Install Piston and Conrod

3612 GENERATOR,INDUSTRIAL,LOCOMOTIVE AND MARINE JANUARY 1...
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Product: GEN SET ENGINE

Model: 3612 GEN SET ENGINE 9RC00274
Configuration: 3612 GENERATOR,INDUSTRIAL,LOCOMOTIVE AND MARINE JANUARY 1998 TO CURRENT 9RC00001-UP
Disassembly and Assembly

3612 and 3616 Engines
Media Number -SENR3594-12 Publication Date -01/08/2008 Date Updated -05/08/2008
i05040289
Piston and Connecting Rods - Install

SMCS - 1225-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Qty
Part Description
4C-6357 (1)
A or Connecting Rod Guide 1
8T-3022 (2)
B 235-0612 Lift Bracket 1
C 136-1452 Retaining Ring Pliers As 1
D 4C-8995 Ring Expander Gp 1
Board
F - 51 mm by 102 mm by 2.44 m (2 inch by 4 inch by 8.00 ft) 2
G 1U-8692 Piston Pin Guide 1

H 4C-5719 Piston Ring Compressor 1
8T-5096
J or Dial Indicator 1
1U-8869
K 334-0519 Molylube Anti-Seize Lubricant -
(1)
Use with V-engines
(2)
Use with in-line engines
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NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Inspect connecting rod bolts at each service of the connecting rod bearings. There
should be no fretting on the shank of the connecting rod bolt. This includes 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.
Illustration 1 g00775406
Note: Do not reuse a connecting rod bolt if Dimension (X) is more than 329.00 mm (12.953
inch).
1. Clean the piston. Inspect the piston for damage. Use a piston ring groove cleaner in order to
clean the piston ring grooves.
2. Check the piston ring grooves for damage. Refer to Specifications, "Piston and Rings" for
the width of the piston ring groove.
3. Before the piston rings are installed on the piston, check the end gap on each piston ring.
Install each piston ring evenly in the cylinder liner in order to ensure a small amount of
wear.
NOTICE
Do not install the piston rings without the use of the piston ring
expander. Piston ring breakage and piston damage may result if the
piston ring expander is not used.
4. Use Tooling (D) in order to install the piston rings on piston (2) .
5. The piston ring gaps should be separated by 120 degrees. Install the piston rings in the
following manner:
a. Install the piston ring expander on the piston. The ends of the oil ring spring should
be installed 180 degrees from the oil ring end gap. The white portion of the oil ring
spring must be visible at the ring end gap.
b. The second piston ring must be installed with Mark "UP-2" upward.
c. The top ring must be installed with Mark "UP-1" upward.
6. After the piston rings have been installed, measure the side clearance between the piston
rings and the piston grooves. Refer to Specifications, "Piston and Rings".
7. Locate Mark (V) on the top of the piston. Draw an alignment mark on the side of the piston.
8. Place piston (2) on a suitable surface.
9. Attach a suitable lifting device to connecting rod (5) . The weight of connecting rod (5) is
approximately 50 kg (110 lb). Align the slots in the piston pin bearing with Mark (V) on
piston (2) . Carefully lower connecting rod (5) in piston (2) .
10. Apply clean engine oil to piston pin (4) . Use Tooling (G) in order to install piston pin (4) .
11. Remove Tooling (G) . Use Tooling (C) in order to install retaining rings (3) . Tap the
retaining rings in order to be sure that the retaining rings are seated properly in the piston
grooves.
Note: Install the retaining rings with the word "OUT" away from the piston.
12. Attach Tooling (B) and a suitable lifting device to the top of piston (2) . The weight of
piston (2) and the connecting rod is approximately 101 kg (225 lb).
Note: The piston ring gaps must not be aligned after installation.
13. The piston ring gaps should be separated by 120 degrees.
14. Apply clean engine oil on the piston rings. Install Tooling (H) on the piston.
15. Install the upper half of connecting rod bearing (6) in connecting rod (5) . Ensure that the
tabs of the upper half of connecting rod bearing (6) are engaged with the slots in the
connecting rod.
16. Install Tooling (A) onto the bolts for the connecting rod. Tooling (A) will hold the upper
half of connecting rod bearing (6) in position. Apply clean engine oil to the upper half of the
connecting rod bearing.
17. Position the piston and the connecting rod over the proper cylinder liner. Remove the
protective cover from the cylinder liner.
18. The crankshaft must be rotated until the connecting rod bearing journal is at the top dead
center position.
Note: Ensure that Mark (V) on the piston and Mark (V) on the cylinder block are aligned.
19. Ensure that the notch on the piston and the piston cooling jet will be in alignment.
20. Carefully lower the piston and the connecting rod in the cylinder liner.
NOTICE
Do not use excessive force in order to move the piston into the cylinder
liner. Piston ring breakage may occur.
21. Gently tap the piston with a rubber mallet in order to move the piston rings away from the
piston ring compressor and into the cylinder liner.
22. If the piston will not move into the cylinder liner, remove the piston and the connecting rod.
