Kioti EX45 Injector Pump Repair.

[Tim Middo]

Hi just repaired my 2008 Kioti IP by replacing the control sleeves (typical Fail Mode) it only had 260 Hours on it, sheared the teeth off the crown gear for cylinder No 3.

If you have an issue and you stumble across this thread the magic part No is (Make)Zexel (Description)Control Sleeve (Part No)1402412700.

I had to come and say thanks for the resources I found linked to this site, Including part Nos I needed which I was able to order from Japan for (wait for it) $15 plus postage.

Cheers Tim :thumbsup:

 

[TBN Support]

:welcome:

I'm glad we could help

:tractor: I'm going to move your thread over to our Kioti section so it will be easier to find.

 

[ritcheyvs]

Tim, Thanks for the report. I added your experience to the tracking table linked in the first (sticky) post in this forum. I notice these failure reports are less frequent now, which I hope is a good sign. Scott

 

[Aaron957]

I too would like to say thanks to everyone that has posted and shared information about these pumps. I was able to use the information to diagnose and repair the pump on my 2008 Bobcat CT230. I would like to add however that my gears were not plastic like I've been reading, they were more like a pot metal or powdered metal. One gear had already been replaced as it had all of the teeth fully machined, the other 2 I assume were original. They both had an area unmachined that prevented them from being rotated 180 degrees. Of course it was one of those that was missing 3 teeth. I will say for anyone with the ability and necessity, I work in a machine shop and I machined the unmachined area of the gear so that I could rotate it 180 degrees. I then went ahead and purchased new gears from H&H in Washington ($35 shipped for 3) but I really needed to get the tractor back up and running quickly. It's not very practical but it can certainly be done if needed.

 

[Tim Middo]

....They both had an area unmachined that prevented them from being rotated 180 degrees....

Aaron mine also had an area that was not machined. The replacement ones I got from Japan had all their teeth and at less than 4 bucks each I got 8, 4 for now and 4 for next time. Hopefully they have improved the materials on the new ones. I was also thinking about machining some out of 4140 or similar but the squared section in the center could be a challenge.

 

[Tim Middo]

Thanks Scott. Just Had a look at the spreadsheet and I aged a year. Its only 2017 hear in Australia

 

[Aaron957]

I'm fairly convinced it's the violent motion of the shut off solenoid that's causing the damage. Since my repair I've been utilizing the old manual shutoff lever on top of the injection pump housing to start/stop the engine. I plan to install a cable and eliminate the solenoid altogether.

 

[ritcheyvs]

Tim: Thanks, fixed (I need new glasses).
Aaron: I am sure you are right about the cause. Zexel must have improved the metallurgy because the problem stopped after the 2008 build year. Hopefully, "new" replacement gears are the new stuff. Even so, these failures are fairly rare, even in the vulnerable year models. The fact that we can fix it cheaply (vs buying a new $1000-1500 IP) makes this threat less serious, IMO, but a stranded machine is no fun. As the Tier 4 folks are discovering, switching to a new design (even if theoretically better) is not without risks. There is much to be said for mature technology, IMO.

 

[Coyote machine]

Yeah, another repaired pump, and for WAY less than a new IP!
Glad the forum sticky note on first page is proving useful, AND good to hear less reported failures of the gears as time goes on.

Thanks Scott for your spreadsheet work too!:thumbsup:

 

[thepumpguysc]

Aaron has it correct.. I do his for a living.. ALOT of "armchair" engineers will argue the point BUT.. they're "armchair engineers".. Lol
MOST probably don't even own a tractor.. its the S/O solenoid SLAMMING the segments to the s/o position..
I'm HAPPY you found & fixed the problem.. TPG