Visual Inspection of Connecting Rods (1218) : Pautas de Reutilización y Recuperación

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Producto: TRUCK ENGINE

Modelo: C-12 TRUCK ENGINE 1YN
Configuración: C-12 Truck Engine 1YN00001-UP
Pautas de reutilización y recuperación

Visual Inspection of Connecting Rods{1218}
Número de medio -SEBF8063-03 Fecha de publicación -07/07/2006 Fecha de actualización -07/07/2006
i02504688
Visual Inspection of Connecting Rods{1218}

SMCS - 1218
Engine:Commercial All
3044C (S/N: 3441-UP)
Engine:Truck All
Industrial Engine:with Turbochargers All
Machine Engines: All
Marine Engine:with Turbochargers All
Introduction
This Reuse and Salvage Guideline contains the necessary information in order to allow a dealer to
establish a parts reusability program. Reuse and salvage information enables Caterpillar 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. 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 additional information about this guideline, consult Repair Process Engineering of the Marketing
& Product Support Division at 1 (309) 675-5434.
Summary
This guideline shows visual examples of connecting rods that were used in Caterpillar engines. Some
examples can be reused and some examples cannot be reused. This guideline contains a list of
servicing information for reconditioning connecting rods.
Parts that are used in the same application should be expected to give normal performance until the
next overhaul. The connecting rods may be reused only if the connecting rod meets the criteria in
this guideline and the other applicable guidelines.
Salvage operations and specifications for connecting rods that are not serrated are available in Reuse
and Salvage Guideline, SEBF8064, "Procedure and Specifications for Connecting Rods".
References
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 17/07/2006
ReferenceReuse and Salvage Guideline, SEBF8064, "Procedure and Specifications for Connecting
Rods"
ReferenceReuse and Salvage Guideline, SEBF8039, "Inspection of Crankshafts for Cracks"
ReferenceApplied Failure Analysis, SEBF9066, "Guideline for Examining Failed Parts"
ReferenceReuse and Salvage Guideline, SEBF8187, "Standardized Parts Marking Procedures"
ReferenceReuse and Salvage Guideline, SEBF9074, "Salvage Procedures for Connecting Rods"
ReferenceReuse and Salvage Guideline, SEBF8242, "Connecting Rod Eye Bushing Installation and
Removal and Retention Verification Using the 5P-8639 Connecting Rod Bushing Press Group "
Required Tooling
Table 1
Part Number Description

