CS2220 Started smoking/rough idle

[Coyote_CS2220]

Before I take it to the dealer for warranty work, just thought I would check out real world experience here with the experts.

CS2220 with 115hrs 7months old all of a sudden (engine running fine for over an hour at operating temperature) started smoking (white) with definite un-burnt diesel smell and at idle it shakes like it is running on 2 cylinders.
Increasing the rpm reduces - but does not eliminate the shaking, but the smoke just keeps coming.

No idiot lights on the dash showing. Three oil changes to date with 15W40 semi-syn. None of the oil changes were particularly dirty, although the first one had a definite metallic shine.

Your experience is appreciated.

J

 

[ROUSTABOUT]

FuEl injector cleaner.

 

[thepumpguysc]

A stuck injector..??
If u feel like turning wrenches, with the engine at idle and smoking, loosen the steel line AT THE INJECTOR 1 at a time and watch the exhaust.. when the smoke disappears, that’s your suspect cylinder..
If it was under warranty, I’d say drop it off..
If it’s not under warranty, swap the injector with one furthest away from the suspect cyl and see if it follows the injector or stays w the original cyl..
If it follows the injector, u can get them all rebuilt or just the one..

 

[Coyote_CS2220]

It went back to the dealer in a cloud of white smoke yesterday........does not run well on 2 cylinders, but well enough to climb the grade onto a trailer deck.

Will update on what transpires at the dealer.

 

[Robin Veerman]

White smoke is unburnt diesel. Keep us updated…

 

[Coyote_CS2220]

First weeks news:

Preliminary findings from dealer/daedong

1) Broken push rod on intake valve for cylinder #1 (front of engine)
2) Exact cause is not yet finalized, but primary observations leaning towards manufacturing imperfection in the push rod and/or cylinder head. Wear marks are observable on the rod shaft, but cannot absolutely determine yet if the imperfection is in the head casting or the push rod itself.
3) Next week they will try to isolate the exact wear point to the head or the rod thru measurements & testing with a new rod (to see if head needs replacement or machining in addition to a new push rod).

Anyone else out there have experiences with head or push rod imperfections from Daedong equipment?

What are your expert thoughts or experience with this?

It will be at least a couple of weeks before it will be home from the hospital.

Will keep you updated.

 

[Coyote_CS2220]

Second weeks news:

Definitive findings from dealer/Daedong

1) I and the dealer do not know the exact production/casting/finishing process so we do not know if this is a systemic issue or a one-off.
2) The casting/finishing of the cylinder head is the issue.
3) The issue is the flanges at the top of the cylinder head in the push-rod/valve well in cylinders 1 and 2.
4) When cold there is enough clearance so the flange edge does not contact the valve push rod, but when the engine heats up to operating temperature the casted flange makes contact with the valve push rod.
5) The intake and exhaust on cylinders 1 and 2 look like the cast/finishing did not grind off enough metal on the flange.
6) Cylinder 3 is fine.
7) Do not know if the manufacture process for the heads on these engine are all machine/robotic or if there are any humans involved, but the tolerance on the valve well flanges are out for cylinders 1 and 2.
8) Without knowing anything about the manufacture process it could be a one off.......or there are more out there waiting to break?
9) Daedong is not saying much, other than it is warranty work that the dealer will be compensated for.

The Fix:
1) New valves/push rods are on order. Nothing else was damaged.
2) The head will be pulled and the casted flanges in the valve rod wells will be machined down (by a human) so that there is no chance they can contact the valve rod when the engine heats up to operating temperature.

If the parts come early next week, the tractor will be back home by weeks end. If not the early the following week.

Bottom line:
If you have a CS engine.......make sure you use it during the warranty period. My push rod did not crack and break till the 115 hr mark. My experience tells me that this is not likely a one-off as the head made it thru the manufacture process without any tolerance check alarm bells going off. When the engine was put together it was cold and no one noticed any issues with push rod clearances.

The dealer said there did not appear to be a shortage or valves/push rods for this engine when he ordered the parts.........so then again it could be a one-off?

 

[Coyote_CS2220]

Not much chatter about this experience?

Either there are not many CS engine owners here, not many CS's out there, or hopefully, mine is the one-off and the CS is largely issue-free (I am hoping for this one myself, as I will likely keep mine now that it is fixed).

Post Surgery Epilogue: It is fixed and waiting for a ride home from the hospital. The list of repairs and replacement parts includes: 3 head, valve well flanges ground down, 6 new valves (apparently they are somehow new and different from the originals??), 3 new glow plugs, 3 new injectors, 1 new head gasket, oil & filter change and some top up of lost coolant fluid. Tech check torques and marked the nuts/bolts (see pics). Outside the pistons and the crank shaft it was pretty much a top end rebuild.

I asked if I could keep the old parts to have a look for myself, but was told they were covered by Kioti warranty, so they go back to Kioti Engineering. No look see and no keeping. Security clearance required?

In addition, the fuel filter was changed and the fuel replaced in the tank - this one is still a bit fuzzy to me - even after a long discussion about this, but as I am to understand the fuel injectors "exhibited visual signs of malfunctioning at the injector ends" - as I am unfamiliar with what the "visual sign" would look like or actually be, anyone here with expertise in this area - please feel free to help enlighten me more than has already been attempted!

My tractor has been missed, as our fork lift does not have pneumatic tires, but I use the time to rent a Kubota 121 trackhoe to dig out some stumps and clean up an area we logged near our workshop in the spring to store metal in a more organized fashion.

Will keep monitoring the thread for any feedback and if anything new happens on my end I will shout it out. My engine number is NJ5LAzero21zero and was built 06/2022 - if anyone wants to check their numbers and build dates.

Cheers all!