Author: José Cotino Escrivá

Volvo D12DAAE2 Engine Tuning

Engine timing is a crucial task to ensure optimal performance and engine longevity. In this blog, Taoparts experts will guide you through the process of tuning the Volvo D12DAAE2 engine, used in the A35D articulated dump truck. We will also discuss the specific tolerances for the intake and exhaust valves.

Materials Needed

  • Adjustment tools (torque wrench, micrometer, valve gauge)
  • Volvo D12DAAE2 engine service manual
  • New engine oil and filters
  • Protective gloves and glasses

Engine Tuning Steps

Volvo A35D swing motor

1. Preparation

  • Disassembly: Start by disassembling the engine and making sure all parts are clean and free of debris.
  • Component Inspection: Inspect engine components such as pistons, connecting rods, and rings to make sure there is no damage.

2. Adjusting the Intake Valves

  • Valve Clearance: Use the valve gauge to measure the intake valve clearance. Adjust the valves to the specified tolerance of 0.2 mm.
  • Check: Check the valve clearance again to make sure it is within tolerance.

3. Adjusting the Exhaust Valves

  • Valve Clearance: Similar to intake valve adjustment, measure the exhaust valve clearance and adjust to the specified tolerance of 0.5 mm.
  • Check: Check the exhaust valve clearance again to ensure it is within tolerance.

4. Displacement Adjustment

  • Compression: Perform a compression test to ensure the engine is under proper pressure.
  • Cylinder Adjustment: Adjust the cylinders to service manual specifications.

5. Assembly and Testing

  • Reassembly: Reassemble the engine and replace all components that were removed.
  • Functional Tests: Perform functional tests to ensure that the engine runs properly and without problems.
Volvo D12DAAE2

Conclusion

Volvo D12DAAE2 engine timing is a detailed process that requires precision and attention to detail. By following these steps and ensuring that the valves are adjusted to the specified tolerances, you can keep your engine in top condition and extend its life.

The importance of a good timing cannot be underestimated. A well-tuned engine not only ensures smooth and efficient operation, but also prevents premature component wear. By keeping intake and exhaust valves within proper tolerances, combustion is optimized and engine power is maximized, resulting in superior performance and lower fuel consumption.

Additionally, regular engine tuning is essential to detect any potential problems early. By inspecting and adjusting valves and cylinders, mechanics can identify and correct small problems before they become major failures. Not only does this save time and money on costly repairs, it also extends engine life and ensures vehicle safety.

At Taoparts, our highly trained mechanics use the most advanced tools and techniques to perform engine tune-ups with the utmost precision. We are committed to quality and customer satisfaction, ensuring that every engine that passes through our hands performs to the best of its ability.

Proper care and maintenance of your A35D articulated dump truck not only improves its performance, but also ensures that it’s ready to meet any challenges that come your way on the jobsite. Trust Taoparts to keep your equipment in top condition and maximize its efficiency and durability.

Contact us for all your spare parts needs!

Do you need spare parts for your heavy machinery? Look no further. Contact Taopparts and we will provide you with the original spare parts you need to keep your machine running at peak performance.

www.taopparts.com

Valve adjustment in Komatsu engine

Valve timing on a diesel engine, such as the Komatsu SAA6D125E-5, is a critical procedure to maintain its optimal performance. This engine is mounted on Komatsu machines, such as the PC450LC-7 excavator, the WA480-6 loader or the HM300-2 articulated dumper. In this blog we will also address the verification of the axial play of the engine of this machine.

Komatsu SAA6D125E-5 Engine Valve Adjustment

1. Tools needed:

Before you begin, make sure you have the following tools on hand:

  1. Ratchet wrench: Useful for loosening and tightening valve nuts.
  2. Wrench and screwdriver set: To access the relevant engine parts.
  3. Calibration thickness gauge: Also known as gauges or calipers, it is used to measure the clearance between valves and camshafts.
  4. Torque wrench: Necessary to apply the correct force when tightening the valve nuts.
  5. Calibration Sheets: Provide precise specifications for valve adjustment.
  6. Engine service manual: contains precise information about the engine and manufacturer’s recommendations.

