This is gwoods again with more questions about the d4 7u (7U11300). I can’t turn pony motor or move pinion engagement lever. If anyone has idea where to start trouble shooting I would be grateful. The shop manual have torque requirements for the pony motor if I remove cylinder heads? I don’t have one as yet. Thanks

is the trans in neutral with clutch released? other wise your trying to turn the trans aswell. also have you opened the drain cocks to clear the starting engine cylinders

okay most likely the pinion is engaged, if it is there should be no weight on the lever test it with 2 finger pressure if it feels weighted dont lift it. the pinion lever lays flat when not in use. check the decomprssor is set for starting
can you turn the main engine over?using a bar with two pegs try and bar the main over via the crank pulley(remember to decompress the engine you wont turn it by hand without it)
if the main and pony turn together then the pinion is engaged. the starting clutch should snap over centre if it dont its out of adjustment or just pain worn out and needs repair.

This is what I have found so far today. The motor turn just fine (diesel), cannot turn the pony rope wheel. The pony motor has the electric start, don’t know if that makes a difference? Hand clutch cannot be pulled out. Shifter will go in the two middle slots and into one in upper right. Not familiar with shift pattern. The pinion lever is in down position and will not pull up. The other lever move fine. Most likely clutch for pinion? I finding I know so little. If you don’t get to aggregated at my ignorance, please any help will be appreciated.

I watch the Sasquatch vedios. They are very informative and well done. I have watched the Pacific North West Hillbilly and have already used in working and moving dozer. I have also used everyone’s help with water pump removable and disassembling. Acmoc Members

I have the operations and maintenance manual. Thanks for head up on that information.

Sounds like you have some rusted/seized parts, the big motor turning is a plus the pony motor not turning isn't. When you get the parts book it will help you understand where there could be problems. The electric pony start won't make any difference on the rope start unless something is stuck. Good luck and keep us updated

the lever with a sort of s curve is the starting clutch lever. the other lever beside it is for engaging the starting pinion.

the main clutch lever is push forward to release pull back to engage and it should take a force around 75 lb to pull it into position you should feel a nice over centre snap if its working and adjusted properly. it is the lever on the left when seated on the machine the other 2 are the steering clutch levers.

has this machine sat out in the weather without covers on the exhuasts? if so water may have entered and siezed the pony engine. dip the pony oil is there signs of water ingress? drain its oil and check for water. refill with fresh oil.
is the magneto got its top and endcovers? if water has got in and seized it the motor wont turn. same with the starter motor. if water has entered remove the item and try again.
have you opened the cyl drain cocks make sure there clear with a bit of wire. if water drains out then that could be why it wont turn.

try to rock the pilot engine over after each check.
a broken magneto gear can also seize the engine that happened to ours a tooth dropped down and jammed the timing gear train. remove the magneto to check condition of the gear. if gear is damaged often that means the pilot needs new main bearings and other work.

remove the spark plugs and pour diesel into the cylinders leave it soak for a few days each day try and rock the engine

if the pilot engine does need a rebuild most of the parts are available through the dealer network.