JCB 803 Mini-digger Fuel Injection Pump queries

[MOG]

Excuse the large image. Best I could find on the net.

So I have an issue with the injection pump on my mini digger. It is a 1990s JCB 803 fitted with the Perkins 103 3 cylinder diesel which would appear to be the same as the one pictured below. It has always been a great starter (have owned for 15 years) but has started to get wet around the FIP of late. Today she failed to start and after trying to bleed it up I noticed quite a bit of fuel is coming out of the flange where the fuel injector supply pipes attach to the top of the pump. The ones held down by the 5 sided bolts on the picture below. I did manage to bleed to the injectors and she started up straight away but fuel was dribbling out of the unions of at least the first 2 aforementioned flanges and dripping on the floor. When I stopped the engine and tried to start it again, it took some cranking to get it going, suggesting it is emptying the fuel lines pretty quickly. So my questions are:

1. is there a simple way to service those seals under the flange (guessing not as they are fixed down with 5 sided anti-tamper nuts)
2. is it as easy to remove the FIP as the manual would suggest - simply undo the 2 nuts and 2 bolts holding the pump into the body of the drive unit and lift out? The manual makes it look that simple. There is no mention of setting timing or anything like that? It is unclear if one or more of the bolts holding it in may be reverse thread. Is anyone able to confirm reality?
3. where would I be looking to sent the unit to, in order to get those seals changed or the whole pump reconditioned?

All help gratefully received.

Mog

 

[MOG]

What the FIP appears to be on removal

 

[agrimax]

This is from the 803 manual...This pump doesn't appear to have the 5 sided bolts but removal should be the same...Pay attention to parts C and D which is the connecting point of the sliding rack on the side of the pump. Timing isn't an issue but make sure and keep the shims(if fitted...usually is at least one) when you send the pump off and remember to fit them again on reassembly. Different thicknesses alter the fine timing of injection.

 

[biggles]

I’ve had two of those pumps leak there and sent them in for repair, both times I’ve had a £300 odd bill for what can only be a few washers or seals, pentagon sockets are available to buy to fit the nuts but knowbody wants to supply me the bits, I’m thinking of just stripping the next one and see if I can fit an off the shelf copper washer or similar.

 

[MOG]

I have found a source of the bits. Debating whether to bite the bullet and buy the socket for £45. The actual seal kits are under £25. I did ask if the place selling them would do the job for me but they say they are flat out and can't do anything for a few weeks. Videos on Youtube of disassembly and rebuild actually make the job look pretty straightforward, providing you can undo those sodding pentagonal nuts.

Thanks for the replies so far.

Zexel Seal Repair Kits Archives - Diesel Injection Pumps

Zexel injection pump seal repair kits – formerly Diesel Kiki made under license from Bosch

injectionpumps.co.uk

 

[biggles]

I’ll be the Guinea pig then, I’ve got one weeping now but hasnt got to the poor starting stage yet. I’ll get a socket ordered tomorrow

 

[MOG]

knowing my luck you will buy the last one

If yours is an 803 like mine then I am pretty sure you need to get the 20mm ones not the 17mm ones. You may also need to order the seals #32 on the diagramme seperately. I was going to call them tomorrow to see exactly what I needed

Good luck if you go for it and tell us how you get on

 

[MOG]

Socket can be had cheaper here...

SOCKET PENTAGONAL FOR ZEXEL PUMP - Merlin Diesel

SOCKET PENTAGONAL FOR ZEXEL

www.merlindiesel.com

 

[biggles]

 

[biggles]

Everything has arrived, I’ll pull it apart at the weekend and see how it goes. Have watched a few videos and it all seems straight forward enough. Could just do with finding out the torque of the pentagon bolts.

 

[MOG]

Good luck. Mine is running well and there are no external leaks. HOWEVER! It isn't starting well from cold without a bleed making me suspect it may be leaking fuel back through the pump into the sump rather than out through the seals. I will have to keep an eye on the oil level. I may yet need to take it all apart and have a look as to whether I have one of the pumps 1 tooth out.

 

[weirdfish]

I have just joined and am having this very problem, leaking from at least one flange and struggling to start.
Where did you get the five sided socket from and the repair kit in the picture.
Also, how hard was it to service the pump, I’m a retired engineer so hopefully know my way around spanners etc
Thanks.

 

[MOG]

Hi WF. Strangely, my memory of the job is very poor. Maybe that is a protective thing to sheild me from the horrors of it or just old age, I am not sure. I think I bought the socket and the seal kit from the 2 sites linked to above but cannot be 100% sure. (99% though). The actual job was made a lot more difficult by me changing every single part of the pump that came in the kit rather than simply the upper seals that might of been all that needed changing. Basically I sat at a clean desk and stripped the pump (very carefully) to basic components, noting how it all came apart (but be careful as I seem to remember something dropping out before I was able to see how it had been together and that cost me a rebuild as I had everything 180 degrees out!). It certainly wasn't rocket science just careful, methodical, logical, procedure. On of the hardest bits I recall was getting the sliding mechanism to line up with the stop solenoid. Anyway, after several teething issues getting it timed and lined up and back in the machine it has been faultless now ever since. Starts on the button every time, runs like a swiss watch and no longer leaks fuel everywhere. If you are competent and confident then give it a go. Where abouts in the country are you? I have no idea where that socket is now but I could probably send it to you to use if it helps (assuming I can find it again).

EDIT: My cold starting issues turned out to be a loose connection on the end of the glow plug bus bar!

 

[weirdfish]

Thanks for that, I’ll check a few sites for repair kits.
I’m in the Forest of Dean between gloucester and Chepstow.
If you can locate the socket I’m more than happy to cross your palm with silver

 

[MOG]

I am quite often in the FOD with my mountain bike so could drop off for you. Just need to find it! Am only in Abergavenny so not million miles away

 

[biggles]

I to can’t remember which site I purchased from but I’ve done 3 now the last 2 I only bought the 3 seals for the outlets that were leaking, there’s no point striping it all and changing everything in my mind , just make a note of the flange locations as they alter the fueling .I find just a dob of paint is sufficient as it doesn’t need to be dead accurate but pretty close else it can cause a bit of black smoking

 

[weirdfish]

I found this one that looks promising

Overhaul repair kit for 3 cylinder NP-PFR3KD50, NP-PFR3KD55, NP-PFR3KX55 and NP-PFR3KX60 injection pumps - Diesel Injection Pumps

Repair kit for Bosch/Zexel 3 cylinder diesel pumps

injectionpumps.co.uk

 

[biggles]

I think that could be the firm I’ve used, if so they do a seal kit just for the leaky bits for just a few quid as you won’t need all the rest of the kit, give them a ring and if it’s the ones I used they are very helpfull

 

[weirdfish]

I think that could be the firm I’ve used, if so they do a seal kit just for the leaky bits for just a few quid as you won’t need all the rest of the kit, give them a ring and if it’s the ones I used they are very helpfull

 

[weirdfish]

Well, it’s stripped down, now for the fun part.
The only thing I didn’t note was the position of the actuator bar, the bar with the notches in that moves the gear wheels.