SEBF8149 - Specifications For Connecting Rods Used in 3500 Family of Engines

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Reuse And Salvage Guidelines

Specifications for Connecting Rods Used in 3500 family of Engines
Media Number -SEBF8149-12 Publication Date -26/03/2003 Date Updated -26/03/2003
SEBF81490001
Specifications for Connecting Rods Used in 3500 family of Engines

SMCS - 1218
SEBF8149-12
March 2003
SMCS Code: 1218
GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE OPERATIONS
Specifications for Connecting Rods
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Used in 3500 Family of Engines
Summary of Revisions
Page Description
All Updated information.
Introduction
This guideline enables dealers and their customers to benefit from cost reductions made possible through
an established parts reusability and salvage program. Every effort has been made to provide the most
current and relevant information known to Caterpillar Inc. Since the Company makes ongoing changes and
improvements to its products, this guideline must be used with the latest technical information available from
Caterpillar to ensure such changes and improvements are incorporated where applicable.
For questions or additional information concerning this guideline, contact Caterpillar Service Support
Division, Dealer Service Operations (309) 636-5833.
Summary
This guideline gives the specifications necessary to measure and visually inspect the connecting rods used
in the 3500 Family of Engines. If a connecting rod meets these specifications and the inspection guidelines
shown in SEBF8063, it can be expected to give normal performance until the next overhaul when used in
the same application.
References
References
Media Number Title
Guideline for Reusable Parts and Salvage Operations
SEBF8051 Piston Pins and Retaining Rings
SEBF8063 Visual Inspection of Connecting Rods
SEBF8242 Verification of Connecting Rod Eye Bushing

Retention Using the 5P-8639 Connecting Rod
Bushing Press Group
SEBF8274 Using Rod Eye Bushing Installation and

Removal Tools
Special Instructions
GMG00981 Using 1P-3537 Dial Bore Gauge Group to

Check Cylinder Bore Size
SMHS6870 Using the 5P-3550 Connecting Rod Boring

Machine
SMHS7366 Using the 5P-2050 Connecting Rod Checking

Fixture
SMHS8036 Using the 6V-6030 Size Setting Fixture Group
SMHS8037 Using the 6V-6000 Dial Bore Gauge Group
SMHS8253 Use if 6V-7898 Dial Bore Gauge Group
SMHS8254 Using the 6V-7899 Size Setting Fixture Group
Tooling and Equipment

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 Rod Checking Fixture
5P-8639 Hydrualic Press Group
5P-9725 Hydraulic Cylinger Group
6V-2032 Adapter
6V-2033 Brush
6V-4876 Lubricant
6V-6000 Dial Bore Guage

6V-6030 Size Setting Fixture
6V-7898 Dial Bore Gauge

6V-7899 Size Setting Fixture
8T-0820 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
materials.
Failure to heed this warning can lead to

premature failure, product damage,
personal injury, or death.
Measurement Nomenclature
Illustration 1
Connecting rod nomencalture. Refer to the "Nomenclature References" chart for item identification.
Illustration 2
Example of twist and bend of a connecting rod. Refer to the "Nomenclature References" chart for item identification.
Illustration 3
Torque sequence for connecting rods. Refer to the "Nomenclature References" chart for item identification.
Nomenclature References
Item Description
1 Connecting rod bolts
2 Bore in connecting rod for crankshaft bearing
3 Bore in connecting rod piston pin bushing
4 Bore in the piston pin bushing
5 Piston pin diameter
6 Center-to-center distance
7 Twist; see the section, "Corrections for Bend and Twist

Measurements"
8 Bend; see the section, "Corrections for Bend and Twist

Measurements"
9 Side of connecting rod with chamfer
10 Tighten connecting rod bolts using the "Tightening

Procedure for Connecting Rod Bolts".
11 Location pin for correct installation of connecting rod cap
12 Connecting rod thickness
Tightening Procedure for Connecting Rod Bolts

