Machine Inspection Manual (Excavator)

【Engine】
Part 1
【Check point】 Engine Oil gauge
【Inspection method】 Draw out the oil gauge, and clean it with a cloth. Then
insert the gauge and draw it out again.
【Tools】 Cloth
【Standard time】3 min
【Safety】When performing the following work, please follow Technical
Manual (Trouble shooting manual) of the target model in accordance with
the "caution" the contents of the description, advancing the work safely.

【Failure case】・・・・▶ Engine oil level low

Inspection and judgment

If the oil level is between the upper and lower scale

marks, the oil volume is appropriate. If the oil is lower
bound scale mark, the oil volume is insufficient.

Causes

Even in a normal situation, the engine oil will decrease

because of normal consumption. Meanwhile, in case of oil
leakage or abnormal consumption is caused by abnormal
combustion, may be factors causing reduction of the oil,
white smoke from the muffler, and increasing of blow by
gas.

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【Risk on customer】
If operation is continued as it is, machine might
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cause wear of internal parts, seizure of engine,
and as result it effect to lifetime of the engine.

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【Point of proposal】

Temporary support for CS

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To start the engine, it is necessary to fill up the
engine oil in advance. To improve customer
satisfaction, it is better to fill up the engine oil
free of charge.

Proposal to customer

In the case of oil leakage or high oil

consumption caused by abnormal combustion,
please explain to the customers the necessity
of repairing or replacing the relevant parts.
In the case that no abnormality is observable,
please instruct the operator daily check of oil
level.
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【Repair and Maintenance job order】

❶ Engine oil, Engine oil filter

❷ Fuel filter

❸ Repairing or replacing the relevant parts

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 【Failure case】・・・・▶ Engine oil condition

Inspection and judgment

Check engine oil condition about dirtiness, the engine oil

becomes blackish by normal operation. You are difficult to
judge the change of dirtiness, so please refer interval of
replacement by operation manual and check maintenance
record to check previous replacement.

Normally engine oil becomes blackish by running. And

Causes
improper maintenance effect to oil condition.

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【Risk on customer】
If the dirty oil is continuously used, it might cause
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wearing or burning-in on internal parts and effect
in lowering the life time of the engine.
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【Point of proposal】

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Proposal to customer

Please propose to the customer to do proper periodical

replacement about the relevant elements and oil. Please use
the catalog or leaflet, and make a proposal which could
be easily understood by the customer

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【Repair and Maintenance job order】

❶ Engine oil, Engine oil filter

❷ Fuel filter

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 【Failure case】・・・・▶ Engine oil to milky-white

Inspection and judgment

Check oil color by oil gauge, the color of the engine oil will
change into milky-white.

Causes

It caused by water entry from the engine oil cooler.

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【Risk on customer】
If it is used as is, it would soon result in damage to the
】 is required promptly. as soon as possible.
engine. Repairing
Don't start the engine when the color of the engine oil
changes to milky-white.

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【Point of proposal】

Proposal to customer

Please propose to the customer to do proper periodical replacement about

the relevant elements and oil. Please use the catalog or leaflet, and
make a proposal which could be easily understood by the customer

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【Repair and Maintenance job order】

❶ Re-Man Engine or Engine over haul

❷ Gasket of oil cooler

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 Machine Inspection Manual (Excavator)

【Engine】
Part 2
【Check point】 Matching surface of engine part
【Inspection method】Check oil or water leakage from matching surface.
【Tools】 Light torch, waste cloth
【Standard time】5 min
【Safety】When performing the following work, please follow Technical
Manual (Trouble shooting manual) of the target model in accordance with
the "caution" the contents of the description, advancing the work safely.

【Failure case】・・・・▶ Oil leakage

Inspection and judgment

Check engine by visual, and check oil leakage about each

matching surface (between oil sump, oil cooler and
body).

Causes

Main cause of oil leakage is degradation of gasket.

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【Risk on customer】
If operation is continued like as it is, oil is not
】 in seizure of the sliding
sufficient, resulting
portion such as metal bearing and so on.

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【Point of proposal】

Temporary support for CS

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As a temporary countermeasure, re-tightening
is effective. However, it is dependents on the
portion of oil leaking.

Proposal to customer

Propose to the customer about necessity of

replacing the gasket.

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【Repair and Maintenance job order】

❶ Gasket replacement

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 【Failure case】・・・・▶ Exhaust leakage

Inspection and judgment

Check exhausts gas leakage in the engine room.

Causes

It is caused by degradation of the gasket or damage of the

muffler.

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【Risk on customer】
If the operation is continued as is, it is effect in
degradation of】 the parts which is around engine
exhaust line such as electrical harness, wire cable,
fuel hose, and oil hose.
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【Point of proposal】

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Proposal to customer

Explain to the customer that it is better to replace every

gasket as well as the engine exhaust line which is degraded.
In the case that there is damage to the muffler, propose to
replace the muffler.

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【Repair and Maintenance job order】

❶ Gasket

❷ Muffler

❸Damaged parts

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 Machine Inspection Manual (Excavator)

【Engine】
Part 3
【Check point】Measure blow by gas flow volume or pressure
【Inspection method】Put flow meter at blow by gas house and measure the
blow by gas flow to check flow level is under limit.
Condition: Engine water temperature shall be 70℃ to 80℃.
*Measure the flow volume or pressure in low idle, high idle, high idle and
boom raise, high idle boom relief.
【Tools】 Blow by gas flow meter, pressure gauge.
*Tool and standard shall be selected by engine manufacture.
【Standard time】20min
【Safety】When performing the following work, please follow Technical
Manual (Trouble shooting manual) of the target model in accordance with
the "caution" the contents of the description, advancing the work safely.

【Failure case】・・・・▶ Blow by gas flow volume or pressure is abnormal

Inspection and judgment

Measure blow by gas flow volume or pressure by tools.

Engine condition is abnormal if figure isn't within the
standard limit, and you can refer the measurement log to
judge the trend about wear of internal parts like piston
ring, liner, and so on.

Causes

It is caused by wear of internal engine parts, piston ring, and liner.

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【Risk on customer】
Engine oil consumption is increased by ware of
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internal engine parts. If you use machine as is,
ware of parts will be preceded and then it effect
to seizure of engine or life time of engine.

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【Point of proposal】

Temporary support for CS

Fill up the oil when】oil level is low.

Proposal to customer

In case of blow by figure is over the limit and worth than

】 explain to customer about
previous data, please
requirement of engine overhaul.
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【Repair and Maintenance job order】

❶ Engine overhaul (piston ring, liner, and relevant parts)

【Reference】

Blow by gas slandered for Isuzu engine (reference from service manual）
Model Remark
ZX230 Less】than 100L/min
ZX340H Less than 100L/min
ZX240K Less than 100L/min
ZX270 Less than 100L/min
ZX450 Less than 150L/min
ZX450H Less than 150L/min
ZX500LC Less than 150L/min
ZX600 Less than 150L/min
ZX650H Less than 150L/min
ZX800 Less than 150L/min
ZX850H Less than 150L/min
Blow by gas slandered for Cummins engine（reference from service manual）
Engine hp(rpm rating New/Rebuilt Used Engine Limit
CPL8353
0 to 860 hp 453mmH2O 4.44kPa 802mmH2O 7.86kPa
861 to 950 hp 543mmH2O 5.32kPa 881mmH2O 8.63kPa
CPL8352
All ratings 624mmH2O 6.11kPa 900mmH2O 8.82kPa