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Specifications for Connecting Rods in 3500 Family of Engines{0761, 0767, 1218}
Número de medio -SEBF8149-15 Fecha de publicación -05/04/2010 Fecha de actualización -05/04/2010
i03900264
Specifications for Connecting Rods in 3500 Family of Engines
{0761, 0767, 1218}
SMCS - 0761; 0767; 1218
Engine: All 3500 Engines
Introduction
This guideline enables dealers and customers to establish a parts reusability program. A parts reusability
program allows dealers and customers to benefit from cost reductions. Every effort has been made in
order to provide the most current information that is known to Caterpillar Inc. Since the company makes
ongoing changes and improvements to products, this guideline must be used with the latest technical
information that is available from Caterpillar to ensure such changes and improvements are
incorporated.
For additional information about this guideline, consult Caterpillar Service Support Division of Dealer
Service Operations at (309) 636-5833.
Summary
This guideline gives the necessary specifications for measuring and visually inspecting the connecting
rods that are used in the 3500 Family of Engines. If a connecting rod meets these specifications and the
inspection guidelines that are shown in Reuse and Salvage Guideline, SEBF8063, "Visual Inspection of
Connecting Rods", normal performance can be expected until the next overhaul when the connecting rod
is used in the same application.
References
Reuse and Salvage Guideline, SEBF8051, "Inspection and Measuring Procedures for Piston Pins"
Reuse and Salvage Guideline, SEBF8063, "Visual Inspection of Connecting Rods"
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Reuse and Salvage Guideline, SEBF8242, "Procedure to Replace the Connecting Rod Eye Bearing or
Test the Bearing Retention"
Special Instruction, SEHS7295, "Use of Piston Pin Bearing Removal and Installation Tools"
Special Instruction, GMG00981, "Using the 1P-3537 Dial Bore Gauge Group to Check Cylinder Bore
Size"
Special Instruction, SMHS6870, "Using the 5P-3550 Connecting Rod Boring Machine "
Special Instruction, SMHS7366, "Using the 5P-2050 Connecting Rod Checking Fixture "
Special Instruction, SMHS8036, "Using the 6V-6030 Size Setting Fixture Group "
Special Instruction, SMHS8037, "Using the 6V-6000 Dial Bore Gauge Group "
Special Instruction, SMHS8253, "Using the 6V-7898 Dial Bore Gauge Group "
Special Instruction, SMHS8254, "Using the 6V-7899 Size Setting Fixture Group "
Tooling and Equipment
Table 1
Required Tools
Part Number Part Description
1P-3537 Dial Bore Gauge Group
1U-5778 Die Grinder
4C-8626 Reconditioning Star
4C-8629 Mandrel
5P-2050 Alignment Fixture Gp
5P-8639 Hydraulic Press Group
5P-9725 Hydraulic Cylinder Group
6V-2032 Adapter
6V-2033 Brush
6V-4876 Lubricant
6V-6000 Dial Bore Gauge Group
6V-6030 Fixture Gp
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6V-7898 Dial Bore Gauge Group
6V-7899 Fixture Gp
8T-0820 Hydraulic Pressure Gauge
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.
Nomenclature
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Illustration 1 g01948487
Nomenclature of the connecting rod
(1) Connecting rod bolts
(E) Bore in connecting rod for crankshaft bearing
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(F) Bore in connecting rod for the piston pin bushing
(G) Bore in the piston pin bushing
(H) Piston pin diameter
(J) Center to center distance
Illustration 2 g01640553
Example of twist and bend of a connecting rod
(2) Twist
(3) Bend
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Illustration 3 g01640561
Torque sequence for connecting rods
(4) Side of connecting rod with chamfer
(5) Connecting rod bolts
(6) Location pin for correct installation of connecting rod cap
(K) Thickness of the connecting rod
Tightening Procedure for Connecting Rod Bolts
1. Before assembly, put 6V-4876 Lubricant or Fel-Pro C110 Lubricant on the bolt threads and all
surfaces that make contact between the bolt and the cap.
2. Tighten bolts (A) and (B) to 90 ± 5 N·m (66.4 ± 3.7 lb ft). Refer to Illustration 3.
3. Tighten bolts (C) and (D) to 90 ± 5 N·m (66.4 ± 3.7 lb ft).
4. Tighten bolts (A) and (B) again to 90 ± 5 N·m (66.4 ± 3.7 lb ft).
5. Tighten bolts (C) and (D) again to 90 ± 5 N·m (66.4 ± 3.7 lb ft).
6. Tighten each bolt again with a 90 ± 5 degree turn.
Table 2
Connecting Rod Bolts
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First Rebuild Reuse the bolts.
Second Rebuild Replace the bolts.
Third Rebuild Reuse the bolts.
Fourth Rebuild Replace the bolts.
Fifth Rebuild Reuse the bolts.
