Repair Common Kioti Mechanical Injection Pump Failure

[ritcheyvs]

UPDATE: In the years since this original post we learned that a DIY repair with inexpensive parts will usually fix these IPs, providing you have the tools and skills. The link three paragraphs down goes to a table containing considerable detail on parts sources and owner experiences. If possible, the loader should be removed (very difficult repair with loader installed). The repair requires removing (or tying back) the hood and removing the injector lines, intake manifold, injection pump. and whatever else is in the way. The parts (control sleeves and gaskets) are probably still under $200. Unfortunately, the best link with "how-to" details (Welcome 2881neches.com - Justhost.com) is a dead end now. The lack of recent reports gives me hope that this IP problem is no longer a factor (knock wood).

New: Apologies folks. I changed ddns providers and failed to update my links until just now. Sorry 'bout that. Scott

I just got some good news from Joel at Conestoga Diesel. In short, Joel reports success repairing a Kioti Doowan injection pump (IP) with broken gear teeth using the standard Zexel parts he has in stock.

By way of background, a number of Kioti owners with 2005-2008 model tractors reported injection pump failures and the cause was usually broken teeth on the gears that control the amount of injected fuel. I got interested because my tractor was identical to the one sherrym was trying to fix which had this problem. Several other owners reported similar failures. For tractors out of warranty, the only fix (according to Kioti) was to replace the entire injection pump, which cost about $1K-$2K just for the parts. On the plus side, an owner with good mechanical skills could do the job himself (herself). Also, some owners were able to buy the same injection pump from Bobcat for slightly less money. Bobcat has since stopped selling re-branded white Kioti tractors and I don't know what the parts situation is with Bobcat now. Some dealers on this list reported getting IPs repaired locally while other members reported that local Diesel shops would not touch their Kioti/Doown IP.

I started tracking Kioti IP failures reported on this website and made the information available to anyone who is interested NEW LINK:
https://kioti.ddns.net/Kioti_IP_Data

I had some prior experience with Diesel engines in cars and boats I have owned and I became aware of Conestoga Diesel through the Mercedes Benz Diesel community. By all reports, Conestoga has an excellent reputation. I contacted Joel Shenk, the shop manager at Conestoga, to see if they can fix the Doowan IPs in our tractors. At that time, Joel said they fix a lot of agricultural IPs, and could probably fix the Doowan IPs but he couldn't say for sure because he couldn't recall ever fixing that specific brand. Now he has. Here's what he said:

"Hi Scott,
I wanted to follow up on this conversation after receiving a Doowan injection pump from a Kioti this week. It had the teeth missing from one of the gears as you've reported seeing. We were able to repair the pump using Zexel parts which were in stock and an exact match. I can now say with confidence that we can indeed repair this problem for you and the other Kioti owners on tractorbynet. Were we to run into a situation where we needed some other hard parts such as plunger and barrel assemblies or delivery valves I would hope to be able to overcome that as well, but haven't made that determination conclusively at this point.

Thanks,
Joel Shenk
Shop Manager
Moose Diesel, formerly Conestoga Diesel Injection
1321 Byerland Church Road
[Willow Street, PA 17584-9776]
717-806-5561"
[Moose Diesel]


So, for the next Kioti owner with a bad injection pump, I'd urge them to give Conestoga try before shelling out big$$$ for a new IP from Kioti.

Hope this helps a Pack member.

Scott

 

[Coyote machine]

Good news! Thanks for following this important issue to a successful conclusion. Maybe you could ask the admin to make this thread a 'sticky' in the Kioti owner/operator forum?

 

[rmorey]

Good job Scott. I hope nobody has to take advantage of this information, but its good to know there is an option for someone who needs it. Thanks. :thumbsup:

 

[murphy1244]

Good Scouting job. Thanks. CM is right we need to make this a stickey

 

[Gittyup]

Thanks Scott. Great information to know should I ever need it. Thanks for posting.

 

[seacap04]

Thanks Scot. You have given this "07" owner some peace of mind.

 

[ritcheyvs]

Here is an update/correction to Conestoga Diesel's web site:

Conestoga Diesel

The only change was adding www at the front end.

 

[Coyote machine]

I made a request to 'sticky' this thread to the admin. Hopefully it will come to pass.:thumbsup:

 

[IslandTractor]

Any ballpark number on what Conestoga charges for the repair to the IP? I haven't had a problem myself but assuming someone with moderate mechanical skills could remove and reinstall the IP themselves, it would be a very nice option.

 

[Coyote machine]

It would depend on what parts it needs. I've spoken to the head guy, Joel a while back about an IP repair on a different brand tractor, where the IP was in need of hard to obtain parts. They did a good job finding what it needed. They test the pumps prior to disassembly, to get a baseline and after repairs to see where they are at. From my conversation with them they are very thorough and fair in their pricing/estimates. Give them a call to find out more.

 

[ritcheyvs]

Any ballpark number on what Conestoga charges for the repair to the IP? I haven't had a problem myself but assuming someone with moderate mechanical skills could remove and reinstall the IP themselves, it would be a very nice option.

