1989 Cat D4H II Shut off and won't start

[Treecutter16]

Hello again, start with some background: our old D4H SN 9DB01545 was having trouble starting about a month ago when I needed it to pull a stuck truck out of the snow. Turns out it had ice in the fuel and blocked up the strainer. Cleaned that out and it started after a prime and ran for 5 mins shut off again, blocked up with ice again, must have been bad fuel, I added some fresh fuel and a bottle of Diesel treat and left it for a week or so. Tried again on a warm day well above freezing, It started and ran for long enough to pull out the truck that was stuck although ran weird and seemed to have low power I assumed there was still some water in the fuel working its way through but it kept running so I left it for a bit to charge the batteries and then it shut off on its own after about 15 minutes total run time. It wouldn't start again. I checked the strainer wasn't blocked, drained all the old fuel this time and replaced with new fuel to no avail. I replaced the fuel transfer pump still no luck. It appears the fuel makes it through every line up to the injector pump then hardly comes out the lines to the injectors. I also don't know how much pressure it should look like coming from the the transfer pump so maybe the pump is still bad or something else affecting that? It does have an oil leak that seemed to be getting worse but still had oil on the dipstick after it shut off, although substantially less than it had when I checked before trying to start it. It seems the lever going to throttle/fuel shut off to turn it off may have something loose inside that cover but I didn't open it as I cant tell if some springs will go flying and possibly cause harm for nothing.
I guess my questions are is it possible the oil leak is causing low oil pressure and not allowing the fuel to go past the injector pump? Could something inside the fuel shutoff have broke while it was running and shut it off, and can I open that cover where the lever goes in the governor to safely look? Or did running dry twice from the ice blockage cause just enough damage that it still started and ran for about 15 minutes before giving up?
Thanks for any info you can provide!

 

[Mquinista]

Halloo,
First of all wich engine does it has... 3300 Direct Injected series or 3200 pc engine? cause IP differ quite a lot, being one of them with a Hydro governor...
The other thing that might be happening is when it died by its own, considering u had fuel contamination, the system is not completely free of obstructions.

In that machine u should have diesel leaking by gravity at IP main gallery, if u dont something may be wrong, fuel should pass all filters and leak at IP inlet.
This Injection pumps need to be bleed, otherwise it wont start, crack the lines open at injectors, it has to have fuel spitting before tight the lines.

If this simple checks reveal no fuel spitting at injectors, u have to search the governor, and or pump or both.

 

[Treecutter16]

Thanks it is the Cat motor and injector pump number starts with 7W2216 but the second half to show what variation is unreadable. I could get fuel to the IP inlet but when I cracked an injector line very little came out, likely just what was left in there before, while engine was turning over.

 

[Treecutter16]

Here is a link to how much fuel came out at an injector. Posted on youtube since can’t add my video to here. Not sure if this is the proper amount. Injector line fuel

 

[Mquinista]

Thats not a 3300 DI engine... it looks pre cup and if so glow plugs go to function too.
I see enough diesel coming out, get all 4 lines like that and give it a litle brake cleaner in intake, just to get it roaring.

if its pump/governor related it wont idle correct or THR up and dwn as it should.

If not familiar with ether starts be carefull, do not flood it too much as it may turn sour

 

[HarleyHappy]

Looks like plenty of fuel to fire.

 

[Treecutter16]

Okay sounds good I will get into this again later today.
What motor would it be? I just assumed cat since theres cat parts on it.
Thanks!

 

[Nige]

What motor would it be? I just assumed cat since theres cat parts on it.

Your engine is a Cat 3204.

 

[Treecutter16]

I bled the lines to the injectors until fuel was coming out like that other video on all of them. This is now where we’re at with the ether attempting to start. I tried it the first time while I had someone holding it on start and I tightened the lines one by one then cranked it with ether until the batteries died.
This video is the second or third try after that, lines should still be primed I would think.
Here is the link:

 

[Treecutter16]

Thats not a 3300 DI engine... it looks pre cup and if so glow plugs go to function too.
I see enough diesel coming out, get all 4 lines like that and give it a litle brake cleaner in intake, just to get it roaring.

if its pump/governor related it wont idle correct or THR up and dwn as it should.

If not familiar with ether starts be carefull, do not flood it too much as it may turn sour

Tried this with no luck unfortunately, I posted a video on here forgot I should have replied instead. Thanks

 

[pittsburgh cat man]

Did you have someone work the throttle while you watched leaver at governor

 

[HarleyHappy]

Def wants to go, no fuel though. Don’t care for either though. Diesel in an old spray bottle will work.

 

[Treecutter16]

Did you have someone work the throttle while you watched leaver at governor

What should I be looking for? Seems to move like it should. Can I open that cover where the lever goes in and look inside?

 

[pittsburgh cat man]

You should be able to see if rack is moving thru here that is where you time the pump and center the rack move the governor lever and see if rack moves a little

 

[Mquinista]

Quite funny behaviour...
Naaa, even if governor got damaged disconnected some how, the nomal rest position should be with full rack i guess.
Its also strange it did not run away a litle with all that ether... quite funny hein...
From experience, Injection Pumps don´t use to fail like that...
U can remove the governor off, nothing will fall off, assembly its usually the problem, check if something is out of place ,broken and so on... u can push rack by hand and see if it runs.
If it does , well compression test, valve adjusting, IP to repair shop ... good luck then

 

[Treecutter16]

Little update,
We got it started after some more messing around. Took the valve cover off and the gasket was swolen up and there was fuel coming out the small breather holes where injector lines goes through the side. It seemed to run alright and started again on its own multiple times, although it would shut itself off at low idle. We adjusted the idle limiting bolts and it seems to work. Unfortunately in the process of bleeding the air out it seems a fuel line must have slightly cracked and when I attempted to start today it lost its prime. Now to find some new lines…

 

[Treecutter16]

Hello again, If anyone was curious there was an injector leaking into the oil and diluting it, I didn't notice the diesel as it was leaking a good bit so I was topping up the oil every time anyway. Turns out the diesel must have been leaking into that cylinder for a while and long story short we are into full rebuild territory.
I have all the parts back and we are reassembling it all with new everything.

Does anyone have the torque specs I would need for it or can the dealer get them for me? TIA

 

[chidog]

I'd think you'd need more than just torque specs.

Nige is the man for all the info.

 

[Nige]

Best thing I can recommend is Service Manual(s).

For the machine Serial Number Cat Publication reference SENR5290 covers Disassembly & Assembly then there is SENR3115 covering SysOp, Specifications, Test&Adjust, & schematics. Quite why it is split into two manuals I have no idea.