1. Before assembly, put 6V-4876 Lubricant or Fel-Pro C100 Lubricant on the bolt threads and all surfaces
that make contact between the bolt and cap.
2. Tighten bolts A and B to 90 ± 5 N·m (65 ± 4 lb ft). (Refer to Illustration 3)
3. Tighten bolts C and D to 90 ± 5 N·m (65 ± 4 lb ft).
4. Tighten bolts A and B again to 90 ± 5 N·m (65 ± 4 lb ft).
5. Tighten bolts C and D again to 90 ± 5 N·m (65 ± 4 lb ft).
6. Tighten each bolt again by turning it 90 ± 5 degrees.
Connecting Rod Bolts (Molykote)
Life
1st Rebuild 2nd Rebuild 3rd Rebuild 4th Rebuild 5th rebuild
New Reuse bolts from new Replace with new bolts Replace with new bolts
Reuse bolts from 2nd Reuse bolts from 4th
rebuild rebuild
Chart A.
Specifications
Connecting Rod Thickness (new and used) 67.575 ± 0.076 (2.6604 ± .0030)
Crankshaft Bore - Diameter Specifications1
After Machining Additional Surface Texture Clearance Between Crankshaft Journal and Rod Bearing
Torque2
Turn
143.028 ± 0.015 90 ± 5 N·m (65 ± 90° ± 5° 0.63 to 2.5 µm 0.107 0.152 0.229
(5.6310 ± .0006) 4 lb ft) (25 to 100 µ in) (.0042) (.0060) Nominal (.0090)
Minimum Maximum
Rod Pin Bore - Diameter Specifications
Rod Eye Bore Diameter (new and used) Surface Texture (new and used)
75.760 ± 0.015 (2.9827 ± .0006) 0.63 to 2.5 µm (25 to 100 µ in)
Pin Bearing Bore - Diameter Specifications
After Machining Surface Texture (new and used)

Use Again Maximum4
70.000 ± 0.008 (2.7559 ± .0003) 70.058 (2.7582) 0.25 µm or smoother (10 µ in or smoother)
Piston Pin - Diameter Specifications3
Pin Diameters
Clearance Between Pin and Bushing6
New New
Use Again Minimum5 Use Again Maximum7
69.962 ± 0.005 (2.7544 ± .0002) 69.947 (2.7538) 0.025 to 0.051 (.0010 to .0020) 0.10 (.004)
Note: Unless specified otherwise, all dimensions are in mm (inch).
1 Refer to Chart D for "Use again" specifications.
2 Refer to Tightening Procedure; Steps 1 through 6, on preceding page.
3 Piston pins must be inspected for a wear step, refer to SEBF8051.
4 0.050mm (0.0019 inch) of wear is permitted over the specified diameter of a new bearing.
5 0.010 mm (0.0004 inch) of wear is permitted over the specified diameter of a new piston pin.
6 Bushings should be proof tested to 15,500 kPa (2250 psi) before putting the assembly into the engine. Refer to "Testing Pin
Bushings" in this Guideline.
7 The clearance between the pin and the pin bushing cannot be greater that 0.10 mm (0.004 inch). New and used pins and bushings can be assembled
together, if the 0.10 mm (0.004 inch) clearance is not exceeded.
Chart B.
Tolerances
Center-to-center distance 380.00 (14.961)
Do Not Salvage, New Bushing,

Use Again8
Measurement If More Than After Machining
(Original Bushing)
Center-to-center distance ±0.076 (0.0030) ±0.076 (0.0030)

