Kioti Fuel Injection Pump Failure.....Timing of Pump??????

[MotorSeven]

25 min @ 4K....man I bet you did some sweating......

Gary, since we don't have a fuel shut off on out DK's, why did you not remove the air filter and shove a rag(or your shirt) into the air intake tube?

 

[RickB]

25 min @ 4K....man I bet you did some sweating......

Gary, since we don't have a fuel shut off on out DK's, why did you not remove the air filter and shove a rag(or your shirt) into the air intake tube?

It's easy to be a Monday quarterback when you aren't the one facing that situation. Everything's easier and more clear when one isn't involved directly.

 

[GaryRo]

MotorSeven.....LOL....As everything in life we need to know all the facts, which i did not give you. Picture this, its a nice fall day, clear, leaves turning different colors on the trees and you are bush hogging at 5 mph and your tractor stalls, you recrank it and it goes to 4,000rpm and you are off and runing at a speed you have never experienced in your tractor. It felt like 90 mph in a car. You go up and down the field turning off the key, slaming the cruise controll and throttle pedel over 100 times and nothing and i mean nothing will turn your tractor OFF. You see i am 71 years old, a hobby farmer with only about 500 hours on a tractor and living a nice laid back life and just can't take a lot of excitment like this. After reading one of our SMART fellow Kioti owners, he put it in 4 gear, held the brake pedel and stall it. Should wishe i had read that post BEFORE my experience.

Coyotemachine......you said i and/or anyone else "just unlikely to be killed". Food for thought......After 5 minutes of 4,000rpm the tractor was red hot, in the red and i kept thinking i am going to blow up the whole engine. So i move from the field to the road, moved the bucket up where the radiator could get air and continued to try everything to shut the engine off. At that time i almost crashed into the ditch at least three times and almost hit a truck.Last but but not least, i almost had a heartattack but i did not. I do know i aged at least 10 years and at 71, i now feel like i am 81. LOL

Ritcheys.....you said....tractor affected are "2005-2008". I do not understand your statement when your own spreadsheet show bob42 has a 2010 Dk40 that had a FIP that failed at 100 hours????????

I am taking the FIP out today and taking it to the shop tomorrow. I will keep everyone informed.

 

[Coyote machine]

Well GaryRo, when you put it like that, I guess one could be hurt or killed driving recklessly like you do!
You know anyone older than me, 62, needs a yearly drivers exam and eye check!
Sounds like a very scary ride and going at WOT would be very unnerving too.
Glad you survived it with no harm to you or your machine. You should read the thread. 'Lucky to be alive' for some perspective. That's a real horror story.
I think Ritcheys is saying in general, most IP failures happen to 2005-08 machines.
Though it is an infrequent occurrence when it happens it certainly gets ones immediate attention, above all else going on. No time to think through what might be best thing to do in the heat of the moment.

 

[ritcheyvs]

... Ritcheys.....you said....tractor affected are "2005-2008". I do not understand your statement when your own spreadsheet show bob42 has a 2010 Dk40 that had a FIP that failed at 100 hours????????... .

Actually, I don't know the build year of bob42's tractor. In 2011, he reported a failure which occurred in 2010 with about 100 hours on the clock. I'd guess his machine at 2008 or 2009, but that's purely a guess. Besides, tractors are sold new that were actually built 1, 2, or 3 years previous so build-year is unknown unless bob42 tells us (based on his serial number).

Most of these IP gear tooth failures occur when the tractor is shut off normally and the IP rack jams in the full-off position. In that case the tractor won't restart. But sometimes the broken tooth fragment is lose enough to allow the engine to restart and the IP rack gets jammed in some other position. The IP rack will try to move to the max fuel/max power position as soon as the stop solenoid retracts (key turned to on) so an IP jam at high power is likely in this case.

I recall two cases where the IP jammed at high power. One was a gear transmission where the owner was able to stall the engine with the brake and clutch, in high gear. The other was you (GaryRo). With a hydrostat, you probably did the best possible thing by cutting the fuel line. The manual shutoff lever operates on the IP rack just like the stop solenoid; so if the stop solenoid didn't work the manual lever probably won't work either. Cutting off engine air is risky. If the rag (or whatever) gets sucked into the engine it WILL damage something. Besides I wouldn't relish removing the air cleaner on a screaming, out-of-control engine. If I had a hydrostat tractor (mine is gear) from the vulnerable period (2005-2008/9?), I think I'd install a fuel shutoff petcock in the fuel line, just in case.

 

[Coyote machine]

<snip> If I had a hydrostat tractor (mine is gear) from the vulnerable period (2005-2008/9?), I think I'd install a fuel shutoff petcock in the fuel line, just in case.

Can't speak to 2008 but both my 2009 and 2010 DKs with HST have/had fuel petcocks at the fuel filter housing, a 3 way lever allowing run/off/air?

 

[MotorSeven]

Hey, I was not slamming...just asking a question. For me w/a Hydro I doubt I could stall it in High range, so the only option to me would be air intake. Btw...my DK40 is a 2008.................

 

[GaryRo]

Update.......Took out my FIP over the weekend. Almost like sherrym described but not only did i have to take off the intake manifold but i had to take off the fuel filter and bracket to get the manifold out of the way to get the FIP out. When i tried to pull the pump up and out it would not come out. It was hanging up on something. Noticed a tube looking part on the left side of the FIP and took it off. This part is called the Idle Adjusting assembly. It says it is preset at the factory and do not take it apart. It has a little rod on it like the engine stop solenold which was sticking out and hanging up on the FIP and that was why the pump would not come out. Also, like sherrym my pump is not a Bosh/Kenzel, it is a Doowoon/Kenzel. I do not remember if i said this is a second pump that was replaced at around 186 hours. Took it to the rebuilder and he took it apart right in front of me and one of the four gears that run on the rack had broken, just like everyone else that has reported this problem. The rebuilder and i agreed we should just go aheard and replace all four gears since there seems to be a problem. He has over 26 years of experience rebuilding FIP and could not figure out what was causing the teeth to break. My total cost was just under $200. I was shocked because some Kioti owner on this fourm has been paying around $500 to $800. Now i do not know what parts they replaced so maybe they replaced more than i did. I live in Northwest Missouri and my rebuilder said he would be happy to help anybody with this problem. I have posted some pictures as i have seen some of you like to see what happen.

My rebuilder is:
Diesel Performance Engineering
201 N. 5th
Savannah, MO 64485
877 367-3835
Rod Davison
email: dpefuel@stjoelive.com


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[MotorSeven]

Thanks for posting that info Gary....his prices are really good!