A port terminal in Zhejiang reported that a Caterpillar forklift equipped with 0R-3002 diesel injectors had cylinder missing during operation, the engine power dropped significantly, and there was obvious jitter. The maintenance team rushed to the site to carry out fault diagnosis and found that the problem was caused by the sticking of the needle valve of the 0R-3002 injector.
The maintenance technicians first used a stethoscope to listen to the working sound of the injectors and found that there was no regular "click" sound from one of the 0R-3002 injectors, indicating that the injector was not working normally. After disassembling the injector, it was found that the needle valve was stuck in the closed position and could not move flexibly. The reason for the sticking was that the forklift used low-quality diesel fuel containing water and acidic substances, which caused corrosion and carbon deposition on the needle valve, leading to sticking.
The maintenance team used a professional cleaning agent to soak and clean the needle valve and valve seat, and polished the contact surface with oxide chromium abrasive paste to restore the flexibility of the needle valve. After reassembly and debugging, the cylinder missing fault was eliminated, and the forklift resumed normal operation. The maintenance experts reminded that the use of qualified diesel fuel is the key to preventing the needle valve sticking of Caterpillar 0R-3002 injectors, and regular cleaning of the injectors can also effectively reduce the occurrence of such faults.