±0.102 (0.0040)10
Twist
5P-2050 Fixture (0.000 to 0.012) (0.012) (0.000 to 0.012)
Tobin-Arp Fixture (0.000 to 0.020) (0.020) (0.000 to 0.020)
Other Fixtures9 - - -
Bend
5P-2050 Fixture (0.000 to 0.0045) (0.012) (0.000 to 0.003)
Tobin-Arp Fixture (0.000 to 0.008) (0.020) (0.000 to 0.0055)
Other Fixtures9 - - -
Note: All dimensions are in mm (inch).
8 Inspect the bushing for damage as shown in SEBF8063.
9 Refer to "Corrections for Bend and Twist Measurements" to calculate specifications for other fixtures.
10 If this dimension is exceeded with the bushing out, it may be possible to install a new bushing and machine it to acceptable "After Machining"
specifications. The bushing, however, must "clean up" completely (no steel can show through the bronze).
Visual Inspection
Parting Line Area
NOTICE
Normal wear at the parting line, 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 4 for location
of misalignment and cutting edge.
Illustration 4
Typical Wear Locations
Two main procedures to reduce or eliminate this problem are, Proper Tightening Procedure For Connecting
Rod Bolts and Deburring Sharp Edges on Rod Cap.
Body
The pin slot area and the bolts hole opening walls should be inspected for cracks. If any cracks are present
in these areas, do not use again.
Illustration 5
Pin slot crack
Do not use again
Illustration 6
Crack in bolt opening wall
Do not use again
Visually inspect the body of the connecting rod at the point where the connecting rod makes contact. For
reusability, the wear step on the side of the body, as shown in Illustration 7, should be 0.18 mm (0.007 inch)
or less.
Illustration 7
Typical wear on the side of the connecting rod body.
Use again-
if the wear step (total across the bore) is 0.18 mm (0.007 inch) or less.
When measuring the wear step, 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 [0.13 mm (0.005 inch)] than the opposite side
793C Off-Highway Truck ATY00001-UP (MACHINE) POWERED BY 3516 Engine(SEBP3022 - 66... Page 10 of 24
[0.03 mm (0.001 inch)]. When both sides are added together, the result is still acceptable [0.16 mm (0.006
inch)].
A connecting rod with a wear step less than 0.18 mm (0.007 inch) can be polished with a
6V-2033 Brush for cosmetic purposes. The brush and adapters are shown in Illustrations 8 and 9.
Illustration 8
6V-2033 Brush
Illustration 9
Brush and 6V-2032 Adapters
Deburring Sharp Edges on Rod Cap

The purpose of deburring is to remove the sharp edges shown in Illustration 10 on the rod cap that can form
a cutting edge which causes crankshaft wear.
Illustration 10
Debur sharp edges.

(13) Sharp edge
Precautions
1. Do not grind in the shot peened areas especially the raised area of the rod (knuckle). Any shot
peened area touched by the grinder must be needle peened.
2. Do not leave burrs or rolled edges in the deburred area.
3. Debur only in the described zone.
After the rods have been deburred, they should be properly cleaned to remove any debris or metal filings
that were left by the debur process.
Procedure
1. Mount a circular grinding wheel (grit size A80, 50 mm (2.0 inch) diameter, 12 mm (0.5 inch) long) into a
pencil or hand-held grinder.
2. Follow the contour from Point A to Point B carefully grinding the area shown in Illustration 11. Remove
the sharp edge but do not remove large amounts of material.
Illustration 11
Debur the rod cap following the contour from point A to point B.
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.
Illustration 12
Properly deburred rod cap.

(14) Deburred edge
Illustration 12 shows what the completed debur should look like. 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 connecting rod
body. For reusability, the wear step as shown in Illustration 13 should be 0.03 mm (0.001 inch) or less.
Illustration 13
Typical wear on the connecting rod cap at the parting line (cap to body joint).
Use 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 (easily seen) damage, or if the hardware was
loose before it was removed. To tighten hardware, follow the procedures below. Also follow any
specifications given in Chart A, Specifications, 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 bolt seat area. For additional information on the reusability of
connecting rod bolts, refer to SEBF8063, "Visual Inspection of Connecting Rods", in section, Visual
Inspection of Hardware.
Repair of Bolt Seat Area

In some cases, a bolt seat area showing signs of galling, can be reconditioned by spot facing the damaged
area. When reconditioning the seat area, do not machine into the fillet radius as this radius has been
carefully machined and shot-peened to relieve stress. This radius is indicated by the arrow in Illustration 13.
Illustration 14
The location of the fillet radius on the connecting rod cap.
Illustration 15
Reconditioning specifications of connecting rod caps.
(A) 0.75 mm (0.030 inch) maximum

(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) counterbore diameter
Connecting Rod Bolts

