Excavator engine rebuild: short block assembly (Hitachi EX120-2/Isuzu 4BD1T)
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- Опубліковано 1 чер 2024
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Price sheet for this project:
docs.google.com/spreadsheets/...
Here are the previous videos from this project: • I bought a broken exca...
0:00 intro
0:36 crankshaft
18:27 pistons`
36:24 front cover
41:20 cleaning parts
47:35 oil cooler
55:40 cam and lifters
1:03:11: rear main and cam plug
1:09:45 oiling system
1:18:55 injection pump
#excavator #hitachi #isuzu - Авто та транспорт
33:27 look closely at the bottom of the engine while you rotate it - there is blasting sand/glass or metall blasting media falling out, and not just a few grains , the block is not properly cleaned out , you need to blow out the oil passages - id dissasemble tbh before this gets shoved into the new bearings on first start
I'm amazed and honored that so many people are watching close enough to have caught things like this over the years and then told me about it. It has really helped me out many times when I made a mistake or missed something. This time fortunately (for me), it was some junk in a coolant passage I had just noticed and ran a pick over to break up.
Man, that was a really good catch!
WOW...holy smoke...I had to watch that particular few seconds over and over 3x times to catch it...
Sure enough..a pretty solid stream of "dust" fell out of one of the holes when the engine rotated over with the pan up...daggum!
yeah I saw that too.. was going to mention something but you already have :)
Well during close examination I was not able to see anything. However 780 pixel is very likely the reason? Well done ya jammy prick! You have my respect sir.
I am a technician and simply blown away by some of the disparaging comments. I do this type of stuff for a living and let me tell you he is better than most professional technicians. The only gripe I could come up with was doing the the torque angle after the click on the torque wrench... not a big deal. A easy reference is each bolt flat is 60°. Love the videos, keep up the good work. 👍
Or each peak.
Excellent tip on the torque angle!
Disparaging comments! Those people are the incompetent ones of society that haven’t completed anything in life so they bitch about others
I love the longer format for these videos. One tip my mechanic mentor taught me when assembling parts that have lots of bolts is to use locator pins to guide the parts together. He had a large selection of home made pins of different diameters. He cut the heads off of the bolts and then cut a slot in the end for a screwdriver. On oil pan, he would use at least four pins to locate and hold the pan and gasket in place while he started the bolts. This was especially useful when attaching a transmission to an engine after replacing the clutch.
Yes! I had to discover that myself 30 years ago. NO internet or UA-cam.
Hello Matt. I am an old retired Scottish pen pusher. Here's my take, for what it's worth.
You got courage, young fellow.
That's a complex machine you took apart. However, I think you deserve success for your courage.
I hope, minor setbacks aside, that the whole project gives you real joy and many many years of use.
Matt, I am more than positive that if anyone would ask you anytime of the day or night to spell forward or backward the word PATIENCE you would pass the test, without fail within a split second of the request!
It is just a tremendous pleasure to watch you work without complaints, just simply getting the work done and it is done simply when it is done. Just a very peaceful atmosphere that you create, with no expletives, etc. Congratulations! And we are waiting, almost as patiently, for the completion of the repair and rebuild of this peace of equipment and wish you much pleasure in operating it, in due time!
My heart was in my mouth when unbolted the engine from the stand and hung on one bolt! YIKES!!
Yeah...when it flexed I was like "oooh" (cringe face)
Worked out well though!
*-Why he didn't use his jack and a piece of wood to hold up the back end?*
Matt, I really hate to mention this, but the mismatch paint color between the block and oil pan is sure to cost you major points at the Pebble Beach Concours d'Elegance. Sorry to break the news to you this way. 🤣 Love watching you struggle!
Unfortunate for sure.
‘If one of these broke off, i would take up a new hobby’ 😂😂
Never knew fisting was a thing, in cleaning engine blocks😂
I was looking for this comment 😂
"I'd pitch it across the room" is more likely
never was a more confident "I think this goes this way" stated.
Clean, clean again, then clean some more! You can never be too clean when assembling an engine. Great job Matt! 👌
And yet, when you open one up it's always filthy.
Matt, an easier way to torque mains & rods is to turn the block sideways. Then you don't have to hold the engine stand while you pull the torque wrench. Same on the head bolts.
great tip!!
