Injection Pump BX2200D

Whilst tilling, the motor stopped. It didn't hunt or run abnormally as if fuel had water in it or as if it was running out of fuel. It just stopped.

Having looked at the manual and on every website I could find, it seemed that no one had an answer to my problem. The closest I got was a Youtube video of a guy in Australia, showing how he serviced his injection pump - a 2 cylinder unit - and mine is 3 cylinders.

What he showed in his video was that a spring had broken, in the low pressure side of the pump and because of this one injector was receiving no fuel.

He replaced the spring, proved the high pressure side of the pump was providing fuel to both outlets (from pump to injectors), reinstalled the pump and the tractor started and ran as normal.

Contrary to all advice, suggestions & recommendations I could find, I removed my injection pump & stripped it down - even though all advice told me that the pump had to be serviced by a qualified engineer / Kubota service agent etc.

The pump in question is a Zexel unit and Zexel is a subsidiary of Bosch. So, I contacted Bosch...who recommended 3 "local" service companies...the nearest was 350 miles away!

Having already opened the pump, I knew that all 3 springs in the low pressure side were broken and yet none of the Zexel service outlets would sell me the springs....but would look at it for $250...so I looked online, found a supplier, bought the springs and replaced them.

I installed and removed that pump 50 times but every time I had no fuel output from the high pressure side (the top end of the pump)....nothing being sent to injectors....and before anyone says anything about filters / fuel pump / shut off solenoid and more....I had fuel to the injection pump.

So far, I have only replaced the springs, hoping that this was the cure and I left the top of the pump / the high pressure side as it was....but then opened that up too.

When you have people quoting you $400...just to collect & return the tractor, you start to think seriously if it's better to buy a new unit for $800....especially when your told that the $400 doesn't include any mechanic's time or inspections / investigations....and that "They", Kubota will not service the pump...they outsource.

Bottom line, I took the pump to the local service company Kubota use and watched the "expert" strip it down & rebuild.

I was expecting this to take place in a surgically clean workshop, have all of my attempts at repair criticised and, after repair...a complete test performed on certified equipment....no!!

It was stripped apart in a filthy workshop...tools and parts everywhere...nothing was torqued to ft/lb....no fancy test equipment or proving other than priming the pump and pushing the cam followers / rollers and ejecting diesel from the HP side.

Yes, it was $135....but money well spent....just to see behinds the scene and also learn.....and I saw my mistake....the bottom end / low pressure side pistons actually connect to washers underneath the springs.... a piece of information I couldn't find anywhere.

What caused the 3 springs to fail...I have no idea, other than it happened.

I photographed the procedure & components at various stages of disassembly and will gladly share them with anyone interested....but I will say this....anyone, with the correct information and tools can take these pumps apart & service them....they run a simple tractor, not the International Space Station.

The unit only had 500hrs on the clock even though it's a 2002 model.
During the previous 5 or 6 days, on 2 separate morning startups, the engine started at full engine revs. Both times it stopped (by itself) after a short period and then started normally on the first restart. I always leave the throttle at it's lowest speed setting before switching off and had never had the throttle anywhere near full speed position.
At the time the problem happened, I'd been tilling for an hour or so and all was functioning normally until the engine stopped - as if I'd turned the key.
If I could give any insight or advice on "what not to do" or what caused the problem, I would.
However, the purpose of my post was to highlight the fact that it is possible to service to service an injection pump on these units.....and I looked everywhere on the internet but couldn't find anyone with the information I needed. As I said in my 1st comment, I have photos available and can describe the process if anyone is interested. Just give me an email address and I'll reply.