Connecting rod bolts must be inspected at each overhaul. If the bolts meet the "Use again" criteria in
Guideline for Reusable Parts, SEBF8063, "Visual Inspection of Connecting Rods", they can be used again.
Also refer to "Chart C. Bolt Reuse Schedule".
Chart C.
Bolt Reuse Schedule
1st 2nd 3rd 4th 5th

Life
Rebuild Rebuild Rebuild Rebuild Rebuild
New Reuse Replace Reuse Replace Reuse

bolts with bolts with bolts
from new from 2nd new from 4th
new bolts rebuild bolts rebuild
Procedure to Measure Equipment

Use a good quality dial bore indicator and master setting fixture (Illustration 16) to measure the crankshaft
and pin bushing bore diameters. Accuracy to 0.002 mm (0.0001 inch) is needed.
Illustration 16
Typical dial bore gauge and setting fixture.
For more information on the necessary tools, refer to the Tool Guide for Caterpillar Dealers, and the correct
Special Instruction.
Chart D.
Tooling
Special
Tools Range Instructions
6V-6000 Dial Bore Gauge 30.000 SMHS8037

6V-6030 Size Setting Fixture to SMHS8036
(necessary for use with 50.800
6V-6000)
1P-3537 Dial Bore Gauge Group (2.000 GMG00981

to
8.000)
6V-7898 Dial Bore Gauge 50.800 SMHS8253

6V-7899 Size Setting Fixture to SMHS8254
(necessary for use with 203.000
6V-7898)
Crankshaft Bore - Thickness
Illustration 17
Typical wear locations.
Measure the crankshaft bore thickness within the 120 degree zones (Illustration 18) at points E through K
(Illustration 19). If two or more locations within one 120 degree zone measure 67.200 mm (2.6457 inch) or
less, do not use again. The rod thickness of a new part is 67.575 ± 0.076 mm (2.6604 ± 0.0030 inch).
Illustration 18
Locations of 120 degree zones.
Illustration 19
Thickness measurement locations. If two or more locations within one 120 degree zone measures
67.200 mm (2.6457 inch) or less, do not use again.
(E-K) Thickness measuring points.
Crankshaft Bore - Diameter and Roundness

Before measuring, tighten the bolts to the correct torque, plus torque-turn, as given in Chart A.
NOTICE
Before each tightening, be sure to cover

the threads, shank, and area under the
head of each bolt with 6V-4876 Molykote
Paste Lubricant.
Illustration 20
Measurement locations. Refer to Chart E for specifications.
(M) 16.0 mm (0.62 inch)

(L, N, O) Bore diameter
Measure the bore diameter at points (L, N, and O) in Illustration 20.
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 (L) and (N) as your guide.
The correct diameter of the crankshaft bore and tolerances are shown in Chart E. Use the tolerances in the
chart for both the (O) dimension (Illustration 20) and the average of (L) and (N). It is important that the
difference between the average of (L) and (N), and the reading at (O) must be 0.066 mm (0.0026 inch) or
less. Also, the difference between (L) and (N) must be 0.051 mm (0.0020 inch) or less.
Chart E.
Large End Bore of Connecting Rod
Nominal diameter 143.028 (5.6310)
Immediately after boring (new- ± 0.015 (± 0.0006)

never been apart)
Used rods or if bolts have been + 0.025 (+ 0.0010)

retightened after machining - 0.065 (- 0.0026)
Roundness avg. L + N - 0 0.066 (0.0026)