- Sharpening Stones
150-1197 Disc
6V-2010 Polishing Stone
6V-2032 Adapter
6V-2033 Brush
Fractured Connecting Rods
Illustration 1 g01277400
Fractured connecting rod assembly
Fractured connecting rod and connecting rod cap
A fractured connecting rod cap
NOTICE
The joint between the connecting rod and the connecting rod cap is
produced by fracturing. The connecting rod assembly must be handled
with care in order 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.
Nomenclature
Illustration 4 g
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 5 g
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
Servicing Information
z Do not use glass beads on the crankshaft bore, the thrust face, or the piston pin bore.
z 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. Mark the ground area of a new
connecting rod with an electric scribe. The correct ground area of a connecting rod is shown in
Illustration 6. 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. Refer to Reuse and
Salvage Guideline, SEBF8187, "Standardized Parts Marking Procedures".
z Be careful removing, installing, and cleaning connecting rods in order to prevent damage.
z Apply a layer of clean oil on cleaned parts and machined parts as protection from corrosion.
Refer to the ""Storage Procedures" " section.
z Reuse the connecting rod once the dimensions are correct. See the correct Service Manual or
Reuse and Salvage Guideline, SEBF8064, "Procedure and Specifications for Connecting
Rods" for measurements of connecting rods and specifications of connecting rods.
z Clean the connecting rod in order to remove dirt, oil and light rust before the inspection or
before the measurement. See Illustration 6. Use 150-1197 Disc in order to remove the light
rust from the connecting rod.
Visual Inspection
Crankshaft Bore
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. Refer to Reuse and Salvage Guideline, SEBF8064, "Procedure
and Specifications for Connecting Rods".
Use the connecting rod 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 .
Use 150-1197 Disc in order to 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.
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 in order to be used again.
Boring the connecting rod did not clean up the dark area inside the crankshaft bore. The connecting
rod should only be used again if no more than 15.0 mm (0.60 inch) of dark area appears on both
sides of the parting line.
NOTICE
Never use a connecting rod that shows heat discoloration caused by a
failure such as connecting rod bearing failure.
The connecting rod has discoloration around the crankshaft bore.
Do not use the connecting rod again.
The connecting rod has heavy damage in the crankshaft bore.
The connecting rod has damage to the bolt hole.
The connecting rod has heavy damage to the thrust face.
Parting Line Areas
Caterpillar does not recommend machining the parting line on a 3500 Series Engine connecting rod.
Body of the Connecting Rod
Inspect the parting line of connecting rods that are not serrated. Machine the connecting rod
according to the correct salvage operations. Refer to Reuse and Salvage Guideline, SEBF8064,
"Procedure and Specifications for Connecting Rods".
Note: Do not remove more than 0.03 mm (0.001 inch) from the parting line of the connecting rod.
NOTICE
Caterpillar does not recommend to grind 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.
The connecting rod has typical wear on the body.
Use the connecting rod again if the wear step is 0.18 mm (0.007 inch) or less.
6V-2033 Brush
6V-2033 Brush and 6V-2032 Adapter
Visually inspect the body of the connecting rod at the point of contact with the connecting rod cap.
The wear step on the side of the body of the connecting rod should be no more than 0.18 mm (0.007
inch). Refer to Illustration 17.
A connecting rod with a wear step less than 0.18 mm (0.007 inch) can be polished with a 6V-2033
Brush . The brush and adapters are shown in Illustrations 18 and 19.
Connecting Rod Cap
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 Reuse and Salvage Guideline, SEBF8064,
"Procedure and Specifications for Connecting Rods".
Note: Do not remove more than 0.15 mm (0.006 inch) from the connecting rod cap.
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).
NOTICE
Caterpillar does not recommend to grind 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.
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.
Seat Areas for the Hardware
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. In some cases, the connecting rod can be used again. The information for
reconditioning the connecting rods is in the ""Repair of Bolt Seat Areas" " section of this guideline.
The fillet around the bolt holes on the connecting rod and the cap are carefully machined. The fillets
have been shot peened. Shot peening releases the stresses that are caused by sharp corners. No
damage is acceptable in the fillet or the blended area indicated in Illustration 23.
Smearing in the seat area of the connecting rod is acceptable if the smearing cannot be felt with the
fingernail.
The connecting rod has a large nick on the top of the counterbore of the seat area. The connecting
rod cannot be repaired.
The seat area of the connecting rod has fretting and galling.
The connecting rod may be used again if the seat area has been machined. Refer to Illustration 31.
Repair of Bolt Seat Areas
(1) Fillet
Reconditioning specifications for the 3500 Series connecting rod cap
(C) 0.75 mm (0.030 inch) maximum depth
(D) 0.75 mm (0.030 inch) maximum chamfer
(E) 14.75 mm (0.581 inch) reference diameter
(F) 25.0 mm (0.98 inch) counterbore diameter
(2) 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 shot
peened after machining in order to relieve stress. The fillet is indicated in Illustration 29. Refer to
Table 2 for reference dimensions for the counterbore diameter of the area for the bolt seat. No more
than 0.75 mm (0.030 inch) material should be removed from the area for the bolt seat over the whole
life of the connecting rod.
Table 2
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 ACERT 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 ACERT
3.0 mm (0.12 inch) 17.84 ± 0.16 mm (0.702 ± 0.006 inch)
C-12
C12 ACERT 6.0 mm (0.24 inch) 17.84 ± 0.16 mm (0.702 ± 0.006 inch)
C13 ACERT
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 ACERT
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 ACERT
C27 ACERT
6.0 mm (0.24 inch) 18.85 ± 0.20 mm (0.742 ± 0.008 inch)
C30 ACERT
C32 ACERT
3100 Family
3.5 mm (0.14 inch) 21.25 ± 0.25 mm (0.837 ± 0.010 inch)
3200 Family
3.18 mm (0.125 inch) 13.87 ± 0.13 mm (0.546 ± 0.005 inch)
3300 Family
