Oil & Fuel Injector trouble CK 30

[Steve_Miller]

Well my time was up yesterday my CK 30 injector pump went. Talked to a Kioti mechanic and found a local injector repair shop although I ended repairing using the thread at the top of this forum. The thread is pretty thorough and explained a lot. It took me about 6 1/2 hours from start to finish but the first hour was cleaning. At first I didn’t remove the oil filler cap at their old manual stop or the solenoid or the return plunger spring at the end, I had to remove these later. When I got it all back together and tried bleeding the injectors to no avail. Tried for roughly 10-15 mins with no results, so i removed the manual stop. return plunger and the oil filler cap. Come to find out the rack was sticking closed not allowing fuel to the injectors (once I figured out how everything worked). Had to push the rack open and closed several times with my finger, appeared to be jamming at the solenoid end where it goes through a Teflon sleeve. Thought I put something together wrong, so i pushed the rack open and cranked half dozen times and fuel started to bleed around the cracked injector nuts, Tightened them back up and it took off but sputtered and died. Pushed the rack open again and it started again, kept sticking my finger in to push the rack open each time it started to die fighting the governor as it was trying to throttle it back. After about five or six times it started to work fine. From what I could tell it was just a lack of lubrication until some oil/diesel got pumped up and around the rack gears and sleeve assembly. Only other issue I had was the middle injector line at the pump was painted/corroded so bad that the flare nut wouldn't let go and started to turn the fitting out of the block. The fittings are so close together that you can't get a wrench on the center one (of course it would be that one), tried jamming a pair of needle nose pliers between the two fittings and after several attempts got it to break free. Tighten that back up with a deep socket once I had all the lines off. There was only one gear damaged despite all the pictures I posted.

If I think of anything else I will update.

Steve

 

[DieselBound]

When I got it all back together and tried bleeding the injectors to no avail. Update more later.

Could you expound on that/this?

I gather you're not getting fuel to the injectors?

Bleeding the injectors is minor, and nearly irrelevant, when an IP has been opened up and emptied. The IP is going to be full of air, and purging air out of an IP is a bit of a battle, often best facilitated by using a vacuum pump to pull fuel through it (fuel return side) or to use an IV-drip; one can, of course, do a LOT of cranking, but it'll be a LOT and one needs to be mindful of overheating the starter.

Of course, I'm being optimistic in that I'm hoping it's just an air issue and not an assembly problem (I'm impressed with anyone who opens up and puts back together an IP).

 

[Steve_Miller]

Could you expound on that/this?

I gather you're not getting fuel to the injectors?

Bleeding the injectors is minor, and nearly irrelevant, when an IP has been opened up and emptied. The IP is going to be full of air, and purging air out of an IP is a bit of a battle, often best facilitated by using a vacuum pump to pull fuel through it (fuel return side) or to use an IV-drip; one can, of course, do a LOT of cranking, but it'll be a LOT and one needs to be mindful of overheating the starter.

Of course, I'm being optimistic in that I'm hoping it's just an air issue and not an assembly problem (I'm impressed with anyone who opens up and puts back together an IP).

updated. I was nervous going into this but very relieved and confident when she fired up.

Steve

 

[DieselBound]

Awesome!

 

[Billrog]

You did good Steve :thumbsup:

 

[Fuggley]

Nice work Steve!
Almost 50 CK owners have logged the problem on the group spreadsheet. Kioti Corp sourced a defective IP and stuck CK owners with it... sad!

 

[xcgreene]

Thank you for taking the time to put up these pictures, its a great reference.

 

[powerscol]

Is there a year range that this issue exists. I have a Bobcat and am wondering if it is when, not if it will happen to me

Great information here - Thanks

 

[coobie]

How many hours on your tractor when the failure occurred ?

 

[DK35vince]

Is there a year range that this issue exists. I have a Bobcat and am wondering if it is when, not if it will happen to me

Great information here - Thanks

2005-2008 appeared to be the problem years with injector pumps