Hi Team,
if the pony turned the main previously and now does not then check and see if the 2 Speed pony transmission has slipped into a Neutral between the High and Low speed engaged positions.
Cheers,
Eddie B.

Hi, Larry B.
Also check to see if the starter pinion clutch is engaged or disengaged.

Just my 0.02.

no need to dispose of the old diesel if its clean and water free its fine diesel doesnt go rotten. it can grow diesel bug though but additives exist to kill that. and water trap filters take care of any moisture.

So I'm hoping to get a few hours to work on the dozer today (after I get other chores done).
I wonder if the pinion was engaged when I first looked at the dozer but got damaged in transit because it's not engaged now. The clutch is pushed all the way back toward the engine block and the 2 speed gear box will shift between low and high but the pinion lever still has zero resistance on it and feels like it is doing nothing. I'll see about taking some covers off and try to get access to the small hole where I can look in there.
Also didn't know about ATF to help clean out an engine. I'll look into that.
I'm used to dealing with gasoline that goes bad, so the chance of salvaging 40 gallons of diesel sounfs good to me. I'll drain some out and see what it looks like.
Main focus today will be to try and get the pony to kick over. I'll let you guys know how it goes.
Thanks again all.

edb- You were right about the 2 speed pony transmission being in neutral. I thought it was in low but the cover behind it was bent and not allowing it to fully engage. Once it was in high I couldn't turn the pony again. I released the pinion like old magnet said and it all works as it should.

Spent some time freeing up the electric starter motor for the pony motor. It got a bunch of water in it and was pretty stuck. Got it back on but still wont spin. Sounds like its grounding out to itself so have to pull that back off again and figure that out.

Spun the pony around a bunch with the hand crank looking for spark but no luck. Cleaned the points and checked the gap but didn't change the result. It looks like there is some timing that has to be done, so gonna try figure that out and see if that fixes the no spark issue

Hi Larry,
could you hear the impulse coupling on the magneto clicking when you turned to pony over?
Also suggest you disconnect the pony magneto grounding switch wire at the magneto to see if you may have a shorted wire or faulty switch.
Cheers,
Eddie B.

I didn't hear the magneto clicking but I guess I also wasn't really listening for it. I will pay more attention tomorrow. I did disconnect the wire going to switch to make sure it wasn't that though.

mag problems are often the result of poor return path to the magneto the mating surfaces should be even and clean metal. a light rub of graphite pencil can help.
and the cheapest fix is always a new spark plug just because it sparks in open air doesn't mean it will under cyl pressure i have learnt that the hard way. condensers are another common failure part and cheap to replace. if you get the mag rebuilt go the whole hog and have a new winding fitted saves doing it all over again.

as for the starting pinion and clutch there are 3 levers where as my machine only has the 2. no high low box.

the pinion lever is over centre in operation and when fully engaged has no weight on the lever. im not sure if the clutch lever also works a clutch brake ie stops the pinion shaft turning when pushed fully forward to allow smooth pinion/ring gear engagement like the d2/d4 models and the when pulled back engages the pinion drive finally locking over Centre when pulled back fully. that is the recommended method is to use the brake to stop the pinion turning and then engage the pinion. correct me if im wrong.

Hi Team,
the starter pinion brake is actuated by pushing the clutch engagement lever, (1) in the diagram, towards the Diesel engine Cyl. block to stop said pinion spinning and then engage the pinion using lever (2) without grinding on the ring gear, when engaged then smoothly snap the clutch over center into play using lever (1) by pulling back outwards.
One of Toby's tutorials may help from his RD6 that is similar but does not use a two speed trans. due to space and being a smaller Diesel engine, 3 Cyl.



Cheers,
Eddie B.

So I had some success today. After a few attempts got the mag timing right and the pony motor fired up. Found out there is a freeze plug in the diesel engine intake that I need to get put in because its missing.

Drained the main engine oil and wasn't to excited to see probably 2 gallons worth of water come out before the oil started to drain. Had a really hard time telling if it was water that was tinted by the oil or if it was coolant. Its been sitting for 10-15 years so I guess some could get in there but that seems like an awful lot. I'm assuming I have a bigger problem somewhere in the engine where coolant is getting into the oil system.

After the oil change I decided to try and turn the main engine over with the pony but I cant get the clutch to stop spinning the pinion. With the cover plate off looking in at the clutch I cant see that anything is moving, no matter what direction the clutch handle is moved. Also tried to engaged the pinion but it just made a terrible grinding noise. There was some water and goop in the clutch housing that I drained. Thought maybe things were rusted in place but I lubed everything and it looks like everything wants to move, just something binding it up. Gonna try to figure out how the clutch is supposed to work so I have a better idea of what's going on.

Probably be a few weeks before I get a chance to work on it again, but at least it was a start. Thanks for all the help in getting to this stage.