Hello everyone first of all I'm new to the forum. I'm a forklift dealer in th UK. I have a FD 25 with an 4D95s motor. It's recently had reconditioned injectors, new rings and honed bores. With the new head gasket fitted, skimmed head and valves adjusted I started it up to find it ran poorly and struggled to rev up. I cracked the injectors and found that cracking no.1 made no difference to the engines running which suggested the problem being on that cylinder. When number 2, e and 4 were cracked the engine cut out. I compression tested 1 and 2 which had pretty much the same reading. I swapped 1 and 2 injectors around and the same problem. Any suggestions? Also the fuel stop solenoid doesn't work and is stopped manually by cable. Thank you.
Cracking an injector line relieves pressure to that injector and if it made no difference it could be from a couple of things
if no fuel dripped from the nut then there is air in that line and it should be left loose until fuel drips from the nut
if you have fuel dripping from the nut and there is no difference then that indicates a faulty injector
cracking 2 and 4 and the engine stopped indicates that 3 also is in trouble
Basically I would be taking the injectors back to a specialist diesel shop for a re-calibration and new tips rather that reconditioned tips
next --when dealing with injectors and injector pipes , if the pipes have been removed and allowed to sit around for a while , they can collect dust from the fuel still in the pipes and so before fitting they should be blown out with compressed air as that small speck of dust can jam the injector needle and prevent operation
The engine is running (albiet at low performance ) but it is running so that would indicate that any mechanical work done is ok and the problems are in the fuel deliver system--injectors and pump
if the pump has been removed the low performance could also be from pump timing so have that rechecked
if it is an inline pump ( where all the pipes come out of the top ) there is a simple procedure to check and adjust the timing accurately and if it is a rotary ( distributor) type pump with the lines from the back end , thee is a special tool and a dial gauge that is used to set the timing accurately
SO being a dealer and a reputation for reliable equipment is essential for your business I would suggest that you now bring in an accredited specialist diesel fitter to tune the fuel system
as to the stop system , a cable is as good as a solenoid as it only stops the fuel and is not part of the problem
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