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In Reply to: CAT D-4 PROBLEMS posted by Diane on Thursday, July 26, 2007:
If it has the older style injection pump like the D2 I've been working on, you should take off the rack cover (cast iron), and take off the linkage cover (stamped steel). The earlier pumps were not sealed to the housing, so if pressure washed or left in the weather water will get into the rack housing and into the injection pump case. First I would spray everything down with some good penetrating oil (not WD 40), and let it sit for while. You can take the rack apart if you need to polish it up, if the teeth are rusted the pump will destroy itself since the aluminum teeth on the pump pistons travel up and down on the rack as the engine runs. The rack and pistons have timing marks, be sure you put it back correctly. After you wash all of the crud inside the rack case down into the injection pump crankcase, be sure to change the oil before you start your rig up, you may want to change it a couple times to make sure it is clean. That should be about it. Good luck!
Peter