2
Cap shift (L - N) 0.063 (0.0025)
An example of calculating the roundness average is shown below.
L= (-.0015 inch); N= (-0.002 inch); O= (-0.0015 inch)
Since the result of (-0.00025 inch) is less than the specification of 0.0025, the roundness is acceptable.
If a rod slightly exceeds the tolerances in the chart, make the following additional check before performing
salvage operations or discarding the rod.
Remove the rod bearing from the connecting rod and inspect it for indications of "closing in" near the parting
line area. If the bearing DOES NOT show indications of the rod closing in at the parting line, continue to the
following steps. If the bearing DOES show indications of "closing in", the rod should be replaced or
salvaged.
1. Before installing the new connecting rod bearing, measure the thickness of both bearing halves at the
(L, N, and O) locations (six measurements total). Record the measurements for later use.
2. Install the rod bearing all the way into the bore of the connecting rod. Apply lubricant, and use the
torque turn method to tighten the bolts to the specifications given in Chart A.
Illustration 21
(Typical Example) Install a rod bearing (gray) all the way into the bore of the connecting rod.
(L, N, O) Bore diameter
(L1, L2) Thickness of bearing
3. Measure the inside diameter of the larger end bore of the connecting rod. Take a measurement at
each of the (L, N, and O) locations as close to the center of the bore as possible. Refer to Illustration
21.
4. Add the measurements from the two bearing thicknesses (L1 and L2, for example) to the appropriate
inside bearing dimension recorded from Step 3 (L, for example). Repeat this step for all three locations
(L, N, and O).
5. Compare the results of Step 4 to the specifications in Chart E.
The installation of the bearing allows the bore to be almost the same shape as at final assembly. If the rod is
acceptable, the (L, N, and O) dimensions will be within the specifications given in Chart E.
Piston Pin Bore - Rod and Bushing

Measure the bore of the piston pin bushing and the crankshaft bore of the connecting rod. Use a good
quality dial bore indicator to measure both diameters. Make sure the dimensions meet the "Use again"
specifications of Chart A.
Generally, piston pin bushings 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.
A piston pin bushing can be used again if scoring or fretting cannot be felt, the measurement of the bore is
acceptable, and the bushing passes the proof load test specification given in Chart G. Discoloration caused
by oil is acceptable if the bushing is smooth and undamaged. A piston pin bushing with discoloration
(change in color) cannot be used again, if scoring or seizure marks can be felt.
For additional information on piston rods and bushings, refer to SEBF8063, "Visual Inspection of Connecting
Rods" in the section, Visual Inspection of Piston Pin Area.
Pin-to-Bushing Clearance
To determine the clearance between the pin and 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 OD measurement of the pin from the ID measurement of the bushing.
Note: The maximum allowable clearance between the pin and the pin bushing is 0.10 mm (0.004
inch). Refer to the "Use Again Maximum" specification in Chart A.
If the dimension exceeds the "Use Again Maximum", install a new bushing, and machine it to the correct
size. If new bushings are installed, follow the instructions in "Testing Pin Bushings". The bushing must also
meet the reusability guidelines in SEBF8063.
Note: Refer to Guideline for Reusable Parts, SEBF8051, "Piston Pins and Retaining Rings", for
more information on inspection of piston pins.
Proof Test to Verify Rod Bushing Retention

For details on adapting the 5P-8639 Connecting Rod Bushing Press Group used for this procedure, refer to
Guideline for Reusable Parts, SEBF8242, "Verification of Connecting Rod Eye Bushing Retention Using The
5P-8639 Connecting Rod Bushing Press Group."
The Proof Test must be used to ensure correct bushing retention and prevent rod eye bushing failures after
rebuilding a rod. The bushing must NOT move during the test.
NOTICE
If the rod is NOT at room temperature,

the test results will not be accurate and
could possibly cause the rod to fail. This
would lead to damage of other engine
components.
1. Make sure the rod is at room temperature.

2. Put the rod into the 5P-8639 Connecting Rod Bushing Press Group using the tooling listed in Chart H.
Position the rod with the part number "up" or "down", according to the specifications in Chart H.
Note: Chart G lists the engine models, connecting rod assembly number, the correct position of
the connecting rod in the fixture, and the required tooling. Additional information on the rod can
be found in SEBF8274, "Using Rod Eye Bushing Installation and Removal Tools".
3. Determine the cylinder s cross-sectional area.
a. Measure the head diameter of the hydraulic cylinder. If using the cylinder from the 5P-8639
Connecting Rod Bushing Press Group, refer to Chart F for the cylinder s diameter.
Chart F.
Hydraulic Cylinder Diameter
Cylinder Group Cylinder Diame ter
34.80 mm (1.370 inch)

