Hello all. I have literally read through over 100 posts here in the last 2 days, searching for a conclusive answer to my 863's dying issue. The machine is an old 863(F) Melroe Ingersoll Rand unit, serial #514431251 powered by the Deutz BF4M 4 cyl diesel.
The problem is the same as many others have presented here, but I can not find a conclusive, definitive solution.
The machine runs great for a little bit then will start bogging down and eventually dying while running at full throttle. Even does this at lower RPMs and idle though not as bad. The issue has been getting worse (happening sooner) as time goes on.
This problem all started two years ago with a broken pick-up tube in the fuel tank. I replaced that and things were good for a little while then the problem returned. Thinking maybe the new pick-up tube (not hard-plastic type) was floating up in the tank and sucking air, I pulled it out and replaced with a 2nd new one. I wired a lead fishing weight to the end of the new pick up tube and re-installed in the tank. Same issues, no change.
Things I've done:
Replaced the pick-up tube 3X
Replaced the squeeze-bulb 2X
Removed squeeze-bulb completely (currently)
Added in-line one-way check valve between pick-up tube and canister filter
Removed the one-way check valve (currently)
Replaced the mechanical fuel (lift) pump 3X (Amazon Chinese)
Replaced the external canister fuel filter/water separator 2X
Replaced ALL rubber fuel hoses
Added clear fuel filter in line between pick-up tube and mechanical fuel pump
Added electric fuel pump between pick-up tube and mechanical fuel pump
Bled and bled and bled through bleeder screw on canister filter housing
Made sure bleeder screw is tightly closed.
Checked fuel shut-off solenoid - clicks open with every key-on
Replaced all rubber return hoses at each injector
Cracked each injector individually, with engine running, with a shower of diesel spraying out
Drained and refilled fuel tank 2X
Currently the machine has a new pick-up tube with lead weight on the end, new rubber fuel lines, inline clear fuel filter between pick-up tube and added inline electric fuel pump (7-9psi) before running into the mechanical fuel pump. New mechanical fuel pump, removed squeeze bulb, new canister fuel filter/water separator. Full, fresh fuel in tank, new return rubber lines from injectors.
A few things I read here and haven't had a chance to try yet:
Placing electric fuel pump AFTER the mechanical fuel (lift) pump
Loosening and/or replacing fuel cap
What is going on with this monster of a machine ? ! Could there be an issue with the injector pump ? What about the injectors ? I've read a mention in one thread about checking the governor. Does this Duetz engine have a governor ? If so, where is it located and how would one test it?
I'm just about to the point of putting this machine in the auction and find a newer replacement machine.... Does anybody have any more sage suggestions ? ? ?
Thanks to any who take the time to read through all this and offer their help !
The problem is the same as many others have presented here, but I can not find a conclusive, definitive solution.
The machine runs great for a little bit then will start bogging down and eventually dying while running at full throttle. Even does this at lower RPMs and idle though not as bad. The issue has been getting worse (happening sooner) as time goes on.
This problem all started two years ago with a broken pick-up tube in the fuel tank. I replaced that and things were good for a little while then the problem returned. Thinking maybe the new pick-up tube (not hard-plastic type) was floating up in the tank and sucking air, I pulled it out and replaced with a 2nd new one. I wired a lead fishing weight to the end of the new pick up tube and re-installed in the tank. Same issues, no change.
Things I've done:
Replaced the pick-up tube 3X
Replaced the squeeze-bulb 2X
Removed squeeze-bulb completely (currently)
Added in-line one-way check valve between pick-up tube and canister filter
Removed the one-way check valve (currently)
Replaced the mechanical fuel (lift) pump 3X (Amazon Chinese)
Replaced the external canister fuel filter/water separator 2X
Replaced ALL rubber fuel hoses
Added clear fuel filter in line between pick-up tube and mechanical fuel pump
Added electric fuel pump between pick-up tube and mechanical fuel pump
Bled and bled and bled through bleeder screw on canister filter housing
Made sure bleeder screw is tightly closed.
Checked fuel shut-off solenoid - clicks open with every key-on
Replaced all rubber return hoses at each injector
Cracked each injector individually, with engine running, with a shower of diesel spraying out
Drained and refilled fuel tank 2X
Currently the machine has a new pick-up tube with lead weight on the end, new rubber fuel lines, inline clear fuel filter between pick-up tube and added inline electric fuel pump (7-9psi) before running into the mechanical fuel pump. New mechanical fuel pump, removed squeeze bulb, new canister fuel filter/water separator. Full, fresh fuel in tank, new return rubber lines from injectors.
A few things I read here and haven't had a chance to try yet:
Placing electric fuel pump AFTER the mechanical fuel (lift) pump
Loosening and/or replacing fuel cap
What is going on with this monster of a machine ? ! Could there be an issue with the injector pump ? What about the injectors ? I've read a mention in one thread about checking the governor. Does this Duetz engine have a governor ? If so, where is it located and how would one test it?
I'm just about to the point of putting this machine in the auction and find a newer replacement machine.... Does anybody have any more sage suggestions ? ? ?
Thanks to any who take the time to read through all this and offer their help !