Go to the spreadsheet link in the top sticky post. There you'll find links to many owner reports on their IP problems and solutions. The tutorial by 2881neches is outstanding and was a lot of work for him to produce. There are reports from owners that just bought parts from Conestoga as well as complete repairs by Conestoga and other local Diesel IP shops. Most owners reported their IP repair costs but a few hundred $$ is ballpark; be sure to read the footnotes. IP removal and replacement is definitely within the capability of a moderately-skilled owner.

 

[IslandTractor]

Thanks guys. I don't need it yet but nice to know what the options are.

 

[ritcheyvs]

Over on the Bobcat forum, brotsten reports buying three new gears for his CT235 injection pump from H&H Diesel for $52 (delivered). He said the DIY job took about 6 leisurely hours and he posted photos there.

 

[Grand_Pooba]

Thanks for all the great information. I just did this repair on my CT230 and followed the instructions from 2881neches. The area I did differently was that I never completely removed the control rack. I always left at least on control sleeve engaged with the rack so that I didn't loose the orientation. One gear tooth was broken but it was right at the end of travel and the control sleeve worked fine without it. The entire job took me about 4 hours. Total cost $0.00.

 

[Coyote machine]

Cool. Curious what your running symptoms were when you decided to do the repair? Where did you get the parts? What were the hours on your CT when it broke?
Thanks,

CM

 

[Steve_Miller]

Well here it is, Dec 2017 and I'm pretty sure my injector pump just crapped out. My tractor is a 2006 CK30, 700+hrs. Just talked to a mechanic and he has done a couple at his shop, one on a 30 and one on a CK40, both were sent out to a local shop for repair at around $600-700 to rebuild. Not sure if i will tackle this yet or not. I was just hooking up to my plow to bring it to the garage for repairs when it crapped out. I had it running long enough get the loader off before it ran away at which point I put it in high gear and jammed the brake then stalled it.

Steve

 

[ritcheyvs]

Steve.
Recommend you start a new thread. This thread is quite old and, frankly, I should rewrite the whole sticky post. We have learned a lot since my original post.
It sounds like your IP rack is jammed forward at a high power position, typically caused by a broken gear tooth.
If you are interested, it is easy to check for a jammed IP rack by removing the oil fill plate and checking for smooth rack movement (with the key on or the stop solenoid removed). The rack is spring loaded to the forward position and it has a pin that rests on the governor arm. The stop solenoid is supposed to push the rack full aft when you turn the key off. Forward is max fuel and aft is min fuel.
The IP does not need to be re-calibrated after replacing one or more of the gears providing all other parts go back in their original locations. Just replacing one or all gears should cost much less than $600-700 unless that includes much labor to R&R the IP. If you go to the linked table in my original post you will find parts sources as well as many owners who fixed their IP DIY.
Scott

 

[Steve_Miller]

Will do later, just got up and running with a couple little snags, tidbits, whatever you want to call them. Took a few pics on the iPhone, will see how they look when posted.

Steve

 

[ScottFreeIII]

As this sticky thread seems the most relevant place to post, here's yet another injector pump failure story (abridged version).

2006 Dk45SC 2200 hours:
Started having starting problems first, occasionally requiring 2-3 turns of the key before fuel would flow. Suspected a relay issue.
A few days ago, after starting just fine numerous times that morning, it suddenly runs away on start up. Fortunately my tractor is a mechanical shuttle shift version so I was able to stall it by putting it into 4H and easing out the clutch while standing on the brakes.
Got on to TBN and reviewed all the relevant threads including this one and found my way to 2881neches tutorial page.

The tutorial is excellent and the procedure was the same for my four cylinder. i went with 180 degree rotation of the gears for now but believe I will be able to source parts if need be. With a spotlessly clean workbench and some patience, this is not a difficult repair for a DIY guy.

The local Kioti dealer quoted me $2020 CAD for a new pump, approx $700 for a rebuild, plus labour and float charges! Thank you to TBN, ritcheyvs and 2881neches for doing such a great job documenting this Kioti issue....total cost$10 for a new manifold gasket!

 

[radios1]

As this sticky thread seems the most relevant place to post, here's yet another injector pump failure story (abridged version).

2006 Dk45SC 2200 hours:
Started having starting problems first, occasionally requiring 2-3 turns of the key before fuel would flow. Suspected a relay issue.
A few days ago, after starting just fine numerous times that morning, it suddenly runs away on start up. Fortunately my tractor is a mechanical shuttle shift version so I was able to stall it by putting it into 4H and easing out the clutch while standing on the brakes.
Got on to TBN and reviewed all the relevant threads including this one and found my way to 2881neches tutorial page.

The tutorial is excellent and the procedure was the same for my four cylinder. i went with 180 degree rotation of the gears for now but believe I will be able to source parts if need be. With a spotlessly clean workbench and some patience, this is not a difficult repair for a DIY guy.

The local Kioti dealer quoted me $2020 CAD for a new pump, approx $700 for a rebuild, plus labour and float charges! Thank you to TBN, ritcheyvs and 2881neches for doing such a great job documenting this Kioti issue....total cost$10 for a new manifold gasket!

$10 vs. $400 for an injection pump guy just to look at it shipped to him!. is a very good deal!..