Apologies for delay in response.
"Timing" the pump....I thought this was a complex issue, requiring specialist equipment & procedures but it relates to the gasket that sits underneath the complete assembly. In other words, if you throw the existing gasket away & replace it with a new one, the thickness of each could be different...but we're probably talking of 1000's of an inch. When I took the unit to a service centre, I asked about timing and the engineer / mechanic commented on the fact that if I used the same gasket there's no problem. To be honest, I have no idea what, if any, difference there would be if a new gasket was installed.
The pistons orientation - good question. A word of advice - before you remove them, slide the control rack to the off position or fully open and when you remove the piston, do so carefully, without rotating and make a note of the orientation....because the pistons can be reinstalled correctly or 180 degrees out, the helix slot in the piston is your reference.
Now let's talk about the fancy test equipment that was used when my pump was serviced...with me watching everything that was done. Once reassembled. I was expecting the unit to be taken off somewhere and "installed" on some fancy test rig but it wasn't.
I made a point of asking if the pump could be primed and tested....and all you do is fill the upper, high pressure, chamber with diesel, shake it to get the air out and top it up again....and then push, with your thumb, the roller / cam follower at the bottom of the unit...and, if all is well, diesel is ejected through the port as if it was on it's way to the injector. The whole "test procedure" was done by hand. each roller was pushed. fuel came out and I walked through to reception and paid the bill....job done.
My downfall, my issue was that I didn't know that the pistons connect / slot into the lower washers, under the spring. That was my only mistake....and, the 3 washers were damaged - which I didn't know because I'd never taken one of these apart before. If I'd been wiser or had found a disassembly / reassembly video on Youtube or anywhere else, I would have bought 3 replacement springs + bottom end washers and would have had the pump working without going to a service centre....but you live and learn.
If anyone would appreciate the photos I have...drop me an email to rs2_8(at)hotmail(dot)com and I will gladly show & explain the process, what I did....and, to complete the story, I took the unit home, installed it and the tractor's fine, I use it every day.

Before making statements that are inaccurate, based on your assumptions, not facts....you could have taken a moment to ask any questions about what I did or even if I have any knowledge of anything of a "technical" nature. Instead, you make ridiculous comments like "sometimes you get lucky"!!! Luck had nothing to do with anything.

For you "this is a prime example of....." of your own lack of knowledge but with some need to respond to something you think you know about....and choose to voice your "expertise" through this website.....If only you were right or had the full story....but one thing you need to know, with absolute clarity....you are just like the rest of the world - you think you have all of the answers....and you obviously do...but .. you only have the answers to some of the questions!

I don't know or care what your background is...what technical knowledge or ability you have but mine isn't based on tractors.

I've worked on, maintained and supervised 30 guys working with pneumatic systems and gas pumps / compressors / hyperbaric systems and life support...electrics / electronics from -10VDC to +3,000VAC....750KVA generators, a ton of diesel engines, welding / cutting equipment / computer PCBs repairing at component level....hydraulics systems to 30,000 psi...fibre optics and laser systems...video cameras & recording / processing....and a lot more....and a simple Kubota pump is small change...if you have the right information.

So let me clarify. First. when I wrote the initial comment, as much as I wanted to, I could not include every detail but tried to give a synopsis of events to avoid writing pages & pages that would cover everything.

Just picking up on a few of your statements....my pump has a gasket that sits between it and the engine body....it is not a shim even if it acts like one....it's like a cylinder head gasket...but different material.

On my pump....which you obviously don't know, the shims are internal to the pump LP side and sit above the tappets....and the are marked / identified to confirm their thickness. They are not under the pump! Yours might be but mine ain't!

"There's no way to know if the pump is leaking..." well, there is...and it's obvious...it will leak into the crankcase / sump dilute your engine oil and show an increased oil level on the dipstick....and you'll end up with an empty fuel tank + 15 extra gallons in your engine oil!!!

Timings....you need to learn how to describe component parts.....what 2 screws..on each pump are you referring to???? The is a single injection pump, not several. There are individual cylinders or bores within the injection pump depending on how many cylinders your engine has...2, 3, 4, 6, 8....and as for burning and washing cylinders....someone has obviously convinced you about this either incorrectly or to justify a costly bill.

Of the two of us, I'm the one that doesn't know anything...got the job done on a wing and a prayer....but my tractor is running as smooth as anything, sips fuel like it's in a desert and has to make every drop count! So, instead of using your head to resolve a problem...get your credit card out and pay someone $500-$1,000 at a "qualified injection pump shop" instead of some "fly-by-night shop" to sort something you could have done yourself...for maybe $100.

Last point....because I'm thick / stupid & have no experience of anything...I called my local Kubota main agent, discussed my situation at length with the senior technician, not service manager, and he told me they couldn't even look at it for 3 weeks. So, being a dumbass, I asked who serviced their pumps...and he told me....and I took it down to them and watched exactly what was done by a Kubota accepted service centre!! And all that fancy stuff you think goes on....all the test rigs & jigs etc.......it never happened. A manual test showed fuel output from each port...I took it back an installed it and fired up the first time I turned the key........and I know nothing......but I'm really glad I'm not you.

I think this will be my last comment here...until another issue begins....but, in comment #5, above, I did offer to email photos to anyone who was interested.

I had one request for this... and I think that person now knows a little more about the mysteries of these simple pumps...fuelling a tractor....not a Boeing 747.....

If you want, I will gladly email my photos (annotated) to you....otherwise, I'm done....I can't keep checking this site