Probably IP Gear (Control Sleeve) Failure

[countrybumpkin]

Glad you have it apart, sounds like you’ll have it back running in no time.

 

[Coyote machine]

To the OP, glad to hear you've managed to get done what you have to date without mishap. I agree that wrangling your hood by yourself is too much to expect, if for no other reason than it is awkward and heavy. You might find a ratchet strap helpful to lift the hood and then hold it upright by tethering it to the ROPS as you have described. This way you can raise AND lower it by yourself easily and slowly. I would suggest a secondary backup of rope if you see the need for additional safety while working under the raised hood.
Good luck with the remainder of the repair.

 

[Coyote machine]

Oh my gosh will you drop it, your the one making the big deal out of it. He stated in his original post about securing the loader was for future reference because he knew OP had already had the loader removed !!!

Can't stand being wrong I guess- grow up.

 

[countrybumpkin]

Funny

 

[ritcheyvs]

A rope worked fine for holding the hood. It was very easy to do. In the shot below I've removed the air cleaner housing (but that's all) when I took the photo.



SWMBO decided we need to go food shopping today so I didn't get any work done on fixing the actual IP. Email from MIE said they shipped my gasket today so final reassembly still several days away. On the plus side, MIE charged only about $2 shipping; I guess they combined my two separate orders. Good on them.

 

[ritcheyvs]

Managed to steal an hour for myself today and replaced the four control sleeves in the IP. It was surprisingly easy; took less than 30 minutes. Key tools were a bright flashlight (to see alignment dots on gears), a pick with a hook at the end (for pulling parts out of the bores), a needle nose pliers to remove the keeper wire, and a SMALL magnet (to fish for debris after removing the control sleeve). I guess the magnet also could be used instead of the pick. The OE control sleeves had no timing marks but the new ones had small dots that align with the lines on the rack. Per TPG's advice, I used vegetable oil as assembly lube. Everything was already "wet" except the new parts. Having a half hour to spare I reinstalled the IP, SS, etc. on the engine to keep junk out of the block. Also, I cut some fingers from nitrile gloves to keep junk out of the delivery valves, which worked better that masking tape. I'll do some function tests tomorrow. New intake manifold gasket scheduled to arrive late tomorrow so Friday is my target completion.

 

[countrybumpkin]

Good news for sure, I was also surprised just how easy it all was too.

 

[thepumpguysc]

Its "easy" till something goes wrong..

 

[ritcheyvs]

OP here. To wrap this up, I pulled the IP and replaced all four control sleeves, as discussed in post #26. I did an "ops check" the next day (before installing hard lines or manifold) by cranking the engine. That's when things went south. I got nice little shots of Diesel from the delivery valves #1-3 but nothing from #4. The subsequent trials and tribulations and fixes are discussed in this thread because I wanted to post where thepumpguysc and countrybumkin would see it there and weigh in; and they did. Long story short, after correctly assembling the #4 delivery valve, my DK is running again. Many thanks for great support from TBN members. I'll develop a photo write-up when I get time.

 

[Coyote machine]

Congrats on your successful completion! As often said: "Rome wasn't built in a day."

 

[thepumpguysc]

Congrats..
Theres nothing like THAT FEELING, when an engine roars to life..
& theres nothing like THAT FEELING when it doesn't, after working on it for days..
Glad I could help..

 

[Amvcane]

Glad to hear that you are up and running again. Also noticed that you added yourself to your own list in the Kioti stickies.

 

[ritcheyvs]

Glad to hear that you are up and running again. Also noticed that you added yourself to your own list in the Kioti stickies.

I really need to re-write that sticky. We have learned much in the last 5 years. I also need to do a photo writeup on the repair. Replacing the IP control sleeves/gears is quite easy (and easy to screw up) but well covered by neches. But there were some other tricks worth documenting. In all, I think I had the IP in and out about five times so I got pretty good at it.

 

[thepumpguysc]

Easy huh?? If it was "easy" it wouldn't have taken you 5 tries & countless email questions to get it right..
& to be honest, you got "lucky".. things could have gone very wrong on any one of your "tries"..
You got VERY LUCKY that #4 DIDNT pump.. it could have gone the "other way".. very easily.. the engine could have flooded w/ fuel & the engine rpms could have been uncontrollable.!!! leaving you with a large boat anchor w/ 4 wheels & a big hole in the side of the engine block..
I know you feel a sense of pride & accomplishment, as well you should.. but please stop saying, "Its easy".!!!

 

[ritcheyvs]

I owe thepumpguysc a big debt of gratitude for his prompt and spot-on answers to my many questions, even when I did not understand his answers at first. But replacing control sleeves was easy and I did it correctly the first time. The subsequent "tries" were needed to find and correct a pre-existing assembly error in a delivery valve. If I had TPG's expertise I would have spotted this error on "try" #3 when I first removed the "bad" delivery valve. But it took two more "tries" before I pulled a good delivery valve for comparison. During tests to isolate the problem the injector hard lines were not installed so the engine could not run or become uncontrollable; not having a test fixture, I had to use the engine to test the IP.

 

[countrybumpkin]

Glad you have it running, should be good to go for a long time.

 

[ritcheyvs]

I mowed my field today with the newly repaired IP. Everything worked fine although I did notice that the engine now idles at 1100-1200 RPM compared to 800-900 in the past. To me, this supports my recollection that the #4 deliver valve was mis-assembled (gasket in wrong place) when I got the tractor in 2009. Considering that the engine paint was still intact on the injector hard lines/nuts, the DV was probably mis-assembled at the Doowan. I really wish I had taken more photos vs relying on my memory. Regardless of the cause, all is well now.
This is the first time I mowed without the loader installed. The tractor was more agile and I could get closer at the turns but it was not significantly better than when the loader was installed, IMO.
For some time I noticed the fabric on the OE coolant hosed was getting ratty and the hoses were soft in places. I had ordered new hoses as backup some time back so I installed them and changed coolant after I finished the IP work.
In earlier posts I said replacing control valve sleeves is easy. I would caveat that by saying it was easy ONLY after CAREFULLY studying the excellent material provided by neches.

 

[LouNY]

Congratulations on a job well done.