D2 4U Throttle Stuck closed

Is the problem in the ratcheting mechanism behind the lever on the side of the governor? I would pull the pin between the linkage and the governor crank lever and see what is actually frozen up.

Have heard of folks that couldn't get any fuel when starting the diesel and finally just gave the throttle a healthy snatch and it came past the detent and into the RUN area of the quadrant.

Is the problem in the ratcheting mechanism behind the lever on the side of the governor? I would pull the pin between the linkage and the governor crank lever and see what is actually frozen up.

Have heard of folks that couldn't get any fuel when starting the diesel and finally just gave the throttle a healthy snatch and it came past the detent and into the RUN area of the quadrant.

The key to your repair is to free up the pumps. I expect that the best way for you to proceed is to purchase new pumps and replace the stuck ones. You could keep trying to free them by spraying penetrating oil and prying up and down while still bolted to the housing. I would also consider warming the pumps with a heat gun or very carefully with a torch to help break them free.

In any event, once the the pump plungers are free to move up and down (and to twist) the rack can move and you can check that it is free and moves smoothly and easily back and forth, stretching and collapsing the governor spring.

[quote="ccjersey"]The key to your repair is to free up the pumps. I expect that the best way for you to proceed is to purchase new pumps and replace the stuck ones. You could keep trying to free them by spraying penetrating oil and prying up and down while still bolted to the housing. I would also consider warming the pumps with a heat gun or very carefully with a torch to help break them free.

In any event, once the the pump plungers are free to move up and down (and to twist) the rack can move and you can check that it is free and moves smoothly and easily back and forth, stretching and collapsing the governor spring.[/quote]

Thank you for your timely response ccjersey. I have been fighting this problem for awhile and I'm ready to solve it. I know I need to get the pump plungers free. No pump, no fuel right. However, these plungers are shiny and bright like they were just stroking/working yesterday....albeit 6-7 years since I started this engine. I really can't imagine from the way they look that all 4 of them crapped out at the same time. So, my question is whether the position of the rack is what is actually holding them bound in the up stroke, rather than "sticky or corrosion" etc (I've used a can of penetrant on them by now). If they were not tightly bound, like mechanically bound or wedged rather than just sticky, then I should be able to push any one of them down a little bit, except the one on the cam top stroke, or move them up even against spring return pressure. My question then is have you heard or seen where the position of the rack can actually cause all of the pumps to be wedged/bound up, and in turn freeing the rack will in turn unbind the pumps, and allow me to work the pumps free. Is that a possibility, the rack position is holding the pumps bound on the upstroke? I have also tapped on the rack as I said, not hard enough to break it, or to mess up the timing, but it is not moving either, seemingly wedged/bound up as well. Again, I can move the throttle linkage on the governor maybe 10-15 degrees only. Maybe that movement is only what the governor internal spring return will allow?? What should that throttle linkage full travel be expected to be....45-60 degrees maybe? Also, there must be some way to get access to the internal linkage between the governor and the rack, within the governor housing somehow? Otherwise how would you hook up the linkage in a tear down overhaul between pump housing and governor? Could that internal linkage be holding the rack in a bound-up position? The oblong shaped cover on top of the governor housing is not the answer (what is that for anyway it just covers two bolt heads keeping them from turning, are those the linkage bolts?), that cover does not offer a look inside the governor housing. And the small round view port on the right hand side/end of the governor housing is too small and in the wrong access position to work in or to view anything.... thanks for any help on these follow on questions....

No doubt that the stuck pumps are what is preventing the rack from moving. Just one stuck pump will keep it from moving. Bear in mind that in addition to going up and down the plungers also rotate. you could try freeing them by tapping very lightly on the gear quadrants.

Better yet and safer might be removing the individual pumps and working on them off the engine. You will not disturb the timing settings doing this but rotating the quadrants in relation to the plungers will.

Good luck,

Tom

By your description and as previously mentioned the pump plungers are stuck .
Use a 7/16th spanner and remove the rack. Then with a large screwdriver try and push the plungers up then if they moove try and lever them down.. sometimes they just need a push and they come right. Sometimes they need more help. Get you lever under the forked yoke rather than levering on the toothed quadrant. These plungers are lubricated by the fuel internally so the fuel system should be primed when doing this. With the rack removed the plungers should spin around easily and follow the cam up and down when the engine is rotated. What has happened is the result of the poor quality fuel we now have.
In extreme cases it is possible to remove the injector line. Then unscrew the top out of the individual fuel pump. Then after removing the spring and non return valve use a punch with a flat end and hammer the plunger down.
Hope this helps.
A. K.