5P-01561
5P-9725 37.77 mm (1.487 inch)
1
Replaced by 5P-9725 Cylinder Group.
Note: If a different press group or hydraulic cylinder is used, it will be necessary to measure the
diameter of the cylinder in order to calculate the pressure correctly.
b. Calculate the cylinder s cross-sectional area using the following equation:
Cylinder s Cross-Sectional
Area = 3.1416 x the square of cylinder diameter ÷ 4
Example:
Hydraulic Cylinder Diameter =

34.80 mm (1.370 inch)
3.1416 x (34.80 mm)2 ÷ 4 = 951.06 mm2
3.1416 x (1.370 inch)2 ÷ 4 = (1.474 inch2)
4. Obtain the applied force (load) from Chart G. This is needed to calculate the hydraulic pressure
required to obtain the correct applied force.
Chart G.
Connecting Rod Eye Bushing Proof Load (Tapered Bore)
Engine Connecting Rod Connecting Applied

Series Assembly Part Rod Part Force (Load)
Number Number
7C-8607
101-32811
7C-8607
7C-86081
8N-6020 1W-5030
30 000 N
3500 1W-4800 1W-4799 (6750 lbs)
8N-9647 8N-1271
7C-8607
161-25001
144-0725 140-6472
1
CRB 144-0725
5. Calculate the pressure using the cross-sectional diameter calculation and applied force with the
following equation:
Pressure = Applied Force (Load) ÷ Cylinder s Cross-Sectional Area
Example:
Load = 23 500 N (5290 lbs)
Cross-Sectional Area = 951.06 mm2 (1.474 in2)
23 500 N ÷ 951.06 mm2 = 24 700 kPa
(5290 lbs) ÷ (1.474 inch2) = (3589 psi)
6. Apply the calculated pressure from Step 5 to the connecting rod. The reading on the 8T-0820 Pressure
Gauge is pressure, NOT FORCE.
Note: The pressure applied to the connecting rod bushing should NOT exceed the value
calculated in Step 5.
1. If the bushing moves when the calculated pressure is applied it cannot be used again.
2. It is possible to install a second bushing to attain enough retention to pass this test. If the second
bushing does not meet the specifications, the rod is oversized and must be replaced.
Chart H.
3500 Connecting Rods
Rod Assembly Push Adapter Spacer Bushing Adapter Bar Clamp Position of Part
Number
1W-4800 5P-8649 6V-3043 6V-3042 5P-8640 Down
8N-9647 5P-8649 6V-3043 6V-3042 5P-8640 Down
4C-8727 4C-8726 4C-8725 5P-8640 -

7C-86081
4C-8727 4C-8726 4C-8725 5P-8640 -

101-32811
144-0725 4c-8727 4C-8726 4C-8725 5P-8640 -
1
CRB 144-0725
Note: To make bearing installations easier, the pin bore should be chamfered. If the bore is not
chamfered, put the connecting rod in a vise as shown in Illustration 22 and use an air powered
1U-5778 Die Grinder (13), 4C-8629 Mandrel (14), and 4C-8626 Reconditioning Star (15), to grind
a small chamfer on the end of the bore. Refer to Chart H for the correct positioning of the
connecting rod in relation to the part number.
Illustration 22
Grinding chamfer on pin bore.

(13) 1U-5778 Die Grinder
(14) 4C-8629 Mandrel
(15) 4C-8626 Reconditioning Star
Pin Bore to Crankshaft Bore (center-to-center)

Use a connecting rod fixture like the 5P-2050 Rod Checking Fixture to measure the center-to-center
distance (center of pin bore to center of crankshaft bore). Refer to chart B "Tolerances" or the correct
Service Manual for the necessary specifications.
Twist and Bend

Use 5P-2050 Rod Checking Fixture and Special Instruction SMHS7366, (or similar tooling) to measure the
degree the rod has become bent or twisted. The fixture measures the relation between the pin bore and
crankshaft bore, with or without pin bushing installation.
Chart B "Tolerances" gives specifications for the Caterpillar 5P-2050 Fixture and the Tobin-Arp RI-9000E
Rod Checking Fixture. For others, use the diagrams and formulas given in the section, "Corrections for Twist
and Bend Measurements".
Corrections for Bend and Twist Measurements

