Reuse and Salvage for Connecting Rods {1218} Caterpillar

Caterpillar Products

All Cat Engines

Introduction

Table 1

Revision	Summary of Changes in SEBF8064
39	Corrected C175 bend tolerance. Metal Spray for Machine Caps only. Added new Serial Numbers
38	Corrected table for 3400 connecting rods.
37	Added Bend and Twist Tool and removed inspections of bearings.
36	Combined information from SEBF2124, SEBF8063, SEBF8075, SEBF8108, SEBF8149, SEBF8242, SEBF9074, SEBF9104, SEBF9133, SEBF9197, SEBF9242, and repaired 44 pixelated illustrations.

© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillardealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC). To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, or operating technique is not recommended by Caterpillar, ensure that it is safe for you and for other people. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

This guideline provides visual examples of connecting rods that are used in Caterpillar engines. This guideline contains the necessary information for reusing the connecting rods. the connecting rods that are used in the same application should be expected to give normal performance until the next overhaul. The connecting rods may be used only if the connecting rod meets the criteria in this guideline and other applicable guidelines.

Service Advisories, Service Letters, and Technical Information Bulletins

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NOTICE
The most recent Service Advisories and Service Letters that are related to this component should be reviewed before beginning work. Often Service Advisories, Service Letters, and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information which pertain to the components being repaired.

References

Table 2

References
Media Number	Publication Type & Title
SEBF8042	Reuse and Salvage Guidelines "Reuse and Salvage for Crankshafts"
SEBF8059	Reuse and Salvage Guidelines "Inspection Procedures and Specifications for Pistons and Piston Pins"
SEBF8148	Reuse and Salvage Guidelines "General Salvage and Reconditioning Techniques"
SEBF8187	Reuse and Salvage Guidelines "Standardized Parts Marking Procedures"
SEBF8357	Reuse and Salvage Guidelines "General Cleaning Methods"
SEBF8418	Special Instruction "Cylinder Block Cleaning Procedures"
SEBF9066	Applied Failure Analysis "Guideline for Examining Failed Parts"
SEBF9162	Reuse and Salvage Guidelines "Inspection and Reconditioning Procedures of Main Bearing Bores in Cylinder Blocks"
SEBF9185	Reuse and Salvage Guidelines "Specifications and Salvage for Cylinder Blocks in C175 Engines"
SEBF9236	Reuse and Salvage Guidelines, "Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for Reconditioning Components"
SEBF9238	Reuse and Salvage Guidelines, "Fundamentals of Arc Spray for Reconditioning Components"
SEBF9240	Reuse and Salvage Guidelines, "Fundamentals of Flame Spray for Reconditioning Components"
SEBV0544	Applied Failure Analysis "Engine Bearings"
SEBV0546	Applied Failure Analysis "Connecting Rod Applied Failure Analysis"
SEHS7295	Special Instruction "Use of Piston Pin Bearing Removal and Installation Tools"
SEHS9031	Special Instructions , "Storage Procedure for Caterpillar Products"
SMHS7366	Special Instruction "Using The 5P-2050 Connecting Rod Checking Fixture"
SMHS8037	Special Instruction "Using The 6V-6000 Dial Bore Gauge Group"
SMHS8253	Special Instruction "Use of 6V-7898 Dial Bore Gauge Group"
SMHS8254	Special Instruction "Using the 6V-7899 Size Setting Fixture Group"
Caterpillar Channel 1 Video
Media Title	Reference Media URL
"Mahr Connecting Rod Bend Twist Measurement System"	https://channel1.mediaspace.kaltura.com/media/Mahr+Connecting+Rod+Bend+%26+Twist+Measurement+System/1_5n7cv5o8

Tooling and Equipment

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NOTICE
Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools.

Table 3

Tooling and Equipment
Part Number	Description
1P-2375	Quick Connect Coupler (1)
1P-3537	Dial Bore Gauge Group
1P-7437	Protection Cap(1)
1S-0258	Soft Face Hammer
1U-6242	Adapter for Removal and Installation
1U-6243	Pushing Adapter
1U-6244	Spacer
1U-9034	Pushing Adapter
1U-9032	Adapter for Removal and Installation
1U-9033	Spacer
1W-6267	Spacer
2P-5518	Bearing Removal Tool
2P-5571	Press Guard Kit
4C-8626	Reconditioning Star
4C-8725	Adapter for Removal and Installation
4C-8726	Spacer
4C-8727	Pushing Adapter
4C-8629	Mandrel
4C-9749	Pushing Adapter
4C-9750	Adapter for Removal and Installation
4C-9751	Spacer
5P-0159	Cap (1)
5P-2050	Connecting Rod Checking Fixture
5P-2051	Position Arm
5P-2053	Crank Mandrel
5P-2054	Dial Indicator
5P-8639	Connecting Rod Bushing Press
5P-8640	Bar Clamp
5P-8641	Bar Clamp
5P-8642	Clamp Pin
5P-8643	Post Assembly
5P-8645	Pushing Adapter
5P-8646	Adapter for Removal and Installation
5P-8647	Spacer
5P-8649	Pushing Adapter
5P-8650	Adapter for Removal and Installation
5P-8651	Spacer
5P-8653	Adapter for Removal and Installation
5P-8655	Tool Group
5P-8656	Adapter for Removal and Installation
5P-8661	Spacer
5P-8662	Spacer
5P-8663	Pushing Adapter
5P-9725	Hydraulic Cylinder
6V-2010	Polishing Stone
6V-2012	Depth Micrometer
6V-2032	Adapter
6V-2033	Brush
6V-2049	Adapter for Removal and Installation
6V-3029	Spacer
6V-3042	Adapter for Removal and Installation
6V-3043	Spacer
6V-3197	Spacer
6V-4819	Spacer
6V-4876	Molykote Paste Lubricant
6V-6000	Dial Indicator
6V-6030	Fixture
6V-6100	Tool Group for Tapered Rod Bearings
6V-7898	Dial Bore Gauge
6V-7899	Size Setting Fixture
6V-8237	Washer
8H-8581	Dual Scale Feeler Gauge
8T-0820	Pressure Gauge
8T-7765	Surface Reconditioning Pad
9A-1593	Surface Texture Comparison Gauge
9U-5917	Pin Mandrel (Bushing In)
9U-5918	Pin Mandrel (Bushing Out)
9U-5945	Locating Group for Connecting Rods
9U-5948	Expanding Segments
9U-6600	Hydraulic Hand Pump
164-3310	Infrared Thermometer
185-3998	Thread Lock Compound
222-1154	Air Engraver
222-3074	Die Grinder
223-1693	Hammer
223-1694	Dead Blow Hammer
223-4357	Coarse Needle
226-1901	Punch
237-5181	Respirator
263-9070	Steel File
274-7701	Bolt
303-9339	Lint Free Shop Towels
313-5978	Adapter for Removal and Installation
313-5979	Spacer
322-6227	Bar Clamp
349-4200	Infrared Thermometer
350-7768	Electric Hydraulic Pump Gp (110V)
350-7769	Electric Hydraulic Pump Gp (220V)
360-3040	Induction Heater (110V)
364-1170	Induction Heater (220V)
367-9109	Caliper
383-8887	Dual Scale Feeler Gauge Set
386-3364	Straight Edge Ruler
428-7386	Bolt
434-7091	Go-No-Go Gage
443-7045	Pin Bore Bushing Tool
443-7046	Fixture Assembly
448-3698	Profilometer
473-8688or473-8689	Internal Micrometer Set 2-12 inch
	Internal Micrometer Set 50-300 mm
473-8690	Outside Electronic Micrometer Set 0-4 inch
473-8691	Outside Electronic Micrometer Set 2-6 inch
473-8692	Outside Electronic Micrometer Set (6-12 inch)
477-3314	Rust Preventative Oil
503-5808	Drive Arbor
503-5809	Brush
533-1180	Induction Heater (110V)
533-1181	Induction Heater (220V)
FT-1831	Rod Mask
FT-1833	Rod Mask
FT-1834	Rod Mask
FT-1837	Fixture
-	Loctite Graphite-50 Anti-Seize Lubricant(2)
-	Bel-Ray Molylube 67700
-	Loctite Maxi Coat(3)
-	Sharpening Stones
-	Protective Jaws

(1)	Part of 5P-9725 (Hydraulic Cylinder))
(2)	Go to Loctite.com to purchase LB 8008
(3)	Go to Loctite.com to purchase PC 9660 or SF 7803.

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

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When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Flow Charts

Illustration 3	g06360672

Illustration 4	g06360737

Illustration 5	g06360754

Illustration 6	g06360958

Prepare the Area for Inspection

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Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using.

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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

• Clean all surfaces for inspection before you inspect the part or before the measurement. Make sure that you remove all debris, paint, and oil.

• When you move parts that require cleaning, always use a proper lifting device. This device must protect the part from damage. For the safety of the operator, all lifting devices must be inspected before use.

• During cleaning, do not damage machined surfaces.

• Use pressurized air to dry parts.

• If the rod cannot be inspected immediately after cleaning, put hydraulic oil on all machined surfaces to prevent rust or corrosion. Carefully store the parts in a clean container.

• Use appropriate thread taps to chase all threaded holes.

• Do not use glass beads on the crankshaft bore, the thrust face, or the piston pin bore.

• Connecting rods and connecting rod caps come in sets. Use connecting rods and caps that have the same reference number. If the crankshaft bore needs to be machined, the connecting rods and connecting rod caps should be put back together.

Illustration 7	g06367263
Cleaning the connecting rod bore.

Clean the crankshaft bore with WD-40 and a bronze bristle brush. The crankshaft bore has a honed surface and the bronze brush will not scratch the bore. Remove all the raised carbon build-up. It is not necessary to remove completely all the staining in the bore. Carbon material in the valleys of the honing grooves is acceptable. Rz surface texture must be measured in areas where the valleys are free of carbon deposits.

Do not clean the bore with an abrasive material such as Scotch-Brite. Scotch-Brite can alter the surface finish and leave debris that could cause a bearing seizure. Protect the oil hole from contaminates and visually inspect for cleanliness prior to reuse.

Note: Not all discoloration will be removed by using this method of cleaning.

Illustration 8	g03884238
Connecting rod cap. (Q) Cleaned with WD-40 and a bronze brush (R) Carbon deposits prior to cleaning.

Illustration 9	g06367269
Acceptable carbon left on the after cleaning the connecting rod.

Standardized Parts Marking Procedure

Connecting rods and connecting rod caps come in sets. Use connecting rods and caps that have the same reference number. If the crankshaft bore needs to be machined, the connecting rods and connecting rod caps should be put back together. Refer to Reuse and Salvage Guideline, SEBF8187, "Standardized Parts Marking Procedures"

The code is a Cat standard and is used to record the history of a component. The code will identify the number of rebuilds and hours at the time of each rebuild. This information is important and should be considered for any decision to reuse a component.

Ensure that the mark is not covered by a mating part. Use a metal marking pen to mark the code onto the component.

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NOTICE
Do not use numbering stamp punches or a chisel to mark internal components or to mark the rod cap. The impact from striking the stamp will cause an abnormal stress riser. The added stress riser may cause premature part failure. Do not put a stamp on the connecting rod or the connecting rod cap for identification. Do not put a mark on the connecting rod in the shank area

Illustration 10	g06124077
DO NOT use numbering stamp punches to mark internal components.

The procedure for marking components is a Cat standard. This code is helpful when the machine is sold into a different territory after the first rebuild. During an overhaul, the previous code of a part should never be removed.

Example 1

If the crankshaft bore is remachined, put a mark or etch the letter (R) on the outside of the connecting rod directly above the parting face.

Illustration 11	g06191874
If the crankshaft bore is remachined, put a mark or etch the letter (R) on the outside of the connecting rod directly above the parting face.

Mark the ground area of a new connecting rod with an electric scribe.

Illustration 12	g03856853
Typical Example

Illustration 12 shows code (1-15). The first number (1) indicates that the gear had been rebuilt once. The second number (15) indicates that there were 15,000 hours on the gear at the time of rebuild.

Example 2

Illustration 13	g03856857
Typical Example

Illustration 13 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates that the gear had been rebuilt twice. The second number (10) indicates that 10,000 hours accumulated on the gear between the first and second rebuild.

Note: Add the first and second rebuild hours to obtain the total number of hours for the gear in Illustration 13. In this example, the gear has a total of 22,000 hours.

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

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When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Visual Inspection

Nomenclature

Illustration 14	g01277385
A typical connecting rod that is not serrated (1) Fillet (2) Seat for the nut (3) Seat for the bolt (4) Piston pin bushing (5) Shank (6) Bolt (7) Parting line (8) Connecting rod cap (9) Nut (10) Thrust face (11) Piston pin bore (12) Crankshaft bore

Illustration 15	g01277386
A typical serrated connecting rod on the top and a 3500 Series engine connecting rod on the bottom (1) Fillet (4) Piston pin bushing (5) Shank (6) Bolt (7) Parting line (8) Connecting rod cap (10) Thrust face (11) Piston pin bore (12) Crankshaft bore

Fractured Connecting Rods

Illustration 16	g01277400
Fractured connecting rod assembly

Illustration 17	g01277732
Fractured connecting rod and connecting rod cap

Illustration 18	g01277823
A fractured connecting rod cap

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NOTICE
The joint between the connecting rod and the connecting rod cap are produced by fracturing. The connecting rod assembly must be handled with care to avoid damage to the mating surfaces. The connecting rod assembly must be replaced if any damage occurs to the mating surfaces. New connecting rod assemblies come with the connecting rod caps bolted to the connecting rod. Use only a soft jawed vise to hold the connecting rod assembly when removing the connecting rod cap bolts. Use only a soft faced hammer to tap the connecting rod cap when separating the connecting rod cap from the connecting rod. Failure to use a soft jawed vise and a soft faced hammer may result in damage to the connecting rod assembly.

Caterpillar uses a fractured connecting rod design in some of the engines. The fractured connecting rod is able to accept higher loads because the joint surfaces are precisely matched. The fractured uneven surface helps locate the connecting rod end and the cap. Fretting on the joint face has been eliminated with the fractured connecting rod. The reduced machining steps and the controlled process of machining has produced a higher quality of processing.

Voids in Fractured Connecting Rods

Voids are often present in the bolt keep areas of the connecting rods. This is a normal part of the fractured rod splitting process. The voids should not exceed the specifications that are shown in Table 4.

Illustration 19	g06315781
Example of a void in the fracture joint

Illustration 20	g06010081
Example of a void in the fracture joint

Illustration 21	g06010135
Example of a void in the face of the rod along fractured joint

Some voids are deep enough to allow the connecting rod bolt to be viewed. These voids are still acceptable as long as the voids do not exceed the listed specifications in Table 4.

Illustration 22	g06315790
The voids in the fracture rod can ONLY be present on the outside side (B) and the Thrust Face/ Chamfer Side (C175) (C) of the fractured joint. NO voids are allowed on the inside bore fracture location (A). (A) Inside bore fracture (B) Fracture termination side of the fracture (C) Thrust face/chamfer side (C175) of connecting Rod (D) Non-chamfer side of the fracture

Illustration 23	g06255319
The arrow shows an example of a void in the Thrust Face (C). (C) Thrust Face

Illustration 24	g03418904
Example of a void in a connecting rod that is in both the thrust face and side. (B) Void Location on the side of Connecting Rod (C) Void Location on the thrust face of Connecting Rod

Illustration 24 has a void in a connecting rod that is in both the Thrust Face (C) and in the Side (B). For these corner voids measure both the Thrust Face (C) and the (B) areas of the void, treat the two measurements separately; if either measurement is over the specifications in Table 4, the connecting rod cannot be reused.