2. Preparation:

Locate the valves:

Identify the exhaust and intake valves on the engine. In the case of the SAA6D125E-5, this engine has 6 cylinders and 24 valves (12 exhaust and 12 intake).

Engine position:

Place the engine at the top dead center (TDC) of the number 1 cylinder. Consult your engine manual to find the reference mark on the crankshaft pulley.

What is an intake valve?

The intake valve is responsible for allowing the air-fuel mixture to enter the engine’s combustion chamber. During the intake phase of the engine cycle, this valve opens so that the mixture can enter and prepare for combustion.

What is an exhaust valve?

The exhaust valve, on the other hand, is responsible for expelling the burned gases resulting from combustion out of the combustion chamber. This valve opens during the exhaust phase of the engine cycle, allowing exhaust gases to be expelled through the exhaust manifold.

Main differences

  1. Function: The intake valve introduces the air-fuel mixture, while the exhaust valve expels the burned gases.
  2. Temperature: The exhaust valves support higher temperatures due to the hot combustion gases, reaching between 600º and 800º Celsius, while the intake valves handle lower temperatures, between 200º and 400º Celsius.
  3. Material: Exhaust valves are made of more heat-resistant materials, such as stainless steel alloys, to withstand high temperatures.
  4. Size: Intake valves are usually larger than exhaust valves to allow greater air intake and improve engine efficiency.

3. Measurement and Adjustment:

  • Exhaust valves:
  • Using the torque wrench, loosen the exhaust valve locknut.
  • Use the feeler gauges or calipers to measure the clearance between the cam and the valve. Adjust if necessary.
  • The recommended clearance for the exhaust valves is 0.71 mm
  • Intake Valves:
  • Repeat the same process for the intake valves.
  • The recommended clearance for the intake valves is 0.33 mm
komatsu engine valve adjustment

Tighten the locknut:

Once the valves are adjusted, tighten the locknut without moving the valve position. In the following image you can see a Taopparts mechanic carrying out this task.

Ajuste de valvulas

4. Verification:

1. Turn the engine:

Crank the engine manually several times to ensure there is no interference between the valves and pistons.

2. Check again:

Remeasure the valves after cranking the entire engine.

Make sure all valves are within the specified range.

Valve timing has a significant impact on engine performance. Here are some of the ways it affects:

  • Combustion Efficiency:
  • The valves control the air intake and exhaust gas output. If the valves are not properly adjusted, the air-fuel mixture may be inadequate, which affects combustion efficiency.
  • Power and Torque:
  • Incorrect adjustment can affect engine power and torque. Valves that are too tight or too loose can decrease overall power and performance.
  • Emissions:
  • Valves influence emissions. If the exhaust valves are not closed properly, exhaust gas leaks may occur, increasing pollutant emissions.
  • Noise and Vibration:
  • Poorly adjusted valves can cause excessive noise and vibration. Proper adjustment helps reduce these discomforts.
  • Engine Durability:
  • Poorly adjusted valves can cause premature wear on engine components such as camshafts and valve guides.

In summary, accurate valve timing is essential for optimal performance of the Komatsu SAA6D125E-5 engine in terms of power, efficiency and durability.

How to Check Axial Play on a Komatsu SAA6D125E-5 Engine

Axial play refers to the lateral movement allowed between the rotating parts of the engine. In the case of the Komatsu SAA6D125E-5 engine, it is important to check it to ensure optimal operation. Follow these steps:

  1. Preparation:
  2. Top Dead Center (TDC) Location:
    • Crank the engine manually until the number 1 cylinder reaches top dead center (TDC). Consult your manual to find the reference mark on the crankshaft pulley.
  3. Axial Play Measurement:
    • Use a magnetic dial gauge to measure axial movement in the crankshaft.
    • Place the dial gauge so that its tip touches the end of the shaft.
    • Rotate the crankshaft while checking the end play.
  4. Comparison with Specifications:
    • Consult the manual for the exact end play specifications for the SAA6D125E-5 motor.
    • The axial play should be in the range 0.14 – 0.315 mm.
  5. Registration and Document
    • Record the measured values ​​and any adjustments made on a recording sheet.
Magnetic comparator clock

At TaopParts, each Komatsu engine goes through a rigorous verification process before being offered for sale. Mechanics not only perform axial adjustment, but also perform compression tests and other evaluations to ensure the engine is in perfect condition.