4.8 mm (0.19 inch) 16.38 ± 0.13 mm (0.645 ± 0.005 inch)
3400 Family
4.0 mm (0.16 inch) 18.16 ± 0.13 mm (0.715 ± 0.005 inch)
3600 Family 16.9 mm (0.67 inch) 24.85 ± 0.20 mm (0.978 ± 0.008 inch)
(1) Dimensions for the radius
Piston Pin Bushing
The area for the piston pin has cracks along the edge of the bushing. Use the connecting rod again
after installing a new bushing.
The area for the piston pin has high areas and nicks in the bushing. Use the connecting rod again
after installing a new bushing.
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.
Damage to the bushing was caused by incorrect installation of the piston pin bushing or the bushing
turned in the bore.
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
The junction of the shank and the area for the piston pin bushing is not damaged.
The connecting rod has some damage that was done before shot peening that was permitted by the
factory. Do not use the connecting rod again if the damaged area has not been shot peened at the
factory. Refer to Illustration 45.
The junction of the shank and the area for the piston pin bushing is damaged.
The area below the piston pin bushing on the connecting rod is damaged.
The area below the piston pin bushing on the inside edge of the shank on the connecting rod is
damaged.
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 Reuse and Salvage Guideline, SEBF8242, "Connecting
Rod Eye Bushing Installation and Removal and Retention Verification Using the 5P-8639
Connecting Rod Bushing Press Group " for more information regarding the proof test.
Shank Area
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 shot peened at the factory.
The connecting rod has small nicks on the edge of the shank after shot peening. Improper handling
will cause this type of damage. Use the connecting rod again only after the shank has been
reconditioned. Refer to the ""Reconditioning the Shank" " section. See Illustration 49.
The connecting rod has a small nick on the edge of the shank. Use the connecting rod again after
reconditioning. Refer to the ""Reconditioning the Shank" " section.
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, SEBF8039, "Inspection of Crankshafts for Cracks"
for more information on equipment for the magnetic particle
inspection. Refer to Reuse and Salvage Guideline, SEBF9074, "Salvage
Procedures for Connecting Rods" for more information on connecting
rods that are bent or twisted.
The small nick on the shank of the connecting rod in Illustration 45 was made after the connecting
rod was shot peened at the factory. The dull surface on the remainder of the shank shows shot
peening that was done to give strength to the connecting rod.
The connecting rod has a small nick on the shank that was created after shot peening.
The connecting rod has heavy damage on the shank after shot peening.
The connecting rod has heavy damage on the edge of the shank after shot peening.
The connecting rod has been badly bent. Bent connecting rods or twisted connecting rods cannot be
used again. Refer to Reuse and Salvage Guideline, SEBF8064, "Procedures and Specifications for
Connecting Rods" for slightly bent connecting rods. Refer to Reuse and Salvage Guideline,
SEBF9074, "Salvage Procedures for Connecting Rods" for more information on connecting rods that
are bent or twisted.
Note: The connecting rods should be inspected for bent areas or twisted areas. Visual inspection of
the connecting rod is not enough inspection.
Reconditioning the Shank
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 in order
to recondition the connecting rod:
z Remove any sharp nicks and edges from the connecting rod.
z Make sure that the surface of the connecting rod is smooth to the touch.
z The area that was reworked needs to be shot peened after the nicks are removed.
Note: Refer to the ""Requirements for Shot Peening" " section for more information on shot
peening.
The shank of the connecting rod has been reconditioned.
Requirements for Shot 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 in order 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 shot peening.
Use a suitable method of masking in order to protect the finished surfaces from the shot 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 shot peening in order to completely remove all the shot.
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 in order 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.
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 the hardware again.
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.
The shank area of the hardware has corrosive pitting.
Do not use the hardware again.
Some of the nuts will have polished areas or shallow grooves. The contact surface of the nuts is still
smooth and flat.
Some of the nuts will have polished areas or shallow grooves. The contact surface of the nuts is still
smooth and flat.
The bolt threads are damaged. The flats on the nut are damaged.
The shank of the bolt is heavily damaged.
The serrated section of the bolt has a nick that can be easily felt with a fingernail.
The bottom of the bolt head has fretting and smearing.
Note: Use the correct installation procedures and lubricant at all times to keep fretting to a
minimum.
The nuts have heavy smearing, galling, and fretting. Material has been transferred.
The nuts have heavy smearing, galling, and fretting. Material has been transferred.
Storage Procedures
Proper protection of the connecting rods from corrosion is very important. Corrosion will start in as
little as one hour after the connecting rods have been cleaned.
When the connecting rods will not be inspected for one hour or less the connecting rods should be
coated with a rust or corrosion inhibitor or coated with clean engine oil. The connecting rods should
be individually wrapped in order to prevent contamination, and the connecting rods should be stored
in a protected area in order to avoid damage. See Illustration 61.
When the connecting rods will not be inspected in two days or more the connecting rods should be
coated with a rust or corrosion inhibitor or coated with clean engine oil and the connecting rods
should be individually wrapped. The wrapped connecting rods should be placed in a container which
is clean and structurally solid. The container should be covered or wrapped in plastic in order to
prevent damage and contamination to the connecting rods. See Illustration 62.
See Table 3 for recommended rust inhibitors.
Example of protection for a component that is stored for a shorter term
Example of protection for a component that is stored for a longer term
Table 3
Recommendations for Storage

