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RD-7 D8800 diesel pump frozen plunger

RD-7 D8800 diesel pump frozen plunger

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gggsam
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My RD7 9G with the original D8800 began running rough two weeks ago. By unscrewing the injector lines, I have figured out that one of the fuel pumps (#2) is not pumping any fuel. I think that the plunger is froze.

Any advice on how to free up a frozen plunger?

Do I need to remove the pump to repair?
Can I do it with it in place?
Is there a special socket to remove to top end of the plunger (it's a slotted star drive socket I don't recognize)?

It has been a great machine until this hiccup.

Any help would be greatly appreciated.

Thank you

Sam
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Sat, Oct 7, 2017 12:39 AM
STEPHEN
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If you have the larger pumps, where each pump is secured with four screws (that aren't shared with neighboring pumps) then you can remove the pump and look to see if the internal spring is returning the plunger to the rest position. I've never seen a broken spring there, but it's possible. You should first remove the cover and observe the adjacent pumps for any difference in operation. The large flanged body pumps can be easily disassembled, but reassembly needs to be correct.
In both systems, there is a spring return, one difference is where the spring is located. If a spring is broken, then the pump plunger could be up, but still turning, so the rack will be free.
If this unit ever had water in the housing, rust could cause a broke spring, or a stuck lifter. Or in a bad case the roller tip on the lifter is bad or the injection cam is shot on that lobe, or both
Pics are still welcome for more informed diagnosis
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Sat, Oct 7, 2017 8:46 AM
gggsam
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Reply to STEPHEN:
If you have the larger pumps, where each pump is secured with four screws (that aren't shared with neighboring pumps) then you can remove the pump and look to see if the internal spring is returning the plunger to the rest position. I've never seen a broken spring there, but it's possible. You should first remove the cover and observe the adjacent pumps for any difference in operation. The large flanged body pumps can be easily disassembled, but reassembly needs to be correct.
In both systems, there is a spring return, one difference is where the spring is located. If a spring is broken, then the pump plunger could be up, but still turning, so the rack will be free.
If this unit ever had water in the housing, rust could cause a broke spring, or a stuck lifter. Or in a bad case the roller tip on the lifter is bad or the injection cam is shot on that lobe, or both
Pics are still welcome for more informed diagnosis
Thank you. That is exactly what I needed to know.
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Sat, Oct 7, 2017 11:58 PM
BillWalter
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Reply to gggsam:
Thank you. That is exactly what I needed to know.
That one pump may have a bad check valve. Pump may have to be disassembled and the check valve freed up or resurfaced. Bill Walter---Fuel Pump and injector service repair.
[email protected] 1 816 805 1834
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Sun, Oct 8, 2017 9:31 AM
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