Specifications for Connecting Rod
Table 3
Specifications
Thickness of Connecting Rods for New Rods and Used
67.575 ± 0.076 mm (2.6604 ± 0.0030
Rods
inch)
Crankshaft Bore
Specifications for the Diameter (1)
Diameter
Torque (2) Additional Surface Clearance between Crankshaft Journal
After
Turn Texture and Rod Bearing
Machining
0.63
micrometers
(25
143.028 ± 0.107 mm 0.152 mm 0.229 mm
microinches)
0.015 mm 90 ± 5 N·m 90 ± 5 (0.0042 (0.0060 (0.0090
to
(5.6310 ± (66.4 ± 3.7 degrees inch) inch) inch)
2.5
0.0006 inch) lb ft) Minimum Nominal Maximum
micrometers
(100
microinches)
Piston Pin Bore in the Connecting Rod
Specifications for the Diameter
Pin Bore Diameter in New Rods and
Surface Texture for New Rods and Used Rods
Used Rods
75.760 ± 0.015 mm (2.9827 ± 0.0006 0.63 micrometers (25 microinches) to
inch) 2.5 micrometers (100 microinches)
Bore for Piston Pin Bearing
Specifications for the Diameter
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Diameter After Machining Maximum Diameter for Surface Texture for New Rods and Used
Reusability (3) Rods
70.000 ± 0.008 mm 0.25 micrometers (10 microinches) or
70.058 mm (2.7582 inch)
(2.7559 ± 0.0003 inch) less
Piston Pin
Specifications for the Diameter (4)
Pin Diameters Clearance between Pin and Bushing (5)
Minimum Diameter for Maximum Clearance for
New New
Reusability (6) Reusability (7)
69.962 ±
0.005 mm
69.947 mm (2.7538 0.025 mm (0.0010 inch) to
(2.7544 ± 0.10 mm (0.004 inch)
inch) 0.051 mm (0.0020 inch)
0.0002 inch)
( 1 ) Refer to Table 7 for specifications to use again.
( 2 ) Refer to ""Tightening Procedure for Connecting Rod Bolts" ".
( 3 ) 0.050 mm (0.0020 inch) of wear is permitted over the specified diameter of a new bearing.
( 4 ) Piston pins must be inspected for a wear step. Refer to Reuse and Salvage Guideline, SEBF8051, "Inspection and
Measuring Procedures for Piston Pins".
( 5 ) Bushings should be tested to 15500 kPa (2250 psi) before the assembly is put into the engine. Refer to ""Test for the
Verification of the Retention of the Rod eye Bushing" ".
( 6 ) 0.010mm (0.0004 inch) of wear is permitted over the specified diameter of a new piston pin.
( 7 ) Theclearance between the pin and the pin bushing can not be greater than 0.10 mm (0.004 inch). Pins and bushings that
are new or used can be assembled together, if the 0.10 mm (0.004 inch) clearance is not exceeded.
Table 4
Center to center distance for Standard Rods 380.00 mm (14.961
inch)
Center to center distance for Connecting Rods in high displacement engines
392.5 mm (15.453
inch)
Reusability (8) Maximum Tolerance New Bushing After
Original Bushing for Salvage Machining
Tolerance for the Center to
Center Distance
± 0.076 mm ± 0.102 mm (0.0040 ± 0.076 mm (0.0030
(0.0030 inch) inch) (9) inch)
( 8 ) Inspect the bushing for damage. Refer to Reuse and Salvage Guideline, SEBF8063, "Visual Inspection of Connecting
Rods".
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( 9 ) If
this dimension is exceeded without the bushing, it may be possible to install a new bushing that is machined to
acceptable specifications. The bushing must have no steel showing through the bronze.
Table 5
Tolerances
Original Maximum Tolerance Maximum Clearance for
Fixture
Bushing for Salvage Reusability
0.00 mm (0.000
5P-2050
inch) to 0.00 mm (0.000 inch) to
Fixture 0.30 mm (0.012 inch)
0.30 mm (0.012 0.30 mm (0.012 inch)
Twist inch)
0.00 mm (0.000
Tobin-Arp
inch) to 0.00 mm (0.000 inch) to
Fixture 0.51 mm (0.020 inch)
0.51 mm (0.020 0.51 mm (0.020 inch)
inch)
Other
- - -
Fixtures (10)
0.00 mm (0.000
5P-2050
inch) to 0.00 mm (0.000 inch) to
Fixture 0.30 mm (0.012 inch)
0.114 mm 0.08 mm (0.003 inch)
(0.0045 inch)
Bend
0.00 mm (0.000
Tobin-Arp
inch) to 0.00 mm (0.000 inch) to
Fixture 0.51 mm (0.020 inch)
0.20 mm (0.008 0.140 mm (0.0055 inch)
inch)
Other
- - -
Fixtures (10)
( 10 ) Refer to ""Corrections for Bend and Twist Measurements" " to calculate specifications for other fixtures.