Table 4

Void Specifications of Fractured Connecting Rods
Engine Model	Maximum Void Size with Unrestricted Depth (A)	Maximum Void Size of the Sides (B)(1)	Maximum Void Size on the Thrust Face (C)(2)	Maximum Void Size on the Non-Chamfer Side (C175) (D)	Maximum Number of Voids per Side
C7	No voids allowed	2 mm (0.08 inch) x 6 mm (0.24 inch)	1 mm (0.0394 inch) x 3 mm (0.118 inch)	N/A	2
C9	No voids allowed	3 mm (0.12 inch) x 7 mm (0.26 inch)	1 mm (0.0394 inch) x 3 mm (0.118 inch)	N/A	2
C13	No voids allowed	3 mm (0.12 inch) x 7 mm (0.26 inch)	1 mm (0.0394 inch) x 3 mm (0.118 inch)	N/A	2
C15 and C18	No voids allowed	3 mm (0.12 inch) x 7 mm (0.26 inch)	1 mm (0.0394 inch) x 3 mm (0.118 inch)	N/A	2
C27 and C32	No voids allowed	2 mm (0.08 inch) x 6 mm (0.24 inch)	1 mm (0.0394 inch) x 3 mm (0.118 inch)	N/A	2
C175	No voids allowed	2 mm (0.08 inch) x 6 mm (0.24 inch) 2 mm (0.08 inch) x 7 mm (0.27559 inch) with a max depth of 3 mm (0.11811 inch) (3)	2 mm (0.08 inch) x 4 mm (0.15748 inch) 2 mm (0.08 inch) x 5 mm (0.19685 inch)with a max depth of 3 mm (0.11811 inch) (3)	1 mm (0.0394 inch) x 3 mm (0.118 inch)	2

(1)	Measurements are length x width. Length should be measured to the longest point of the void.
(2)	Measurements are length x width. Length should be measured to the longest point of the void.
(3)	Maximum void size with measured depth

Crankshaft Bore

Illustration 25	g01277461

USE AGAIN

The crankshaft bore contains material that has been pushed into the surface. The crankshaft bore contains some lighter wear. The connecting rod can be reused if the connecting rod is reconditioned with the correct salvage operations.

Illustration 26	g01277474

USE AGAIN

Remove light rust from the crankshaft bore or the thrust face of the connecting rod. Be careful not to remove any metal from the connecting rod.

Illustration 27	g01277480

USE AGAIN

The connecting rod has light deburring at the parting line. These marks are acceptable if the area is small and smooth. The marks must be limited to the parting line to be used again.

Illustration 28	g01277490

USE AGAIN

Boring the connecting rod did not clean up the dark area inside the crankshaft bore. The connecting rod should be used again if no more than 15.0 mm (0.60 inch) of dark area appears on both sides of the parting line.

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NOTICE
Never use a connecting rod that shows heat discoloration caused by a failure such as connecting rod bearing failure.

Illustration 29	g01277493
The connecting rod has discoloration around the crankshaft bore.

DO NOT USE AGAIN

Illustration 30	g01277495
The connecting rod has heavy damage in the crankshaft bore.

DO NOT USE AGAIN

Illustration 31	g03884349
Connecting rod with bearing material transfer.

DO NOT USE AGAIN

After the bore is cleaned, inspect the area near the split line for material transfer from the bearing back to the connecting rod. If material transfer is present, then the rod cannot be reused.

C27/C32 Connecting Rod Inspection

The following section is specific to only the C27/C32 connecting rod inspection. The C27/C32 connecting rods may have additional wear at the thrust face. The thrust face on some C27/C32 connecting rods require an additional inspection procedure. In addition to a visual inspection, a measurement of the rod cap must be taken as well.

Illustration 32	g03813957
Visual inspection of the C27/C32 connecting rod. C27/C32 connecting rod showing excessive thrust face wear with a wear step.

DO NOT USE AGAIN

Illustration 33	g03889584
C27/C32 rod cap measurement inspection

Measure the C27/C32 rod cap thickness using 367-9109 Caliper. The C27/C32 connecting rod may be used again if the minimum width is no less than 41.92 mm (1.650 inch). Remove any high spots or burrs using 6V-2010 Polishing Stone.

C175 Connecting Rod Inspection

The following section is specific to only the C175 connecting rod inspection. In addition to a visual inspection, a measurement of the surface texture is required.

After the bore is cleaned, then inspect the connecting rod bore for the factory hone pattern.

Illustration 34	g03885539
C175 crankshaft bore hone pattern. The hone cross hatch will be approximately 90°.

Look for a honed surface texture with a 90° cross hatch pattern. The new and reuse surface texture specification is 2.5 µm (98.42520 µinch) to 3.5 µm (137.7953 µinch) Rz. The measurement must be taken in areas where the valleys are clean and free from deposits.

Illustration 35	g03884385

USE AGAIN

• Refer to Illustration 35.

• Bore is clean but retained a slight carbon buildup in valleys of hone pattern.

• Bore is free of all raised carbon deposits.

• Hone pattern is present in bearing seat area.

Illustration 36	g03884426

DO NOT USE AGAIN

• Refer to Illustration 36.

• Bore has been cleaned.

• No raised carbon build-up.

• Honed pattern is no longer present in bearing seat area.

Thrust Face Wear

Illustration 37	g03885812
C175 connecting rod with thrust face wear.

Inspect the thrust face (chamfered face) of the connecting rod for excessive wear, heat damage, and side clearance. The connecting rod is acceptable for reuse if the thrust face surface is smooth and without bluing from excessive heat.

Body of the Connecting Rod

The area of the slot for the pin and the walls of the opening for the bolt hole should be inspected for cracks. If any cracks are present in these areas, do not use the connecting rod again.

Illustration 38	g01640693
(8) Crack in the slot for the pin

DO NOT USE AGAIN

Illustration 39	g01640695
(9) Crack in the wall of the opening for the bolt

DO NOT USE AGAIN

Illustration 40	g01277742

Inspect the parting line of connecting rods that are not serrated. Machine the connecting rod according to the correct salvage operations. Refer to the "Specifications for the Connecting Rod" Section.

DO NOT USE AGAIN

Note: Do not remove more than 0.03 mm (0.001 inch) from the parting line of the connecting rod.

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NOTICE
Caterpillar does not recommend grinding the serrations of serrated connecting rods or the parting line area of the connecting rods. Use oversized bearings in the salvage operation for these connecting rods, but only if the parting line areas are not damaged. Refer to parts manual for the correct part numbers and sizes.

Illustration 41	g01277744

The connecting rod has typical wear on the body.

USE AGAIN

Visually inspect the body of the connecting rod at the point of contact with the connecting rod cap.

Illustration 42	g01277472

USE AGAIN

The connecting rod has a small nick on the thrust face. Remove any high areas on the connecting rod with 6V-2010 Polishing Stone.

Illustration 43	g01277503
The connecting rod has damage to the bolt hole.

DO NOT USE AGAIN

Illustration 44	g01277507
The connecting rod has heavy damage to the thrust face.

DO NOT USE AGAIN

Shank Area

Illustration 45	g01281056

The connecting rod has marks on the shank that are not a result of engine failure. Use the connecting rod again only if the area has been peened at the factory.

USE AGAIN

Illustration 46	g01281059

The connecting rod has small nicks on the edge of the shank after peening. Improper handling will cause this type of damage. Use the connecting rod again only after the shank has been reconditioned. See Illustration 52.

USE AGAIN

Illustration 47	g01281062

The connecting rod has a small nick on the edge of the shank. Use the connecting rod again after reconditioning.

USE AGAIN

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NOTICE
Never use any connecting rod that has failed due to a severe event unless the connecting is inspected for cracks. Refer to Reuse and Salvage Guideline, SEBF8042, "Reuse and Salvage for Crankshafts" for more information on equipment for the magnetic particle inspection. Refer to the "Measurement Procedures for Connecting Rods" Section for more information on connecting rods that are bent or twisted.

The small nick on the shank of the connecting rod in Illustration 48 was made after the connecting rod was peened at the factory. The dull surface on the remainder of the shank shows peening that was done to give strength to the connecting rod.

Illustration 48	g01281356

The connecting rod has a small nick on the shank that was created after peening.

DO NOT USE AGAIN

Illustration 49	g01281360

The connecting rod has heavy damage on the shank after peening.

DO NOT USE AGAIN

Illustration 50	g01281363

The connecting rod has heavy damage on the edge of the shank after peening.

DO NOT USE AGAIN

Illustration 51	g01281367

The connecting rod has been badly bent. Bent connecting rods or twisted connecting rods cannot be used again. Refer to the "Specifications for the Connecting Rod" Section for slightly bent connecting rods. Refer to the "Measurement Procedures for Connecting Rods" Section for more information on connecting rods that are bent or twisted.

DO NOT USE AGAIN

Note: The connecting rods should be inspected for bent areas or twisted areas . Visual inspection of the connecting rod is not enough inspection.

Some small nicks in the shank of the connecting rod can be removed. Remove the small nicks from the shank with sharpening stones. The recommended stone is made of aluminum oxide. The combination of stone with a coarse grit and a fine grit is recommended. Follow these steps to recondition the connecting rod:

• Remove any sharp nicks and edges from the connecting rod.

• Make sure that the surface of the connecting rod is smooth to the touch.

• The area that was reworked needs tobepeenedafter the nicks are removed.

Illustration 52	g01281131

The shank of the connecting rod has been reconditioned.

USE AGAIN

Connecting Rod Cap

Illustration 53	g01277811

Inspect the parting line of connecting rod cap that is not serrated. Machine the connecting rod cap according to the correct salvage operations. Refer to "Specifications for the Connecting Rod" Section.

USE AGAIN

Note: Do not remove more than 0.15 mm (0.006 inch) from the connecting rod cap.

Illustration 54	g01277813

The connecting rod cap has typical wear at the parting line. Use the cap again if the wear step is no more than 0.03 mm (0.001 inch). Any wear step beyond 0.03 mm (0.001 inch) cannot be salvaged.

USE AGAIN

Show/hide table

NOTICE
Caterpillar does not recommend grinding the serrations of serrated connecting rods or the parting line area of the connecting rods. Use oversized bearings in the salvage operation for these connecting rods, but only if the parting line areas are not damaged. Refer to parts manual for the correct part numbers and sizes.

Illustration 55	g01277825

The serrated connecting rod has a small amount of polishing on the parting line. Use the connecting rod again if the wear step cannot be felt with the fingernail.

USE AGAIN

The area for the bolt seat on the connecting rod cap should be visually inspected for fretting or galling. Do not use the connecting rod again if there is any evidence of fretting or galling in the area on the bolt seat. Sometimes, the connecting rod can be used again.

Illustration 56	g01277827

The fillet around the bolt holes on the connecting rod and the cap are carefully machined. The fillets have been peened. Peening releases the stresses that are caused by sharp corners. No damage is acceptable in the fillet or the blended area indicated in Illustration 56.

USE AGAIN

Illustration 57	g01277834

Seat Areas for the Hardware

Smearing in the seat area of the connecting rod is acceptable if the smearing cannot be felt with the fingernail.

USE AGAIN

Illustration 58	g01277837

The connecting rod has a large nick on the top of the counterbore of the seat area. The connecting rod cannot be repaired.

DO NOT USE AGAIN

Illustration 59	g01277852

Illustration 60	g01277856

Illustration 61	g01277857

The seat area of the connecting rod has fretting and galling.

DO NOT USE AGAIN

The connecting rod may be used again if the seat area has been machined. Refer to Illustration 124.

Piston Pin Bushing

Illustration 62	g01280940

The area for the piston pin has cracks along the edge of the bushing. Use the connecting rod again after installing a new bushing.

USE AGAIN

Illustration 63	g01280952

The area for the piston pin has high areas and nicks in the bushing. Use the connecting rod again after installing a new bushing.

USE AGAIN

Illustration 64	g01280956

The area for the piston pin has discoloration on the bushing. The connecting rod is reusable if no marks from scoring or seizure can be felt with the fingernail. Use the connecting rod again if the discoloration was not caused by rotation of the pin bushing in the bore. Discoloration that is caused by oil is acceptable if the bushing is still smooth. Install a new bushing.

USE AGAIN

Illustration 65	g01280961

Damage to the bushing was caused by incorrect installation of the piston pin bushing or the bushing turned in the bore.

DO NOT USE AGAIN

If no scoring or fretting can be felt with the fingernail, and the measurement of the bore for the bushing is acceptable, the connecting rod can be used again after installing a new bushing.

Area for the Piston Pin

Illustration 66	g01280976

The junction of the shank and the area for the piston pin bushing is not damaged.

USE AGAIN

Illustration 67	g01280980

The connecting rod has some damage that was done before peening that was permitted by the factory. Do not use the connecting rod again if the damaged area has not been peened at the factory. Refer to Illustration 48.

USE AGAIN

Illustration 68	g01280989

The junction of the shank and the area for the piston pin bushing is damaged.

DO NOT USE AGAIN

Illustration 69	g01280994

The area below the piston pin bushing on the connecting rod is damaged.

DO NOT USE AGAIN

Illustration 70	g01280997

The area below the piston pin bushing on the inside edge of the shank on the connecting rod is damaged.

DO NOT USE AGAIN

Illustration 71	g01280999

Normal operation caused heat discoloration on the connecting rod. The discoloration in the area for the piston pin of the connecting rod is permitted. Perform a proof test on the connecting rod before the connecting rod is used again. Refer to "Procedure for Replacing the Bearing of the Connecting Rod Eye and Testing the Retention of the Bearing" for more information regarding the proof test.

USE AGAIN

Hardware

If there is no obvious damage, the hardware might be able to be used again. If the hardware did not loosen during operation, the hardware might be able to be used again. Follow the procedures and the specifications that are given in the service manual to tighten hardware. Excessive torque can result in damage to the connecting rod. Do not tighten the hardware more than the recommendations in the service manual.

Prior to reusing any connecting rod hardware, inspect the hardware per guidance given in Reuse and Salvage Guideline, SEBF8301, "Inspection and Reuse of Critical Fasteners Used in All Engines".

Illustration 72	g01281377

Normal operation can polish the serrations of the hardware for the connecting rod. Use the hardware again if the mark at the connecting rod parting line cannot be easily felt with a fingernail.

USE AGAIN

Illustration 73	g01281378

Normal operation can polish the serrations of the hardware for the connecting rod. Use the hardware again if the mark at the connecting rod parting line cannot be easily felt with a fingernail.

USE AGAIN

Illustration 74	g01281380

The shank area of the hardware has corrosive pitting.

DO NOT USE AGAIN

Illustration 75	g01281386

Some of the nuts will have polished areas or shallow grooves. The contact surface of the nuts is still smooth and flat.

USE AGAIN

Illustration 76	g01281387

Some of the nuts will have polished areas or shallow grooves. The contact surface of the nuts is still smooth and flat.

USE AGAIN

Illustration 77	g01281404

The bolt threads are damaged. The flats on the nut are damaged.

DO NOT USE AGAIN

Illustration 78	g01281421

The shank of the bolt is heavily damaged.

DO NOT USE AGAIN

Illustration 79	g01281471

The serrated section of the bolt has a nick that can be easily felt with a fingernail.

DO NOT USE AGAIN

Illustration 80	g01281477

The bottom of the bolt head has fretting and smearing.

DO NOT USE AGAIN

Note: Use the correct installation procedures and lubricant always to keep fretting to a minimum.

Illustration 81	g01281479

The nuts have heavy smearing, galling, and fretting. Material has been transferred.

DO NOT USE AGAIN

Illustration 82	g01281480

The nuts have heavy smearing, galling, and fretting. Material has been transferred.

DO NOT USE AGAIN

On C175, replace rod bolts at each engine overhaul. The 290-2541 Bolt with three metal rings must not be reused and replaced by 428-7386 Bolt with elastomer rings.

The rod bolts can be reused one time if a connecting rod is disassembled before the engine reaches overhaul as long as the bolts pass the reuse criteria. Refer to Reuse and Salvage Guidelines, SEBF8301 for additional information on inspecting these rod bolts.

Illustration 83	g06175891

On 3600, inspect the connecting rod bolts at each service of the connecting rod bearings. There should be no fretting on the shank of the connecting rod bolt. There should also be no fretting on the knurled area of the connecting rod bolts. Ensure that the connecting rod bolts meet the guidelines for reusable parts. Do not reuse the nuts.

Do not reuse the bolts if Dimension (F) exceeds 329 mm (12.953 inch).

Requirements for Peening

Use a cast shot that is size SAE S330 or the equivalent. The hardness of the shot must be Rockwell C42 to Rockwell C50. The shot must be conditioned into a spherical shape before using to ensure that the shape of the shot is essentially round with no sharp corners.

All burrs, sharp edges, and sharp corners must be removed before peening.

Use a suitable method of masking to protect the finished surfaces from the peening. The finished surfaces are the thrust face, the crankshaft bore, and the piston pin bore. All cavities and holes should be thoroughly cleaned after peening to completely remove all the shot.

Connecting Rod Bend and Twist Measurement

Illustration 84	g06190970
The connecting rod has an example of a bend or twist. (8) An example of a connecting rod with a twist (9) An example of a connecting rod with a bend

Show/hide table

NOTICE
Precise measurements shall be made when the component and measurement equipment are at 20° C (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° C (68° F). This will ensure that both the surface and core of the material is at the same temperature.

Note: Refer to Table 9 and 8 for pin and crank mandrels.

