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SERVICE BULLETIN

Technical Service Group, Customer Support Dept.


Kobelco Construction Machinery Co., Ltd.
Authorized by; Issued by;
CLASSIFICATION : Technical Information
CS Dept. CS Dept.
2-Jul-09 2-Jul-09
Issue Date : July 2, 2009 Sakutani Arimitsu
Bulletin No. : S030-30-K013
Subject : Inspection items and procedure
at the time of Turbo-Charger breakage
Applicable Area : All
Applicable Model : All models equipped with HINO Engine
Applicable S/No. : All

1. Background of Information
When Blower of Turbo-Charger breaks, it is possible to cause secondary failure due to the
fragments coming into air intake lines and relating parts.
This bulletin is issued to identify the inspection items and procedure in order to prevent such
failures when the turbo-charger on HINO engine breaks .

2. Phenomena at the time when Turbo Charger damaged.


 ① Black smoke or white smoke will emit.
 ② Engine speed will go down when engine is loaded.
 ③ Abnormal noise will sound.

If Engine is continued to run on such condition, the fragments of failed blower of Turbo Charger
will go through Intercooler and come into Combustion Chamber so that fragment will damage
Pistons and Cylinder Liners, resulting of increase of blow by gas due to insufficient compression.
Whenever such phenomena are found, stop Engine promptly.

3. Inspection after disassembly


Both upper and down stream side parts should be checked how far the fragments come into.

Outside View of Turbo Charger Outside View of Inter Cooler

Damaged
Blower
Check of Inter Cooler inside

This bulletin is issued for information only and is not an authorization for warranty claim submission.
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Issue Date :July 2, 2009
Bulletin No. : S030-30-K013

4. Inspection procedure
(1) Upper stream side parts
Check whether the fragments are flown back to Inner Filter inside of Air Cleaner or not.
If the fragments are found, replace Air cleaner. (Fragments are non magnetic material.)
(2) Clean up inside of Hoses and Tubes and blow them by air.
(3) Inter Cooler
Check outlet and inlet ports and, if the fragments with more than 1 mm size are found at Outlet
port, replace Inter Cooler.
(4) In case that the fragments with more than 1.5 mm size are found at Outlet port, measure the
compression pressure of each Cylinder. (Refer to Shop Manual for detail procedure.)
(5) You must order at least Turbo Charger assy and Inter Cooler, when Turbo Charger failed.
(6) Replace Engine oil and Oil Filter Element.

<Inspection and Maintenance Items>


To replace Inner Filter

To clean up Hoses and


Tubes

To clean up Hoses
and Tubes

To check Inlet and Outlet


of Inter Cooler

5. Measurement of Compression Pressure of Cylinders


In case that the fragments with more than 1.5 mm size are found at Outlet port, measure the
compression pressure of each Cylinder. (Refer to Shop Manual for detail procedure.)
To measure Compression Pressure of each Cylinder

OK NG

No need of disassembling of Semi-overhaul is required after disassembling


Cylinder Head Cylinder Head

To replace Piston, Piston Rings, Cylinder liner and


so on according to the condition
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Issue Date : July 2, 2009
Bulletin No. : S030-30-K013
6 Check Injectors perfomance as described in the following, when Engine is
repaired without replacing to new Engine .
Record the change of Common Rail pressure in order to inspect oil tightness of Injectors.
Refer to below graph. This graph shows the change of Common Rail pressure after Engine
stops at 1000 rpm and on no load condition.
(1). Normal Injectors Pattern; 1000rpm運転パターン:1000rpm無負荷→停止
& no load ⇒Stop Engine
1.正常

指示レール圧
Engine stop
エンジン停止
実レール圧
Time for common Rail pressure decrease
レール圧低下時間
Pressure drop from 48 to 5 Mpa

Common Rail
pressure
レール圧

レール圧低下時間【81→5MPa】 SEC
2.#6シリンダー決壊品 1sec
(2) Defective Injectors
Pressure drop from 48 to 5 Mpa

エン ジ ンstop
Engine 停止

Common Rail
レー ル圧
Pressure

レール圧低下時間【48→5MPa】
1sec

As shown in the graphs, Common Rail pressure drops faster on Injector with defective orifice seat.
If leakage quantity is large, fuel injection quantity becomes large and causes too high
combustion pressure , resulting the failure of Turbo Charger.
Recommended replacement standard of Injector
When puressure drops to 5 Mpa within 2 seconds, Injector shall be replaced to new one.

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Issue Date : July 2, 2009
Bulletin No. : S030-30-K013
<Reference>
Service Limit of Compression pressure
To measure compression pressure while Engine rotates by Starter.  【Speed; 150 rpm】

Items Compression Pressure


Mpa (kg/cm2)
Standard 3.4∼3.7 (35∼38)
Service Limit 2.7 (28)
Variance among Cylinders less than 0.3 (3)

Procedure for measuring compression pressure


Detailes should be refered to Maintenance Chapter of HINO Engine on Shop manual
Special Tool ; Compression Gauge Adaptor

Compression Gauge kit Assembly Adaptor


(left side)

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