Matt, your desire to have surfaces very clean is the way to properly reassemble engines. You are so patient and a great teacher with easy to understand video angles. Blessings to you, Matt.
If I built an engine, I'd probably last about 10 hours before shredding its self. 😜
Talking about perishable skills, I'm a retired brain Dr, and I prefer watching your lovely videos and problem solving!
A Dr has to make ALL the repairs while the engine is running!!!
Although doctors and Matt both work with the as-is condition.
I have a suspicion that you will never see the inside of the engine again.. LOL - Great job Matt
The only problem I have whit your channel is that you makes us wait so long for a video 😂😂😂can’t wait to see this excavator finish grea job btw
But it's well worth waiting for .. never a disappointment!! :)
Two things that help (a little) are the "Shorts" videos on his YT page, and his Instagram account. Shorts don't get used much, but every now and then something pops up. Instagram has a little more. They're just single pics, but help a lot to give an idea of progress since last video.
The "nerd stuff" of engine building. Love it.
Great video.
I Just finished watching you starting to work on the trail through your property! What a beautiful property you own! And as you get used to your caterpillar, and it to you, I am very confident that all will get together the way you want it. Take your time to enjoy improving your property to enjoy its beauty and peace!
I've just finished binge watching the Cat 4D and now the EX120 videos. Looking forward to more PNWH. Great stuff Matt.
Matt, when installing pistons engine oil is your friend. I have rebuilt numerous engines, from single cylinders up to big V-8s, I always dunked the piston in engine oil then put on the ring compressor. Makes them slide in easy and lubricates the upper cylinder on start up.
As for break in oil use whatever the equipment mfr. calls for. Do not use any additives to it. The rings need to seat into the cylinders and friction is necessary to get that process started.
Yeah...regular dino oil (the cheap stuff actually) for the first few hundred miles/dozen hours
Then switch over to your permanent expensive synthetic stuff
Just make sure you use quality filters to catch all the initial "break in" metal flakes that will inevitably wear off the first few times the engine heat cycles
I remember my big brother taught me that after I'd fixed my blown head gasket. Said go get the cheapest oil you can buy and run that at first. To flush everything out. Then change it again to the normal stuff. Also had to drive around for half a day with it blowing steam like a volcano while it harmlessly boiled off all the water that'd gone into the muffler/tailpipe.
Dad and I enjoy watching you tackle these the complicated components!
Thanks Aaron!
AINT NO WAY, Pacific Northwest Hillbilly AND FarmCraft101 POSTING ON THE SAME DAY ????????????????? I NEED TO GO BUY A LOTTERY TICKET
Marty T is splitting a tractor, too!
Matt, don't feel bad about forgeting to order a replacement part (like your harmonic balancer) when doing a rebuild. I'm willing to bet that any mechanic on this channel (myself included) has done it at least once. That stuff happens. I can't wait to see your engine all back together and be fired up for the first time.
That engine is looking sweet!
The best thing I have found for cleaning aluminum is phosphoric acid, it is usually the main ingredient in mag cleaner. Great job.
Matt, I may have said this already but.
As a Veteran Coast Guard Aviation Machinist Mate I'd fly in any airplane you rebuilt the engine.
There's absolutely no doubt that if you'd gone to a Aviation mechanic school like Embry-Riddle you'd have graduated top of your class.
Schools of that caliber including the Coast Guard Aviation Machinist Mate A school I attended demand a level of attention to details you achieve.
You pay attention to even the smallest detail and admit it when you make a mistake and you go back and remedy the problem.
Thanks for the entertainment.
I'm sure it's clean enough in the cylinders, but from my very first days of engine builds I was told that hot soapy water was the best to clean the cylinders. You have to get some light oil on them right away or you'll get flash rust. I'm pretty sure that means they are clean of any old oil or packaging lube. Everything is looking great! Sure wish we would've had cell phones with cameras and the internet when I was doing this stuff. In my diesel engines Detroit Diesels I just used shell Rotella and changed it after the first few hours. My shrimp boat engines ran for years with no problems from lubrication.