Using 5P-2050 Connecting Rod Checking Fixture

5P-2050 Connecting Rod Checking Fixture is used to check the center to center distance for the bearing bores. The fixture also checks the alignment of the bearing bore for the piston pin bearing to the bearing bore for the crankshaft. The bearing for the piston pin is not required to use the fixture. For more information, refer to Special Instruction, SMHS7366, "Using the 5P-2050 Connecting Rod Checking Fixture".

Note: ( 5P-2050 Connecting Rod Checking Fixture) can check connecting rods for all Caterpillar engines except for the 3600 Series Engines.

Illustration 85	g06213767
Connecting rod checking fixture with connecting rod and tooling in place (6) Checking Fixture (7) Dial Indicator (8) Crank Mandrel (9) Extension Assembly (10) Position Arm (11) Pin Mandrel (Bushing Out) & Pin Mandrel (Bushing In)

Table 5

Connecting Rod Checking Fixture
Item	Part Number	Description
6	5P-2050	Connecting Rod Checking Fixture
7	5P-2054 5P-2057	Dial Indicator Qty 2 Contact Point Qty 2
8	5P-2053	Crank Mandrel
9	5P-2013	Extension Assembly
10	5P-2051	Position Arm
11	- -	Pin Mandrel, Bushing Out or Pin Mandrel, Bushing In

Adjusting the Fixture

The fixture must first be adjusted to the correct center to center distance for the bores of the bearing to check the connecting rods that will be reconditioned. Use a connecting rod of known length, which is the master rod, to make adjustments.

Illustration 86	g06213771
The plunger is in the mandrel. (8) Crank Mandrel and Plunger Assembly (9) Plunger Extension Assembly (10) Position Arm

1. For all connecting rods, remove the connecting rod bearing and install the cap on the connecting rod. Refer to the "Specifications for the Connecting Rod" Section for the correct torque to tighten the nuts.

2. Put pin mandrel (6) into the piston pin end of the master rod.

3. Install (9) Extension Assembly on the plunger of (8) Crank Mandrel, for 3000 engines drill and tap crank mandrel (8).

4. Install (10) Position Arm on the end of the crank mandrel.

5. Put crank mandrel (8) into the crankshaft bearing bore of the master rod. Verify that position arm (10) and the centerline of the pin mandrel are in alignment.

6. Turn the knob of the actuator on the end of crank mandrel (8) and tighten the mandrel in the connecting rod.

7. Put the master connecting rod on the fixture for checking connecting rods. Move the holder of the dial indicator until both indicators show less than 0.25 mm (0.001 inch) on a complete revolution. Turn the dial face of each indicator until the hand is on zero.

8. Remove the master connecting rod from the fixture. After you horizontally turn the rod 180 degrees, put the rod on the fixture again. If the dial indicators read zero, the fixture is adjusted correctly. If there is a different reading on the dial indicator, move the dial face half of the distance between zero and the reading.

9. Remove the master rod from the fixture, and remove the mandrels from the master rod.

The fixture is now ready to check connecting rods for reconditioning.

Procedure for Checking Bend

The following method should be used to determine if a connecting rod is acceptable for reconditioning.

1. For all engine connecting rods, remove the connecting rod bearing and install the cap on the connecting rod. Refer to the "Specifications for the Connecting Rod" Section for the correct torque to tighten the nuts.

2. Use 5P-2050 Connecting Rod Checking Fixture to measure the bend. The fixture measures the relation between the pin bore and the crankshaft bore. The installation of the piston pin bushing is not required to use the fixture in the pin bore.

3. Place the pin mandrel into the bore for the piston pin bearing. Put the crank mandrel with the extension assembly and the position arm in the crankshaft bearing bore.

4. Move the position arm in alignment with the centerline of the pin mandrel. Turn the knob for the actuator on the crank mandrel, and tighten the mandrel in the connecting rod.

5. Place the connecting rod on the fixture. Make a record of the readings on each of the dial indicators.

6. Add the two readings and divide by two. The result is the average difference from the center to center distance of the master connecting rod bearing bore.

7. Leave the connecting rod in the fixture, and check that both bores are parallel. Make a record of the readings for both dial indicators.

8. The total difference between the indicator readings is the bore's parallel dimension. The maximum allowable bend for engine connecting rods that are acceptable for reconditioning is specified in the "Specifications for the Connecting Rod" Section.

Procedure for Checking Twist

A check can also be made to test the connecting rod for a twist. Use 5P-2050 Connecting Rod Checking Fixture to measure the twist of the connecting rod.

1. Push one end of the pin mandrel against the location behind the connecting rod.

2. Use a thickness gauge on the opposite end to check the clearance between the mandrel and the surface for locating. Check both ends of the mandrel in this way for clearance.

3. The amount of clearance is the twist in the connecting rod. The maximum allowable twist for engine connecting rods that are acceptable for reconditioning is specified in the "Specifications for the Connecting Rod" Section.

Center to Center

Use 5P-2050 Connecting Rod Checking Fixture to measure the center to center distance of the pin bore to the crankshaft bore. Refer to Special Instruction, SMHS7366, "Using the 5P-2050 Connecting Rod Checking Fixture". For all connecting rods, refer to the "Specifications for the Connecting Rod" Section.

Corrections for Bend and Twist Measurements

Most tools measure the amount of twist or the amount of bend in a rod near the end of a pin or mandrel that fits into the pin bore or pin bushing. Specifications can be adjusted to fit distance (V). Refer to Illustration 87. Distance (V) will be different according to the tool that is used for measuring.

Illustration 87	g01651134
To adjust distance (U) for other alignment fixtures, refer to the formula below. (27) Mandrel (28) 5P-2050 Connecting Rod Checking Fixture (29) RI9-000E Alignment Fixture (30) Piston pin (V1) 114.3 mm (4.50 inch) (V2) 203.2 mm (8.00 inch)

Illustration 88	g01651173

Using Mahr Connecting Rod Bend and Twist Measurement System

Illustration 89	g06318958
Mahr Connecting Rod Bend and Twist Measurement System with connecting rod and tooling in place (6) Mahr Connecting Rod Bend and Twist Measurement System (7) Inductive Probe (9) Stop Screw (10) Probe Mount Block (11) Pin Mandrel (Bushing Out) & Pin Mandrel (Bushing In) (12) Mahr Millimar ® S 1840 Column Amplifiers (13) Stop Screw (14) Alignment Post

Table 6

Mahr Connecting Rod Bend and Twist Measurement System
Item	Part Number	Description
6	DFM050918-1	Mahr Connecting Rod Bend and Twist Measurement System
7	P2010	Inductive Probe Qty 4
9	2257210	Stop Screw
10	2257114	Probe Mount Block
11	- -	Pin Mandrel, Bushing Out or Pin Mandrel, Bushing In
12	S1840	Mahr Millimar ® S 1840-Column Amplifiers Qty 2
13	2246483	Stop Screw
14	-	Alignment Post

The Mahr Connecting Rod Bend and Twist Measurement System replaces the discontinued 5P-2050 Connecting Rod Checking Fixture, it measures bend and twist of connecting rods and provides a precise and repeatable method of determining conformance for reuse.

Using the Mahr Connecting Rod Bend and Twist Measurement System requires a new connecting rod to be used as a master for each engine series measured.

Prior to measuring, refer to the supplied owners operating manual for all functions, controls, and adjustments.

Ordering Information:

• Contact Mahr Inc., (401) 784-3100, or e-mail - orders@mahr.com

• Specify Cat® dealer and request quotation for product number DFM050918-1.

To provide addition clarification and details, a Caterpillar Channel 1 video has been created outlining the critical steps in using the Mahr Connecting Rod Bend and Twist Measurement System. Reviewing the videos is recommended prior to starting the measuring process.

Note: A CWS login is required to access Caterpillar Channel 1 Videos.

Table 7

Caterpillar Channel 1
Media Title:	"Reference Media URL"
"Mahr Connecting Rod Bend and Twist Measurement System"	https://channel1.mediaspace.kaltura.com/media/Mahr+Connecting+Rod+Bend+%26+Twist+Measurement+System/1_5n7cv5o8

Pin Mandrels

Table 8

Pin Mandrels (11)
Sales Model	Part Number Description
C175	540-1203 Bushing In
	540-1204 Bushing Out
3114	9U-5918 Bushing In
	9U-5917 Bushing Out
3116	9U-5918 Bushing In
	9U-5917 Bushing Out

Fabricated Pin & Crank Mandrels for 3044 - 3066

Illustration 90	g06213525
Measurements for the mandrels

Table 9

Fabrication Measurements for the Pin Mandrel (11)
Callout	Description	Sales Model 3044, 3046 Dimensions	Sales Model 3064, 3066 Dimensions
(F)	Pin mandrel length	139.7 mm (5.50 inch)	139.7 mm (5.50 inch)
(G)	Pin bore mandrel diameter	30.032 ± 0.012 mm (1.1824 ± 0.0005 inch)	34.032 ± 0.012 mm (1.3398 ± 0.0005 inch)
(H)	Pin mandrel diameter	31.8 mm (1.25197 inch)	31.8 mm (1.25197 inch)
(J)	Pin mandrel length	38.1 mm (1.50000 inch)	38.1 mm (1.50000 inch)
	Fabrication Measurements for the Crank Mandrel (8)
( F)	Crank mandrel length	139.7 mm (5.50 inch)	139.7 mm (5.50 inch)
(G)	Crank bore mandrel diameter	61.009 ± 0.009 mm (2.4019 ± 0.0004 inch)	64.009 ± 0.009 mm (2.5200 ± 0.0004 inch)
(H)	Crank mandrel diameter	50 mm (2.0 inch)	50 mm (2.0 inch)
(J)	Crank mandrel length	70 mm (2.7 inch)	70 mm (2.7 inch)

Measurement Procedures for Connecting Rods

Show/hide table

NOTICE
Precise measurements shall be made when the component and measurement equipment are at 20° C (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° C (68° F). This will ensure that both the surface and core of the material is at the same temperature.

This section gives procedures for measuring connecting rods and should be used after "Visual Inspection" is determined if the connecting rods can be reused.

C4.4 & C6.6 Connecting Rods

There are three different lengths of connecting rods that are manufactured at the factory. The different lengths are used to control the projection of the piston above the cylinder block. The lengths of the connecting rods are determined by finish machining an offset inner bore of the piston pin bearing and is measured from the center of the piston pin bushing to the center of the bore for the connecting rod lower bearing. The inner bore of the bearing will move the piston pin towards the crankshaft or away from the crankshaft causing more piston projection or less piston projection from the cylinder block. The connecting rods are also colored coded from the factory.

If the piston projection is wrong and the length of the connecting rod must be changed, you will need to use a different grade length of connecting rod or replace the pin bushing. The pin bushing must then be finish machined off-center to the correct diameter. Finish machining off-center will move the location of the piston pin and change the projection of the piston.

Illustration 91	g06367308
Moving the centerline of the bushing to change length of the connecting rod.

Measure The Length Of The Connecting Rod

If the mark or the color of the grade of length cannot be observed on the connecting rod, perform the following procedure:

Illustration 92	g06367311
Measure the length of the connecting rod. (1) Measuring pins (2) Connecting rod (CRL) Connecting Rod Length

1. Refer to Illustration 92. Use the following tools to measure the length of the connecting rod:

   • Appropriate gauges for measuring distance

   • Measuring pins (1)

2. Ensure that the measuring pins (1) are parallel. "CRL" is measured when the bearing for the crankshaft journal is removed and the original piston pin bearing is installed.

Table 10

Length Grades for Connecting Rods
Grade Letter	Color code	Length (CRL)
		C4.4 Connecting Rods for SGI Crankshaft		C4.4 Connecting Rods for Steel Crankshaft
		Minimum Measurement	Maximum Measurement	Minimum Measurement	Maximum Measurement
R	Red	163.310 mm (6.429 inch)	163.343 mm (6.430 inch)	165.728 mm (6.52471 inch)	165.761 mm (6.52601 inch)
O	Orange	163.264 mm (6.427 inch)	163.297 mm (6.42900 inch)	165.682 mm (6.52290 inch)	165.715 mm (6.52420 inch)
W	White	163.219 mm (6.425 inch)	163.252 mm (6.427 inch)	165.637 mm (6.52113 inch)	165.670 mm (6.52243 inch)
G	Green	163.173 mm (6.424 inch)	163.206 mm (6.425 inch)	165.591 mm (6.51932 inch)	165.624 mm (6.52062 inch)
P	Purple	163.127 mm (6.422 inch)	163.160 mm (6.423 inch)	165.545 mm (6.51751 inch)	165.578 mm (6.51881 inch)
B	Blue	163.081 mm (6.420 inch)	163.114 mm (6.421 inch)	165.499 mm (6.51570 inch)	165.532 mm (6.51699 inch)

Table 11

Length Grades for Connecting Rods
Grade Letter	Color Code	C6.6 Connecting Rod Lengths
		Length (CRL)
		Minimum Measurement	Maximum Measurement
B	Blue	161.107 mm (6.34278 inch)	161.140 mm (6.34408 inch)
R	Red	161.259 mm (6.34877 inch)	161.292 mm (6.35007 inch)
G	Green	161.183 mm (6.34577 inch)	161.216 mm (6.34707 inch)

Distortion of The Connecting Rod

1. Use the following tools to measure the distances for the connecting rod (2) which are specified in Illustration 92:

   • Appropriate gauges for measuring distance

   • Measuring pins (1)
   Show/hide table

   Illustration 93	g06367319
   Measure the connecting rod for distortion. (1) Measuring pins (2) Connecting rod. (D) The limits are measured at a distance of 127 mm (5.0 inch) from each side of the connecting rod. (L) The length between the centers of the piston pin bearing and the crankshaft journal bearing is shown in Illustration 93.

2. Measure the connecting rod for distortion and parallel alignment between the bores.

   The bores for the crankshaft bearing and the bearing for the piston pin must be square and parallel with each other within the required limits. If the piston pin bearing is removed, the limit "L" is the following value: ± 0.25 mm (± 0.010 inch)

   The limits (D) are measured at a distance of 127 mm (5.0 inch) from each side of the connecting rod.

   If the piston pin bearing is not removed, the limit "L" is the following value: ± 0.06 mm (± 0.0024 inch)

   (L) is equal to 219.08 ± 0.03 mm (8.625 ± 0.001 inch).

3. Inspect the piston pin bearing and the piston pin for wear.

Measuring the Wear Step on 3500 Connecting Rods

Visually inspect the body of the connecting rod for a wear step at the point of contact between the connecting rod and cap. Measure the wear step at point (A) on the dowel side and point (B) on the non-dowel side, refer to Illustration 94. Measure the wear step depth using a dial indicator, refer to Illustrations 96 and 97. Add the measurement value of (A) and (B) and the total should be less than 0.18 mm (0.007 inch). If the wear step is greater than or equal to 0.18 mm (0.007 inch), then the rod must not be reused.

The setup of the rod is critical in making an accurate measurement. Use a level surface plate to take the measurement.

• Support the end of the rod with an adjustable support. Refer to Illustration 95 for a support example.

• Securely mount the rod such that the cap joint is perpendicular to the surface plate, refer to Illustrations 96 and 97.

• Use a clamping fixture as a guide for the dial indicator to ensure that measurement error is not introduced by the curvature of the rod. Refer to Illustrations 96 and 97 for examples of a clamping fixture.

• Use a small tip on the dial indicator and ensure that the measurement is taken within 2.0 mm (0.079 inch) on both sides of the wear step.

Note: The wear step must not be polished in an attempt to improve appearance. Polishing the wear step will make an accurate measurement of total wear more difficult to obtain at the next overhaul.

Illustration 94	g02961100

Illustration 95	g03163479
Adjustable support for rod end.

Illustration 96	g02961105
Rod secured in fixture perpendicular to surface. Use machined edge for sweeping the dial indicator.

Illustration 97	g03163556
Rod secured in fixture perpendicular to surface.

Illustration 98	g03163579
Machined edge for sweeping dial indicator.

Connecting Rod Cap

Visually inspect the connecting rod cap at the contact point between the rod cap and the body of the connecting rod. The wear step should be 0.03 mm (0.001 inch) or less to reuse the rod cap. An example is shown in Illustration 99.

Illustration 99	g01644655
(15) Typical wear on the connecting rod cap

Illustration 100	g03195656
Measuring the wear step.

Use a thin feeler gauge to check the wear step. If any step is felt, then the cap too worn and cannot be reused.

