Cummins 3973228/4954200/5594766 diesel pump
1. Precise fuel injection: Using advanced technology to precisely control the injection quantity and timing, which allows fuel to burn completely, improve engine power and reduce fuel consumption.
2. Durable and durable: Made of high-quality materials and processed by special technology, it can withstand harsh working conditions such as high pressure and high temperature, with high stability and long service life.
3. Good adaptability: Designed for various models of Dongfeng Cummins engines, easy to install, universal, and can be quickly adapted to different equipment.
Product Introduction
Product details
There are different models: for example, injection pump 10403716105 and 4941011, suitable for engines 6CTA8.3 - G2, as well as fuel pump 6BT5.9 4937514, injection pump unit C3973228 CCR1600 4921431, etc.
Design Features: Taking the 6A106 high-pressure fuel pump as an example, its housing design is essentially the same as that of the Type A pump used in domestic non-turbocharged diesel engines, and the plunger components, oil valve components, camshaft, etc. are interchangeable. The speed controller incorporates special mechanisms, such as a boost compensator, an enrichment solenoid starting valve, and a fuel injection phase locking device.
Operating Principle: The high-pressure fuel pump drives a plunger that moves up and down due to the rotation of the camshaft, drawing fuel from the fuel tank and pressurizing it. Based on the engine's firing order and injection timing, high-pressure fuel is transported to the injector through the high-pressure oil line, which then sprays the fuel into the engine's combustion chamber. The fuel enrichment solenoid valve at startup forces the fuel pump to inject more fuel into the cylinder during cranking to facilitate starting, and the boost compensator automatically adjusts fuel delivery according to boost pressure.
Installation steps
Preparation: Have the necessary tools ready, make sure the work area is clean and tidy, and the engine is stopped and cool.
Install the flywheel: Rotate the flywheel counterclockwise (facing the flywheel) to 26° before the top dead center of the first cylinder. The pointer on the flywheel housing will indicate the corresponding position.
Handling the high-pressure fuel pump: Open the timing cover of the new high-pressure fuel pump and remove the dowel pin. Rotate the fuel pump camshaft until the dowel pin is parallel to the center of the dowel pin hole. The dowel pin groove grips the dowel pin and allows it to be inserted downward freely. Then, pull out the dowel pin.
Install the high-pressure fuel pump: Since the high-pressure fuel pump drive gear has helical teeth, slightly tilt the top of the high-pressure fuel pump toward the installer and install the high-pressure fuel pump by gently rotating it in the direction of the gear. Be careful not to over-rotate the high-pressure fuel pump drive gear during assembly. After installation, the top of the high-pressure fuel pump should be slightly tilted toward the engine body, but the oil line should not touch the engine body.
Tighten the bolts: Tighten the bolts between the fuel pump intermediate flange and the transmission cover. If the bore of the intermediate flange is not aligned with the cover, loosen the four nuts securing the fuel pump flange, gently tap the edge of the intermediate flange to rotate it into alignment with the bore, and then tighten the four loosened nuts.
Check the dowel pin: Turn the flywheel clockwise 30°, then turn the flywheel counterclockwise 26° before the top dead center of compression of the first cylinder, and check whether the dowel pin can freely clamp the pin part and be inserted into the bottom.
Reinstall the dowel pin: After checking the dowel pin, pull it out and insert the slotted end upward into the hole (reverse placement), then screw on and tighten the protective cap. If the dowel pin groove cannot be inserted into the camshaft dowel pin part and the error is small, first pull out the dowel pin, loosen the four fastening nuts on the waist-shaped hole of the fuel injection pump mounting flange, press the pump body until the dowel pin part on the camshaft is in the middle of the dowel pin hole, and then repeat the check with the dowel pin. After passing the check, tighten the four loosened nuts.
Connecting parts: Reinstall the removed high pressure oil line, throttle cable, fuel shut-off solenoid valve connecting line, boost compensator line, fuel injection pump line, lubricating oil pipe and injection pump bracket.
Bleed the air: Loosen the bleed bolt on the fuel filter, press the fuel pump several times until there are no air bubbles left in the diesel fuel flowing out of the bleed bolt, and finally tighten the bleed bolt.
Common faults
Starting
Solenoid valve short circuit: If the solenoid valve coil is shorted, a multimeter reading of R = 0 or less will indicate a short circuit. After power is applied, the solenoid valve will quickly heat up or even become too hot, causing difficulty starting.
