Repair Common Kioti Mechanical Injection Pump Failure

[tacticalturnip]

WELL it finally happened to me today. Doing some jobs and suddenly running on 2 cylinders, then one, then stopped. Started up after a few turns but revs quickly died back and stopped again. Tractor is sitting down my paddock. I will tow it home with the Ranger and park it somewhere. Another project too many...
Still, I got around 800 hours on it. Better than some. Wonder what cost for parts in Oz.

No! I'm sorry to hear this, it offends me your tractor has let you down.

 

[Alien]

It is still running... just. Sounds like on 2 cylinders at times. There was a lot of diesel around the IP. I have cleaned it down and dried it with the air compressor and will run it tomorrow to see if/where the leaks are. Not sure it will be an easy solution though I would like it to be.

 

[Alien]

I found a rat had chewed the spill off hose on No1 injector so fuel was spraying everywhere. A rat had built a nest of leaves in there and the hose must have annoyed it. The rat dropped out when I reversed the tractor out of the barn. The tractor will not run at revs. Up to about 950 - 1000 rpm it runs sweet but anything over that No 1 injector stops. It is either partly blocked OR the rack has skipped a tooth on that injector. I will try injector cleaner first and see what happens.

 

[tacticalturnip]

Ugh, rodents!

 

[Alien]

My tractor has 771 Hours on it. Bought new in 2006. I suddenly started losing power especially when I started flail mowing. It would run fine for about 5 - 10 minutes and then start running rough at revs but OK at idle. It would progressively get worse. It starts OK but a bit rich. I have removed and checked the lift pump diaphragm and it is OK.
Naturally I suspected the pump gears then but tried injector cleaner first but no good.
So, I have removed the pump thinking that at those hours maybe the rack gears had lost a tooth or two.
I have it dismantled and can find no fault with the gears, in fact, I can't even see any sign of wear anywhere on the gears or rack. I used magnifying glasses.
Being a 2006 model is it possible I may have a later gear set or have I just been lucky they haven't stripped yet?

Here are some pics. The pump number is shown and some pics of the teeth etc. I have included a pic showing the stop solenoid.
Is there a way to look up the pump number to verify a changeover date for the gears?

 

[ritcheyvs]

If you have a 2006 model with the internal stop solenoid and original IP gears they are certainly the old version. Even though yours have not failed (yet), I would replace them while you have the IP off the tractor. Your symptoms sound more like a plugged fuel filter or fuel tank outlet (where the hose attaches). Verify that you have good fuel flow from the tank by just gravity by detaching the hose. Replace the fuel filter if there is ant doubt. Check also the loft pump by operating it manually and verifying good output, probably pump several cups of diesel to be sure. Lift pumps check valves can fail even if the diaphragm is OK. You will probably need an intake manifold gasket for reassembly.

 

[Alien]

Thank you ritcheyvs. I checked flow from the tank and had to plug off the hose as it poured out. Fuel filter is checked and clean, (I filter all fuel when filling the tank too) I will check the lift pump valves next and manifold gasket came off clean so will just use some sealer on it. Not sure on parts availability as the dealer I bought it off doesn't sell Kioti/Daedong any more. We do have a Bosch dealer here somewhere though.
I will keep you informed as I go. I can only do so much at a time due to my back. I appreciate the responses.

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[ritcheyvs]

For what it's worth my MBZ 300SD had similar symptoms: started and ran fine but lost power after cruising at speed. The problem was crap (rust and microorganisms) in the fuel which gradually plugged the fuel pickup screen in the fuel tank; movement stirred up the gook and it was carried by fuel to gradually plug the screen. And then it settled back to the bottom of the tank after fuel flow subsided. But could be a lift pump issue too where "leaky" check valves fail to support higher fuel delivery rate.

 

[ritcheyvs]

Alien: I just saw your last photo. You have the older, external version of the stop solenoid that was not known for breaking control sleeve gears in the IP. Your stop solenoid energizes to stop the engine and that motion is benign compared to the new style where a spring-loaded plunger can whack the rack with considerable velocity. Disregard my comment on replacing your gears.
Good luck with your intake manifold gasket mine came off in pieces.
Still, I think your symptoms indicate a fuel delivery problem.

 

[Alien]

Thanks richeyvs. Yes I could not fault the 'gear' teeth at all. No sign of wear whatsoever. I guess that way I am lucky as I checked with a local dealer and he said they had never stocked parts and likely not available in Australia. They would have to be ordered so I have reassembled the pump but have another problem.
There is a spring (1) that sits on the end of the rack as in Photo (1) I figured it should have a sleeve or something where it contacts the rack end but I didn't notice it till I started to refit the pump. I have fished around with a magnet but can't find any other part. On the later pumps there is a removable cover and a spring loaded plunger as in the second picture. The cover on mine (2) doesn't screw out, it appears to be pressed in although I can turn it.
My question is, should there be a sleeve on that spring?
After your last post, it seems that I have been worried about those gears unnessesarily for the last few years. LOL

LATER MODEL Sleeve and spring assy. (taken from a video)