Internal Threads of the Connecting Rod

Illustration 101	g02962858
434-7091 No-Go Gage

The internal threads of the connecting rod are formed by a rolling process. The threads cannot be reworked because the strength of the threads will be reduced. The connecting rod bolt should turn freely in the threaded hole. The internal threads of the connecting rod should be checked by using 434-7091 Go-No-Go Gauge. The gage should turn in no more than 3 1/2 turns. If the connecting rod bolt does not turn freely in the threaded hole, or if the threaded hole does not pass the no-go test, the connecting rod should be discarded.

Tooling to Measure Bores

Illustration 102	g06191269
A typical dial bore gauge and a typical setting fixture.

Measure the crankshaft bore with a dial bore gauge. Measure the bore of the piston pin bushing with a dial bore gauge. Refer to Illustration 102. The equipment that is used to measure the connecting rods must be accurate within 0.002 mm (0.0001 inch).

Refer to Table 12 for additional information on necessary tooling.

Table 12

Required Tools
Part Number	Range	Reference Publications
6V-6000 Dial Bore Gauge	40.4 ± 10.4 mm (1.59 ± 0.41 inch)	SMHS8037
1P-3537 Dial Bore Gauge	127.0 ± 76.2 mm (5.00 ± 3.00 inch)	N/A
6V-7898 Dial Bore Gauge	126.9 ± 76.1 mm (4.99 ± 2.99 inch)	SMHS8253 SMHS8254

Illustration 103	g06191276
Measure the bore with a dial bore gauge.

Crankshaft Bore Measurement

The connecting rod must be assembled prior to measuring the crankshaft bore diameter. Refer to the proper manual of specifications for the correct torque of bearing crush, correct assembly procedures and torques.

Note: Be sure that the connecting rod nuts and bolts are at the correct torque when the bore is being measured. Engine damage can be caused if the connecting rod nuts and connecting rod bolts are not properly torqued. The used connecting rod may not be precisely round if the bolts or nuts have been loosened and tightened again. The used connecting rods can also be slightly out of round.

Use a dial bore gauge to measure the diameter of the bore.

Illustration 104	g06362037
The Illustration shows the locations to be measured on standard connecting rods (A, B, C) Diameters to check the roundness. (D) 16.0 mm (0.63 inch)

Illustration 105	g06362026
The Illustration shows the locations to be measured on serrated connecting rods (A, B, C) Diameters to check the roundness. (D) 16.0 mm (0.63 inch)

Measure the bore diameter at points (A, B, and C).

Note: Take the measurements as close to the center of the bore as possible. Because there can be some movement of the cap relative to the rod, it is necessary to use the average of dimensions (A) and (B) as your guide.

Use the tolerances for both the dimension (C) and the average of dimension (A) and dimension (B).

Illustration 106	g06362056

Make sure that the difference between the two findings is 0.033 mm (0.0013 inch) or less unless otherwise noted in specification tables.

Crankshaft Bore Measurement for C175 Connecting Rods

Illustration 107	g03406077
The arrow represents the front of the engine block. Bolt numbering for 434-0486 Connecting Rod, 434-0487 Connecting Rod, 376-4939 Connecting Rod, 376-4938 Connecting Rod, 417-7902 Connecting Rod, and 417-7903 Connecting Rod. Bolt (1) are always identified as the center bolt on the bearing tab side of the connecting rod. (A) Bearing tab side (X) Even numbered connecting rod (Y) Odd numbered connecting rod

The connecting rod must be assembled prior to measuring the crankshaft bore diameter on Type 2 connecting rods. The assembly procedure follows Illustration 107. The torque procedure in the Disassembly and Assembly manual in the section with the phrase "Connecting Rod Bearings" in the title should be followed for assembly in the engine with the bearing installed in the crank end bore of the connecting rod.

Note: The recommended bolt torque specified when preparing a rod for bore measurement (with out a bearing installed) is lower than the torque specified in the Disassembly and Assembly manual for assembly with a bearing. This requirement is specific to C175 Type 2 connecting rods.

Use the following assembly procedure to tighten the 428-7386 Bolt to the Type 2 Connecting Rods.

1. Lubricate each bolt with Bel-Ray Molylube 67700 by fully coating the elastomer rings, threads, and the contact surface under the bolt head.

2. Install all the bolts into the spacers by pushing and rotating the bolt simultaneously.

   Note: Rotating the bolt while pushing will avoid damage to the bolts.

3. Install the bolts into the connecting rod cap by pushing and rotating the bolt simultaneously.

4. Engage the threads by pushing and slowly rotating the bolt. Do not tap the bolt. All six bolts should have the threads engaged before the joint is drawn together on either side. The order of engaging the threads is bolts 1-2-3-4-5-6. Once bolts 1 and 2 threads have engaged, then install the remaining bolts in order.

5. Tighten bolt 1 and bolt 2 to 60 ± 5 N·m (44 ± 4 lb ft)

6. Tighten bolt 3 and bolt 4 to 60 ± 5 N·m (44 ± 4 lb ft).

7. Tighten bolt 5 and bolt 6 to 60 ± 5 N·m (44 ± 4 lb ft).

8. Again tighten bolt 1 and bolt 2 to 60 ± 5 N·m (44 ± 4 lb ft).

9. Again tighten bolt 3 and bolt 4 to 60 ± 5 N·m (44 ± 4 lb ft).

10. Again tighten bolt 5 and bolt 6 to 60 ± 5 N·m (44 ± 4 lb ft).

11. Turn bolt 3 and bolt 4 an extra 90 ± 5 degrees.

12. Turn bolt 5 and bolt 6 an extra 90 ± 5 degrees.

13. Turn bolt 1 and bolt 2 an extra 90 ± 5 degrees.

Illustration 108	g06367330
C175 Crankshaft Bore Measurement Locations (J) Diameter measurement location (1) -65° from 0° (K) Diameter measurement location (2) +65° from 0° (L) Diameter measurement location (t) "Top" plane closest to chamfer (b) "Bottom" plane

Refer to Illustration 108 for measurement locations and Table 29 for specifications. Use a dial bore gauge and measure the diameter at locations (J), (K), and (L) in both planes (t) and (b). Planes (t) and (b) are located 5 mm to 10 mm (0.20 inch to 0.40 inch) in from the edge of where the bearing would be located.

Table 13 provides an example of measurements taken from two rods. The "Example 1" data shows that the rod does not meet the reuse specification. The Bottom Plane diameter taken at location (Kb) has a measurement that is too small for reuse. The "Example 2" data shows that the rod does meet the reuse specification for Top and Bottom Plane diameter and roundness.

Table 13

C175 Crankshaft Bore Diameter Measurement Example
			Example 1(1)	Specification Met(2)	Example 2	Specification Met
Top Plane (t)	Max. Overall Diameter	Max (Jt, Kt, Lt)	-0.016 mm (-0.0006 inch)	Yes	0.000 mm (0.0000 inch)	Yes
	Min Overall Diameter	Min (Jt, Kt, Lt)	-0.024 mm (-0.0009 inch)	Yes	-0.030 mm (-0.0012 inch)	Yes
	Roundness	Abs (Max - Min)(3)	0.008 mm (0.0003 inch)	Yes	0.030 mm (0.0012 inch)	Yes
Bottom Plane (b)	Max. Overall Diameter	Max (Jb, Kb, Lb)	-0.020 mm (-0.0008 inch)	Yes	0.020 mm (0.0008 inch)	Yes
	Min Overall Diameter	Min (Jb, Kb, Lb)	-0.036 mm (-0.0014 inch)	No	-0.010 mm (-0.0004 inch)	Yes
	Roundness	Abs (Max - Min)	0.016 mm (0.0006 inch)	Yes	0.030 mm (0.0012 inch)	Yes

(1)	Diameter is found by taking the measured diameter and subtracting 150 mm (5.91 inch).
(2)	Refer to Table 29 for specifications.
(3)	Absolute value of maximum minus minimum.

Crankshaft Bore Measurement for 3618 Connecting Rods

Illustration 109	g01379566
Angles of measurement for the crankshaft bore

Use a dial bore gauge to measure the bore for the crankshaft. Measurements should be taken at 0 degrees, 40 degrees, 50 degrees, 90 degrees, and 130 degrees. Refer to Illustration 109.

These measurements should be taken in 2 planes at each angle. Take the average of the top and the bottom measurement at each angle.

The roundness of the bore is the difference between the maximum and minimum dimensions. During extended hours of operation, the bore for the crankshaft closes at the joint that is serrated. The maximum allowable roundness for a used connecting rod is 0.330 mm (0.0130 inch). Measurements that exceed the specifications will require replacement of the connecting rod.

Thickness of the Crankshaft Bore on 3500 Connecting Rods

Illustration 110	g01645033
(17) Typical locations of wear

Measure the thickness of the crankshaft bore within the 120 degree zones in Illustration 111 at points (18 - 23) in Illustration 112. If two or more locations within one 120 degree zone measure 67.200 mm (2.6457 inch) or less, do not use the connecting rod again. The thickness of a new connecting rod is 67.575 ± 0.076 mm (2.6604 ± 0.0030 inch).

Illustration 111	g01646634
Locations of 120 degree zones

Illustration 112	g01646654
Locations for measuring thickness If two or more locations within one 120 degree zone measure 67.200 mm (2.6457 inch) or less, do not use the connecting rod again. (18 - 23) Points for measuring thickness

Piston Pin Bore in the Rod and in the Bushing

Measure the pin bushing inside diameter using a good quality dial bore gauge. Make sure that the diameter does not exceed specifications.

Generally, piston pin bushings that are used in 3500 Engines will not require replacement at every rebuild. Under normal operating conditions, piston pin bushings should provide acceptable performance for two life cycles.

Piston pin bushings can be used again under the following conditions:

• Fretting or scoring cannot be felt.

• The measurement of the bore is acceptable.

• The bushing passes the load test that is given in Table 52.

Discoloration that is caused by oil is acceptable if the bushing is smooth and undamaged. Do not reuse a piston pin bushing with discoloration and scoring or marks that can be felt.

For additional information on piston rods and bushings, refer to Visual Inspection for the Area for the Piston Pin in the "Visual Inspection" section.

Clearance between the Pin and Bushing

To determine the clearance between the pin and the bushing, use a micrometer and measure the outside diameter of the piston pin on the contact surface with the bushing. Then measure the inside diameter of the pin bushing. Subtract the measurement of the outer diameter of the pin from the measurement of the inner diameter of the bushing.

Note: The maximum allowable clearance between the pin and the pin bushing is 0.10 mm (0.004 inch).

If the dimension exceeds, install a new bushing, and machine the bushing to the correct size. If new bushings are installed, follow the instructions in 40. The bushing must also meet the reusability guidelines in the "Visual Inspection" Section.

Note: Refer to Reuse and Salvage Guidelines, SEBF8059, "Inspection Procedures and Specifications for Pistons and Piston Pins" for more information on inspection of piston pins.

C175 Pin End Bore Measurement

Illustration 113	g06367334
(M) Diameter measurement location (3) -45° from 0° (N) Diameter measurement location (4) +45° from 0° (P) Diameter measurement location (t) "Top" plane closest to chamfer (b) "Bottom" plane

Prior to measuring, ensure that the bushing is clean and free from damage. Do not reuse the bushing if there is scuffing, excessive discoloration, or evidence of rotation.

Measure the diameter at locations (M), (N), and (P) in both planes (t) and (b). Planes (t) and (b) are located 5 mm to 10 mm (0.20 in to 0.40 in) from the edge of the bearing.

Table 14 provides an example of measurements taken from two rods. The "Example 1" data shows that the rod does not meet the reuse specification. The Top Plane diameter taken at location (Nt) has a measurement that is too large for reuse. The "Example 2" data shows that the rod does meet the reuse specification for Top and Bottom Plane diameter.

Table 14

C175 Piston Pin End Bore Diameter Measurement Example
	Diameter Location	Example 1(1)	Specification Met(2)	Example 2	Specification Met
Top Plane (t)	(At, -45°)	0.008 mm (0.0003 inch)	Yes	−0.008 mm (−0.0003 inch)	Yes
	(Bt, 0°)	0.016 mm (0.0006 inch)	No	0.015 mm (0.0006 inch)	Yes
	(Ct, +45°)	0.012 mm (0.0005 inch)	Yes	−0.007 mm (−0.0003 inch)	Yes
Bottom Plane (b)	(Ab, -45°)	0.006 mm (0.0002 inch)	Yes	−0.005 mm (−0.0002 inch)	Yes
	(Bb, 0°)	0.015 mm (0.0006 inch)	Yes	0.003 mm (0.0001 inch)	Yes
	(Cb, +45°)	0.012 mm (0.0005 inch)	Yes	−0.004 mm (−0.0002 inch)	Yes

(1)	Diameter is found by taking the measured diameter and subtracting 75.04 mm (2.954inch).
(2)	Refer to Table 29 for specifications.

Specifications for the Connecting Rod

Illustration 114	g06364028
(1) Diameter of Crankshaft Bore (2) Bore for the Bushing (3) Bore for the Piston Pin (4) Center to Center Distance (5) Diameter of the Piston Pin (6) Piston Pin

Illustration 115	g06364032
The dimension is the thickness for a connecting rod. (7) Thickness of the connecting rod

Table 15

Description	C4.4 Connecting Rods for SGI Crankshaft		C4.4 Connecting Rods for Steel Crankshaft
	Minimum Measurement	Maximum Measurement	Minimum Measurement	Maximum Measurement
(1)	72.045 mm (2.836 inch)	72.058 mm (2.836 inch)	67.21 mm (2.64606 inch)	67.22 mm (2.64645 inch)
(2)	43.01 mm (1.693 inch)	43.04 mm (1.694 inch)	43.01 mm (1.693 inch)	43.04 mm (1.694 inch)
(4)	219.05 mm (8.624 inch)	219.10 mm (8.625 inch)	219.05 mm (8.624 inch)	219.10 mm (8.625 inch)

Table 16

Description	Specifications for C6.6 Connecting Rods
	Minimum Measurement	Maximum Measurement
(1)	76.025 mm (2.99310 inch)	76.038 mm (2.99362 inch)
(3)	39.723 mm (1.56389 inch)	39.738 mm (1.56449 inch)
(4)	219.05 mm (8.62400 inch)	219.10 mm (8.62597 inch)

Table 17

Specifications for C7 Connecting Rods
Part Number	(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
213-3193	75 +0.025/-0.013 mm (2.95275 +0.001/-0.0005 inch)	43.191 ± 0.013 mm (1.7004 ± 0.0005 inch)	40.028 ± 0.008 mm (1.5759 ± 0.0003 inch)	200.000 ± 0.076 mm (7.8740 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
259-3230		50.640 ± 0.013 mm (1.9937 ± 0.0005 inch)	46.035 ± 0.008 mm (1.8124 ± 0.0003 inch)	193.120 mm (7.6031 inch)

Table 18

Specifications for C9 Connecting Rods
Part Number	(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
160-8199	85.000 +0.025 / -0.013 mm (3.3465 +0.001 -0.0005 inch)	50.640 ± 0.013 mm (1.9937 ± 0.0005 inch)	46.035 ± 0.008 mm (1.8124 ± 0.0003 inch)	217.000 ± 0.076 mm (8.5433 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
256-9658		54.630 ± 0.013 mm (2.1508 ± 0.0005 inch)	50.035 ± 0.008 mm (1.96988 ± 0.00031 inch)

Table 19

Specifications for C10 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
86.8 +0.025 / -0.013 mm (3.41732 +0.001 / -0.0005 inch)	55.435 ± 0.013 mm (2.1825 ± 0.0005 inch)	50.830 ± 0.008 mm (2.0012 ± 0.0003 inch)	247 ± 0.076 mm (9.725 ± 0.003 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 20

Specifications for C11 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
93.8 ± 0.013 mm (3.69291 ± 0.00051 inch)	57.81 ± 0.013 mm (2.27598 ± 0.00051 inch)	53.205 ± 0.008 mm (2.095 ± 0.0003 inch)	247.5 ± 0.076 mm (9.74408 ± 0.00299 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 21

Specifications for C12 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
93.800 +0.025 / -0.013 mm (3.6929 +0.0010 / -0.0005 inch)	57.810 ± 0.013 mm (2.2760 ± 0.0005 inch)	53.205 ± 0.008 mm (2.0947 ± 0.0003 inch)	242.500 ± 0.076 mm (9.5472 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 22

Specifications for C13 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
93.800 ± 0.013 mm (3.6929 ± 0.0005 inch)	57.810 ± 0.013 mm (2.27598 ± 0.0005 inch)	53.205 ± 0.008 mm (2.0947 ± 0.0003 inch)	239.000 mm (9.4094 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 23

