Tag: Komatsu Parts

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.

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What boosts our machines? A glimpse into a key element: The transmission

When we think of heavy machinery, we imagine an imposing power capable of moving earth, gravel, and stone with ease. But behind this vision, there is much more: achieving a longer lifespan with lower maintenance costs. In recent years, heavy machinery has evolved significantly to meet these demands. In this blog, we will explore the heart of these machines, the transmission. With a focus on wheel loaders, we will break down their key components, the fluids that keep them running, and their types.

Emphasizing Their Importance

Transmissions are the backbone of machines, allowing for the efficient transfer of engine power to the wheels or tracks. In a wheel loader, the transmission plays an essential role in adjusting speed and torque (the rotational force a motor can generate to perform work) according to operational needs.

And in the case of a wheel loader… What aspects do we highlight?

Transmisión 714-07-30030

Essential Components of a Loader’s Transmission

Torque Converter

The torque converter is the first piece in a wheel loader‘s transmission. It functions as a hydraulic coupling that allows for the smooth and gradual transmission of power generated by the engine to the transmission. Its design enables jerk-free starts and efficient energy transfer. In situations of heavy loading, the torque converter acts as a torque multiplier, providing greater force to overcome obstacles and challenging terrains.

Convertidor Komatsu 711-53-21001

Gearbox (Powershift)

The gearbox, or powershift transmission, enables control of speeds and gear changes in the wheel loader. The distinctive feature of a powershift transmission is its ability to shift gears seamlessly, ensuring a smooth transition without power loss. It also allows the operator to adapt the machine, such as a wheel loader, to different load and terrain conditions, optimizing efficiency and performance in various tasks.

Caja de transferencia WA500-3

Axles and Driveshafts

Axles and driveshafts serve as crucial foundations in wheel loaders, playing an essential role in transferring the power generated by the engine to the wheels. Axles, designed to withstand loads and torsion, are responsible for maintaining precise wheel alignment and ensuring reliable traction on diverse terrains. Driveshafts, on the other hand, act as vital intermediaries by seamlessly transmitting motion from the gearbox to the axles.

The synergy between these components is fundamental for the optimal performance of the wheel loader, especially in construction, mining, and earthmoving environments.

Keeping them in optimal condition is a priority to ensure the reliability and efficiency of the machine throughout its lifecycle.

Eje transmisión Komatsu WA320-3

Fluids and Lubrication

In the past, powershift transmissions used to rely on engine oil, which was not an optimal choice due to differences in composition and performance required by transmissions. Compared to specialized oils, engine oils could lead to wear and friction issues in components such as clutches and brakes. Changes in fluid technologies and design have given rise to advanced oils that enhance performance and durability.

These modern lubricants fulfill several vital functions, including ensuring friction stability, anti-wear protection, and material compatibility. They also provide control over sludge, protection against rust and corrosion, and thermal stability.

You can choose between single-grade or multigrade oils, depending on the climate and requirements. As the industry evolves, oils will continue to adapt to new engines and emission requirements, remaining essential in maximizing the efficiency and longevity of heavy machinery.

Typology

In the realm of wheel loaders and most heavy machinery, we encounter a variety of transmission types, each designed to meet specific needs and situations:

Transmision WA500-6

  • Powershift: Renowned for its seamless gear shifts, allowing the machine to maintain its momentum and efficiency while changing speeds. Extremely useful in situations of constant load or on uneven terrains. The smooth transition between gears optimizes operation in various conditions, providing greater traction and reducing clutch wear. In construction and mining environments where power and durability are essential, they have proven to be an effective choice.

 

  • Hydrostatic: Hydrostatic transmissions employ hydraulic fluids to transmit engine power to the wheels or tracks. This technology offers precise control and smooth maneuverability, making it particularly valuable for operations requiring precise movements and maneuvers in tight spaces. The ability to vary speed and direction smoothly and continuously makes hydrostatic transmissions ideal for accurately loading and unloading materials in congested work areas.

 

  • Automatic: Automatic transmissions, known for their comfort and ease of use in passenger vehicles, have also been adapted for heavy machinery, including wheel loaders. These transmissions automatically shift gears based on load conditions and machine speed, allowing operators to focus on other critical tasks. Efficiency and the smoothness of gear transitions are standout features of this transmission type, resulting in a more comfortable and productive operation.

Recycling and Sustainability

The recycling of used transmission components plays an essential role in reducing environmental impact and promoting sustainability in the industry. Firstly, recycling helps minimize the accumulation of electronic and metallic waste, reducing pressure on landfills and preventing soil and water pollution. By salvaging and reusing parts from decommissioned transmissions, the need to extract and process new raw materials is decreased, contributing to the conservation of natural resources.

Additionally, it can have a positive impact on the economy by fostering job creation in the recycling and refurbishment industry. Workshops and specialized companies in parts recovery can repair and refurbish used components, extending their lifespan and offering them at a more affordable cost compared to entirely new parts. This benefits both heavy machinery operators and fleet owners by reducing maintenance and replacement costs.

Lastly, it contributes to a circular economy mindset in the industry, where products and materials are reused and recycled instead of being discarded after their initial lifespan. This not only reduces the industry’s environmental footprint but also promotes greater awareness of the importance of resource conservation and environmental responsibility in a critical sector for construction and infrastructure.

WA500-3

In TAOP PARTS, we can provide the necessary spare parts for your machine, including transmissions and their components. Feel free to contact us for inquiries and assistance.

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info@taopparts.com