At Taopparts, we are committed to offering the highest quality spare parts and services so that our customers can operate with maximum efficiency and peace of mind.

Contact us for all your spare parts needs!

Do you need spare parts for your heavy machinery? Do not look any further. Contact Taopparts and we will provide you with the original spare parts you need to keep your machine running at peak performance.

Direct contact form

Exploring the axles and differentials of the Volvo L120F

We explore the main powertrain components in a loader, using the Volvo L120F as an example. To go even deeper, let’s take a look at some additional aspects and expand with examples from other loaders:

Axle: The Base of the Support

The axles of a Volvo L120F loader are crucial components that ensure the mobility, stability and power of this robust machine. Designed and manufactured to the highest quality standards, these axles play a fundamental role in the daily performance of the loader.

Main functions of the axes:

  • Weight support: The axles support the total weight of the loader, including the machine itself, the load in the bucket and any additional accessories.
  • Power Transmission: The axles transmit power from the engine to the wheels, allowing the loader to move forward, backward, twist and turn on its own axis.
  • Shock Absorption: The axles absorb impacts and vibrations from the ground, protecting the machine and operator from damage.
  • Steering: The axles allow the loader to turn and maneuver with precision.

In the photo below you can see some axles of a VOLVO L120F loader

Axles of Volvo L120F

Differentials: Adapting to Every Terrain

The differential is a crucial part of the machine’s transmission system. Its main function is to allow the tyres to rotate at different speeds when the machine is turning or cornering. This helps maintain traction and prevents excessive wheel slip.

Differential components:

  • Crown and pinion gears: These gears are located inside the differential. The ring gear is a large sprocket that connects to the drive shaft, while the pinion is connected to the output shaft to the wheels. Together, they allow the distribution of power between the wheels.
  • Satellites and planetaries: Satellites are small gears that rotate around planetary gears. The planetaries are connected to the pinion and the ring gear. When one tyre spins faster than the other (for example, in a curve), the satellites allow the planetary gears to move, adjusting the speed of the wheels.
  • Differential housing: It is the structure that contains all the components mentioned above. It also provides support and protection.

Functioning:

When the machine turns, the differential allows the outside wheels to spin faster than the inside wheels. This prevents slipping and improves traction. If one wheel loses traction (for example, on slippery terrain), the differential redirects power to the wheel with the best grip.
In short, the differential is essential for the stability, handling and traction of the Volvo L120F. Without it, the wheels would not be able to rotate independently, making operation on varied terrain difficult.

Types of differentials

  • Open Differential: This is the most common type of differential and allows the wheels to spin at different speeds. However, it can allow one wheel to spin faster than the others, which can lead to uneven tire wear and loss of traction.
  • Locking Differential: This type of differential locks the wheels to rotate at the same speed, which improves traction on difficult terrain. However, it should not be used on hard surfaces as it may damage the drivetrain.
  • Limited Slip Differential: This type of differential combines the features of open and locked differentials. It allows the wheels to spin at different speeds up to a point, but then locks up when more traction is needed.

In the photo you can see a differential 11103282 of a Volvo L120F loader

Differential Volvo L120F ref 11103282

A Crucial Shipment to Mozambique

Recently, two axles, one front and one rear, along with two differentials, were shipped from Valencia, Spain, to Mozambique. These components will be used to repair or replace worn parts on a Volvo L120F machine operating in that country. The shipment of these critical parts ensures that the machine can continue to operate efficiently and safely, contributing to the development and progress of Mozambique.

At Taopparts, our expert mechanics carefully inspect each part before shipping it to our customers. In this case, one of our technicians is meticulously checking an axle on a Volvo L120F loader.

This exhaustive review ensures that the axle meets the highest standards of quality and performance, ensuring that the customer receives a reliable and long-lasting part for their work equipment.

At Taopparts, we are committed to offering the highest quality spare parts and services so that our customers can operate with maximum efficiency and peace of mind.

Contact us for all your spare parts needs!

Do you need spare parts for your heavy machinery? don´t look any further. Contact Taopparts and we will provide you with the original spare parts you need to keep your machine running at peak performance.