GE Power & Water

Michael SCHULLERUS
Service Engineering
GE Jenbacher GmbH & Co OG
Distribution list Achenseestr. 1-3
Jenbach, Subsidiaries, Service Providers A-6200 Jenbach, Austria
T +43 5244 600 3153
michael.schullerus@ge.com

Service Technician Instruction ST-030 13 May 2014

Engine type 2, 3, 4 and 6

Subject Correct installation and handling of connecting rods

Service Technician Instruction ST-030 is intended to ensure that both during production and in the field, only
connecting rods and big-end caps that belong together are assembled together and use of the wrong big-end
caps is avoided.

AFFECTED ENGINES / SCOPE OF THIS BULLETIN

All Type 2, 3, 4 and 6 engines.

DESCRIPTION OF THE FACTS

Correct assembly and handling of connecting rods - all engine types
This Instruction must be observed absolutely both during production and in the field to ensure that only matching
connecting rods and big-end caps are assembled together, and to prevent the use of the wrong big-end caps.

1 Before unbolting the big-end cap from the connecting rod:

Compare the serial numbers on the big-end cap and the connecting rod. The two numbers must be the same.

Serial number = matched pair numbers, applied by the manufacturer (rod and cap)

The serial number, year of manufacture and the machine number must always be identical.

Data about the connecting rod blanks (cast, forged or stamped) is irrelevant for fitting.

Connecting rods from earlier than 2009/2010 may still have the old inscription.

GE PROPRIETARY INFORMATION

The information contained in this document is General Electric Company proprietary information and is disclosed in confidence. It is the property of GE and may not be used, disclosed to
others or reproduced without the express written consent of GE. This includes, but is not limited to, use of the information to create, manufacture, develop or derive any repairs, modifications,
spare parts, designs or configuration changes, or to obtain government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set
out on each page of this document shall appear in any such reproduction in whole or in part.

ST-030_EN.docx Index: 02 1/7

GE PROPRIETARY INFORMATION – CLASS III (CONFIDENTIAL) UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
 SERVICE TECHNICIAN INSTRUCTION ST-030
Correct installation and handling of connecting rods
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Connecting rod Big-end cap

Serial number =
matched pair number

Year of manufacture

Machine number

Fig. 01: Current pair numbers

EXAMPLES OF OLD INSCRIPTIONS:

a: Cracked connecting rods of Types 3 and 4 engines:

e.g. 8840E

Fig. 02: Old pair numbers on a blank, e.g. 8840E

b: Types 2 and 6 engines and connecting rods of older designs: the numbers are stamped on with punches.

e.g. S50

Fig. 03: Older pair numbers with stamped numerals, e.g. S50

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GE PROPRIETARY INFORMATION – CLASS III (CONFIDENTIAL) UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
 SERVICE TECHNICIAN INSTRUCTION ST-030
Correct installation and handling of connecting rods
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These serial numbers are not always visible from outside after the connecting rods have been fitted in the engine.

Connecting rods must therefore have the cylinder numbers marked on both
sides. Use an oil-resistant paint marker for this, and degrease the surfaces first.

If unmarked connecting rods are removed in the course of a service, the serial
numbers must also be compared and the connecting rods and big-end caps
that belong together marked with the cylinder number.

Fig. 03: Cylinder number applied on both sides with an oil-resistant paint marker

Fig. 04: Marking on the both sides of the connecting rod so that both connecting rods can be identified from the B side through the inspection hole
cover

On Type 6 engines, marking the short side of the big-end cap and connecting rod is sufficient (as there are
inspection hole covers on both sides of the engine).

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 SERVICE TECHNICIAN INSTRUCTION ST-030
Correct installation and handling of connecting rods
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2 Unbolting and refitting the big-end cap

The big-end cap can now be unbolted.

Use protective jaws (aluminium or similar) when clamping the connecting rod in the
vice. Never clamp the connecting rod shank without using protective jaws.