Specifications for C15 Connecting Rods
Part Number	(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
9Y-6054	96.200 +0.025 / -0.013 mm (3.7874 +0.0010 / -0.0005 inch)	59.64 ± 0.013 mm (2.34803 ± 0.0005 inch)	55.035 ± 0.008 mm (2.1667 ± 0.0003 inch)	261.620 ± 0.076 mm (10.3000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
224-3245	103.200 +0.025 / -0.013 mm (4.0630 +0.0010 /-0.0005 inch)	64.592 ± 0.013 mm (2.5430 ± 0.0005 inch)	60.035 ± 0.008 mm (2.3636 ± 0.0003 inch)	270.760 ± 0.076 mm (10.6598 ± 0.0030 inch)

Table 24

Specifications for C16 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
96.200 + 0.025 / -0.013 mm (3.7874 +0.0010 / -0.0005 inch)	59.64 ± 0.013 mm (2.34803 ± 0.0005 inch)	55.035 ± 0.008 mm (2.1667 ± 0.0003 inch)	261.620 ± 0.076 mm (10.3000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 25

Specifications for C18 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
103.200 +0.025 / -0.013 mm (4.0630 +0.0010 / -0.0005 inch)	64.592 ± 0.013 mm (2.5430 ± 0.0005 inch)	60.035 ± 0.008 mm (2.3636 ± 0.0003 inch)	270.760 ± 0.076 mm (10.6598 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 26

Specifications for C27 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
103.500 +0.025 / -0.013 mm (4.0748 +0.0010 / -0.0005 inch)	64.592 ± 0.013 mm (2.5430 ± 0.0005 inch)	60.035 ± 0.008 mm (2.3636 ± 0.0003 inch)	274.910 ± 0.076 mm (10.8232 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 27

Specifications for C30 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
103.5 ± 0.013 mm (4.07479 ± 0.0005 inch)	64.592 ± 0.013 mm (2.5430 ± 0.0005 inch)	60.035 ± 0.008 mm (2.3636 ± 0.0003 inch)	278.41 ± 0.076 mm (10.961 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 28

Specifications for C32 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
103.500 +0.025 / -0.013 mm (4.0748 +0.0010 / -0.0005 inch)	64.592 ± 0.013 mm (2.5430 ± 0.0005 inch)	60.035 ± 0.008 mm (2.3636 ± 0.0003 inch)	274.910 ± 0.076 mm (10.8232 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 29

Specifications for C175 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Diameter of Bore for Piston Pin Bearing	(4) Center to Center Distance (1), (2)	Bend Tolerance	Twist Tolerance	Roundness	(7) Minimum Thickness
150.00 + 0.020 / - 0.030 mm (5.90550 + 0.00079 / - 0.00118 inch) Surface Texture: 2.5 µm to 3.5 µm (98.42520 µinch to 137.7953 µinch)	82.985 ± 0.015 mm (3.26712 ± 0.00059 inch) Surface Texture: 0.63 µm to 2.5 µm (24.80315 µinch to 98.42520 µinch)	75.04 + 0.015 / - 0.008 mm (2.95432 + 0.00059 / - 0.00031 inch) Surface Texture: 2.5 µm (98.42520 µinch)	420.0 ± 0.05 mm (16.53540 ± 0.00197 inch)	0 mm to 0.03 mm (0.0 inch to 0.00118 inch)	0 mm to 0.05 mm (0.0 inch to 0.00197 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)	65.5 ± 0.1 mm (2.57873 ± 0.00394 inch)
(5) Diameter of Piston Pin(3)
75.0 ± 0.005 mm (2.95275 ± 0.00020 inch)

(1)	Inspect the bushing for damage. Refer to "Visual Inspection" Section.
(2)	If this dimension is exceeded, then salvage may be possible by replacing the existing bushing with a new bushing that is machined to acceptable specifications. The bushing must have no steel showing through the bronze.
(3)	Piston pins must be inspected for a wear step. Refer to Reuse and Salvage Guideline, SEBF8059, "Inspection Procedures and Specifications for Pistons and Piston Pins".

Table 30

Specifications for D-Series Connecting Rods
Part Number	(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center distance	Bend Tolerance	Twist Tolerance
1M-1079	82.550 ± 0.013 mm (3.2500 ± 0.0005 inch)	41.288 ± 0.013 mm (1.6255 ± 0.0005 inch)	38.143 ± 0.008 mm (1.5017 ± 0.0003 inch)	228.600 ± 0.076 mm (9.0000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
1P-0009	136.766 +.025/-0.013 mm (5.3845 +0.001/-0.0005 inch)	68.008 ± 0.013 mm (2.6775 ± 0.0005 inch)	62.263 ± 0.008 mm (2.4513 ± 0.0003 inch)	457.200 ± 0.076 mm (18.0000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
3S-8285	97.917 +0.025/-0.013 mm (3.855 +0.001/-0.0005 inch)	55.435 ± 0.013 mm (2.1825 ± 0.0005 inch)	50.830 ± 0.008 mm (2.0012 ± 0.0003 inch)	282.575 ± 0.076 mm (11.1250 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
4N-6018	97.917 ± 0.013 mm (3.8550 ± 0.0005 inch)	46.355 ± 0.013 mm (1.8250 ± 0.0005 inch)	43.210 ± 0.008 mm (1.7012 ± 0.0003 inch)	254.000 ± 0.076 mm (10.0000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
4N-9001	119.901 +.025/-0.013 (4.7205 +0.001/-0.0005 inch)	55.436 ± 0.013 mm (2.1825 ± 0.0005 inch)	50.833 ± 0.008 mm (2.0013 ± 0.0003 inch)	320.800 ± 0.076 mm (12.6299 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
4S-6867 7M-4835	100.762 +0.025/-0.013 mm (3.9670 +0.001/- 0.0005 inch)	66.472 ± 0.013 mm (2.6170 ± 0.0005 inch)	60.739 ± 0.008 mm (2.3913 ± 0.0003 inch)	381.000 ± 0.076 mm (15.0000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
5S-2793	82.550 ± 0.013 mm (3.2500 ± 0.0005 inch)	46.355 ± 0.013 mm (1.8250 ± 0.0005 inch)	43.210 ± 0.008 mm (1.7012 ± 0.0003 inch)	243.710 ± 0.076 mm (9.5949 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
5S-6360	82.550 ± 0.013 mm (3.2500 ± 0.0005 inch)	41.288 ± 0.013 mm (1.6255 ± 0.0005 inch)	38.143 ± 0.008 mm (1.5017 ± 0.0003 inch)	243.710 ± 0.076 mm (9.5949 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
9S-8492	112.776 +0.023/-0.13 mm (4.4400 +0.001/-0.0005 inch)	68.009 ± 0.013 mm (2.6775 ± 0.0005 inch)	62.236 ± 0.008 mm (2.4502 ± 0.0003 inch)	381.000 ± 0.076 mm (15.0000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 31

Specifications for 1100 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
74.722 +0.025/-0.013 mm (2.9418 +0.001/-0.0005 inch)	41.288 ± 0.013 mm (1.6255 ± 0.0005 inch)	38.125 ± 0.008 mm (1.5010 ± 0.0003 inch)	200.660 ± 0.076 mm (7.9000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 32

Specifications for 1673C and 1674 Connecting Rods
Part Number	(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
1M-1079	82.550 +0.025/-0.013 mm (3.2500 +0.001/-0.0005 inch)	41.288 ± 0.013 mm (1.6255 ± 0.0005 inch)	38.143 ± 0.008 mm (1.5017 ± 0.0003 inch)	243.710 ± 0.076 mm (9.5949 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
5S-2793		46.355 ± 0.013 mm (1.8250 ± 0.0005 inch)	43.210 ± 0.008 mm (1.7012 ± 0.0003 inch)

Table 33

Specifications for 1693 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
97.917 ± 0.013 mm (3.8550 ± 0.0005 inch)	55.435 ± 0.013 mm (2.1825 ± 0.0005 inch)	50.830 ± 0.008 mm (2.0012 ± 0.0003 inch)	282.575 ± 0.076 mm (11.1250 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 34

Specifications for 3044 and 3046 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
61.009 ± 0.009 mm (2.40192 ± 0.00035 inch)	33.012 ± 0.012 mm (1.29968 ± 0.00047 inch)	30.032 ± 0.012 mm (1.18236 ± 0.00047 inch)	180.0 ± 0.05 mm (7.08660 ± 0.00197 inch)	0.0 mm to 0.21 mm (0.0 inch to 0.00827 inch)	0.0 mm to 0.21 mm (0.0 inch to 0.00827 inch)

Table 35

Specifications for 3064 and 3066 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center Distance	Bend Tolerance	Twist Tolerance
64.009 ± 0.009 mm (2.52003 ± 0.00035 inch)	37.012 ± 0.012 mm (1.45716 ± 0.00047 inch)	34.032 ± 0.012 mm (1.33984 ± 0.00047 inch)	185.0 ± 0.05 mm (7.28345 ± 0.00197 inch)	0.0 mm to 0.21 mm (0.0 inch to 0.00827 inch)	0.0 mm to 0.21 mm (0.0 inch to 0.00827 inch)

Table 36

Specifications for 3100 Connecting Rods
Part Number	(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center distance	Bend Tolerance	Twist Tolerance
2W-9128 213-3193	75.00 +0.025/-0.013 mm (2.95275 +0.001 / -0.0005 inch)	43.19 ± 0.013 mm (1.7004 ± 0.00051 inch)	40.028 ± 0.008 mm (1.576 ± 0.00031 inch)	200 ± 0.076 mm (7.87 ± 0.003 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
4P-2232 9Y-1171 113-8984	86.80 +0.025 / -0.013 mm (3.417 +0.001 / -0.0005 inch)	55.435 ± 0.013 mm (2.183 ± 0.0005 inch)	50.830 ± 0.008 mm (2.0012 ± 0.0003 inch)	225.0 ± 0.076 mm (8.858 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
9N-8002	74.722 +0.025 / -0.013 mm (2.9418 +0.0010 / -0.0005 inch)	41.288 ± 0.013 mm (1.6255 ± 0.0005 inch)	38.135 ± 0.008 mm (1.5014 ± 0.0003 inch)	200.660 ± 0.076 mm (7.9000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
104-3565 155-6629	86.80 +0.025 / -0.013 mm (3.417 +0.001 / -0.0005 inch)	55.435 ± 0.013 mm (2.183 ± 0.0005 inch)	50.830 ± 0.008 mm (2.0012 ± 0.0003 inch)	247.00 ± 0.076 mm (9.724 ± 0.003 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
113-9016	93.800 +0.025 / -0.013 mm (3.6929 +0.0010 / -0.0005 inch)	57.810 ± 0.013 mm (2.2760 ± 0.0005 inch)	53.205 ± 0.008 mm (2.0947 ± 0.0003 inch)	242.500 ± 0.076 mm (9.5472 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 37

Specifications for 3200 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center distance	Bend Tolerance	Twist Tolerance
74.722 +0.025 / -0.013 mm (2.9418 +0.0010 / -0.0005 inch)	41.288 ± 0.013 mm (1.6255 ± 0.0005 inch)	38.125 ± 0.008 mm (1.5010 ± 0.0003 inch)	200.660 ± 0.076 mm (7.9000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 38

Specifications for 3300 Connecting Rods
Part Number	(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center distance	Bend Tolerance	Twist Tolerance
5S-2793 8N-1721	82.550 +0.025 / -0.013 mm (3.2500 +0.0010 / -0.0005 inch)	46.355 ± 0.013 mm (1.8250 ± 0.0005 inch)	43.211 ± 0.008 mm (1.7012 ± 0.0003 inch)	243.710 ± 0.076 mm (9.5949 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
5S-6360 8N-1984		41.288 ± 0.013 mm (1.6255 ± 0.0005 inch)	38.143 ± 0.008 mm (1.5017 ± 0.0003 inch)

Table 39

Specifications for 3400 Connecting Rods
Part Number	(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center distance	Bend Tolerance	Twist Tolerance
4N-0390 7N-3229 7N-3231 8N-1726 8N-1728 160-8178	103.500 +0.025 / -0.013 mm (4.0748 +0.0010 / -0.0005 inch)	55.436 ± 0.013 mm (2.1825 ± 0.0005 inch)	50.830 ± 0.008 mm (2.0012 ± 0.0003 inch)	261.620 ± 0.076 mm (10.3000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
7E-5996 9Y-6400	96.200 +0.025 / -0.013 mm (3.7874 +0.0010 / -0.0005 inch)	55.436 ± 0.013 mm (2.1825 ± 0.0005 inch)	50.830 ± 0.008 mm (2.0012 ± 0.0003 inch)	261.620 ± 0.076 mm (10.3000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
9Y-6054	96.200 +0.025 / -0.013 mm (3.7874 +0.0010 / -0.0005 inch)	59.640 ± 0.013 mm (2.3480 ± 0.0005 inch)	55.035 ± 0.008 mm (2.16673 ± 0.00031 inch)	261.620 ± 0.076 mm (10.3000 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)
232-3232	103.500 +0.025 / -0.013 mm (4.0748 +0.0010 / -0.0005 inch)	64.592 ± 0.013 mm (2.5430 ± 0.0005 inch)	60.035 ± 0.008 mm (2.3636 ± 0.0003 inch)	274.910 ± 0.076 mm (10.8232 ± 0.0030 inch)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)

Table 40

Specifications for 3500 Connecting Rods
(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Maximum Diameter of Bore for Piston Pin Bearing	(4) Center to Center Distance (1), (2)	Bend Tolerance	Twist Tolerance	Roundness	(7) Minimum Thickness
143.028 +0.025 / -0.065 mm (5.6310 +0.0010 / -0.0025 inch) Surface Texture: 0.63 µm to 2.5 µm (24.80315 µinch to 98.42520 µinch)	75.760 ± 0.015 mm (2.9827 ± 0.0006 inch) Surface Texture: 0.63 µm to 2.5 µm (24.80315 µinch to 98.42520 µinch)	70.058 mm (2.75818 inch)(3) Surface Texture: <2.5 µm (98.42520 µinch)	380.0 ± 0.102 mm (14.96060 ± 0.00402 inch)(4) 392.5 ± 0.102 mm (15.45273 ± 0.00402 inch) (5)	0 mm to 0.08 mm (0.0 inch to 0.003 inch)	0 mm to 0.30 mm (0.0 inch to 0.012 inch)	0.066 mm (0.00260 inch)	67.20 mm (2.64566 inch)
Piston Pin(6)
Type of Piston	(5) Minimum Pin Diameter for Reusability(7)			Maximum Clearance between Pin and Bushing(8)(9)
Articulated Piston	69.947 mm (2.754 inch)			0.10 mm (0.004 inch)
Monotherm Piston	69.915 mm (2.753 inch)			0.13 mm (0.005 inch)

(1)	Inspect the bushing for damage. Refer to "Visual Inspection" Section.
(2)	If this dimension is exceeded, then salvage may be possible by replacing the existing bushing with a new bushing that is machined to acceptable specifications. The bushing must have no steel showing through the bronze.
(3)	0.050 mm (0.00197 inch) of wear is permitted over the specified diameter of a new bushing.
(4)	Standard Displacement Engines
(5)	High Displacement Engines
(6)	Piston pins must be inspected for a wear step. Refer to Reuse and Salvage Guideline, SEBF8059, "Inspection Procedures and Specifications for Pistons and Piston Pins".
(7)	0.10 mm (0.004 inch) of wear is permitted over the specified diameter of a new piston pin.
(8)	Bushings should be tested to 15500 kPa (2250 psi) before the assembly is put into the engine when using a 5P-9725 Hydraulic Cylinder on the press. When using a different hydraulic cylinder on the press refer to the section: "Procedure for Replacing the Bearing of the Connecting Rod Eye and Testing the Retention of the Bearing" within this document to calculate the pressure required.
(9)	The clearance between the pin and the pin bushing cannot be greater than 0.10 mm (0.004 inch). Pins and bushings that are new or used can be assembled, if the 0.10 mm (0.004 inch) clearance is not exceeded.

