Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection of thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of thermopump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection of safety controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection of heating rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection of compressor stop valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection of coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspection of crank main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspection of connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
How to determine usability of cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection of connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspection of safety springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspection of piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspection of pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SeviceGuide_0178_948TOC.fm

Inspection of valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Inspection of unloading mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

0178-948 - ENG 1/30

Rev. 04.04
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

2/30 0178-948 - ENG

Rev. 04.04
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Service intervals
The service interval for a reciprocating compres- Fig. 1.3 R717 - TSMC 100 S-L
sor should be determined in the following way: E-type: Multiply by 0.75
1. Choose the appropriate diagram corre- TC
sponding to refrigerant and compressor qF qC
type. 14060

12250
Service interval diagrams 5,000

Condensing temperature
Fig. 1.1 R717 - SMC 100 S-L 10440
6,000
E-type: Multiply by 0.75 86 30 8,000
10,000
TC 68 20
11,000
qF qC
50 10 12,000
140 60
32 0
122 50 5,000 --60 --50 --40 --30 --20 --10 0 qC
--76 --58 --40 --22 --4 14 32 TE
104 40
qF
6,000 Evaporating temperature
T0113098_0
Condensing temperature

86 30 8,000
10,000
68 20 Fig. 1.4 HCFC/HFC/R290 - TSMC 100 S-L
50 10
01 introduction.fm

11,000
32 0
TC
14 --10 12,000 qF qC
13,000
--4 --20 140 60
--22 --30
122 50
5,000
Condensing temperature

--60 --50 --40 --30 --20 --10 0 10 20 30 40 qC

TE 6,000
--76 --58 --40 --22 --4 14 32 50 68 86 104 qF
104 40
T0113097_0 Evaporating temperature 8,000
86 30
10,000
Fig. 1.2 HCFC/HFC/R290 - SMC 100 S-L 68 20
11,000
50 10
TC
12,000
qF qC 32 0
--60 --50 --40 --30 --20 --10 0 qC
158 70 TE
--76 --58 --40 --22 --4 14 32 qF
140 60 Evaporating temperature
5,000
T0113100_0
122 50
Condensing temperature

6,000
104 40
8,000 2. Read the service interval from the curves in
86 30 10,000
the diagram.
68 20

50 10
11,000
If the compressor operates at another speed than
32 0 1460 rpm, correct the service interval according to
12,000
14 --10 table.
--4 --20

--22 --30 13,000

--60 --50 --40 --30 --20 --10 0 10 20 30 40 qC
TE
--76 --58 --40 --22 --4 14 32 50 68 86 104 qF
T0113099_0 Evaporating temperature

0178-948 - ENG 3/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Table 1.1 Note: The oil filter must always be replaced when
Rpm 970 1,170 1,460 1,760 changing oil or if indicated by control lamp or
UNISAB II.
Correction
1.5 1.25 1.00 0.83
factor The scope of the overhaul must follow the scheme
below:
Correction may also be calculated according to
• 1 x service interval: Use service set “A”
the formula below:
• 2 x service interval: Use service set “B”
1460
Correction = • 3 x service interval: Use service set “A”
Rpm
• 4 x service interval: Use service set “C”
Example The service sets include parts which must always
A compressor has a service interval of 10,000 be replaced regardless of appearance when com-
hours according to the diagram. pressor is opened. The above cycle is repeated as
If the compressor runs at 970 rpm, the service in- long as the compressor is in operation. The con-
terval will be 1.5 x 10,000 = 15,000h. tent of the individual service set is shown in the
annex.
Diagrams After the first 200 hours of operation, use the com-
The entire reciprocating compressor program will missioning set supplied with the compressor.
be covered by 7 diagrams: Inspection parts
SMC-CMO/R717 Besides the predetermined replacement accord-
ing to above service sets, an inspection of certain
SMC-CMO/R22-R134a-R404a
parts is prescribed. Parts for inspection are shown
TCMO-TSMC/R717 in the annex. Criteria for replacement of inspected
TCMO-TSMC/R22-R134a-R404a parts are shown in separate instruction.

HPC-HPO/R410A Nice-to-have-parts
HPC-HPO/R744 A list of recommended parts supporting the parts
inspection is available. The list contains all parts
HPC-HPO/R717 necessary if the inspected parts must be replaced.
In other words, these lists tell the service techni-
cian what to bring to the inspection.