Fig. 05: Inscription

Any intermediate storage of connecting rods and big-end caps must always ensure that the cracked surface cannot
be damaged.

After the connecting rods have all been fitted, check the cylinder numbers again and enter them in the assembly
check list together with their associated serial numbers. Keep the check list with the assembly report after it has been
filled in. One copy should remain on site.

Check-lists are attached with the bulletin, or can be downloaded at any time.

Cracked connecting rods: When paired correctly with the matching cracked
surface, the parting joint is visible as a smooth line.

Fig. 06: Cracked connecting rod with a smooth line

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 SERVICE TECHNICIAN INSTRUCTION ST-030
Correct installation and handling of connecting rods
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Fitting the bearing shell in the connecting rod:

When placing the bearing shell in position, make sure that its locating lip is seated in the middle of the
groove in the connecting rod. Push the bearing shell evenly into the correct position to achieve this.

Fig. 07: Locating lip of the bearing located in the middle of the groove in the connecting rod

Then check the final position of the installed bearing:

Check that the edges of the bearing are parallel with the outer edges of the connecting rod. This ensures that the
bearing shell is not seated with any offset (twisted). The maximum permissible twist according to the drawing is
0.5 mm.

Fig. 08: Twist must not be greater than 0.5 mm

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GE PROPRIETARY INFORMATION – CLASS III (CONFIDENTIAL) UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
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 SERVICE TECHNICIAN INSTRUCTION ST-030
Correct installation and handling of connecting rods
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3 General information:
Transporting cracked connecting rods:

Cracked connecting rods may only be transported in the assembled condition, i.e. with the matching big-end cap
fitted and the big-end bolts tightened to at least 100 Nm. This prevents any relative motion between the connecting
rod and big-end cap, thereby avoiding any damage to the crack surface.

Note: There is no point in tightening the bolts to the full torque - this only makes it difficult to undo them.

The crack surface must not exhibit any damage. An incorrectly-

fitted big-end cap and its associated connecting rod and bearing
must not be used any more.

Fig. 09: Undamaged connecting rod crack surface

Torques:

The torques for tightening the big-end bolts are set out in the respective Technical Instructions. These are:

for Types 2 and 3 engines..............TA 1902-0212

for Type 4 engines .............................TA 1902-0213

for Type 6-C engines.........................TA 1902-0228C

for Type 6-E/F engines.....................TA 1902-0228E/F

for Type 6-G/H engines ...................TA 1902-0228G/H

Big-end bolts

Big-end bolts from different manufacturers must not be mixed on the same connecting rod.

e.g.: B.B

Fig. 10: Big-end bolt from B.B

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GE PROPRIETARY INFORMATION – CLASS III (CONFIDENTIAL) UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
 SERVICE TECHNICIAN INSTRUCTION ST-030
Correct installation and handling of connecting rods
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RELEVANT DOCUMENTS
All the relevant instructions are part of the plant documentation handed over to every customer on delivery of an
engine. The latest versions of documents referred to here can be downloaded from the Jenbacher web portal
at http://information.jenbacher.com under the heading "Technical Knowledge Base".
• Technical Instruction TA 1902-0212, Screwing and tightening torques for Types 2 and 3 engines
• Technical Instruction TA 1902-0213, Screwing and tightening torques for Type 4 engines
• Technical Instruction TA 1902-0228C, Screwing and tightening torques for Type J6..GS-C engines
• Technical Instruction TA 1902-0228E/F, Screwing and tightening torques for Type J6..GS-E/F engines
• Technical Instruction TA 1902-0228G/H, Screwing and tightening torques for Type J624-G/H engines

REVISION CODE
INDEX DATE DESCRIPTION / REVISION SUMMARY
02 May 13, 2014 Basic revision
01 Jul. 28, 2005 First version of this document
Table 01: Revision history

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GE PROPRIETARY INFORMATION – CLASS III (CONFIDENTIAL) UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.