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Do you have any idea what caused the runaway? My only experience with those pumps was that a customer brought me an 016D which had a frozen IP. He had "freed it up" but from then on, as the governor tries to reduce fuel, the IP would increase the fuel, resulting in a similar run away condition...

It sounds to me like both batteries were actually discharged, but one was still showing a 12.2v surface charge. Napa Legend are excellent batteries and yours are not very old ( still under warranty ) I would start with Guy's suggestion to remove and fully charge both batteries, then load test...

Yes it's fine to Y the 2 pipes together. I would not use 2.5" pipe if only extending a short distance. its too big. 2" is actually bigger area wise, than the two 1 1/4" pipes coming off your mufflers. 2" will be cheaper, lighter and it will keep more heat in the pipe, lessening the chances of...

Glad to hear you're moving forward and it's now running good. keep us informed on the gages, they can be a pain but easily fixed. I 2nd ChainBreaker's OptiLube XPD suggestion, this low sulfur diesel is absolute garbage. Keep your fuel treated and exercise the machine regularly or you will get...

I've seen it a dozen times. When installed 180* off it will still run ( but may be hard starting ) for a short period of time because although the fuel is injecting at the wrong time, there is still fuel in the cylinder that will ignite on the next compression stroke. The issue is that because...

Wow, 7 shims? I think that will make that pump fire off a little late. I've had a few sets that would smoke gray/white out of 1 cly. until it warmed up. They had probably 4 or 5 shims , removing a couple shims ( leaving 2 in place ) fixed most of them.

As a last resort on the bottle, I have successfully used the bottle for a 85'-95' Suzuki Samauri available new for about $25 The overflow hoses need to be reconfigured because the hose goes to the bottle cap rather than base, but the bottle fits perfectly in the holder bracket.

If you search around on this forum you will find several folks who have torn that pump down to rebuild as well as links to videos showing how to rebuild them. Try searching on line for Bosch PFR Zexel pump rebuild and you should find a couple good videos. The pump is designed to be removed and...

On the filters, the Fram filters fit perfectly. They do cross to WIX 33113, but with minor fitment issues. The Wix 33113 fuel filters have a different opening in the center which requires you to either remove the 3 finger alignment tab on the center tube in the filter canister, or bend the...

Try removing the valve cover again, rotate it again beyond the intake valve closing, continue rotating through the compression stroke until "PC" is at the pointer, then check the IP alignment hole with drill bit again to see if it's aligned with the slot at that point. If not, pull the pump off...

Your description of how you installed the IP does not sound correct! Rotate the motor clockwise. Watch the exhaust close, Intake open, then intake CLOSE, then continue rotating 3/4 of the way through the compression stroke until PC comes up to the timing pointer. It sounds to me like you stopped...

Sounds to me like 2 possible problems, both of which you have already touched on. The symptoms of hard start, quickly getting hot , smoke and shut down after warm up can be related to either the IP being 180* out ( or otherwise installed out of time ) or you could have injectors that are...

I usually measure the underside angle of where the exhaust port casting sticks out of the head, just be careful as the fan can play tricks on you, making temps seem lower at the front of motor. Block the air for a little bit, then measure temps.

I've seen dozens of those sets with bad transducers. You have 2 choices, replace the Hz. gage with a direct read analog or digital gage ( available for as little as $20 ) and ditch the transducer, or there used to be NOS newer style transducers for 802/803 machines on ebay for $12. ( L.I.T.D...

Sounds like you are already aware of the same concerns I would have. Egg shaped bore, bent valve ( luckily you have a spare head ) I think you will be ok as far as the bores, but I'm hesitant on that piston. If it was mine I would replace it. You should be able to get one on line fairly cheap...

Should be labeled FU1

Inside the control cube to the left of the AC select switch. Its the gray tube fuse holder, 30A fuse. Sticks through a bracket with a black circuit breaker button near it.

Since it was a success I'm thinking you should drink a beer or 3 anyway, regardless of the brand! BUT, I have to agree... no fault lights is pretty odd for that failure mode. If you have the ability, maybe you should overload it briefly just to ensure the fault panel is working correctly...

I think I used too many words and L.I.T.D was able to hit send before I did! (y) But we were both thinking the same thing!

First thing I would do is exercise both the AM/VM switch on the control panel ( also try spraying some contact cleaner into the back of the switch first ) also exercise the AC select switch on the back wall inside the control cube. The only thing that is odd is that typically you would get an...