LCA078
Senior Member
I'm working on a crank-no start issue for Kubota V2403-CR-TIE4 engine in a Hyster H60FT 6k forklift. This is the common rail Tier 4 emissions engine that I think is quite common in many applications. If I keep the forklift, I may put 10-20 hours of use on it a year so not looking to toss many dollars at it at this time. From what I can tell, the high pressure pump is a Bosch 1J801-50501 like shown below.
The forklift was a military turn-in and was sitting for a while before I got it so I don't know any history other than it wouldn't start. It's not throwing any ECU codes and there's no fuel in the common rail during crank so my first guess was fuel supply to the pump or the pump itself was bad. Only 1023 hrs on the clock and it looks pretty clean so my first thought was a gunked up fuel cutoff or metering valve. I pulled the Bosch metering valve (PN 0928400617 etched on it) and verified it was stuck. It ohm'd out at 2.4 ohms (2.1 is expected) but a 9V battery wouldn't activate it. Brake cleaner and soaking in Kroil quickly made the valve free again so the 9V battery could open/close it. This valve is a normally open (when no voltage is applied) and appeared to be functioning good now so I tossed it back in. I also cleaned out the pump's inlet banjo fitting as it was gunked up too. I also plumbed in a hand-pump garden sprayer full of clean diesel at the tank pick-up line so I verified positive flow to the banjo fitting with only a few pumps. Without any pressure on the hand sprayer, I verified the lift pump was pulsing fuel at the banjo fitting so I assume I'm getting clean fuel to the actual high-pressure piston. But cranking the engine with a little bit of pressure on the garden sprayer still gives me no fuel out of pump high pressure outline fitting so I'm thinking the pump check valve is gunked open with tar...just like the metering valve was.
So here's my question: Can I pull the pump's outlet fitting off (circled in blue below) and try to clean out the check valve or verify the plunger is moving during crank? And yes, I understand that I should remove the whole pump for a bench rebuild but since it's buried in a forklift body with no room for my hands, I'm just trying to figure out a quick way to figure out the problem. I think pulling the inlet fitting allows me to pull the check valve and see the top of the plunger. Or, if I pull it out, will I never be able to get it back together with the pump still on the machine?
The forklift was a military turn-in and was sitting for a while before I got it so I don't know any history other than it wouldn't start. It's not throwing any ECU codes and there's no fuel in the common rail during crank so my first guess was fuel supply to the pump or the pump itself was bad. Only 1023 hrs on the clock and it looks pretty clean so my first thought was a gunked up fuel cutoff or metering valve. I pulled the Bosch metering valve (PN 0928400617 etched on it) and verified it was stuck. It ohm'd out at 2.4 ohms (2.1 is expected) but a 9V battery wouldn't activate it. Brake cleaner and soaking in Kroil quickly made the valve free again so the 9V battery could open/close it. This valve is a normally open (when no voltage is applied) and appeared to be functioning good now so I tossed it back in. I also cleaned out the pump's inlet banjo fitting as it was gunked up too. I also plumbed in a hand-pump garden sprayer full of clean diesel at the tank pick-up line so I verified positive flow to the banjo fitting with only a few pumps. Without any pressure on the hand sprayer, I verified the lift pump was pulsing fuel at the banjo fitting so I assume I'm getting clean fuel to the actual high-pressure piston. But cranking the engine with a little bit of pressure on the garden sprayer still gives me no fuel out of pump high pressure outline fitting so I'm thinking the pump check valve is gunked open with tar...just like the metering valve was.
So here's my question: Can I pull the pump's outlet fitting off (circled in blue below) and try to clean out the check valve or verify the plunger is moving during crank? And yes, I understand that I should remove the whole pump for a bench rebuild but since it's buried in a forklift body with no room for my hands, I'm just trying to figure out a quick way to figure out the problem. I think pulling the inlet fitting allows me to pull the check valve and see the top of the plunger. Or, if I pull it out, will I never be able to get it back together with the pump still on the machine?