Table 41

Specifications for 3600 Connecting Rods
Engine Model	(1) Crankshaft Bore Diameter	(2) Bore in the Connecting Rod for the Bushing	(3) Bore in the Bushing for the Pin	(4) Center to Center distance	Roundness	(7) Thickness
3606 3608	225.000 +0.025 / -0.065 mm (8.8582 +0.0010 / -0.0025 inch) Surface Texture: 0.63 µm to 2.5 µm (24.80315 µinch to 98.42520 µinch)	130.000 ± 0.015 mm (5.1181 ± 0.0006 inch) Surface Texture: 0.63 µm to 2.5 µm (24.80315 µinch to 98.42520 µinch)	120.114 ± 0.008 mm (4.7289 ± 0.0003 inch) Surface Texture: 0.8 µm (31.49606 µinch)	600 ± 0.05 mm (23.62200 ± 0.00197 inch)	0.330 mm (0.01299 inch)	109.50 ± 0.08 mm (4.31102 ± 0.00315 inch)
3612 3616 C280–12 C280–16						96.50 ± 0.08 mm (3.79921 ± 0.00315 inch)
3618	244.000 +0.030 / -0.50 mm (9.6063 +0.0012 / -0.0020 inch) Surface Texture: 1.8 µm to 2.5 µm (70.86614 µinch to 98.42520 µinch)	140.000 ± 0.015 mm (5.5118 ± 0.0006 inch) Surface Texture: 0.63 µm to 2.5 µm (24.80315 µinch to 98.42520 µinch)	130.104 ± 0.010 mm (5.1222 ± 0.0004 inch) Surface Texture: 0.8 µm (31.49606 µinch)			103.5 ± 0.08 mm (4.07479 ± 0.00315 inch)

Procedures to Machine

Deburring Sharp Edges on the Connecting Rod Cap

Illustration 116	g06367340
Deburr the sharp edges. (13) Sharp edges

Deburr the connecting rod cap. The sharp edges are shown in Illustration 116. These burrs can form a cutting edge that causes damage to the crankshaft.

Parting Face

Illustration 117	g01640653
(7) Typical locations of wear

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NOTICE
Normal wear at the parting face, between a used connecting rod and the rod cap, can cause the potential for rod and cap misalignment during reassembly. Misalignment causes the rod cap to form a cutting edge that can remove material from the crankshaft if not properly deburred. If allowed to progress, this problem can cause a crankshaft to be unusable at the next overhaul. Indications of this problem are usually iron in the oil filters and not in oil samples. See Illustration 117 for the location of misalignment and cutting edge.

Precautions

• The areas that are peened should not be ground especially in the raised area of the rod. Any such area that is touched by the grinder must be needle peened.

• Edges and burrs should not be left in the area that is deburred.

• Only the described area should be deburred.

After the rods have been deburred, clean the rods properly to remove any debris and any metal filings left by the process of deburring.

Procedure

1. Mount a small, circular grinding wheel into a pencil or a hand-held grinder.
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   Illustration 118	g06190993
   The connecting rod cap should be deburred by following the contour from Point (A) to Point (B).

2. Follow the contour from Point (A) to Point (B) and carefully grind the area shown in Illustration 118. Remove the sharp edge but do not remove large amounts of material. Only remove the necessary amount of material.

Note: Do not deburr any of the areas that have been peened. The connecting rod cap can fail if the area is not peened.

Illustration 119	g06367342
A connecting rod cap that has been properly deburred (14) An edge that has been deburred

Illustration 119 shows a connecting rod cap that has been properly deburred. The shaded area should be deburred.

Illustration 120	g06180891
Shaded area illustrates the shot peened cap seat and adjacent fillet areas.

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NOTICE
When deburring do not come in contact with any of the shot peened areas with the tooling. Be careful to debur only the sharp edges and do not damage any of the shot peened areas. If the shot peening is touched by the grinder, that area must be repeened using a needle peen. Failure to repeen the area can result in failure of the rod cap. Refer to Illustration 120 for shot peened areas.

Parting Face

Note: This section is not for fractured/serrated rods.

Note: Do not remove material from the connecting rod unless it is necessary. Removing an uneven surface or removing fretting is the only reason to machine the following area.

Illustration 121	g06191807
Machine the cap parallel to the original surface. Do not put an angle on the parting line. An example of a machined parting face. Bore the cap and connecting rod to a standard size. (E) Face of the connecting rod. Material should not be removed from this surface unless it is necessary. (F) Remove only a minimum amount from the surface of the connecting rod cap.

Note: Be sure not to heat the cap of the connecting rod too much or cause grinder burns as the cap is ground. Either of the conditions will cause rod to be damaged and will need to be scrapped.

Note: A connecting rod should not be reconditioned if a crankshaft bearing has been spun. The heat that is generated by a bearing that is spinning can cause the connecting rod to become soft. This can result in a failure.

To salvage the connecting rod bore, machine a minimum amount of material from the connecting rod cap and rebore the connecting rod to a standard size. Remove only enough material to clean up the bore. Refer to Illustration 121 and the "Visual Inspection" Section.

Repairing the Area of the Bolt Seat

Illustration 122	g06191808
The location of the radius in the fillet on the connecting rod cap

Illustration 123	g06191820
Reconditioning specifications for connecting rod cap. (A) 0.75 mm (0.030 inch) maximum (B) 0.75 mm (0.030 inch) maximum chamfer or radius (C) Reference diameter (D) Counterbore diameter

Illustration 124	g01705973
(G) Counterbore diameter

In some cases of galling, the area of the bolt seat can be reconditioned by spot facing the damaged area. Do not machine the fillet of the area for the bolt seat. The fillet has been carefully peened after machining to relieve stress. Refer to Table 42 for reference dimensions for the counterbore diameter of the area for the bolt seat. No more than 0.75 mm (0.030 inch) of material should be removed from the area for the bolt seat over the whole life of the connecting rod.

Table 42

Engine Model	Fillet (1)	Counterbore Diameter
C7	3.5 mm (0.14 inch)	21.25 ± 0.25 mm (0.837 ± 0.010 inch)
C-9 C9	3.5 mm (0.14 inch)	22.25 ± 0.15 mm (0.876 ± 0.006 inch)
C-10	3.5 mm (0.14 inch)	22.25 ± 0.15 mm (0.876 ± 0.006 inch)
C11	3.0 mm (0.12 inch)	17.84 ± 0.16 mm (0.702 ± 0.006 inch)
C-12 C12	6.0 mm (0.24 inch)	17.84 ± 0.16 mm (0.702 ± 0.006 inch)
C13	5.0 mm (0.20 inch)	17.84 ± 0.16 mm (0.702 ± 0.006 inch)
C-15	6.0 mm (0.24 inch)	20.84 ± 0.16 mm (0.821 ± 0.006 inch)
C15	6.0 mm (0.24 inch)	18.85 ± 0.20 mm (0.742 ± 0.008 inch)
C-16	6.0 mm (0.24 inch)	20.84 ± 0.16 mm (0.821 ± 0.006 inch)
C-18 C18 C27 C30 C32	6.0 mm (0.24 inch)	18.85 ± 0.20 mm (0.742 ± 0.008 inch)
3100	3.5 mm (0.14 inch)	21.25 ± 0.25 mm (0.837 ± 0.010 inch)
3200	3.18 mm (0.125 inch)	13.87 ± 0.13 mm (0.546 ± 0.005 inch)
3300	4.8 mm (0.19 inch)	16.38 ± 0.13 mm (0.645 ± 0.005 inch)
3400	4.0 mm (0.16 inch)	18.16 ± 0.13 mm (0.715 ± 0.005 inch)
3500	4.0 mm (0.16 inch)	25.40 ± 0.25 mm (1.000 ± 0.001 inch)
3600	16.9 mm (0.67 inch)	24.85 ± 0.20 mm (0.978 ± 0.008 inch)

(1)	Dimensions for the radius

Salvaging of Crankshaft Bore - For Machine Caps only - Not for Fracture Faced Rods

Use a boring machine to rebore the end for the crankshaft of the engine connecting rod. For all connecting rods. When the crankshaft bore is machined, install a new piston pin bushing because the center to center distance will not be correct.

A connecting rod should not be reused if heat discoloration can be seen around the crankshaft bore. Refer to the "Visual Inspection" Section for additional information.

You can salvage the crankshaft bore in one of two ways. Machining the crankshaft bore is one way to salvage the crankshaft bore of the connecting rod. The crankshaft bore must be machined to a larger dimension. Thermal spray is another technique for salvage that may be used for reconditioning crankshaft bores on connecting rods. Be sure that the connecting rod is bare before you utilize metal spray for the connecting rods. For complete information about a thermal spray application, refer to "Metal Restoration".

Piston Pin Bearing Replacement Procedure C4.4 & C6.6 Connecting Rods

Note: This procedure requires personnel with the correct training and the use of specialized equipment for machining.

If the piston pin bearing requires replacement but the original connecting rod is not replaced, the following procedures must be performed:

1. Determine the grade of length of the connecting rod. Use one of the following characteristics:

   • The mark

   • The color

   • Measuring the length

2. Determine if the original grade length of the connecting rod will be use, or if another grade length of connecting rod is needed for proper projection of the piston.

3. Ensure that the connecting rod is not distorted. Refer to "Distortion of The Connecting Rod" in this manual.

4. Tighten the connecting rod cap bolts or nuts to 20 N·m (15 lb ft).

   Note: Do not reuse the connecting rod bolts.

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   Illustration 125	g03453796
   443-7046 Fixture Assembly

5. Use 443-7046 Fixture Assembly to support the connecting rod at both ends. Refer to Illustrations 125 and 127. The connecting rod needs adequate support because the connecting rod is an offset design.
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   Illustration 126	g03675489
   (A) 443-7045 Pin Bore Bushing Tool

6. Use 443-7045 Pin Bore Bushing Tool to remove the pin bore bushing.
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   Illustration 127	g03453808

7. Position the connecting rod assembly onto the fixture. Be sure that the connecting rod is supported at both ends. Install the connecting rod assembly onto a suitable press. Use the fabricated tool to remove the piston pin bushing.
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   Illustration 128	g06367348
   Oil hole in pin bore bushing

8. Inspect the pin bore of the connecting rod for damage. Remove any burrs in the pin bore, if necessary.

9. Position the new pin bore bushing onto the connecting rod. Make sure that the oil hole in the bushing is aligned with the oil hole of the connecting rod, if applicable. Use the Fixture Assembly and the Pin Bore Bushing Tool to install the new pin bore bushing. When complete the bushing should be centered in the bore, be careful not to drive the bushing too deep into the bore.

10. Machine the profile of the ends of the bushing to be parallel to the sides of the connecting rod of 10 degrees. This must be performed before the bore is machined.

11. Machine the bore of the bushing to the correct offset diameter, depending on the grade length of connecting rod that is required.

12. Make sure that the connecting rod is the correct grade length. Refer to "Measure The Length Of The Connecting Rod" in this document.

13. If the grade length of the connecting rod was changed, label the connecting rod with the new grade. DO NOT stamp the connecting rod. Etch a new grade letter onto the connecting rod.

Procedure for Replacing the Bearing of the Connecting Rod Eye and Testing the Retention of the Bearing

Summary

This section enables verification of the retention of connecting rod pin bearings and the procedure to replace the sleeve bearings. This guideline provides the added quality assurance that the connecting rod meets the specifications of standard reusability.

Verification

Factory assembly of the connecting rod includes a test for retention. The test for retention is performed at room temperature to ensure the minimum interference fit. To prevent the failure of the connecting rod pin bearing, the test for retention should be performed on each connection rod during a rebuild.

5P-8639 Connecting Rod Bushing Press can be adapted for this procedure. The test for retention must be performed at room temperature and the bearing must NOT move under the test for retention.

If a connecting rod meets the specifications in this guideline and the criteria in the "Visual Inspection" Section, then the connecting rods can be expected to give normal performance until the next overhaul, that is used in the same application.

Removal and Installation

Use 5P-8639 Connecting Rod Bushing Press with the correct adapter or the correct spacer to remove the piston pin bushing. This may also be used to install the piston pin bushing. Refer to Special Instruction, SMHS7295, "Use of Piston Bearing Removal and Installation Tools" for the correct procedure. Refer to"Procedure for Replacing the Bearing of the Connecting Rod Eye and Testing the Retention of the Bearing" Section for a complete list of the spacers and adapters.

Heat all tapered connecting rods before installation of the piston pin bushings. Use 533-1180 Induction Heater 110 V, 50 Hz, 533-1180 Induction Heater 220 V, 60 Hz, or a similar method to install the piston pin bushings.

Note: To use the 360-3040 Induction Heater 110 V, 50 Hz or 364-1170 Induction Heater 220 V, 60 Hz you must override the shutoff for the automatic temperature. Fasten the thermistor probe to the case of the handle for the heater. Only heat the piston pin end of the connecting rod.

Note: An oven or an oil heater should not be used since the application of heat must be limited to the area of the piston pin bushing only.

Heat the bore for the piston pin bushing to a temperature of 180° ± 80° C (356.0° ± 144.0° F). Use a 164-3310 Infrared Thermometer to measure the temperature of the connecting rod.

Note: This is not applicable for C175 engines.

Note: For the 3200 series of engines that have tapered connecting rods, you should grind a small chamfer on the end of the bore to make the installation of the piston pin bushing easier.

The piston pin bushing must not extend outside the tapered faces on tapered connecting rods.

Illustration 129	g06191867
(G) 10 degrees on either side of the connecting rod

Refer to Illustration 129 for the location of the joint on straight connecting rods.

The proof test must be used to ensure that the correct bushing retention and the test must be used to prevent rod eye bushing failures after rebuilding a rod. The bushing must NOT move during the test.

Installation of new rod pin bearings and removal of the old rod pin bearings is now easier and faster when the correct tools are used with 5P-8639 Connecting Rod Bushing Press.

This guideline gives the procedure and the correct tooling for removal and installation of the following.

• Straight Bearings

• Tapered Bearings

The old bearing is removed from the rod and the new bearing is installed in the rod in one movement of the press. This procedure can only be used when the connecting rod is not being checked for straightness. If a connecting rod is being checked for straightness, the old bearing must be removed first. Check the connecting rod for straightness and install the new bearing with these same tools. Refer to the"Visual Inspection"to make sure that the rod is reusable before installing a new bearing.

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When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Required Tooling

Table 43

Tooling for Standard Connecting Rods(1)
Model	Adapter for Pushing	Spacer	Adapter for Removal and Installation	Position of Part Number
D330 D330A-B D333 D33A-B 1670 1673	5P-8663	5P-8662	5P-8656 or 5P-8657	N/A
D330C D334 1673C 1674 3304-6	5P-8663	5P-8662	5P-8656	N/A
D339 D342 D353	5P-8663	5P-8661(2)	5P-8659	N/A
D343 1693	5P-8663	5P-8647(2)	5P-8656	N/A
D379 D398 D399	5P-8663	5P-8661(2)	5P-8660	N/A
1100 3204 3208	5P-8663	5P-8664	5P-8656	N/A
3400	5P-8663	5P-8651	5P-8658	N/A
				UP (3)

(1)	This information is also for natural gas engines for the above models.
(2)	The large end of connecting rod must be held by hand.
(3)	For part number 4N-0390

Table 44

Tooling for Tapered Connecting Rods
Model	Adapter for Pushing	Spacer	Adapter for Removal and Installation	Bar Clamp	Position of Part Number
C7 (12.5°)	4C-9749	4C-9751	4C-9750	5P-8641	N/A
C-9 (12°)	N/A	1U-6244	N/A	5P-8641	N/A
C15 (12°)	5P-8649	313-5979	5P-8650	5P-8641	N/A
C15 (10°)	4C-8727	313-5979	313-5978	322-6227	UP
C18	4C-8727	313-5979	313-5978	322-6227	UP
C-27 C-32	4C-8727	313-5979	313-5978	322-6227	UP
D346 D349	5P-8645	5P-8647	5P-8646	5P-8641	UP
D348	5P-8645	5P-8647	5P-8646	5P-8641	DOWN
3116 (12°)	4C-9751	4C-9751	4C-9750	5P-8641	UP
3116 (12.5°) 3126 (12.5°)	5P-8649	4C-9751	4C-9750	5P-8641	N/A
3176 (12°)	1U-6243	1U-6244	1U-6242	5P-8641	N/A
3204	5P-8645	6V-4819	5P-8653	5P-8641	DOWN
3208	5P-8645	6V-4819	5P-8653	5P-8641	UP
3300	5P-8645	6V-3029	6V-2049	5P-8641	N/A
3400 (6°)	5P-8649	5P-8651	5P-8650	5P-8640	UP
3400 (9°)	5P-8645	6V-3197	5P-8646	5P-8640	N/A (1)
					UP (2)
		N/A			DOWN (3)
3400 (12°)	1U-9034	1U-9033	1U-9032	5P-8640	N/A
3500 (6°)	5P-8649	6V-3043	6V-3042	5P-8640	DOWN
3500 (10°)	4C-8727	4C-8726	4C-8725	5P-8640	DOWN

(1)	For part number 7E-5996
(2)	For part numbers 8N-1726 and 8N-2486
(3)	For part numbers 8N-1728 and 160-8178

Verifying the Retention of the Bearing

Illustration 130	g01395524
Tooling for Proof Test (1) 5P-8639 Connecting Rod Bushing Press (2) Push adapter (3) Adapter for the removal and installation of the bearing (4) Spacer plate (5) Base plate

Setup

Before you start the test for retention, make sure that all tooling is compatible. Make sure that the tooling has been reworked for the test procedure. Review the following items to determine the necessary setup procedures.