Most tools measure the amount a rod twists or bends 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 23), which will be
different, according to the tool that is used to measure.
Illustration 23
To adjust (U) for other rod checking fixtures, refer to the formula below.
(16) Mandrel
(17) 5P-2050 Fixture
(18) 9000E Rod Checking Fixture
(19) Piston pin
(V1) 114.3 mm (4.50 inch)
(V2) 203.2 (8.00 inch)
Note: The figures in Chart B "Tolerances" for the Tobin-Arp fixture are specific to its design. The
Tobin-Arp specifications are for length (V) of 203.2 mm (8.00 inch). Since the Tobin-Arp scale is
limited to 0.51 mm (0.02 inch), the dimensions given for this fixture are also limited to 0.51 mm
(0.02 inch).
Copyright 1993 - 2006 Caterpillar Inc. Mon Jul 3 17:20:15 UTC+0700 2006
All Rights Reserved.
Private Network For SIS Licensees.

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793C Off-Highway Truck ATY00001-UP (MACHINE) POWERED BY 3516 Engine(SEBP3022 - 66) -...

Reuse And Salvage Guidelines

Specifications for Connecting Rods Used in 3500 family of Engines

Used in 3500 Family of Engines

All Updated information.

Media Number Title

Guideline for Reusable Parts and Salvage Operations

SEBF8051 Piston Pins and Retaining Rings

SEBF8063 Visual Inspection of Connecting Rods

SEBF8242 Verification of Connecting Rod Eye Bushing

SEBF8274 Using Rod Eye Bushing Installation and

GMG00981 Using 1P-3537 Dial Bore Gauge Group to

SMHS6870 Using the 5P-3550 Connecting Rod Boring

SMHS7366 Using the 5P-2050 Connecting Rod Checking

SMHS8036 Using the 6V-6030 Size Setting Fixture Group

SMHS8037 Using the 6V-6000 Dial Bore Gauge Group

SMHS8253 Use if 6V-7898 Dial Bore Gauge Group

SMHS8254 Using the 6V-7899 Size Setting Fixture Group

Tooling and Equipment

Part Number Part Description

1P-3537 Dial Bore Gauge Group

1U-5778 Die Grinder

4C-8626 Reconditioning Star

5P-2050 Rod Checking Fixture

5P-8639 Hydrualic Press Group

5P-9725 Hydraulic Cylinger Group

6V-6000 Dial Bore Guage

6V-7898 Dial Bore Gauge

8T-0820 Pressure Gauge

When replacement parts are required for

parts with equivalent specifications

Failure to heed this warning can lead to

1 Connecting rod bolts

2 Bore in connecting rod for crankshaft bearing

3 Bore in connecting rod piston pin bushing

4 Bore in the piston pin bushing

5 Piston pin diameter

7 Twist; see the section, "Corrections for Bend and Twist

8 Bend; see the section, "Corrections for Bend and Twist

9 Side of connecting rod with chamfer

10 Tighten connecting rod bolts using the "Tightening

11 Location pin for correct installation of connecting rod cap

12 Connecting rod thickness

Tightening Procedure for Connecting Rod Bolts

Connecting Rod Bolts (Molykote)

Crankshaft Bore - Diameter Specifications1

Rod Pin Bore - Diameter Specifications

75.760 ± 0.015 (2.9827 ± .0006) 0.63 to 2.5 µm (25 to 100 µ in)

Pin Bearing Bore - Diameter Specifications

After Machining Surface Texture (new and used)

Piston Pin - Diameter Specifications3

Note: Unless specified otherwise, all dimensions are in mm (inch).

1 Refer to Chart D for "Use again" specifications.

2 Refer to Tightening Procedure; Steps 1 through 6, on preceding page.

3 Piston pins must be inspected for a wear step, refer to SEBF8051.

Center-to-center distance 380.00 (14.961)

Do Not Salvage, New Bushing,

Center-to-center distance ±0.076 (0.0030) ±0.076 (0.0030)

Note: All dimensions are in mm (inch).

8 Inspect the bushing for damage as shown in SEBF8063.

Normal wear at the parting line, between

Typical Wear Locations

Pin slot crack