4/30 0178-948 - ENG

Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Table 1.2

Service A Service B Service C

Oil filter Oil filter Oil filter

Ring plates
Valve springs
Lock nut for discharge valve
Piston rings
O-rings for shaft seal
(+ needed gaskets)
01 introduction.fm
Ring plates Ring plates
Valve springs Valve springs
Lock nut for discharge valve Lock nut for discharge valve
Piston rings Piston rings
Half section bearings Half section bearings
Bolt for connecting rod / lock nut Bolt for connecting rod / lock nut
Parts for unloading frame Parts for unloading frame
Shaft seal Shaft seal
(+ needed gaskets) Piston pin
Small end bearings
Main bearings
Discharge valve seat / bolt

(+ needed gaskets)

TSMC 100 TSMC 100 TSMC 100

Needle bearing + piston pin HP´ Needle bearing + piston pin HP Needle bearing + piston pin HP

0178-948 - ENG 5/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Table 1.3 Additional “nice to have” parts

Additional / Nice to have

Change: Change: Change:

V-belts V-belts V-belts
Rocker for unloading Rocker for unloading
Oil pump
(Change based on inspection) (Change based on inspection) (Change based on inspection)

Half section bearings Discharge valve seat / bolt Piston complete

Lock nut conrod screws Oil analysis kit Cylinder liner
Discharge valve seat / bolt Coils solenoid valves Discharge valve complete
Oil analysis kit Control equipment: Suction valve retaining plate
Shaft seal pressostat Coils solenoid valves
Coils solenoid valves thermostat Oil analysis kit
Control equipment: Control equipment:
transducers
pressostat pressostat
Heating element
thermostat Coupling parts
thermostat
transducers Oil return system parts transducers
Heating element Valve seats Heating element
Coupling parts Safety springs Coupling parts
Oil return system parts Stop valve gaskets Oil return system parts
Valve seats Cylinder liners Valve seats
Safety springs Pistons Safety springs
Bearing half sections Piston pins
Stop valve gaskets Piston pin bushings

6/30 0178-948 - ENG

Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

If the service interval exceeds one year, an annual
service and inspection is recommended. Oil and
gas suction filters should be changed, one top
cover should be dismantled and the discharge
valve and cylinder liner should be inspected.
Further a side cover must be removed and one
connection rod bearing half should be removed to
Table 1.4
inspect crankshaft journal and the big end of the
connection rods.
While service sets A, B and C are intended for ac-
tual service, the recommended annual service
is intended to ensure that the compressor is in-
spected each year.

Recommended annual service

Oil filter
Gas suction filter
Bolt and nut for one connecting rod
Gaskets for two top covers

Additional / nice to have:

(Change based on inspection)
01 introduction.fm

Gaskets for shaft seal

Oil analysis kit

0178-948 - ENG 7/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4
Inspection of thermostats
Depending on temperature range, thermostats
are checked as follows:
• Low temperature range, by means of ice
water ( +/-0ºC ).
• High temperature range, by means of boil-
ing water ( +100ºC ).
• Actual temperature setting is checked by
slowly increasing or decreasing the setting
while monitoring temperature cut off.
After checking, reset to actual condition.
Inspection of thermopump
Check the general function of the thermopump by
checking the pumping cycle – monitored by the
light diodes inside the control box.
The pumping cycle of the thermopump, i.e. a filling
and an evacuation period, lasts between 4 and 8
minutes depending on the oil temperature, operat-
ing conditions and number of cylinders of the com-
pressor. The filling period takes about 45 sec.
8/30
Filling and evacuation of the pump vessel is con-
trolled by the two level sensors pos. 98C. By
means of the control box, pos. 98B, the sensors
control the solenoid valves pos. 98G and pos.
98H. The solenoids open and close simultaneous-
ly – open during filling of the pump vessel and
closed during emptying of the pump vessel.
Check the function of the thermostat pos. 98X.
The thermostat is factory set to start operation
once the discharge gas temperature is above
80°C.
If the above inspection reveals malfunctioning:
• Clean the filter pos. 80 and possibly the noz-
zles pos. 98M.
• Check the function of the non-return valves
pos. 98K and 98Z by blowing compressed
air opposite the normal flow direction.
• Check the level sensors and the control box
according to instructions in the Service
manual.
0178-948 - ENG
Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4
Inspection of shaft seal
During operation a small amount of oil leaks from
the shaft seal. The oil forms a lubricating film be-
tween the rotating and the static face and thus
performs the sealing effect. Due to the differential
pressure, a certain flow out of the shaft seal can-
not be avoided.
Usually the amount of leaked oil is fairly small but
even when there is no mechanical fault, the shaft
seal leak rate may vary considerably. This may be
the result of different operating conditions as well
as the actual vibration condition and also the state
of the oil as temperature, viscosity, purity and re-
frigerant content will influence the sealing effect.
The leak may be somewhat more extensive at the
initial start-up of the compressor as the sliding sur-
faces have to a adapt to each other.
01 introduction.fm
The actual leak rate must be checked according to
the compressor logbook by comparing it with the
table below.
Litres per 24 hours
Good below 0.2
Worn 0.2 – 0.6
Defect above 0.6
“Good”: leave the shaft seal as it is unless per-
forming service “B” or “C”. At these services the
shaft seal must always be replaced.
“Worn” or “Defect”: replace the shaft seal. In
some cases the replacement of a “Worn” shaft
seal may be postponed to the next scheduled
service.
It is recommended to exercise great care with the
lapped slide surfaces as even the slightest scratch
or other damage to the slide surfaces will result in
leaks.
0178-948 - ENG
Rev. 04.05
If a shaft seal for any reason has been dismantled,
always replace O-rings before assembling. Check
that the sealing faces are clean, smooth and free
of scratches and wear marks.
Inspection of safety controls
If equipped with mechanical controls
1. Low suction pressure cut out, KP1(A) or
KP15(A):
a. Check the correct setting of the pressure
cut out – Service manual, section 4.
b. Slowly close the suction stop valve while
monitoring the suction pressure gauge.
c. Note the pressure where compressor
cuts off.
d. If necessary, adjust setting and repeat
above process.
e. Open suction stop valve and - check au-
tomatic reset on low pressure cut out.
2. High discharge pressure cut out, KP5(A) or
KP15(A) or KP7(A)BS:
a. Check the correct setting of the pressure
cut out – Service manual, section 4.
b. Slowly close the discharge stop valve
while monitoring the discharge pressure
gauge.
c. Note the pressure where compressor
cuts off – NB! KP7(A)BS dual high pres-
sure control.
d. If necessary adjust setting and repeat
above process.
e. Open discharge stop valve and check
manual reset (pressure diff. 4 bar.) on
high pressure cut out.
3. Oil pressure cut out, MP55(A):
9/30
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

a. Check the correct setting of the pressure a. Check the correct setting of the high dis-
cut out – Service manual section 4. charge pressure warning/alarm – UNIS-
b. Slowly and stepwise open the oil pres- AB manual section 5.
sure regulating valve while monitoring b. Slowly and stepwise close the discharge
the oil pressure. stop valve while monitoring the dis-
c. Allow reaction time of 60 seconds for charge pressure.
each step. c. Allow reaction time of 5 seconds for
d. Note the oil pressure where compressor each step.
cuts off and check manual reset (after 2 d. Note the discharge pressure where
min.). warning/alarm appears and compressor
e. If necessary, adjust setting and repeat cuts off.
above process. e. If necessary, adjust setting and repeat
f. Adjust oil pressure (on regulating valve) above process.
to 4.5 bar. f. Open discharge stop valve and check
4. Oil and discharge pipe thermostat, KP98: manual reset on high pressure alarm.

a. Check the correct setting of the thermo- 3. Oil pressure warning/alarm:

stat – Service manual, section 4. a. Check the correct setting of the low oil
b. Slowly decrease temperature settings pressure warning/alarm – UNISAB man-
while monitoring temperatures cut off. ual section 5.

c. Adjust actual settings and check manual b. Slowly and stepwise open the oil pres-
reset (temp. diff. oil/HT = 14/25 K). sure regulating valve while monitoring
the oil pressure.
If equipped with UNISAB control
c. Allow reaction time of 60 seconds for
1. Low suction pressure warning/alarm.
each step.
a. Check the correct setting of the low suc-
d. Note the oil pressure where warn-
tion pressure warning/alarm – UNISAB
ing/alarm appears and compressor cuts
manual section 5.
off and check manual reset.
b. Slowly close the suction stop valve while
e. If necessary, adjust setting and repeat
monitoring the suction pressure.
above process.
c. Note the pressure where warning/alarm
f. Adjust oil pressure (on regulating valve)
appears and compressor cuts off.
to 4.5 bar.
d. If necessary, adjust setting and repeat
4. Temperature warnings/alarms – discharge
above process.
gas, oil, suction superheat and discharge
e. Open suction stop valve and check auto- superheat.
matic reset on low pressure alarm.
a. Check the correct settings of above
2. High discharge pressure warning/alarm: warnings/alarms – UNISAB manual sec-
tion 5.