• Rework the base plate for connecting rods that are used in 3000 and 3100 engines. Refer to "Rework the Base Plate for 3000 and 3100 Engines".

• Adapt the hydraulic press with 8T-0820 Pressure Gauge. Refer to "Adapt the Hydraulic Press With a 8T-0820 Pressure Gauge".

• Assemble 5P-8639 Connecting Rod Bushing Press. Refer to "Assemble 5P-8639 Connecting Rod Bushing Press".

• Determine the piston area of the press. Refer to "Determine the Piston Area of the Cylinder".

• Use the piston area to calculate the pressure that is applied to the bearing during the test for retention.

Rework the Base Plate for 3000 and 3100 Engines

An extra threaded hole must be added to base plate (5) to perform a test for retention.

Illustration 131	g06367384

Put the rod into 5P-8639 Connecting Rod Bushing Press with the use of the tools that are outlined in the Table 44. An additional threaded hole must be drilled into the base plate to test an engines connecting rod eye bushing. Refer to the illustration 131 and the Table 45 for the dimensions, the location, and thread type of the new hole in the plate.

Table 45

Specifications for the Base Plate
Item	3000 Engines	3100 Engines
29	35/64 drill through 5/8-11 UNC thread	35/64 drill through 5/8-11 UNC thread
30	179.99 mm (7.086 inch) distance for 103-9680 184.99 mm (7.283 inch) distance for 5I-7668	224.99 mm (8.858 inch) distance for 113-8984, 9Y-1171, 4P-2232 246.99 mm (9.724 inch) distance for 155-6629
31	19.0 mm (0.75 inch) × 90 degree chamfer	19.0 mm (0.75 inch) × 90 degree chamfer

Adapt the Hydraulic Press With a 8T-0820 Pressure Gauge

To adapt a hydraulic press, a pressure gauge must be added to the hydraulic press group. The gauge will allow the operator to monitor the pressure that is applied to the bearing.

8T-0820 Pressure Gauge or a similar gauge is recommended for the use with 9U-6600 Hydraulic Hand Pump, 350-7768 110 V Electric Hydraulic Pump, and 350-7769 220 V Electric Hydraulic Pump.

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Illustration 132	g01626543
Install the pressure gauge into the pressure port. (6) 8T-0820 Pressure Gauge (7) Pipe plug

1. Remove pipe plug (7) from the gauge port.

2. Install 8T-0820 Pressure Gauge (6) into the gauge port that is shown in Illustration 132.

Assemble 5P-8639 Connecting Rod Bushing Press

1. Assemble 5P-8639 Connecting Rod Bushing Press.

2. Use the correct adapter (2), bearing adapter (3), and spacer (4) according to the size of the components.

Determine the Piston Area of the Cylinder

1. Determine the cross-sectional area of the cylinders.

   1. Measure the head diameter of the hydraulic cylinder. Use the Table 46 for information about the cylinders diameter that is used in the 5P-8639 Connecting Rod Bushing Press Group.
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      Table 46

      Hydraulic Cylinder Diameter
      Cylinder Group	Cylinder Diameter
      5P-0156	34.80 mm (1.370 inch)
      5P-9725(1)	42.87 mm (1.688 inch)

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      (1)	Replaces 5P-0156 Cylinder Group

      Note: If a different press group or hydraulic cylinder is used, it will be necessary to measure the diameter of the cylinder to calculate the pressure correctly.

   2. Calculate the cylinders cross-sectional area with the use of the following equation:
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      Table 47

      Calculation of the Piston Area for the Cylinder
      Piston Area = 3.1416 × (Cylinder Diameter) square ÷ 4
      Calculating the Piston Area for the Cylinder
      Hydraulic Cylinder Diameter = 42.87 mm (1.688 inch)
      Example	3.1416 × 42.87 mm2 ÷ 4 = 1443.4 mm2
      Example	3.1416 × (1.688 inch)2 ÷ 4 = (2.238 inch)2

   3. Obtain the applied force “Load” from the Table 52.

   4. The applied force “Load” is needed to calculate the hydraulic pressure that is required to obtain the correct applied force.

   5. Calculate the pressure with the use of the cross-sectional area diameter calculation and applied force with the following equation.
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      Table 48

      Calculation of Pressure

      Pressure = Applied Force (Load) ÷ Cylinder's Piston Area

      Example of a Calculation for Pressure

      Load = 10000 N (2250.0 lb)

      Piston Area = 1443.4 mm2 (2.238 inch2)

      10,000 ÷ 1443.4 = 6928 kPa

      (2250) ÷ (2.238) = (1005 psi)

Procedure To Test Retention

The test for retention must be used to ensure the correct bearing retention. The correct bearing retention is necessary to prevent possible failures of the rod pin bearing after a rebuild. The bearing must NOT move during the test.

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NOTICE
If the rod is not at room temperature, then the test results will not be accurate and a possible inaccurate test can cause a rod to fail. This would lead to damage of other engine components.

1. Make sure that the rod is at room temperature.

2. Put the rod into 5P-8639 Connecting Rod Bushing Press. Position the rod with the showing of the part number in an upward position or downward position according to the specifications that are in Table 52.

3. Determine the load. Refer to "Determine the Piston Area of the Cylinder".

4. Apply the calculated pressure from Step 1e to the connecting rod. The reading that is on 8T-0820 Pressure Gauge is pressure that is applied to the bushing.

   Note: The pressure that is applied to the connecting rod eye bushing should NOT exceed the value that is calculated in Step 1e.

   If the bushing moves during the application of the pressure, then the bushing cannot be used again. Refer to "Removal and Installation of Piston Pin Bearing".

   Note: If a second bearing can be installed, then the bearing must be able to attain enough retention to pass the test. If the second bearing does not meet the specifications that are outlined, then the rod is oversized and the rod must be replaced.

Removal and Installation of Piston Pin Bearing

Positioning of the Connecting Rod for Removal and Installation

Illustration 133	g06367385

Some of the connecting rods must be put in a specific position for removal and/or installation of a rod pin bearing. This is due to some connecting rods that have an offset (A) between the two ends of the connecting rods on one side of the connecting rod. The connecting rod would not lie flat if the offset is facing downward. This would not allow the bushing to be installed correctly. Reference Table 52 for the correct position of the part number of the connecting rod, the correct tooling, and type of connecting rod. For those connecting rods in Table 52 that do not have a specific position for the part number, the connecting rod can be installed on the press group with the part number in either the upward position or the downward position.

Note: The removal and installation are performed simultaneously with the same tooling except for 3116, 3176, C-9, and 3400 connecting rods with a 12° taper.

Illustration 134	g06213532
1U-6242 Pin bushing adapter

Table 49

Fabrication Measurements for the 1U-6242 Pin Bushing Adapter
Dimension	Description	Sales Model
		3044, 3046	3064, 3066
(K)	Length	37.0 mm (1.46 inch)	37.0 mm (1.46 inch)
(L)	Length	8.0 mm (0.32 inch)	8.0 mm (0.32 inch)
(M)	Length	27.0 mm (1.06 inch)	27.0 mm (1.06 inch)
(N)	Diameter	29.94 mm (1.179 inch)	33.94 mm (1.336 inch)
(P)	Diameter	32.67 mm (1.286 inch)	36.67 mm (1.417 inch)
(R)	Internal Diameter	27.75 mm (1.093 inch)	27.75 mm (1.093 inch)
(S)	Length	72.0 mm (2.84 inch)	72.0 mm (2.84 inch)

Illustration 135	g06213533
1U-6244 Spacer

Table 50

Fabrication Measurements for the 1U-6244 Spacer
Dimension	Description	Sales Model
		3044, 3046	3064, 3066
(T)	Internal Diameter	35.0 mm (1.38 inch)	39.0 mm (1.54 inch)
(U)	Diameter	101.6 mm (4.00 inch)	101.6 mm (4.00 inch)
(V)	Width	15.88 mm (0.625 inch)	15.88 mm (0.625 inch)

Illustration 136	g06213534
1U-6244 Pushing Adapter

Table 51

Fabrication Measurements for the 1U-6244 Pushing Adapter
	Sales Model
Dimension	Description	3044, 3046, 3064, 3066
(W)	Internal Diameter	28.58 mm (1.125 inch)
(X)	Diameter	51.18 mm (2.015 inch)
(Y)	Width	63.5 mm (2.50 inch)
(Z)	Width	15.88 mm (0.625 inch)

Procedure to Replace Tapered Bearings

The following procedure is used for both the removal and the replacement of bearings.

Be sure that there is a chamfer on the bore to make installation of the bearing easier. If there is no chamfer on the bore, grind a small chamfer on the end of the bore. Refer to Illustration 137.

Put the connecting rod on the vise with the showing of the part number upward, as the rod is shown in Illustration 137. Use 222-3074 Die Grinder that is powered by air, 4C-8629 Mandrel, and 4C-8626 Reconditioning Star (BP) to grind a small chamfer on the end of the bore.

Illustration 137	g06367388
Grinding the chamfer on the bore (8) 222-3074 Wheel Grinder (9) 4C-8629 Mandrel (10) 4C-8626 Reconditioning Star (11) Protective jaws

The 230-2516 Long Stroke Connecting Rod needs to have the oil passage hole chamfered before the new pin bearing is pressed into position. The oil passage hole for the crankshaft end of the rod also needs to be chamfered. Use the following procedure to chamfer both oil passage holes.

Illustration 138	g02736597
Typical tooling used. (1) Carbide tipped cutter on 90 degree drill for chamfering oil passage hole (2) Polishing cone to polish the oil passage hole after chamfer process (3) Emery paper (4) Nylon brush for cleaning oil passage hole

Illustration 139	g06367390
Bushing that has been scratched during installation into pin bore

Make sure that the oil passage hole in the pin bore is free of burrs. The oil passage in the crank bore should also be free of burrs. A sharp edge could scratch the bushing during installation, possibly causing a burr in the oil passage that could result in a bearing failure.

Illustration 140	g06367396
Oil passage hole in pin bore (A) and in crank bore (B)

If a burr is present in the oil passage of the pin bore, a chamfer is needed. Use the following procedure to produce the proper chamfer.

1. Clamp the rod in a soft jawed vise so the chamfer tool can be used in a vertical direction perpendicular to the pin bore.
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   Illustration 141	g02738318

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   Illustration 142	g02735001
   Chamfer diameter (A).

2. Use a 90 degree angle head drill with a carbide chamfer tool. The drill should be a variable speed drill that is operated at low RPM.

   The maximum chamfer diameter of the oil passage in the pin bore should be 7.5 mm (0.30 inch). The maximum chamfer diameter of the oil passage in the crank bore should be 7.0 mm (0.28 inch).

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   Illustration 143	g02738577

3. Polish the chamfer hole by using a 120 grit cone shaped lap wheel to remove any chatter marks.
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   Illustration 144	g02738628

4. Use Emery cloth with polishing oil along the circumference of the hole. This will ensure that there are no raised areas around the oil passage hole.
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   Illustration 145	g02738697

5. Use a tube brush to clean out the oil passage hole.
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   Illustration 146	g02738838

6. Visually inspect the oil passage for burrs.

7. Repeat steps 1 through 6 for the oil passage hole in the crankshaft bore of the connecting rod.
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   Illustration 147	g06367417

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   Illustration 148	g02739398

8. De-burr the weight bosses on both the crank end and the pin end of the connecting rod. This will help eliminate any stress risers that may be present.

1. Remove the crankshaft bearing from the large end of the connecting rod, and install the cap on the rod.
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   NOTICE
   Do not use an oven or oil bath heater to heat the connecting rod since the heat should only be applied to the area of the piston pin bearing. Also, do not use a direct flame to heat the connecting rod.

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   Illustration 149	g01627076
   533-1180 Induction Heater 110V, 60 Hz

2. Heat the pin bearing of the rod between 180° ± 80° C (356° ± 144° F). Use 533-1180 Induction Heater 110 V, 60 Hz, or a similar method. 533-1181 Induction Heater 220 V, 50 Hz is also available.

Note: 349-4200 Infrared Thermometer ( is a portable non-contact thermometer that can be used to obtain the correct temperature. This tool does not have any limitation to the temperature range.

When you are using tooling 533-1180 Induction Heater (110 V, 60 Hz) or 533-1181 Induction Heater (220 V, 50 Hz) the automatic shutoff of the temperature must not be used. Fasten the thermistor probe to the case or the handle of the heater.

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Illustration 150	g01383997
Install the appropriate spacers. (4) Spacer (5) Base plate

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Illustration 151	g01626546
Use the ejector to make installation of the spacer easier. (12) Ejector

1. Put the correct spacer (4) into the counterbore of base plate (5). For easier installation of spacer (4), lift ejector (12) far enough to put the spacer in alignment with the bore in the base plate (5). Be sure that the spacer is in the bore straight and be sure that the spacer is in the bottom of the counterbore.
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   Illustration 152	g01626547
   Install connecting rod. (5) Base plate (13) Pin (14) Connecting rod (15) Post assembly

2. Put connecting rod (14) on base plate (5) with the showing of the part number in an upward position or downward position according to the specifications that are in Table 52, so that post assembly (15) is in the center of the piston pin bearing. Install pin (13) in the large bore of the connecting rod so the pin is in the center of the bearing bore.

   Note: The following engine models with 12° connecting rods should be installed with the chamfer in the upward direction 3116, 3176, C-9, and 3400.

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   Illustration 153	g01626548
   Install the adapter. (3) Adapter (16) Hole in the adapter for the removal and installation (17) Hole in the base plate

3. Make sure that hole (16) in adapter (3) is in line with hole (17) in the base plate.
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   Illustration 154	g01626549
   Install clamp bar and pin. (18) Clamp pin (19) Clamp bar

4. Install the correct clamp bar (19) and clamp pin (18).

   Note: Some installations may require 6V-8237 Washer that is between the clamp bar and clamp pin.

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   Illustration 155	g01626573
   Install new bearing (20). (3) Adapter (20) New bearing

5. Install new bearing (20) on adapter (3).
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   Illustration 156	g01626575
   Install adapter (23). (15) Post assembly (16) Hole in the adapter for removal and installation (17) Hole in the base plate (21) Bearing joint (22) Holes in the adapter for pushing (23) Adapter for pushing

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   Illustration 157	g06367422
   A connecting rod with an oil passage

   Note: It is important for connecting rods with an oil passage to maintain proper alignment of the oil hole between the oil passage in the connecting rod and the oil hole in the bearing.

   Note: Make sure that the taper on the bearing is aligned with the taper on the connecting rod. Shaving of bearing material can be an indication of improper alignment.

6. Put the correct adapter for pushing (23) over the post assembly (15) and into the bore for the piston pin bearing. Align holes (16) and (22) with bearing joint (21). Align hole (16) with the hole (17) that is in the base plate.
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   Illustration 158	g01626580
   Install the pusher . (23) Adapter (24) Pusher

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   Illustration 159	g01626582
   Completely install the bearing into connecting rod. (25) The location is at the full contact of the connecting rod and the pusher.

7. Put pusher (24) onto adapter (23).

8. Use the press to push the old bearing out of the rod. Use the press until adapter (23) makes full contact with the connecting rod shown at location (25).

9. Remove the tooling and the connecting rod.
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   Illustration 160	g01626583
   Use the pin for ejecting to remove the worn rod pin bearing. (12) Pin for ejecting (26) Old bearing

10. Lift the pin for ejecting (12) to remove the worn rod eye bearing (26) from the press group.

11. Machine the bearing to the correct inside diameter. Refer to"Specifications for the Connecting Rod" for the correct specifications.

12. For connecting rods that have a drilled oil passage hole, the opening in the bushing should be closely examined after machining to determine if a de-burr operation is required.

A test for retention needs to be done to make sure of the correct retention of the bearing. The test must be performed to prevent failures of the bearing after the rod has been rebuilt. See the "Verifying the Retention of the Bearing" section for this procedure.

Procedure to Replace Straight Bearings

The following procedure is used for both installation and removal of the bearings.

