Yesterday I got the pony to run on one cylinder. Today, I pulled the head on the dead cylinder, and found a stuck intake valve. Once that was taken care of, I re-assembled the pony and went about starting the main.

I got it rolling over and oil pressure built up. Bled the fuel filter, rack, injector lines and injectors. Hmm... There seems to be a river of oil coming from under the machine.. Woops.. I guess when I took that generator off I missed a bolt on the side cover. (I hate it when I leave a project for two years and then get back to it...)

Oil leak fixed, back to trying to start. After a long, long time, it came to life, but only the #1 and #3 cylinders are firing. And there are copious amounts of smoke coming from the clutch housing...

So, I have re-checked the rack, plungers, and re-bled everything. I have good fuel pressure (in the green or run area of the gauge) I re-checked the valves and they are set right. I would have to say I have bad injectors in those two holes.. Anything I am overlooking? I tried to remove one of the bad injectors, and it didn't want to budge. I didn't bring air with me so I will try again next week with a rattle gun if unless anyone has a better idea or hint.

The main clutch is stuck engaged, as are the steering clutches. It will roll back and forth using the starter.

I would like to get my main running before pulling it again to get after the clutch. I have not done a clutch in a D2 before, I assume that I have to pull the motor the get it out?? I am going to try soaking the steering clutches before I go in after them.

This machine has been idle for the 4 years I have owned it, and probably at least 10 more prior to me buying it.

Jdnut

Hi jdnut,

Cut a couple blocks of wood to prop the steering levers back when you fill the housings with solvent. Yup, I had to pull the engine when I rebuilt my master clutch. If it's just stuck engaged you might back the adjustment off all the way and pry around in there a little bit. Never know, it might let go. But why so much smoke from the clutch? Is it frying the clutch brake?

Good luck,

Jack

The recommended process of ID-ing bad injector/bad pump/bad cylinder is to remove the injector and swap it for one from a "good" cylinder that is firing and see if the miss follows the injector or stays with the cylinder. If you want to take them and have them checked, they should crack at around 450psi and have a good even spray pattern.

You can also check the spray pattern on the tractor by installing an injector line from a good cylinder so it points out over the track. Loosen all the other injector lines so the engine cannot start and motor the diesel over with the pony motor using the clutch to start and stop it so you can change valves etc. A known good injector "valve" can be installed on the line from a suspect pump to check it.

Be careful and don't inject fuel into a finger etc.

torque on the hold down nuts is 100 ft pounds. I would soak them before you leave even if it's just diesel so they will have a chance to loosen up before you try again.

Before pulling the injectors, you might try taking the side cover off the injection pump and check for stuck plungers or tappets. I have had them stick up, resulting in no high pressure fuel to the cylinders they service. with the rack in the 'off' position, there will be fuel to the injector when bleeding, but none with the rack in the run position.

Dale M

My D2 had a similar problem, the advice to remove the side cover on the pump is good. I did that, found one plunger stuck up, WD40 and a little prying got it loose, but another had a broken spring so that the cam follower wouldn't return to down position. Only fix is to pull the pump off, total disassembly and new spring. Got a spring from Cat, about $8, took a few hours to do a complete tear down, clean and reassemble, but then started right up.

When I was first getting my 2U D8 started on site, before I brought it home, I learned the hard way to check that injector rack.

I tried and tried and tried to get that think started, It finally took off, and boy did it take off. It started up wide open. There was a back column of smoke heading up into the stratorphere, the cat was jumping up and down in place, I didn't know whether to run away as fast and as far as I could, or try to shut it down..

After a brief moment of panick I realized that it was only running on 4 cylinders so that was sort of self governing it, so I ran back to the machine and cracked all the injectors, which slowed it down even more (and created a nifty diesel fog around that side of the machine) and then shut the fuel down.

The rack was stuck wide open, and the two cylinders not fireing had the plungers stuck in the up position.

Needless to say, I had already looked at that on the D2, and that portion is working fine... I learned that the hard way.

Chris