Open circuit of solenoid valve: If the solenoid valve coil is open, when measured with a multimeter resistance block, the needle does not move, the display is endless, there is no suction sound, the diesel engine cannot get enough starting oil and is difficult to start.
Line fault: If the line is shorted or open, the solenoid valve cannot be turned on and operate normally when the starter is running, which will affect the starting performance.
Fuel supply
Plunger spring is broken: the axial clearance of the camshaft is too large, the tappet positioning screw is loose, the plunger spring preload is too large or uneven, the spring force is too large or poor quality, there is a problem with the assembly of the lower seat shoulder of the plunger spring, etc., which may cause the plunger spring to break and affect the oil supply.
Boost compensator malfunction: If the adjusting pin is stuck, the fuel supply cannot be adjusted normally according to the boost pressure, resulting in a decrease in the diesel engine output and deterioration of its power performance.
Oil pump leak: Leakage of the oil pump main shaft seal, damage to the O-ring or leakage of the seal will cause diesel fuel to enter the engine oil, which will affect the normal operation of the fuel system.
Operation
Crack in the fuel pump pulse damper: poor deceleration, unstable engine operation, unstable idle, unexpected stopping and other phenomena.
The fuel pump gear or shaft does not rotate, the gear pump check valve is always open, or the pressure regulating valve is stuck: This will result in low fuel pressure, causing the engine to be hard to start, run rough, fail to reach rated speed, and have low power.
After sales service
Service Network: Dongfeng Cummins has a comprehensive service center network throughout the country, which can quickly respond to customer needs and provide users with timely maintenance services.
Professional Maintenance: Maintenance technicians have high professional capabilities and rich experience, can quickly and accurately diagnose and repair various faults of high pressure fuel pumps.
Diverse Services: We offer a wide range of services, covering equipment installation, commissioning, maintenance, and more. We can optimize performance to meet customer needs, conduct regular comprehensive inspections of injection pumps and motors, and promptly troubleshoot any issues.
Customer Care: We focus on customer care, deeply understand their needs, provide pre-sales consultation, during-sales support and after-sales service, answer customers' questions about the selection, use and maintenance of injection pumps, so that customers can use them with greater peace of mind.
Common Dongfeng Cummins fuel injection pump malfunctions cover many aspects. Below is a more detailed overview:
It's hard to start or impossible to start
Solenoid valve malfunction: The solenoid valve is shorted. If the coil is shorted, the resistance reading is low when tested with a multimeter. After power is applied, the solenoid valve quickly heats up or even becomes hot, causing malfunction, affecting fuel delivery to the fuel pump and making it difficult to start the diesel engine. The solenoid valve is open. If the coil is open, the needle does not move when measured with a multimeter resistance block, the displayed resistance value is infinite, and there is no suction sound. The diesel engine cannot receive sufficient starting oil and will not start.
Fuel filter clogging: After long-term use, the fuel filter may become clogged with impurities and dirt in the fuel, resulting in poor fuel flow, reduced fuel flow to the high-pressure fuel pump, and the inability of the high-pressure fuel pump to provide sufficient fuel pressure and oil volume, causing difficulty starting or failure to start.
Fuel line problem: Air may be trapped in the fuel line, causing an airlock, which interferes with normal fuel delivery and prevents the high-pressure fuel pump from delivering fuel properly. Furthermore, damage or a leak in the fuel line will cause a drop in fuel pressure, which will also lead to difficulty starting the engine.
Injection timing error: If the fuel pump's injection timing is inaccurate, either too early or too late, fuel will not be sprayed into the combustion chamber at the correct time, resulting in incomplete combustion and difficult or impossible starting. This may be caused by improper installation of the high-pressure fuel pump, wear on the camshaft, or looseness of associated components.
Abnormal fuel supply
Plunger spring failure: There are many reasons that can lead to plunger spring failure, such as excessive camshaft end play, loose tappet positioning screws, excessive preload when installing the plunger spring or uneven force, quality problems with the spring itself (excessive spring force or poor quality material), problems with the assembly of the lower seat shoulder of the plunger spring, etc. If the plunger spring breaks, it will disrupt the normal movement of the plunger, resulting in unstable or insufficient oil supply.
Boost compensator malfunction: For example, if the adjusting pin is stuck, the boost compensator will not be able to properly adjust fuel delivery in response to changes in boost pressure. As boost pressure increases, fuel delivery cannot be increased accordingly, resulting in reduced diesel engine power output and deterioration of its performance. Conversely, as boost pressure decreases, fuel delivery cannot be reduced in a timely manner, which can lead to excessive fuel consumption and reduced engine performance.