Hey PNH, if you think about it, by the time you're done, you bought a pre assembled excavator kit that you disassembled and then reassembled. Now that you've shown me these kits are available on the open market, I may go pick one up myself. Thanks!😊
Enjoy watching this come together. I was already a fan of Area Diesel Services but liked watching them rebuild your pump. Thanks for bringing us along. Give Charlie dog pets for me
57:45, that camshaft end plug at the back of the motor, you should use Form A Gasket number 2 on the edges before you hammer it into place... Please don't ask me how I know😮 1:04:57 you did just that...
I bet that engine never had that kind of care when it was being built . You are doing a fantastic job. Love to watch your channel. Great work JeffinMaine
It's going to outlive its owner!! .. Imagine if it went up for auction and this video series was required reading to bid!! It could sell for the price of a new machine!!!!
You took more care rebuilding this engine than they did when it was originally assembled. Great video I am learning a lot. You would make a awesome teacher.
Matt, some mighty fine "surgery" there sir! Thanks for taking us along.
Man that engine block is a work of art, especially those cylinder bores!!!
👍👍👍👍👍👍 as a diy daydreamer you give me hope, (maybe I’ll do something like this someday) as far as the tools and work conditions(like in the basement of a barn or backyard under a tarp) the harbor freight tools( that’s all what a lot of us diy’ers can afford), in the knowledge and skill department you are impressive, way above me , like you willingness to try stuff and to show and redo the mistakes, love the videos just the way you are doing them, honest straight forward.
buena restauracion matt
You know you can make your own orings with a oring set? Nice to have that option when you are in a pinch. You are doing a better job on this rebuild than I would have! 😂
It's the principle of it, the engine seal kit should have it all! Keep up the great work over there!
A good trick for torqueing additional degrees i learned from Adept Ape is to mark the degrees on the outside of the socket with 2 lines then with the socket on the bolt make a mark on the part for a stationary reference, now torque from one line o the socket to the other. I didn't want to use a paint marker on my sockets so I use painters or masking tape and a Sharpe.
I have 20 years of selling auto parts. I'm retired now. I have sold the wrong parts to people who told me what they thought they had but later found that it was something different. So it's all part of the game
Great job Matt!
Like this kind of video very interesting
Matt, tech tip, never use your torque wrenches to untorque your bolts. Use a breaker bar. Throws wrench out of cal. Love watching, great vids!
Pro tip, use denatured alcohol for cleaning, cheaper than parts cleaners
Ether works good also
Yair, denatured alcohol is bipolar too so it also helps to remove water from the hard to get to bits.
DYI tip... A roll of butcher paper kept at the back of the bench makes a handy pull out 'clean' surface for gasket dressing or taking apart debris sensitive parts. Or just keep pulling from the endless pile of amazon boxes for fresh cardboard!
I really enjoy your videos and the way you work. Maybe out of interest for you I did a small project on the clamping force of bolts whilst doing my Mech Eng degree. To cut to the chase I used a 1/2" UNC bolt and two metal plates, one tapped for the bolt and one clearance. Between the plates was a 1/8" soft copper washer. The clamping force of the bolt was measured by the crush on the copper washer. Three conditions were tried, dry, thread only oiled and tread and under the head of the bolt oiled. Three oils were tried thin sewing machine oil, 20/50 engine oil and EP90 gear oil. Predicably the greatest clamping force was the oiling of the threads and bolt head with EP 90 oil. The whole thing was repeated with a washer under the bolt head and that increased the clamping force significantly. Very few manuals adequately specify the conditions for torquing the bolt but if you are going near the yield point of the bolt it is important.
As a retired mechanic I use to put the connecting rod bolts in then put rubber fuel line over them as you install the pistons in the block so they don't scratch the crank and always put the crank in first
This is a great tip I've done that on chevy small blocks. BUT it does NOT apply to this engine, the connecting rod bolts go in from the bottom, the rods them self are drilling tapped. There are no connecting rod nuts :) 28:40 20:50
Cast iron. No matter how many times you wipe it clean it always leave some on towel)
Get yourself a 'Speed Brace". Makes spinning bolts in and out a breeze and you get feedback on the torque required so you can catch problems before they happen. Love your work.
Guinness Book of Record: the cleanest excavator in the world. The cabin should have a leather chair with massage!
