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D2 fuel plunger problem

D2 fuel plunger problem

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catsteve
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My D2 has been sitting for a while. I recently returned home and tried to turn it over. Issue. No fuel. I have not had any fuel problems before and have not had to play with the pumps at all.

On opening the inspection plate it was half filled with what looked to be ATF. (light pink colour). On turning over the main the number2 plunger is stuck up. It appear the the plunger gear has jumped above the rack.

I have gently tried to knock it down without success.
Questions.
1. Is there an easy fix to this?
2. Will the setting be incorrect if the plunger does come down at this point?
3. Should there be anything (lubricant) in the pump casing?

Thanks in advance
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Wed, Mar 13, 2013 11:38 AM
drujinin
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There have been previous discussions on lubing those with your favorite penetrant and GENTLY working them loose with screwdrivers/small pinch bars.
You would need to recheck the Plunger Timing after working it free.
This has been discussed previously also.
I would wipe that cruddy looking ATF looking stuff out, then drain the Pump housing and refill with 30 weight Non-Detergent Oil if it is available.
I'm thinking there is a drain line coming out of that area that drains off any fuel that leaks by the plungers but don't remember without referring to a manual.
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Wed, Mar 13, 2013 9:09 PM
ccjersey
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The plunger gear quadrant will still be engaged in the rack, should not be out of time, but wouldn't hurt to check. there should be a dot on both rack and plunger quadrant that align.

I would attempt to pry the stuck plunger UP slightly to break it loose and then attempt to punch or pry it back down working only on the lifter that is hooked to the bottom of the pump plunger. If it won't turn loose, some warmth applied to the outside of the pump barrel might give you some slack. I'm not talking about heating it hot enough you can't put your hand on it, but just warming it up with a heat gun etc.
D2-5J's, D6-9U's, D318 and D333 power units, 12E-99E grader, 922B & 944A wheel loaders, D330C generator set, DW20 water tanker and a bunch of Jersey cows to take care of in my spare time😄
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Thu, Mar 14, 2013 9:40 AM
Jack
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Reply to ccjersey:
The plunger gear quadrant will still be engaged in the rack, should not be out of time, but wouldn't hurt to check. there should be a dot on both rack and plunger quadrant that align.

I would attempt to pry the stuck plunger UP slightly to break it loose and then attempt to punch or pry it back down working only on the lifter that is hooked to the bottom of the pump plunger. If it won't turn loose, some warmth applied to the outside of the pump barrel might give you some slack. I'm not talking about heating it hot enough you can't put your hand on it, but just warming it up with a heat gun etc.
I would pull that pump out and soak the whole thing in laquer thinner or such, then gently work it apart and thoroughly clean it. It's not that hard, though it may be a little tough to disengage it with the plunger stuck. Timing the rack is easy also and pretty obvious when you get in there. Just be careful that it is right before you button it up.
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Fri, Mar 15, 2013 9:08 AM
catsteve
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Reply to Jack:
I would pull that pump out and soak the whole thing in laquer thinner or such, then gently work it apart and thoroughly clean it. It's not that hard, though it may be a little tough to disengage it with the plunger stuck. Timing the rack is easy also and pretty obvious when you get in there. Just be careful that it is right before you button it up.
Hello guys thanks for the responses.
In the end i got the plunger moving with some steel drift persuasion but another problem surfaced.
The rack had some corrosion at one end that was causing it to stick. i got it moving by giving it a rub with some 1200 grit sandpaper.
She runs again.
thanks again

steve
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Mon, Mar 18, 2013 4:35 PM
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