Perkins Specialty Tooling
Hello all. Let me start by saying thank you for taking the time to read this. One of my fleet customers has a Hyster H20 (I believe that's the model. Data plate & model decals are missing and so far I haven't been able to find the serial number stamped on the frame.) In any case, it's a 20K pound forklift with a Perkins 1106C engine which utilizes a Bosch VP30 injection pump. I was called out the other day because it had progressively began to run worse and then eventually stalled and wouldn't restart. When I got there to diagnose the issue, it became quickly apparent that the studs and nuts retaining the injection pump to the engine had loosened up. There was only one stud and nut remaining and it was finger tight. You could actually see the pump rocking back and forth as the engine was cranked. Ok cool. Pretty straightforward diagnosis there. As I began digging into the way this injection system is set up, I discovered the need for several specialty tools in order to properly set the injection timing. There's also doesn't appear to be any timing marks on the cover & crank pulley which necessitates the need for a fairly lengthy procedure to find TDC compression on #1. Near as I can tell, the special tools needed run somewhere between $600 - $1000 depending on whether or not I can do without one of them. Seeing as how this will likely be a purchase for tools I only use once, I have a hard time justifying their cost. As much as I hate to turn the job down, that may be what's in everyone's best interest. Before I do so though, I thought I'd ask if anyone knows of a place that might rent said tools. I haven't found anyone yet but the cost involved there would probably be manageable for this repair. I've had some other thoughts about fabrication of 2 out of 3 of them and the use of a cam degree wheel to get around the third, but all that may just be wishful thinking. Below are the tool part numbers and the engine's serial number. I appreciate any feedback on this, thanks for making through the long post.
… - Timing Pin For Injection Pump
… - Spanner Wrench For Injection Pump Flange Nut
… - Piston Displacement Tool
Engine Serial No. VK51160 U114490N
See if what is in here helps any.
Thank you for your response. I ran across that upload previously but it looks just like the information I found in a Perkins manual. I'm just wondering if anyone offers the specialty tools for rent. Based on what I read, I can't see a situation where you'd be able to get around having at least the piston displacement tool. The timing for the injection pump is 4 degrees after top dead center and there aren't any marks on the balancer and timing cover. That's the tool you need to set the engine to that position. In any case, I know I'm probably grasping at straws here. Just figured it was worth an ask. Once again thanks for your input regardless.
Zachery, I am checking with a customer that is an authorized Perkins Parts and Service location. If they have them I will be able to borrow them. We would have to work out something on a refundable deposit. I should know tomorrow.
Rex that's incredibly generous and very appreciated. Absolutely no problem on the deposit and would be happy to pay a rental fee also if they'd like. Thanks so much!
Zach, Lost a day. Finally got in touch with my customer. He knows this engine and the timing procedure. Biggest question is this. Did the gear on the pump loosen up? That is a problem that has to fixed by a pump shop. No way to in the field to get the gear in proper location on the pump shaft. I think a small fee to talk to him would be money well spent. He says that not all three tools are needed and he thinks he has the 1 maybe 2 that are essential. Let me know.
Hey Rex, no worries on that. I know how things can be. To the best of my knowledge, the pump hub hasn't been loosened. I believe it's only the studs and nuts that retain the pump to the timing gear case. I haven't yet removed the pump because I didn't want to start a job I couldn't finish. I read in the Perkins manual what I believe he's referring to. They caution about not loosening the center nut on the hub as that relationship is critical and set at the factory. There are I believe four bolts that hold the gear to that hub and that's what's loosened when removing the pump. Yes I'd absolutely be interested in speaking with him. Let me know what sort of fee or how to get in touch with him. Thanks so much for all your time and effort on this Rex!
Zach, I left you a voice mail with the name and phone # of the Perkins guy I know. Good luck Mr. Phelps
Rex I just wanted to tell you thanks again for your help. I spoke with your customer Friday and he was able to get me squared away. Can't thank you as well as the entire Diagnostic Network community enough for your help and support. This is what I love about groups like this and our business in general. None of us are as smart as all of us. I'll be sure to post a follow up once I've had the chance to tear into the machine and get it repaired.
Harry is a good guy. Let me know how it turns out.
My apologies for the long delay in response here. This machine wound up being an interesting repair journey but it all worked out in the end. I'll probably make a post under the case study section that goes deeper into the details of this machine's repair. Forklift is running great now and the customer is all too happy to have it working again. Thanks again Rex for putting me in touch with Harry. The information he gave was incredibly helpful and kept me from turning this job away. Thanks to all in general for your time and input.