XQC1200 and XQC1600 Power Modules Caterpillar

Installation Procedure

Show/hide table

Illustration 1	g03700478

1. Use Tooling (C) to install the piston rings onto the piston.

   1. For the oil control ring, ensure that the ends of the spring are 180 degrees from the ring gap. The white portion of the spring must be visible at the ring gap.

   2. Install the intermediate ring with the side marked "UP-2" toward the top of the piston.

   3. Install the top ring with the side marked "UP-1" toward the top of the piston.

   4. After the rings are installed, rotate the rings so that the gaps are spread apart by 120 degrees. Orient the oil control ring gap toward the bore for the piston pin.
   Show/hide table

   Illustration 2	g03700479

2. Place the piston crown into the piston skirt. Use clean engine oil to coat the bore of piston (3), piston pin (4), and the piston pin bearing in connecting rod (5). Position connecting rod (5) inside piston (3). Insert piston pin (4) through piston (3) and the bearing.
   Show/hide table

   Illustration 3	g03700480

3. Use Tooling (B) to install the retaining rings. Orient the retaining ring gaps toward the top of piston (3).

4. Install the upper half of the connecting rod bearing in connecting rod (5). Ensure that the tab on the back of the bearing is in the bearing tab groove in connecting rod (5).

5. Coat the piston rings, the cylinder liner, and the upper half of the connecting rod bearing with clean engine oil.
   Show/hide table

   Illustration 4	g03700482

   Show/hide table

   Illustration 5	g03700483
   Chamfer on one side of the connecting rod bore

6. Use Tooling (H) to compress the piston rings.
   Show/hide table

   NOTICE
   Improper installation of the piston and connecting rod assembly will result in severe damage to the engine. Make sure that the side of the connecting rod bore with the chamfer is oriented next to the surface of the crankshaft thrust plate. The square side of the connecting rod bore must be next to the other connecting rod that is on the same crankshaft journal.

7. Install the piston and connecting rod assembly into the cylinder liner. Ensure that the side of the connecting rod bore with the chamfer is oriented next to the surface of the crankshaft thrust plate. The square side of the connecting rod bore must be next to the other connecting rod that is on the same crankshaft journal.
   Show/hide table

   Illustration 6	g03700484

8. Install the lower half of the connecting rod bearing in connecting rod cap (2). Ensure that the tab on the back of the bearing is in the bearing tab groove on the connecting rod cap (2). Coat the bearing with clean engine oil.

9. Apply Tooling (J) to the bolt threads and to all of the surfaces of the bolts that contact connecting rod cap (2).

10. Position connecting rod cap (2) on the connecting rod and install the bolts.
    Show/hide table

    Illustration 7	g01006031
    (12) Side of the connecting rod with the chamfer (13) Location pin

    1. Tighten Bolts (A) and (B) to 90 ± 5 N·m (65 ± 4 lb ft).

    2. Tighten Bolts (C) and (D) to 90 ± 5 N·m (65 ± 4 lb ft).

    3. Tighten Bolts (C) and (D) again to 90 ± 5 N·m (65 ± 4 lb ft).

    4. Tighten all of the bolts for an additional 90 ± 5 degrees (1/4 turn).

11. Check the side clearance that is between two of the connecting rods that are on the same journal. The clearance must be 0.85 ± 0.332 mm (0.034 ± 0.0130 inch).

End By:

1. Install the piston cooling jets.

2. Install the cylinder head.