Very good job! Nice little engine. I ran a EX100 for several years, back in the early 1990s, doing forestry work. Also its sister, the JD490. Very solid and capable machines for their size.I can't remember ever breaking anything! I liked the pilot control feel better than todays electric/hydraulic..and easier to fix. Also you have no DPF or DEF! Good luck with your machine, and thanks for the excellent videos!
I don't think a formula 1 engine is built with as much attention and care. 😀👍
I am pretty sure I might want to punch a formula one engine builder after 5 minutes of them telling us how great they are. And never mention if something don't fit they have to call for help!
It must be rewarding to assemble it compared the dirty disassembly.
Ya gotta love a fresh mint spotless engine Eh?!! Even if it's full of broken ball bearings there still is no doubt it will start and run beautifully straight away. ( obviously there is no pile of broken ball bearings anywhere) Well I think we get the point, yeah?! That is a really superb assembly Matt. ( right name?)Future Matt will be running the best damn Hitachi this age in the continental USA. Bloody exciting!
Love watching your channel. At times I think your brilliant with your ability to take on intricate, and complex tasks you admit too never having done before. Then in the next moment you show complete lack of common sense or inability to research tasks prior to taking them on. My wife loves watching me talk to and yell at my iPad when you frustrate me with your continued nonsensical antic's...
Keep the great entertsinment coming😊😊😊
“.999 Repeating Sure” 🔥🔥🔥 I’m totally stealing this line. It’s a 🎤 dropper for sure.
Hell ya. This is my favorite series on UA-cam 😊
I dunno if you've had this done in the past few years, but my malfunctioning Craftsman click torque wrench was just repaired and certified calibrated by CSC Force Measurements out in Mahhh sahhhh choooosets. They did a great job.
Love all your videos. I just had to rebuild a hydrogear motor on a Snapper mower and don't you hate when they send you the rebuild kit with 15 o-rings that you have to figure out which one goes where. Also those little green grinder pads from Harbor Freight are great for removing gaskets and silicone from aluminum parts.
I didn't know that you used a cheat sheet. I just thought that you had a incredible memory & knew where everything went.
The hardness of a rubber material is measured by the Shore Method for determining Durometer. Hard rubber materials would be used in high temperature application. Softer materials are used for better sealing in cooler application. The should be a Shore number on the packaging of "O" rings and rubber gaskets. Hope this helps!
*- What a great rebuild video, Matt.*
*- Too scary for me.*
*- I would be lost trying to remember what comes first and which bolts or screws go where.*
*- { apologies for all my attempts to help with the poorly worded nit-picky comments below }*
Look forward to the next installation Matt
I applaud you for taking on this task...I am fixed to the vid completely. Looking forward to the start up..
Re the ring markings the dimple faces to the top or if it has a bevel on the inside it also faces the top. If it has a step on the 2nd/3rd ring in most cases that faces down, except on the. Acl rings we got in South Africa in the 1990's.
Just make sure about the rings again.
BTW I like to use aresol chain lube for assembly, stuff sticks and works a treat!
Be very careful to avoid hitting the spray tubes with the rods when you install the piston and rod assemblies. In frame overhaul, we install the spray tubes last.
Advice about oil for when running it that you might already know. Be careful of using modern grade oils, as for 'environmental' reasons they are much lower zinc content and the likes, so keep to the service classification (not just oil viscosity) recommend from factory. Penrite oils has a good run down on API service classifications and the likes, it's especially important in these older diesels. These older style diesel engines like higher zinc contents than modern ones.
Your attention to detail is better than most engine rebuilders found on UA-cam... Great video.
Good job!😎
One job I had many years ago, I fit and adjusted babett bearings the same as this but each bearing block was the size of an large SUV :)
It was for the steam turbine for a popular Electric Steam Generating Facility in my area :) I love it how when it comes to high horsepower bearings, nothing works like 200 Year Old technology!!
I have several giant 'coins' of old Babbett, with a image of Isaac Babbitt himself cast into the face of the coin.
