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Kobelco Excavator Repair

Kobe Steel Excavator Hino J08 Engine Troubleshooting and Maintenance Methods (3)

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(6) Using special tools, tap gently while turning the valve to perform a slip fit. (1) Do tapping from below the cylinder head to the nozzle seat. Use appropriate bolts for fastening. dirt. After installing the new O-ring to the nozzle holder socket of the cylinder head, TB1211 (white)], then install it on the cylinder head. ! Caution • The O-ring must be replaced with a new one. If you use an old O-ring, it may cause water or air leakage, and cause overheating and cracks in the cylinder head. Use special tools to rive the nozzle holder. a. Measure the deformation under the cylinder head and the mounting surface of the manifold with a ruler. b. If the measured value exceeds the limit of use, replace it. ! Caution • Do not correct the underside of the cylinder head by grinding, etc., otherwise the backlash of the timing gear may change. a. Check whether there is any crack or damage on the cylinder head by the dye penetrant flaw detection method (red liquid detection). (1) On the flange surfaces of the cylinder block and the cylinder pad.

Use oily markers to make alignment marks. ! Caution • Identify and store the removed cylinder gaskets in the order of the cylinder numbers. • Do not make alignment marks by punching. Use special tools to remove the cylinder head from the upper side of the cylinder block. ! Caution • Be careful when handling the cylinder head. Do not reuse a dropped cylinder gasket. • Do not touch the oil nozzle during operation. Apply engine oil to the inside of the cylinder block bore. (4) Align the alignment marks of the cylinder head and the cylinder block, and then install the cylinder head with a special tool. ! Caution • When installing a new cylinder head, install the cylinder head with the same mark (A, B, C). • The legend shows the cylinder head of # 1 cylinder B. (1) Use special tools to fix the cylinder head. (2) Using a dial indicator, measure the amount of overhang at the flange. (1) Loosen the standard lubricating oil check valve and use special tools to install the oil nozzle on the cylinder block. SAPH is from the underside of the cylinder block.

On the inspection bolt. ! Caution • The oil used during injection must be new engine oil. The pressure regulator places special tools above the cylinder block. Special tools: 09470–1280 tool assembly sprays oil from the nozzle of the oil nozzle under the hydraulic pressure of 196kPa {2kgf / cm2, 28lbf / in.2}. SAPH jet calibration standard circular bad bad normal Normal if the center of the jet is within the standard line of the scale, it is normal. ! Caution • Engine oil is prone to splashing and flammable. Therefore, no smoke or fire is allowed around the work environment to avoid fire. • Work in a well-ventilated area. (6) Confirm the injection position confirmation positioning hole at the top of the tool assembly, and the oil injector must not interfere with each other. (7) If the spray cannot reach the range of the specified circle, adjust the line. Special tools: 09472-1620 tool SAPH, if it cannot be corrected, check. (9) Loosen the detection bolt.

Install the oil nozzle on the cylinder block using a regular lubricant check valve. Tightening torque: 22Nm {220kgfcmlbfft} After the piston is assembled, confirm that the oil nozzle and the piston do not interfere with each other at the bottom dead center of the piston. a. Use a ruler to measure the deformation on the cylinder block. b. If the measured value exceeds the limit of use, replace it. ! Caution • Do not correct the underside of the cylinder head by grinding, etc., to change the backlash of the timing gear. a. Check whether the cylinder block is cracked or damaged by the dye penetrant flaw detection method (red liquid detection). (1) Loosen the bolts and remove the flywheel cover. ! Caution • The bolts for attaching the flywheel cover from the cylinder block side also need to be removed. (1) Use a scraper to scrape off the dirt on the joint surfaces of the flywheel cover and the rear end cover. (2) Apply liquid sealant [equivalent to TB1207D (silver) manufactured by THREEBOND] to the flywheel cover as shown in the figure. ! Caution • Apply evenly without breaks.