10/30 0178-948 - ENG

Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

b. Slowly increase/decrease temperature If equipped with UNISAB control and high

settings while monitoring warn- pressure safety cut out,
ings/alarms. KP 7(A)BS
1. First, do the test procedures for the me-
c. Adjust actual settings and check manual
chanical safety cut out as described above.
reset.
• Set the UNISAB high discharge pres-
5. Emergency stop:
sure alarm a little higher than the me-
a. Activate the emergency stop by a light chanical cut off.
pressure when compressor is in opera-
2. Second, do the test procedures for the UN-
tion.
ISAB control as described above.
b. Before restarting, reset the alarm and re-
• Set the UNISAB high discharge pres-
lease the emergency stop by turning it
sure alarm a little lower than the me-
clockwise.
chanical cut off.
Note: Local rules and standards are mandatory
and overrule the above recommendations if in
conflict.
01 introduction.fm

0178-948 - ENG 11/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4
Inspection of heating rod
When the compressor is stopped, the heating rod
must be activated and the oil temperature during
standstill must be clearly ( 10K or more ) above
ambient temperature.
Check if the power supply is switched on and
check the resistance of the heating cartridge by
using a multi-meter. If the heating circuit is cut off,
the resistance is infinitely great.
12/30
Inspection of compressor stop valves
Check the tightness of the gland at the valve spin-
dle by appropriate leak detection while turning the
valve spindle.
In case of leak, the packing gland pos. 25M and
the gasket for bonnet pos. 25J must be changed.
Check the tightness of the valve seat by appropri-
ate leak detection inside the compressor.
In case of leak, the sealing ring pos. 25H and the
gasket for bonnet pos. 25J must be changed.
When changing sealing rings and gaskets, the
sealing surfaces have to be clean and free from
scratches and wear marks.
0178-948 - ENG
Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Inspection of coupling
For coupling of the lamella type, see if there are
any signs of cracks in lamella (disc) package.
(To be inspected in-place).
Fig. 1.5
01 introduction.fm

0178-948 - ENG 13/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Fig. 1.6

Apply lever bar to

load joints

No cracks allowed
between rubber and
steel bushes.

For coupling of rubber type, check if vulcanization Check and adjust coupling alignment as de-
between rubber and steel bush is intact. Apply a scribed in manual.
lever bar to load joint.
Apply lever bar to load joints.

14/30 0178-948 - ENG

Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Inspection of crank main bearings

1. Make sure the journals are not seized up 3. The diameter of the intermediate bearing
(picture). journals on long blocks (112 and 116)
2. The diameter of the crankshaft journals should not be less than 79.87 mm.
should not be less than 79.81 mm.
01 introduction.fm

0178-948 - ENG 15/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Inspection of connecting rod bearings

1. Check the connecting rod bearings with no scratches. The bearing surfaces be-
your fingertips and make sure that you feel tween the individual stages must be even.
Fig. 1.7

Scratches are not acceptable.

Transitions between bearing sur-
faces must be even.

2. The diameter on the journals should not be 3. Check the axial clearance of the crank.
less than 79.89 mm.

(T)SMC 100 (T)SMC 100

CMO Mk1 & 2
4-10 cyl. 12-16 cyl.

minimum 0.30 0.40 0.75

maximum 0.55 0.64 1.0

16/30 0178-948 - ENG

Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

4. Check appearance of thrust bearing.

Fig. 1.8

Scratches and material dis-

placement are unacceptable.
01 introduction.fm

0178-948 - ENG 17/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

How to determine usability of cylinder liners

• See if there are any visible lengthwise
scratches on the running face:
Fig. 1.9

Visible lengthwise
scratches that you can
feel with your fingertips
are not acceptable.

18/30 0178-948 - ENG

Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

• See if the suction valve seats are damaged.

