Deere 4045 Engine - Weird Problem

I have a mechanically injected Deere 4045 in one of our compressors. This is probably a 2005 or so machine. No computers just a mechanical injection pump. So the engine fires right up and runs clean as can be. Issue is when I load the compressor air end and that puts a load on the engine it can't put out the power. The entire machine only has about 200 hours (really!). So to give you an idea...this is what happens...compressor is running at 50psi no problem...I turn the switch to load up the compressor to 100psi and the throttle on the engine is pulled to full throttle...however the engine starts vibrating and running rough but without any smoke...just feels like its gonna stall. My first thought is that the original 16 year old lift pump isn't putting enough fuel to the injection pump. There is a new lift pump in the mail. If that doesn't fix it what else would you think it is? The air end spins freely as we separated it from the engine to test and it turns by hand no issue and when we had the engine disconnected from the air end we started the engine and it does free rev without any issues. Also there is no smoke when the throttle is pulled to full throttle which again makes me feel like there isn't enough diesel being delivered to the engine. Sorry for the long winded message but any thoughts would be amazing.

I think you are right.

200 hours on a mechanical diesel, it's almost 2022, Delmarva, isn't exactly the desert, I'd guess your fuel tank screen is plugged up with dark colored snot. disconnect the line at the fuel tank, run it into a can of fuel, start it up and let it run for a few minutes to bleed the air, then load it up and see what happens.

I had a 05 jd 160 exc. had similar problems. Would run fine at idle, but when you revved it up it would lurch all over the place. It seemed to work better with a full tank, I chased it for a whole season replacing crank sensors, lift pumps, fuel lines, inline screens, vacuuming tank, you name it. It turned out to be injection pump

alaskaforby4 said:

I had a 05 jd 160 exc. had similar problems. Would run fine at idle, but when you revved it up it would lurch all over the place. It seemed to work better with a full tank, I chased it for a whole season replacing crank sensors, lift pumps, fuel lines, inline screens, vacuuming tank, you name it. It turned out to be injection pump

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Did you have the injection pump rebuilt? Any recommendations on where to go for that? I have an injection pump shop I've used before but having trouble reaching out. And did they indicate what the issue was?

Delmer said:

200 hours on a mechanical diesel, it's almost 2022, Delmarva, isn't exactly the desert, I'd guess your fuel tank screen is plugged up with dark colored snot. disconnect the line at the fuel tank, run it into a can of fuel, start it up and let it run for a few minutes to bleed the air, then load it up and see what happens.

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This is a good idea. I will check to see if there is a pickup screen or just a dip tube as well as try to clean out the tank. When the new lift pump shows up I think I will run it from a fresh tank or separate can.

If it's spent a lot of time sitting with old fuel, it might help to spin a fuel filter on with a mix of ATF and powerservice or acetone, run it for 30 seconds so it gets into the pump, then shut if off and let it sit for a couple of days or so. It definitely can help with pump issues causes from sitting with old/bad fuel.

MarshallPowerGen said:

If it's spent a lot of time sitting with old fuel, it might help to spin a fuel filter on with a mix of ATF and powerservice or acetone, run it for 30 seconds so it gets into the pump, then shut if off and let it sit for a couple of days or so. It definitely can help with pump issues causes from sitting with old/bad fuel.

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I do believe it sat for a while before I got it but I just don't know...it like a brand new machine under the hood (minus the fact that it doesn't run right...). I can get some powerservice/atf/acetone and let it run through the system tomorrow. Would certainly be a good idea to try anything simple before I ultimately send the pump off for remanufacturing .

Lift/supply pump is a good start..
Most of the air compressors I’ve worked on are full of rust from sitting so long..
Check the running conditions w the new lift pump aslong as it’s ordered..
Then pull the top off the inj pump to check for rust..

What machine is that?
Currently working on P185WGD. That one has 4039.

Be glad that it is not XAS machine with darned 4024 in it - that is pain in the soft tissue to sort out fuel system problems.

Why don't I see "fuel filter changed" in the first post?

If it has the lock ring fuel filter with a water bowl, i don't have enough fingers to count how many times that the water bowl O-ring was omitted. It'll give the same symptoms.

Do you have primary filter before the one on the engine?
Is this a turbo engine, and if it is - does it have aneroid?

TVA said:

What machine is that?
Currently working on P185WGD. That one has 4039.

Be glad that it is not XAS machine with darned 4024 in it - that is pain in the soft tissue to sort out fuel system problems.

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This is a sullair but FYI I work on a 4039 every week it seems. Let me know if I can help I may have some guesses.

heymccall said:

Why don't I see "fuel filter changed" in the first post?

If it has the lock ring fuel filter with a water bowl, i don't have enough fingers to count how many times that the water bowl O-ring was omitted. It'll give the same symptoms.

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It is the lock ring style and I do need to replace it along with the lift pump at the same time! Which O-ring am I looking for on the filter - just want to make sure I get it right.

TVA said:

Do you have primary filter before the one on the engine?
Is this a turbo engine, and if it is - does it have aneroid?

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No primary and no turbo. Just the engine mounted filter.

Parts said:

This is a sullair but FYI I work on a 4039 every week it seems. Let me know if I can help I may have some guesses.

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Thanks. But I am fine. I have found all the problems and got the parts, just cleaning and reassemble left.

Letter "E" if a water bowl is utilized.

No separate bowl on this filter. I still have a new one coming as of a minute ago. Can't hurt to sling on a new filter at the same time as the fresh lift pump.

I will let Pumpguysc chime in on it, but as far as i remember, the return line restrictions will reduce the power of the engine, with those Stanadyne pumps.
But then again - I might be wrong.

TVA said:

I will let Pumpguysc chime in on it, but as far as i remember, the return line restrictions will reduce the power of the engine, with those Stanadyne pumps.
But then again - I might be wrong.

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I think I will replace both feed and return lines tomorrow as well. Draining the tank and refilling with fresh diesel won't be too tough either...at least I'll be able to see how the tank looks and realistically I should be doing all these steps before I determine the injection pump needs to come off anyway.