Visual Inspection
Parting Face
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
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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 4
for the location of misalignment and cutting edge.
Illustration 4 g01640653
(7) Typical locations of wear
Refer to ""Tightening Procedure for Connecting Rod Bolts" " and ""Deburring Sharp Edges on Rod
Cap" " for the two main procedures for reducing this problem or for eliminating this problem.
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.
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Illustration 5 g01640693
(8) Crack in the slot for the pin
Do not use the connecting rod again.
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Illustration 6 g01640695
(9) Crack in the wall of the opening for the bolt
Do not use the connecting rod again.
Visually inspect the body of the connecting rod at the point of contact between the connecting rod and
cap. The wear step on the side of the body should be 0.18 mm (0.007 inch) or less in order to reuse the
connecting rod. Refer to Illustration 7.
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Illustration 7 g01640696
(10) Typical wear on the side of the body of the connecting rod
Use the connecting rod again, if the wear step (total across the bore) is 0.18 mm (0.007 inch) or less.
When the wear step is measured, the wear on both sides of the rod (opposite sides of the bore) must be
added together. For example, one side can have greater wear of 0.13 mm (0.005 inch)than the opposite
side with 0.03 mm (0.001 inch). When both sides are added together, the result of 0.16 mm (0.006 inch)
is still acceptable.
A connecting rod with a wear step less than 0.18 mm (0.007 inch) can be polished with a 6V-2033
Brush for the purpose of looks. Illustrations 8 and 9 show the brush and adapters.
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Illustration 8 g01643045
6V-2033 Brush
Illustration 9 g01643049
Brush and 6V-2032 Adapters
Deburring Sharp Edges on Rod Cap
Deburring is used to remove the sharp edges on the rod cap. Sharp edges on the rod cap can form a
cutting edge that can cause crankshaft wear. Refer to Illustration 10.
Illustration 10 g01643174
Deburr sharp edges.
(11) Sharp 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.
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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, the rods should be properly cleaned in order to remove any debris
and any metal filings left by the process of deburring.
Procedure
1. Mount a circular grinding wheel with a grit of A80, a diameter of 50 mm (2.0 inch), and a length
of 12 mm (0.5 inch) into a pencil or a hand-held grinder.
2. Carefully grind the area along the contour from point (12) to point (13) that is shown in
Illustration11. Remove the sharp edge but do not remove large amounts of material.
Illustration 11 g01643294
Deburr the rod cap along the contour from point (12) to point (13) .
NOTICE
Be careful to only debur the sharp edges and do not debur any of the
shot peened areas. If the shot peening is touched by the grinder, that
area must be re-peened using a needle peen. Failure to re-peen the area
can result in failure of the rod cap.
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Illustration 12 g01643393
Rod cap that is properly deburred
(14) Edge that is deburred
Illustration 12 shows a rod cap that is properly deburred. The shaded area should be deburred.
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 in order to reuse the rod cap. An
example is shown in Illustration 13.
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Illustration 13 g01644655
(15) Typical wear on the connecting rod cap
Use the connecting rod cap again, if the wear step is 0.03 mm (0.001 inch) or less.
Hardware
Hardware can normally be used again unless there is obvious damage or unless the hardware was loose
before being removed. To tighten hardware, follow the procedures below. Also, follow any
specifications that are given in Table 3 and the Service Manual. Do not tighten hardware more than the
recommended torque. Excess torque can result in damage to the bolt or the internal threads. Never use a
bolt with fretting and/or smearing in the area of the bolt seat. For additional information on the
reusability of connecting rod bolts, refer to Visual Inspection of Hardware in Reuse and Salvage
Guideline, SEBF8063, "Visual Inspection of Connecting Rods".
Repair of the Area of the Bolt Seat
In some cases, an area of the bolt seat that is showing signs of galling can be reconditioned by spot
facing the damaged area. Do not machine the fillet because the fillet has been machined and the fillet
has been peened in order to relieve stress. This fillet is indicated by the arrow in Illustration 14.
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Illustration 14 g01644831
(16) The location of the fillet on the connecting rod cap
Illustration 15 g01644832
Reconditioning specifications of connecting rod caps
(A) 0.75 mm (0.030 inch) maximum
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(B) 0.75 mm (0.030 inch) maximum chamfer or radius
(C) 14.75 mm (0.581 inch) reference diameter
(D) 25.40 ± 0.25 mm (1.000 ± 0.010 inch)
Connecting Rod Bolts
Connecting rod bolts must be inspected at each overhaul. If the bolts meet the "Use again" criteria in
Reuse and Salvage Guideline, SEBF8063, "Visual Inspection of Connecting Rods", the bolts can be
used again. Also refer to Table 6.
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