Part Number
Quantity Description Storage Protection
Hard film
Up to one year storage
222-3121 355 mL (12 oz) Rust Preventive
Aerosol Outside conditions for
storage
1U-8809 3.79 L (1 US gal) One year storage

Caterpillar 450 Rust Preventive
Oil
Covered conditions for
1U-6523 208 L (55 US gal)
storage
Film of wax
1U-8801 3.79 L (1 US gal)
Caterpillar 4A Rust Preventive Up to one year storage
Oil
1U-6526
208 L (55 US gal) Outside conditions for
storage
Copyright 1993 - 2006 Caterpillar Inc. Mon Jul 17 15:35:04 CDT 2006
Todos los derechos reservados.
Red privada para licenciados del SIS.

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C-12 Truck Engine 1YN00001-UP(SEBP2692 - 16) - Estructura del documento Página 1 de 40

Producto: TRUCK ENGINE

Pautas de reutilización y recuperación

Visual Inspection of Connecting Rods{1218}

ReferenceReuse and Salvage Guideline, SEBF8039, "Inspection of Crankshafts for Cracks"

ReferenceApplied Failure Analysis, SEBF9066, "Guideline for Examining Failed Parts"

ReferenceReuse and Salvage Guideline, SEBF8187, "Standardized Parts Marking Procedures"

Part Number Description

Fractured Connecting Rods

(2) Seat for the nut

(3) Seat for the bolt

(4) Piston pin bushing

(7) Parting line

(8) Connecting rod cap

(10) Thrust face

(11) Piston pin bore

(12) Crankshaft bore

(4) Piston pin bushing

(7) Parting line

(8) Connecting rod cap

(10) Thrust face

(11) Piston pin bore

(12) Crankshaft bore

Use the connecting rod again.

Use the connecting rod again.

Use the connecting rod again.

Use the connecting rod again.

Use the connecting rod again.

The connecting rod has discoloration around the crankshaft bore.

Do not use the connecting rod again.

The connecting rod has heavy damage in the crankshaft bore.

Do not use the connecting rod again.

The connecting rod has damage to the bolt hole.

Do not use the connecting rod again.

The connecting rod has heavy damage to the thrust face.

Do not use the connecting rod again.

Parting Line Areas

Body of the Connecting Rod

Use the connecting rod again.

The connecting rod has typical wear on the body.

Use the connecting rod again.

Connecting Rod Cap

Use the connecting rod again.

Use the connecting rod again.

Use the connecting rod again.

Seat Areas for the Hardware

Use the connecting rod again.

Use the connecting rod again.

Do not use the connecting rod again.

Do not use the connecting rod again.

Repair of Bolt Seat Areas

(C) 0.75 mm (0.030 inch) maximum depth

(D) 0.75 mm (0.030 inch) maximum chamfer

(E) 14.75 mm (0.581 inch) reference diameter

(F) 25.0 mm (0.98 inch) counterbore diameter

Engine Model Fillet (1) Counterbore Diameter

Piston Pin Bushing

Use the connecting rod again.

Use the connecting rod again.

Use the connecting rod again.

Do not use the connecting rod again.

Area for the Piston Pin

Use the connecting rod again.