Fig. 1.10
01 introduction.fm

0178-948 - ENG 19/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

• See if valve seats are worn, i.e. has rounded

shoulders:
Fig. 1.11

Edges of valve seat

surfaces should be
sharp and not rounded

• Measure the inside diameter of the cylinder
liner at the top and bottom of the running
face.
Perform the measurement with a micrometer
gauge. The diameter should not exceed 100.25
mm anywhere.
If a measuring gauge is not at hand, wear may be
measured indirectly by a piston ring and a feeler
gauge (oil must be wiped away before measur-
ing):
1. Insert a piston ring (preferably a new one) in
the lower non-worn part of the cylinder
sleeve. Measure the gab between the ends
of the ring with a feeler gauge.
2. Secondly, move the piston ring to approxi-
mately 10 mm below the top of the sleeve.
Again, measure the gab between the ends
of the ring.
3. Finally, move piston ring to the lower part of
the worn area, approximately 10 mm above
the transition between worn and non-worn
area. Measure the gab.
4. Compare the measurements. The maxi-
mum difference between measurements in
non-worn and worn area (running face)
should not exceed 0.6 mm.
If a cylinder sleeve shows any of the above de-
fects, it must be replaced.

20/30 0178-948 - ENG

Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Inspection of connecting rod

1. Small end: Must be free from distinct Shiny areas are acceptable.
scratches (material displacement) on the
bearing surface.
Fig. 1.12
01 introduction.fm

Distinct scratches and

material displacement
are not acceptable

The picture shows a useless connecting rod bush- If the connecting rod and the piston are not sepa-
ing with scratches. rated a check can be made as follows:
2. The bushing diameter must not exceed
40.08 mm.
Can be measured with a good digital slide
gauge.

0178-948 - ENG 21/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Fig. 1.13

Press small end towards

one side of the piston.

3. Hold the piston steady against a level sur- Try to move the big end of the connecting
face. Press the small end of the connecting rod sideways. The big end should not move
rod towards one side of the piston. more than 1 mm sideways.

22/30 0178-948 - ENG

Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Fig. 1.14

Shiny areas are acceptable

- material displacement is
not.
01 introduction.fm

The picture shows a bushing after

normal operation.

0178-948 - ENG 23/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Inspection of safety springs

The safety springs on the discharge valves must
be intact and have the following minimum heights
in unloaded condition:
Table 1.5
(T)SMC (T)SMC Mk2&3 (T)SMC Mk4 S&L (T)SMC Mk4 E
Mk2&3 9.5 mm wire 12 mm wire 10.5 mm wire
9.0 mm wire

Minimum height 62 mm 58 mm 73 mm 69 mm

24/30 0178-948 - ENG

Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Inspection of piston pin

1. At normal workshop temperature, you gers. The hotter the piston gets, the more
should be able to just slightly rotate and the fitting will loosen. There should be no
move sideways the piston pin with your fin- clearance in the fitting.
Fig. 1.15
01 introduction.fm

2. The diameter of the piston pin should not be 3. Feel the bearing surfaces on the piston pin
less than 39.96 mm. with your fingertips and make sure that they
are even.

0178-948 - ENG 25/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Inspection of pistons
1. Make sure there are no deep scratches in 2. The width of a worn area must not exceed
the piston skirt. 30 mm.
Fig. 1.16

Worn area. Scratches are

visible and you can feel
them with your fingertips.

max. 30 mm

The picture shows a useless piston.

In order for a piston to be reused, it must be in a considerably better condition than this one.
3. The diameter of the piston should not be 5. Check the axial clearance between the pis-
less than 99.7 mm. ton and the ring using a feeler gauge. It must
4. Check that the piston rings can be turned not exceed 0.2 mm with a new piston ring.
freely in the piston groove.

26/30 0178-948 - ENG

Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

Inspection of valve seats

The valve seats must not be damaged...
Fig. 1.17
01 introduction.fm

0178-948 - ENG 27/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

or corroded...
Fig. 1.18

28/30 0178-948 - ENG

Rev. 04.05
 Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

or have rounded shoulders.

Fig. 1.19

The valve seat edges

must not be rounded.
01 introduction.fm

0178-948 - ENG 29/30

Rev. 04.05
Service guide SMC and TSMC 100 Mk1, 2, 3 and 4
Inspection of unloading mechanism
Make sure that wear has not made oval holes in
the spring eye fittings.
Connect the prelubrication pump to each unload-
ing cylinder. Press the pump handle with a con-
stant pressure of approx. 20 kp. The handle must
not sink more than 5 cm in 60 seconds. Observe
30/30
that the unloading frame moves between extreme
positions when the pressure is activated and re-
moved.
Check for broken springs and wear on rocker
arms and the bushing in the unloading system.
0178-948 - ENG
Rev. 04.05