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.

T122228-19: Cylinder Block Grade Mark Locations

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.

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

T122225-UN: Use Straight Edge/Feeler Gauge to Measure

T122224-UN: Upper Face Out-of-Flat Measurement Points

LEGEND:

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

T165700-UN: Measure Cylinder Block Height

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

T122056-UN: Grade Mark

T165681-UN: Measure Piston OD at Height Shown

LEGEND:

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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OUO1020,000125B-19-2003/02/24