Oil & Fuel Kioti CK30 will not start

[Bernty]

I have never had a problem starting my CK30 but today it will not start. It does crank ok so the battery is ok (new). I have checked and bled the fuel line up to bolt #1 in the enclosed picture. or http://2881neches.com/kioti/fuel.jpg. No problem. However, if I lose the fuel line going to the injectors (#3) I get nothing. Thought the fuel shut of solenoid #4 would not work but it does.
There is an orange cap shown here as #2. Can't find any reference to it in my manual. What is suppose to go in here. Oil or what?
Any hint would be appreciated.

 

[Amvcane]

The orange cap is the engine oil fill. You should use that instead of the cap on the valve cover. If you fill at the valve cover to fast oil will not be able to get to the sump fast enough causing it to flow through the breather hose into the intake filling any cylinder with the intake valve open causing hydraulic lock when you start the engine.
What year is the tractor?

 

[Bernty]

It is a 2007.

 

[ritcheyvs]

I would first check the glow plugs to ensure they are getting power with the switch in the ON position and also while cranking. My DK key switch got wonky (not unusual) in a way that cut power to the glow plugs while cranking. I mention this first because (while unlikely) it is the cheapest and easiest to fix.

The lack of fuel to the injector while cranking suggests an IP gear tooth failure. The typical symptoms of this failure are: ran fine, shut off, won't restart. See: http://www.tractorbynet.com/forums/kioti-owning-operating/296793-repair-option-kioti-tractors-broken.html

This is harder and more expensive to fix. You can check the IP by removing the oil-fill cover (#2 in your photo) to see if the IP rack moves freely or if it's jammed. You have a LOT of crud in that area so clean it before you unbolt anything. The stop solenoid will force the rack to the OFF, full aft, position by spring pressure when the switch is off. So turn the key to ON to retract the stop solenoid before you do the "feel" test on the IP rack. The rack should be lightly spring loaded to the forward (max fuel) position and rest against a lever from the centrifugal governor. You should be able to move the rack aft by light finger pressure if it's not jammed internally. If your IP is jammed, refer to the above link for options.

Scott

 

[Bernty]

P.S. Someone told me that when removing the solenoid I should be able to put my finger in the hole and be able to move the aperture inside. I can't. Should I be able to press this in. Could it be stuck in? I can't see it but it feels like a washer with a hole in the center for the solenoid arm. Is there a simple way to see if this aperature (or whatever it's called, moves freely.

 

[ritcheyvs]

P.S. Someone told me that when removing the solenoid I should be able to put my finger in the hole and be able to move the aperture inside. I can't. Should I be able to press this in. Could it be stuck in? I can't see it but it feels like a washer with a hole in the center for the solenoid arm. Is there a simple way to see if this aperature (or whatever it's called, moves freely.

Maybe not. In theory, yes but your finger may be too short. The solenoid pushes straight aft and I don't know if you can reach that far with a finger. But if you remove the small plate with the oil fill cap you can see the pin (which is attached to the rack) and feel if the rack is jammed or not by pushing on that pin.

 

[Bernty]

Thanks. I think we are getting somewhere. For some reason I'm convinced the stop function, what you call the rack, is stuck causing the problem. Unfortunately very hard to get to with the front loader in place. Need to come up with a way to get the tractor out of the garage, remove the brush hog and loader and then work on it. Something for tomorrow. Again, thanks for your help. You have been most helpfull...

 

[ritcheyvs]

Hate to bug you again but I removed the plate and this is how it looks. I can't move the arm inside forward anything although I can move what you see here back with some spring tension about 1/2 inch. Further, when I removed the solenoid in the front you would expect it to have some tendency to push out if something was resting on it but there is nothing. That leads me to believe the arm is stuck or should it be like this? If not, any quick fix?View attachment 390285

Bernty, I saw your post in another (old) thread (http://www.tractorbynet.com/forums/kioti-owning-operating/312062-new-forum-kioti-ck30-will-5.html#post3893164 but I'm moving this reply back to the thread you started. It's easier for other posters can follow this if it's all in one place. Based on your observations, it sounds like your IP is indeed jammed. See this annotated pic:


Continuing after interruption from SWMBO: With the stop solenoid energized or removed, the rack should move full forward so the round pin rests against the flat face of the other governor lever (which is too far forward to see it in your photo). I think you are saying that the rack is still full aft and jammed in that position. If so you probably have broken gear teeth inside the injection pump. The official Kioti solution is to replace the injection pump. This is not too difficult and several owners have done this job DIY. The bad news is that a new IP costs in the vicinity od $1K. The same IP from a Bobcat dealer is slightly less. Several owners have had their IPs repaired at a local or regional Diesel shop (see the sticky post at the top of the Kioti Owning/Operating forum. These gears are symmetrical and some owners "fixed" their IP by reinstalling the bad gear 180 rotated degrees.

If you IP rack is truly jammed your next step is to remove the IP. I recommend you review the maintenance manual before attempting this. You may want to send a private message to other CK owner(s) who have done this job (see the spreadsheet linked in the sticky). One piece of good news: you don't need to re-time a new/rebuilt IP, just be sure to keep the spacers and gaskets under the IP which establish the injection timing.

Good luck. Please advise what you find and how it got fixed.

Scott

 

[Bernty]

I tend to remember someone offered pictures of this repair but can't find it again. Anyone know?

 

[Bernty]

I forgot to ask one more thing. Found many service manuals for the Kioti on the net. Any recommendation for the best one?