on: November 10, 2019, 09:52:24 PM »
look around this site for a member called glort. He has a collection of engines and he's knowledgable if somewhat verbose
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glort

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Re: How to remove fuel injection pump in 295d engine ?
« Reply #2 on: November 10, 2019, 11:32:23 PM »

No experience or knowledge with these engines sorry.

While it can happen, in my experience it's a bit unusual for a pump with diesel in it to stick unless it has been sitting a very long time.  Fired one of mine up the other day for the first time in 4 years and was like it was run last week. Given you played with the fuel tank, air seems a bit more likley.

I take it you did bleed the fuel lines of air and make sure fuel was reaching and entering the pump? Bubbles in fuel line can be as effective in stopping fuel flow as a physical blockage particularly if the fuel line is quite vertical.

 Did you remove the line from the injector and see if that was getting any fuel through? If not make sure the fuel line from the tank is free of any air bubbles. Then crack the injector lines from the pump and see if you can get fuel coming out of there. It is handy to have some pressurisation from a fuel Pump or put a couple of PSI in the feed end of the fuel line to push it through.

From what I can see, it appears so far you have removed the fuel Pump. That type is common on a lot of engines, cars included and do fail. The primers are handy for pushing air through.  When they fail they tend to be a blockage however.  If you have the tank mounted above the engine, I'd put an inline fuel filter in the fuel line, purge it and by pass the fuel pump and feed it into the injector pump directly. see if you can get fuel out the injector pump from there.

Again see if you get fuel coming out the injector  lines when you loosen or remove them which is the way to bleed the air out.

Johndoh

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Re: How to remove fuel injection pump in 295d engine ?
« Reply #3 on: November 11, 2019, 09:21:08 AM »
I think the 2 holes you are asking about may be for using with a puller.
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Halfwalker

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Re: How to remove fuel injection pump in 295d engine ?
« Reply #4 on: November 11, 2019, 02:45:22 PM »
I found the thread by Boxelder in https://listerengine.com/smf/index.php?topic=8248.0  I'm hoping he might chime in here.

For a puller - of course.  Who woulda thunk they would think ahead like that ?    I can't find any docs anywhere on assembly/disassembly though.  Light tapping with a soft hammer on the end of the shaft doesn't budge it, and I don't want to whack on it too hard.

If I can't get anywhere with it this upcoming weekend I'll reassemble and be really thorough with bleeding all the air out.  I did notice when rotating the assembly that oil came out of the hole where the plunger goes, not much.  Looks like it needs to be oiled, but I don't know how much.

sirpedrosa

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Re: How to remove fuel injection pump in 295d engine ?
« Reply #5 on: November 11, 2019, 10:23:13 PM »
Hi Halfwalker

Your IP must come off smoothly without any puller.

Have you taken off IP pinion? If so, you must get the IP right timed.

Just my thoughts by now!

Regards
VP

PS: those threaded holes are not for tightening the IP?
PS2: Post more pics please.
« Last Edit: November 11, 2019, 10:57:13 PM by sirpedrosa »
Bernard 18A - 1968 (mama's water pump - year of my birth)
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Petter PAZ1 - Nov 1979, 3HP, sn 425xxxx
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Halfwalker

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Re: How to remove fuel injection pump in 295d engine ?
« Reply #6 on: November 15, 2019, 12:33:52 AM »
No, I haven't removed the injection pump pinion - I'm assuming that's the bigger gear that the shaft is in ?  I'll get more pics on Sat - I don't get home till after dark and lighting is miserable out there.

I've just realized that the rotation of the whole injection pump assembly is how it's timed ...  Re-reading the "Adjust of the Advance Angle of Fuel Delivery" section in the manual indicates that you have to loosen those 3 bolts holding it to the engine and rotate it to set that angle.  Well, those bolts are out and I've rotated it a few times while trying to remove it ...

So this weekend will re-assemble it all, then try to fully bleed the system of air.  I haven't found anything to indicate how much oil should be in the injection pump yet.  When I rotated it with the plunger off, a small amount dribbled out.  I read *somewhere* about someone filling it till oil came out of the vent ?  I think ?

Ah ha - found a video sort of about it.  It's almost the exact same injection pump as I have

https://www.youtube.com/watch?v=vTAmjyfddvI
« Last Edit: November 15, 2019, 03:28:38 PM by Halfwalker »

Halfwalker

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Re: How to remove fuel injection pump in 295d engine ?
« Reply #7 on: November 30, 2019, 04:40:26 PM »
Well dang.  Double dang.  I did the cardinal sin .........

Dropped a damn bolt down that large opening.  I managed to fish the washer out with a telescoping magnet, but can't find the bolt.  I think (hope) it may have dropped all the way down to the oil pain.  I think I can drop the oil pan without TOO much trouble.  If it's not in the oil pan, that means it's stuck up higher, and I may have to take the front plate off the engine to get to it.  Which would be a major pain ...

This is the exact genset I have - https://www.youtube.com/watch?v=mLXWlOPgDCk

<sigh>