• The liquid sealant has a coating width of 1..5mm {0..0984in.}. • Install within 20 minutes after applying the liquid sealant. Install the flywheel cover on the cylinder block with bolts. AA! Caution • The bolts that attach the flywheel cover from the cylinder block side also need to be tightened. (1) Remove the bolt. (2) Remove the torque bolt using a special tool. (1) Install the rear cover and new gasket with bolts. Caution • Make sure that there is no dirt or foreign matter on the cylinder block mounting surface or in the screw holes. (2) Apply sealant (equivalent to SUPER5M) to the threaded part of the torque bolt. (3) Install the torque bolt with a special tool. The flywheel cover SAPH uses a scraper to cut the gasket of the rear end cover on the same side. (1) Use two crankshaft shock absorber mounting bolts.) The baffle is mounted on the crankshaft. Special tools: 09420–1731 oil seal puller Hang the hook of the oil seal puller (special tool) on the claw of the oil seal in front of the crankshaft.

Then use the bolt to install the hook on the baffle of the oil seal puller (special tool). Remove the 2 bolts on the crankshaft mounting oil seal puller (special tool) baffle. (4) Install the center bolt on the oil seal puller (special tool) and tighten it, and then pull out the front oil seal of the crankshaft. (1) Insert a new crankshaft front oil seal at the duct of the oil seal press. ! Caution • Pay attention to the front and rear directions of the crankshaft front oil seal. Side). SAPH removes the dirt on the joint surface of the crankshaft front oil seal and the cylinder block. (3) Apply a small amount of engine oil to the sealing surface of the crankshaft front oil seal. (4) Install the oil seal press pipe with the new crankshaft front oil seal on the crankshaft using the guide bolt. Align the hole of the oil seal press with the guide bolt, and then insert the oil seal press. (6) Install the center bolt on the oil seal press until it stops, and then press it into the front oil seal of the crankshaft. (1) Using two flywheel cover assembly mounting bolts, install the baffle of the oil seal puller on the crankshaft.

! Caution • Align the large hole of the baffle with the colored pin of the crankshaft. Hang the hook of the oil seal puller on the claw of the oil seal behind the crankshaft, and then install the hook on the baffle of the oil seal puller with bolts. (3) Remove the two bolts on the crankshaft where the oil seal puller baffle is installed. After the center bolt is installed on the oil seal puller and tightened, the oil seal is pulled out after the crankshaft is pulled out. (1) Insert a new crankshaft oil seal at the duct of the oil seal press. ! Caution • Pay attention to the front and rear directions of the crankshaft oil seal. (The felt surface is on the flywheel side). SAPH removes dirt from the crankshaft oil seal and the joint surface of the flywheel cover. (3) Apply a small amount of engine oil to the sealing surface of the crankshaft rear oil seal. (4) Use the guide bolt to install the oil seal press duct with the new crankshaft oil seal inserted on the crankshaft. ! Caution • Align the large hole of the guide tube with the colored pin of the crankshaft. Align the hole of the oil seal press with the guide bolt, and then insert the oil seal press. Install the center bolt to the oil seal press.

Tighten the bolts until it stops, then press the oil seal into the crankshaft. (1) Loosen the bolts and remove the connecting rod cover. ! Caution • To prevent co-rotation of the crankshaft, the crankshaft is caught in the gear of the flywheel cover on the side of the measurement window. • In order not to change the cooperation between the connecting rod and the connecting rod cover, identify and store the removed connecting rod cover in the order of the cylinder number. The oil nozzle uses a scraper or sandpaper (about 50) in the circumferential direction to remove the carbon deposits adhered to the inner surface of the cylinder pad. ! Caution • Be careful not to damage the underside of the carbon deposition area during removal. (3) Fix the cylinder head with bolts and steel plates. Using a hoe handle, tap the connecting rod from the underside of the engine to remove the piston and the connecting rod as a whole. Note • When pulling out the piston, rotate the connecting rod as shown in the figure, taking care not to bend the oil nozzle. ! Caution • Save the removed piston and connecting rod. • Be careful not to touch the oil nozzle. (1) Use elastic snap ring pliers to remove the retaining ring. (2) Remove the piston pin using the ejector pin.


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