Inspect the piston and the piston rings.
23. Ensure that the connecting rod is in alignment with the crankshaft. Lower the piston and the
connecting rod until the connecting rod and the upper half of the connecting rod bearing is
seated on the crankshaft.
24. Remove Tooling (A) from the connecting rod bolts.
25. Position Tooling (F) across the opposite access cover under connecting rod cap (1) .
26. Install the lower half of the connecting rod bearing in connecting rod cap (1) . Ensure that
the tabs of the lower half of the connecting rod bearing are engaged with the slots in
connecting rod cap (1) . Ensure that the flat surfaces of the connecting rod and the
connecting rod caps for each crankshaft connecting rod journal are facing.
27. Apply clean engine oil on the lower half of the connecting rod bearing.
28. Ensure that the numbers on the connecting rod and the connecting rod cap are identical.
Ensure that the numbers are aligned. Put the connecting rod cap in position under the
connecting rod bolts. The weight of connecting rod cap (1) is approximately 16 kg (35 lb).
Note: Use Tooling (K) to lubricate the threads of the bolts, of the nuts, and the seating face
of the nut after the bolt for the connecting rod is installed in the connecting rod.
Note: This torque procedure was developed with Tooling (K) . The use of any other
lubricant may result in an incorrect torque value and in subsequent failure of the connecting
rod bolt.
29. Raise Tooling (F) . Carefully guide connecting rod cap (1) on the bolts. Install the nuts on
the bolts in order to hold the connecting rod caps.
30. Remove Tooling (F) .
31. Use the following steps in order to properly tighten the nuts:
Note: Nut (1) and Nut (2) are on the same side of the connecting rod as the raised
bosses and the tab slots for the connecting rod bearing.
a. Turn all four nuts by hand until the nuts contact the face of the cap. No resistance
should be felt that would indicate thread damage or debris in the joint. Threading the
nuts by hand will provide an opportunity to identify problems with the threads. If the
nuts and/or bolts cannot be threaded by hand, the nuts and/or bolts must be replaced.
Do not use an impact wrench to install the nuts up to the face of the cap.
b. Tighten Nut (1) , Nut (2) , Nut (3) , and Nut (4) to a torque of 105 ± 15 N·m (75 ± 10
lb ft).
c. Tighten Nut (1) to a torque of 375 ± 15 N·m (277 ± 11 lb ft).
d. Tighten Nut (4) to a torque of 375 ± 15 N·m (277 ± 11 lb ft).
e. Tighten Nut (2) to a torque of 375 ± 15 N·m (277 ± 11 lb ft).
f. Tighten Nut (3) to a torque of 375 ± 15 N·m (277 ± 11 lb ft).
g. Without loosening the nut, tighten Nut (2) again to a torque of 375 ± 15 N·m (277 ±
11 lb ft).
h. Without loosening the nut, tighten Nut (3) again to a torque of 375 ± 15 N·m (277 ±
11 lb ft).
i. Without loosening the nut, tighten Nut (1) again to a torque of 375 ± 15 N·m (277 ±
11 lb ft).
j. Without loosening the nut, tighten Nut (4) again to a torque of 375 ± 15 N·m (277 ±
11 lb ft).
k. Place an index mark on Nut (1) . Rotate Nut (1) for 180 ± 5 degrees in a clockwise
direction.
l. Place an index mark on Nut (4) . Rotate Nut (4) for 180 ± 5 degrees in a clockwise
direction.
m. Place an index mark on Nut (2) . Rotate Nut (2) for 180 ± 5 degrees in a clockwise
direction.
n. Place an index mark on Nut (3) . Rotate Nut (3) for 180 ± 5 degrees in a clockwise
direction.
32. Use Tooling (J) in order to check the clearance of the side with the connecting rod in the
crankshaft. Place a pry bar between the crankshaft and the connecting rod. Carefully move
the connecting rod until the clearance is 0.33 to 0.68 mm (0.0130 to 0.0268 inch).
33. If the clearance is not within the range that is given in Step 32, remove the connecting rod
cap. Ensure that the connecting rod cap is on the correct connecting rod. Check for damage.
34. Install the cylinder liner sleeve. Ensure that the cylinder liner sleeve is clean prior to
installation.
35. Install the crankcase covers on the cylinder block.
End By: Install the cylinder heads. Refer to Disassembly and Assembly, "Cylinder Head -
Install".
Copyright 1993 - 2012 Caterpillar Inc. Tue Nov 6 15:41:59 UTC-0200 2012
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Install Piston and Conrod

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3612 GENERATOR,INDUSTRIAL,LOCOMOTIVE AND MARINE JANUARY 1...

Product: GEN SET ENGINE

Disassembly and Assembly

Piston and Connecting Rods - Install

G 1U-8692 Piston Pin Guide 1

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

c. The top ring must be installed with Mark "UP-1" upward.

8. Place piston (2) on a suitable surface.

13. The piston ring gaps should be separated by 120 degrees.

24. Remove Tooling (A) from the connecting rod bolts.

30. Remove Tooling (F) .

c. Tighten Nut (1) to a torque of 375 ± 15 N·m (277 ± 11 lb ft).

d. Tighten Nut (4) to a torque of 375 ± 15 N·m (277 ± 11 lb ft).

e. Tighten Nut (2) to a torque of 375 ± 15 N·m (277 ± 11 lb ft).

f. Tighten Nut (3) to a torque of 375 ± 15 N·m (277 ± 11 lb ft).

35. Install the crankcase covers on the cylinder block.

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