Oil pump leak: A leak through the oil pump main shaft seal, a damaged O-ring, or leaks through other seals can allow diesel fuel to enter the engine oil. This will not only affect the lubricating properties of the engine oil but also cause problems with fuel delivery to the high-pressure fuel pump, resulting in inconsistent or insufficient fuel delivery.
Uneven fuel injection
Injector failure: Wear, clogging, or damage to the injector's internal components will result in uneven fuel injection and inconsistent fuel delivery to each cylinder. This will lead to unstable engine operation, vibration, loss of power, etc.
Wear of the internal parts of the high-pressure fuel pump: The internal parts of the high-pressure fuel pump, such as the plunger and oil supply valve, will wear out after long-term use, resulting in reduced sealing efficiency, uneven fuel injection volume and injection pressure, affecting engine performance.
Unstable operation (interruptions, unstable idle)
Damaged fuel pump pulse damper: If the fuel pump pulse damper is broken or fails, it cannot effectively absorb the pulses generated by the fuel pump, resulting in large fluctuations in fuel pressure and causing poor engine acceleration, rough running, unstable idling, etc.
Fuel pump failure: Faults such as a non-rotating fuel pump gear or shaft, a constantly open gear pump check valve, or a stuck pressure regulating valve can result in low or unstable fuel pressure. This will prevent the engine from delivering a consistent fuel supply during operation, resulting in rough running, loss of power, speed hesitation, and other problems.
Abnormal noise
Worn or damaged internal components: Worn or damaged gears, bearings, camshafts, and other components inside the high-pressure fuel pump will cause abnormal noise during operation. For example, worn gears can cause poor engagement and sharp noises; damaged bearings can cause vibration of rotating parts and a dull noise.
Installation Issue: If the high-pressure fuel pump is not securely installed or installed in the wrong position, vibration and noise may occur during operation. Loose components connected to the high-pressure fuel pump may also cause noise.
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Exhibition cabinets
Getting to know the plant
The plant employs a team of highly qualified and experienced engineers who continuously innovate and improve its products. The company currently holds a number of independent intellectual property rights and patented technologies. Its construction equipment includes a wide range of excavators, loaders, cranes, bulldozers, and other machines. These products are distinguished by their high productivity, reliability, energy efficiency, and environmental friendliness, as well as the ability to adapt to challenging operating conditions in a variety of climates and environments worldwide.
Awards and qualificationsfication
frequently asked questions
1. Which countries do we export to?
Asia: Vietnam, India, Indonesia, Pakistan, Kazakhstan, Uzbekistan, etc.
Europe: Russia, Belarus, Ukraine, Lithuania, Saudi Arabia, etc.
South America: Brazil, Chile, Paraguay, Argentina, etc.
Africa: South Africa, Ethiopia, Libya, etc.
2.What payment terms can we accept?
Usually we can work on T/T, 30% TT before production and 70% TT before shipment
3.What logistics methods can we use for delivery?
1) For most of Europe, South America and Africa etc. countries, we can go by container or Roro via ocean freight.
2) For China's neighboring countries, such as Russia, Vietnam, Kazakhstan, Uzbekistan, etc., we can deliver by road or rail.
3) For light spare parts in urgent requirement, we can ship it by international courier service, such as DHL, TNT, EMS or other air freight.
4. How can you guarantee that you have delivered the goods to customers?
A: We will provide you with full delivery information for you confirmed.
5.What are our advantages compared with other manufacturers/factories?
1) Reliable quality: Carefully select reliable manufacturers to support spare parts such as engines, axles, transmissions, and many parts designed and produced by ourselves, always adopting the best materials.
2) Competitive price: Concentration of mechanized production in large quantities reduces production costs to ensure competitive price.
3) Service Team: Our sales managers are available 24/7, ready to answer your questions at any time. Our professional technical support team, with senior technicians, is ready to provide support to users and dealers. Most issues can be resolved within 24 hours.
4) Fast delivery: Generally, we can delivery within 10 working days in factory after receiving the advance payment from customers.
6. How can you provide after-sales service to customers?
A: We will reply you at the first time and help you solve the problems within 24 hours. If we really need your local, we
We will send your professional person to your locality to help you solve the problems without any hesitation, supply you with all-round