1. Before installing the piston pin bearing, heat the bearing end of the rod.

   Note: Be sure to remove the crankshaft bearing from the large end of the connecting rod before the rod is heated.

   1. Remove the crankshaft bearing from the large end of the connecting rod, and install the cap on the rod.
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      NOTICE
      Do not use an oven or oil bath heater to heat the connecting rod since the heat should only be applied to the area of the piston pin bearing. Also, do not use a direct flame to heat the connecting rod.

   2. Heat the pin bearing of the rod between 180° ± 80°C (356° ± 144°F). Use 533-1180 Induction Heater 110V, 60 Hz, or a similar method. 533-1181 Induction Heater 220V, 50 Hz is also available.

      Note: 349-4200 Infrared Thermometer is a portable non-contact thermometer that can be used to obtain the correct temperature. This tool does not have any limitation to the temperature range.

      When you are using 533-1180 Induction Heater 110V, 60 Hz or 533-1181 Induction Heater 220V, 50 Hz the automatic shutoff of the temperature must not be used. Fasten the thermistor probe to the case or the handle of the heater.

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   Illustration 161	g01383997
   Install the appropriate spacers. (4) Spacer (5) Base plate

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   Illustration 162	g01626586
   Use the pin for ejecting to make installation of spacer easier. (12) Pin for ejecting

2. Put correct spacer (4) into the counterbore of base plate (5). For easier installation of spacer (4), lift ejector (12) far enough to put the spacer in alignment with the bore in base plate (5). Be sure that the spacer is in the bore straight and be sure that the spacer is in the bottom of the counterbore.
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   Illustration 163	g01626587
   Install connecting rod. (3) Adapter (5) Base plate (14) Connecting rod (15) Post assembly

3. Put connecting rod (14) on base plate (5) with the showing of the part number in an upward position or downward position according to the specifications that are in Table 52, so that post assembly (15) is in the center of the piston pin bearing. Install pin (16) in the large bore of the connecting rod so the pin is in the center of the bearing bore.

4. It is necessary for some connecting rods to be held by hand. If the rod is held by hand, the large end of the connecting rod should be held 90 degrees to the right or to the left.
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   Illustration 164	g01626588
   Install new bearing (20). (15) Post (20) New bearing (23) Adapter

5. First install new bearing (20) on adapter (3). Then install the adapter for pushing (23) on post (15) with the counterbore of the connecting rod in the upward direction.
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   Illustration 165	g01626590
   Install the pusher. (23) Adapter (24) Pusher

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   Illustration 166	g01626593
   Completely install the bearing into connecting rod (23) Adapter (25) The location is at the full contact of the connecting rod and the pusher.

6. Put pusher (24) onto adapter (23) and use the press to push the old bearing out of the rod. Use the press until adapter (23) makes full contact with the connecting rod shown at location (25).
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   Illustration 167	g01626594
   Use the ejector to remove the worn rod pin bearing. (12) Pin for ejecting (26) Old bearing

7. Remove the tooling and the connecting rod. Lift ejector (12) to remove the worn rod pin bearing (26) from the press group.

8. Machine the bearing to the correct inside diameter. Refer to the"Specifications for the Connecting Rod" Section for the correct specifications.

A test for retention should be performed to make sure that there is correct retention of the bearing. This test must be performed to prevent failure of the bearing after the rod has been rebuilt. See the "Verifying the Retention of the Bearing" section for this procedure.

Specifications

The last column in Table 52 specifies the orientation of the part number once the connecting rod is positioned on the tooling. The dashes indicate that the part number can face upward or the part number can face downward.

Table 52

Engine Model	Force Applied to the Bearing.	Pressure Applied Using 5P-9725 Hydraulic Cylinder	Tapered or Straight Bearing	Position of Part Number
C-7 C7	9000 N (2023.0 lb)	6235 kPa (904 psi)	T	UP
C-9 (8.8 L)	10000 N (2248.0 lb)	6928 kPa (1005 psi)	T	N/A
C9 (9.3 L)	10000 N (2248.0 lb)	6928 kPa (1005 psi)	T	N/A
C-10	10000 N (2248.0 lb)	6928 kPa (1005 psi)	T	UP
C11	10000 N (2248.0 lb)	6928 kPa (1005 psi)	T	N/A
C-12	10000 N (2248.0 lb)	6928 kPa (1005 psi)	T	UP
C13	10000 N (2248.0 lb)	6928 kPa (1005 psi)	T	N/A
C15 C-15	11000 N (2473.0 lb)	7621 kPa (1105 psi)	T	N/A
C-16	11000 N (2473.0 lb)	7621 kPa (1105 psi)	T	N/A
C18 C-18	11000 N (2473.0 lb)	7621 kPa (1105 psi)	T	N/A
C27	11000 N (2473.0 lb)	7621 kPa (1105 psi)	T	N/A
C-30	11000 N (2473.0 lb)	7621 kPa (1105 psi)	T	N/A
C32	11000 N (2473.0 lb)	7621 kPa (1105 psi)	T	N/A
D342 D343 D353 D379 D398 D399	15599 N (3507 lb)	10808 kPa (1568 psi)	S	N/A
D346 D348 D349	15599 N (3507 lb)	10808 kPa (1568 psi)	T	N/A
3044 3046	8800 N (1978.0 lb)	6100 kPa (884 psi)	T	N/A
3064 3066	9000 N (2023.0 lb)	6235 kPa (904 psi)	T	N/A
3114 3116 3126	9000 N (2023.0 lb)	6235 kPa (904 psi)	T	UP
3160	9000 N (2023.0 lb)	6235 kPa (904 psi)	S	UP
3176	10000 N (2248.0 lb)	6928 kPa (1005 psi)	T	N/A
3196	10000 N (2248.0 lb)	6928 kPa (1005 psi)	T	UP
3204	8896 N (2000.0 lb)	6163 kPa (894 psi)	T	DOWN
3208	8000 N (1799.0 lb)	5543 kPa (804 psi)	T	UP
	9000 N (2023.0 lb)	6235 kPa (904 psi)	S	UP
3300	10000 N (2248.0 lb)	6928 kPa (1005 psi)	S	N/A
3400	11000 N (2473.0 lb)	7621 kPa (1105 psi)	T	N/A
3500	29780 N (6695.0 lb)	20632 kPa (2992 psi)	T	N/A

4N-9002 4N-9001 4N-9002 4N-90014N-9002 4N-9001 4N-9002 4N-9001Removal of Dowel Pins for 4N-9001, and 4N-9002 Connecting Rods

Removal of the Dowel Pin from the Cap.

Illustration 168	g06191839
The spindle must be in the correct position.

Use clamps to fasten FT-1837 (Fabricated Fixture) on a table for the drill with the spindle in line with the drill bushing. Refer to Illustration 168.

Put the cap in position on the fixture and be sure that the dowel in the cap fits the hole in the locator.

Tighten the bolt to hold the cap in place. Drill a 7/32" hole through the dowel pin. Refer to Illustration 169.

Illustration 169	g06191844
The dowel is ready to be drilled.

Remove the cap from the fixture with a hammer and a sharp punch. Breaking the shell will allow the cap to be removed.

Remove the material that is left on the dowel with needle nose pliers. This is shown in Illustration 170.

Illustration 170	g06191850
Be sure to remove the dowel from the cap completely.

Removal of the Dowel Pin from the Connecting Rod.

Refer to Illustration 171 for an example of a spindle that is in the correct position.

Illustration 171	g06191853
The spindle must be in the correct position.

Put the connecting rod in position on the fixture and remove the drill bushing and the drill. Slide the locator over the dowel. If necessary, the shims should be installed between the connecting rod and the lower piston pin.

Illustration 172	g06191857
Tighten the set screw before you drill.

Use a wrench to tighten the set screw. This is shown in Illustration 172. Drill a 7/32" hole through the dowel pin.

Note: After the screw has been tightened and the locator is not easily removable, the screw may be too tight. There may also be too many shims between the connecting rod and the piston.

Illustration 173	g06191861
Be sure to completely remove the dowel from the connecting rod.

Remove the connecting rod from the fixture with a hammer and a sharp punch. Remove the material that is left from the dowel with needle nose pliers. Refer to Illustration 173.

Metal Restoration

For further information on the equipment needed to perform thermal spray processes, refer to the following publications:

• Special Instruction, SEBF9236, "Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for Reconditioning Components"

• Special Instruction, SEBF9238, "Fundamentals of Arc Spray for Reconditioning Components"

• Special Instruction, SEBF9240, "Fundamentals of Flame Spray for Reconditioning Components"

Connecting Rod Crankshaft Bore, except C175 Connecting Rod

Table 53

Base Metal	Forged Steel
Hardness	RC 23-26

Arc Spray Equipment and Procedure

Table 54

Maximum Surface Texture	2.5 µm (98.42520 µinch) Ra
Reason for Spraying	Bore out of round
Mating Part Contact Area & Material	Bearing sleeve
Arc Spray Equipment Type	SmartArc by Oerlikon Metco,TAFA 8830 MHU, or TAFA 8835 MHU
Wire	TAFA Alcro Wire Top Coat, TAFA 75B Wire Bond Coat
Finish Thickness	0.25 mm (0.010 inch)
Finishing Allowance	Machine - 0.64 mm (0.025 inch)
Spray Angle	81° to center line
Substrate Pre-Heat Temperature	66° C (150° F) Do not direct arc on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148° C (300° F)
Auxiliary Cooling	Filtered shop air
Rotation/Traverse Device	Turntable or lathe
Surface Preparation Method	Undercut and grit blast
Machining Method	Machine
Equipment Required	Rod bore machine or mill
Recommended Cutting Tool	ISCAR DNMG 432 TFIC507
Blast Media Recommendation	Pressure Type Only (Aluminum Oxide Grit)
Finishing Equipment Type	Hone
Recommended Abrasive	120 to 180 grit stone

Table 55

Arc Spray		Procedure		Check List
Clean Part		Wash in non-oil base solvent
		Note: Install rod cap and tighten bolts to proper torque (On 133.35 mm (5.250 inch) rods ONLY, torque to 54.2 N·m (40.00 lb ft) plus 120°). Put SP960 Multi-Purpose Grease on the bolt threads and the contact surfaces of the bolt and cap anytime the rods are assembled and torque. Keep grease out of bore to be sprayed.
Chamfer		All edges - 45° x 0.76 mm (0.030 inch)
Remove Oxide		Emery paper or Scotch Brite
Mask for Grit Blast		Use metal mask
Grit Blast Equipment		Pressure type only
Grit Type and Size		20 mesh aluminum oxide
Blast Air Pressure		690 kPa (100.0 psi)
Blast Nozzle to Work Distance		51 to 150 mm (2.0 to 6.0 inch)
Remove Blast Mask		No
Mask for Metal Spray		Use blasting mask
Metal Spray Equipment Type		Smart Arc by Oerlikon Metco	TAFA
	Consumable (Bondcoat)	TAFA 75B	TAFA 75B
	Clamp Pressure	275 kPa (40 psi)	N/A
	Air Jets/Pressure	415 kPa (60 psi)	N/A
	Arc Load Volts	30V	30V
	Amps	125 Amps	150 Amps
	Gun to Work Distance (Standoff)	128 mm (5.0 inch)	128 mm (5.0 inch)
	Spray Rate/Bond Pass	0.038 mm (0.0015 inch)/pass	0.038 mm (0.0015 inch)/pass
	Consumable (Topcoat)	TAFA Alcro	TAFA Alcro
	Clamp Pressure	275 kPa (40 psi)	N/A
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	30V	29V
	Amps	150 Amps	125 Amps
	Gun to Work Distance (Standoff)	76 mm (3.0 inch)	76 mm (3.0 inch)
	Spray Rate/Build Up	0.038 mm (0.0015 inch)/pass	0.038 mm (0.0015 inch)/pass
	Rotation Speed of Part	92 SMPM (300.00 SFPM)
	Traverse Rate of Gun	11 SMPM (36.00 SFPM)
Gun Fixturing Method		Hand held
Finishing Equipment		Rod bore machine / Rod hone
Part/Cutter Rotation (Roughing)		50 SMPM (150.00 SFPM)
Part/Cutter Rotation (Finishing)		75 SMPM (250.00 SFPM)
Coolant		Oil based synthetic - 40:1 ratio
Traverse Speed		0.30 mm (0.012 inch) per revolution
Depth of Rough Cut		0.51 mm (0.020 inch) per side max
Depth of Finish Cut		Hone - (hone last 0.07 mm (0.003 inch) from I.D.)

Flame Spray Equipment and Procedure

Table 56

Maximum Surface Texture	2.5 µm (98.42520 µinch) Ra
Reason for Spraying	Bore out of round
Mating Part Contact Area & Material	Bearing sleeve
Oerlikon Metco Equipment Type	6P-II by Oerlikon Metco
Metco Material	Metco 452 or 453 Grind
Finish Thickness	0 to 0.25 mm (0 to .010 inch)
Finishing Allowance	0.38 mm (0.015 inch) per side
Spray Angle	81° to center line
Substrate Pre-Heat Temperature	85° C (185° F) Do not direct flame on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148° C (300° F)
Auxiliary Cooling	If desired
Rotation/Traverse Device	Turntable or lathe
Rotation/Traverse Speed	61 SMPM (200.00 SFPM)
Surface Preparation Method	Grit Blast
Finishing Method	Machine
Machining Equipment Type	Rod bore machine or mill
Recommended Cutter Grade	C-2 carbide 0.38 mm (0.015 inch) radius
Other Equipment Type	Hone
Media Recommendation	120 to 180 grit stone

Table 57

Flame Spray Process (6P-II)	Procedure	Check List
Clean Part	Wash in non-oil base solvent
	Note: Install rod cap and tighten bolts to proper torque (On 133.35 mm (5.250 inch) rods ONLY, torque to 54.2 N·m (40.00 lb ft) plus 120°). Put SP960 Multi-Purpose Grease on the bolt threads and the contact surfaces of the bolt and cap anytime the rods are assembled and torque. Keep grease out of bore to be sprayed.
Undercut	Not required
Chamfer	All edges - 45° x 0.76 mm (0.030 inch)
Remove Oxide	Emery paper or Scotch Brite
Mask for Grit Blast	Use metal mask
Grit Blast Equipment	Pressure or suction cabinet
Grit Type and Size	Metcolite "C" or equivalent
Blast Air Pressure	550kPa (80.0 psi)
Blast Nozzle to Work Distance	50 mm (2.0 inch)
Remove Blast Mask	No
Mask for Metal Spray	Use blasting mask
Metal Spray Equipment Type	6P-II Hand Held Thermo Spray System by Oerlikon Metco
Auxiliary Cooling	If desired
Nozzle	6P7C-K "K" Nozzle
Air Capacity/Pressure	6P-3/Cooling Air 140 - 170 kPa (20.0 - 25.0 psi)
Oxygen Pressure	210 kPa (30.0 psi)
Oxygen Flow	1190 L/h (42.0 cfh)
Fuel Gas Pressure	100 kPa (15.0 psi)
Fuel Gas Flow	1415 L/h (50.0 cfh)
Carrier Gas Pressure	380 kPa (55.0 psi)
Carrier Gas Flow	1050 L/h (37.0 cfh)
Spray Rate/Build Up	5.5 kg (12.00 lb) per hour or 90 gr (3.2 oz) /min
Gun to Work Distance	230 mm (9.0 inch)
Rotation Speed of Part (RPM)	245 RPM
Rotation Speed of Part	Bore diameter (inches) x 3.14 + 12 x rpm
Traverse Rate of Gun	15 SMPM (50.00 SFPM)
Gun Fixturing Method	Hand held
Top Coat/Thickness	0.25 to 0.28 mm (0.010 to 0.011 inch) per pass
Finishing Equipment	Rod bore machine / Rod hone
Part/Cutter Rotation	92.0 SMPM (300.00 SFPM)
Traverse Speed	0.13 mm (0.005 inch)
Depth of Rough Cut	0.25 mm (0.010 inch)
Depth of Finish Cut	Hone - (hone last 0.07 mm (0.003 inch) from I.D.)

Storage Procedures

Proper protection of the components from corrosion is important. Corrosion will start in as little as one hour after the components have been cleaned.

When the components will not be inspected for one hour or less the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The components should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 174.

When the components will not be inspected in two days or more the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil and should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic to prevent damage and contamination to the components. See Illustration 175.

Refer to SEHS9031 Special Instruction, "Storage Procedure for Caterpillar Products" for more information.

Illustration 174	g06278538
Example of protection for a component that is stored for a shorter term

Illustration 175	g06278539
Example of protection for a component that is stored for a longer period