Fantastic content, keep the videos coming. Very impressed with your knowledge and how you do things…… Go on repaint the oil pan you know you want too… it will always bug you otherwise….lol…. UK
Another exercise in precision. I have no doubt she’ll tick like a Swiss watch. You gave us a long video and still left us wanting more so you’re doing it right. I’ll celebrate right along with you when she takes off and hums! 🥸👍👀🔧🔨✅❗️
Enjoy ur vids, ur raw DIY. Like most of us working in our garages or barns. Great work
Time to talk to Charlie about swimming in the winter while wearing a fur coat 😂
Not sure if anyone watches the humble mechanic, he swears by using coffee filters for cleaning. I have not tried it myself, but thought it a mention...
Damn I love this channel!
Way back in my misspent youth I rebuilt two lawn mower engines, two motorcycle engines (2 and 4 cylinder), and two gas car engines, both straight sixes. I got better with each project but never achieved the level of detail you do. I am pretty sure your rebuild is better than when it left the factory. Thanks for all you do - I’m probably never going to tear into another engine but it is fascinating watching your projects. Greetings from Snohomish WA. 😉
The oil pump gasket being oversized on the oil passage might be by design. There is not much meat between the passage and the bolt hole. Being oversized insures you will have as much sealing between the two as possible. It will also help to overcome any misalignment/dim differences.
engine looking good - meticulous work - should purr like a kitten.
Once the main caps are tightened, the bearing clearance is set. Torquing streches the bolt, but does not change clearance.
Well Matt I love to watch your videos. You are one of the people who pay attention to detail. The only worry I had was the possibility that you may have been given the wrong gasket set for the engine. I had a Major problem with the fact that the timing cover gasket didn't fit and my fear is the cam plug was the wrong diameter, I hope oil pressure doesn't blow it out. Oil pressure originates from cam bearings. I'll keep my fingers crossed. Keep it up buddy you're doing great.
Fantastic video, Matt; you really put in maximum effort and the quality certainly shows!
Hello matt would love to see vidieo on the rebuild or repair process on that dismantled atv you have in background.that is more my speed anyhow,chances of me owning a dozer or excavator are pretty unlikely.but noneless i enjoy your work ethic.sincerly snookie pa.😊😊😊😊😊
Great start to the end of the week a new PNH vid..
Have one of these machines only person on yt to have such indepth info on these. I can't wait to get a garage to work in and *attempt* some of these jobs. Look forward to every vid.
Nice work. This thing will outlast most of us watching. Don’t worry about all the experts and their comments. 👍
Great video. Thanks for sharing your hard work and knowledge.
Matt your doing a great job credit is due
Hat's off Matt, and thanks for letting me watch.
Engine oil. Would think a high zinc. helps with break in. Try and ask the diesel guy that did your injector pump sure they would know.
If I remember right, to get oil pressure without running the motor, we took the distributor shaft out of the distributor and put a drill on it, stuck it back in the hole in the block where the distributor went to power the oil pump and we had oil pressure. Not sure if you can do that with this engine. Great video, Matt.
Great job, that injector pump is massive compared to the engine size. Cheers
thank you for unother good video.. greetings from Estonia .. cant wait for next one .. great job
beautiful work! I have a 4BT you can do next
copper washer alway check with a magnet , Because there are a lot of rebuild kit come with what looks like copper washer but steel painted copper washer
When you put the pistons in bring the crank to bottom dead center. Makes it easier to tighten. Extensions throw off torque.
just use 15-40 change after 10 hrs. Thanks for posting this. It's a pleasure to watch.
Diesel grade. With zinc or additives. Time is correct. Check for the glitter.
Yea Matties back.1!!!! Regarding the rod bolts, 5 to a bag is a perfect "marketing" plan......
Well Done!!!!!!
Great work keep the videos coming
Immense work really appreciate you taking the time to film, edit and share.
I sit and enjoy your videos. You are so careful with everything, it will be better than the original factory. Very good video and very good job 👍
break in oil is often just a lesser quality oil. so don´t worry to much about it. put in regular oil and replace it ahead of time for the first two oilchanges
Thanks Matt for all your video, you are amazing. I myself own a small farm and recently just picked up a Hitachi EX100-3 with a ton of hours on it. Converted it to all Hydraulic with the kit, now looking at fixing her up over the next few years. Your video's on this are and will help with a lot of things I will be working on. Thank you for your great work, great video's and precise information . Be safe and looking forward to your video's.