Post on 19-Feb-2018
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tm2057 - 50C ZTS Excavator
Cylinder Block Repair
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Cylinder Block Repair
Cylinder Block Water Jacket Test
Use hydraulic pressure gauge to check pressure in water jacket.
Item Measurement Specification
Cylinder Block
Water Jacket Water Test Pressure 490 kPa (71 psi) for 3 minutes
Inspect Cylinder Bore
NOTE:
Grade mark is stamped on the top surface of the cylinder block.
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T122228-19: Cylinder Block Grade Mark Locations
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T122226-UN: Measure Cylinder Block Bore Diameter
Take measurements at 13 mm below the top at positions X-X and Y-Y.
Item Measurement Specification
Cylinder Block
Cylinder Block Bore (Grade A) ID 85.000-85.010 mm (3.3464-3.3468 in.)
Cylinder Block Bore (Grade B) ID 85.011-85.020 mm (3.3468-3.3472 in.)
Cylinder Block Bore (Grade C) ID 85.021-85.030 mm (3.3472-3.3476 in.)
If cylinder walls are scored, boring and honing will be required.
Item Measurement Specification
Cylinder Block
Cylinder Block Bore After Boring and Honing ID 85.3 mm (3.358 in.) maximum
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T165681-UN: Measure Piston OD at Height Shown
Measure piston outside diameter at approximately 64 mm from the top of the piston.
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Item Measurement Specification
Cylinder Block
Piston OD 84.945-84.960 mm (3.3443-3.3449 in.)
Piston 0.25 mm Over Size OD 85.195-85.210 mm (3.3541-3.3547 in.)
Subtract the piston OD from the cylinder bore ID to calculate the cylinder bore and piston
clearance.
Item Measurement Specification
Cylinder Block
Cylinder Bore and Piston Clearance 0.040-0.085 mm (0.0016-0.0033 in.)
If piston and cylinder bore clearance exceeds the specification, piston and/or cylinder block
must be replaced.
Upper Face Out-of-Flat Inspection
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T122225-UN: Use Straight Edge/Feeler Gauge to Measure
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T122224-UN: Upper Face Out-of-Flat Measurement Points
LEGEND:
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1 - Straight Edge
2 - Feeler Gauge
Use a straight edge (1) and feeler gauge (2) to measure the four sides and two diagonals of the
cylinder block upper face.
Grind the cylinder block upper face if the measured values are greater than the specification,
but less than the maximum grinding allowance. If the measured values exceed the maximum
grinding allowance, the cylinder block must be replaced.
Item Measurement Specification
Cylinder Block
Cylinder Block Upper Face Out-of-Flat 0.075 mm (0.0029 in.)
Out-of-Flat 0.15 mm (0.0059 in.) maximum
Grinding Allowance Distance 0.3 mm (0.0118 in.) maximum
Cylinder Block Height Measurement
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T165700-UN: Measure Cylinder Block Height
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LEGEND:
1 - Block Height
Measure cylinder block height (1).
Item Measurement Specification
Cylinder Block
Cylinder Block Height 307.94-308.06 mm (12.123-12.128 in.)
Piston Outside Diameter Measurement
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T122056-UN: Grade Mark
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T165681-UN: Measure Piston OD at Height Shown
LEGEND:
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1 - Grade Mark
Measure piston outside diameter at approximately 64 mm from top of piston.
Item Measurement Specification
Cylinder Block
Piston OD 84.945-84.960 mm (3.3443-3.3449 in.)
Piston 0.25 mm Over Size OD 85.195-85.210 mm (3.3541-3.3547 in.)
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