Probably IP Gear (Control Sleeve) Failure

thepumpguysc · May 5, 2018

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 · May 5, 2018

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 · May 5, 2018

Amvcane said:
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 · May 6, 2018

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 · May 6, 2018

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 · May 6, 2018

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

ritcheyvs · May 8, 2018

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.