INSTRUCTIONS Engine Maintenance Manual Section 3. S-A+R- Supplement Now 1 PISTON ASSEMBLY AND CONNECTING ROD Reference : RBWORK OF BLADE CONNECTING ROD Maximum gervice 1ife of blade rods can be obtained if proper aainten~ auce procedures are employed. A specific “CAUTION” against the use of abrasive material to cleaa the blade rod is contained in the Engine Maintenance Manuals. In addition, the following information is provided for the proper maintenance of connecting rods. The blade rod sltpper surface is a highly polished journal with an original finieh of 1ese than 7 microinches RMS. Operation in an engine further polishes the eurface until there is usvally no measurable roughness- When blade connecting rods are removed from an engine during overhaul, this highly polished area should never be cleaned in a caustic solution er hand rubbed with any type of abrasiv. The action of a caustic solution will damage the highly polished slipper surface and way result in. the formation of rust. The use of abrasive eloth of any type, including crocus cloth, will produce a surface finish which ie capable of smearing, wiping, and Burning the bearing area on the upper connecting rod beating during engine operation. The glazed flmtch and the bearing pattern of1 stain usually found on the connecting rod sifpper surface is considered normal, and temoval should not be atteapted- Field service saintenance on the blade rod slipper area should be con- fined to the following itenst 1 Nicks at the extreme edges of the slipper surface should be removed uaing only 2 soft stone and fuel ofl. 2 Using only fuel oft, wineral spirits, or a similar solvent, clean the blade rod. 3 Following the cleaning operatton, the blade rod slipper surface should be coated with engine of1 or 2 suitable rust preventative before being placed in storage and shovld be wiped clean and re-olled before beiag applied to an engine.TASTRUCTIONS: ENGINE MATNTENANCE MARUAL SECTION 9 S.A.R. PUPLICATION NO, 2 PISTON ASSEVELY AND CONNECT INS ONS REFERENCE SPEDISIDATION CONNECTING AOD BASKET BORE NEW AVERAGE + 153,62 — 199,69 mm (7,623" — 7,625") MAXIMUM AVERABE 418370 nm (7,625"" Maximum difference between any two readings at each end of bore (out-of Pound) : 0,23 nm (0,009"), general Motors" letter 4n/6a/ic/es of 1964-01-25 end Pointers 77L 83 of 1968-05-22 end Chie? Nechanical Engineer's Jetier of 5 Acril 1584. Issued per TxD 15/4/18 ofSECTION 3 PISTON ASSEMBLY AND CONNECTING RODS, CONTENTS PISTON AND ROD DPSCRIPTION INSPECTION (IN ENGINE) PISTON AND ROD DISASSEMBLY PISTON CLEANING PISTON PIN AND CARRIER CLEANING PISTON INSPECTION CARRIER INSPECTION PISTON PIN INSPECTION CONNECTING ROD DESCRIPTION 266873 PAGE 38 CONTENTS CLEANING FORK ROD INSPECTION BLADE ROD INSPECTION CHECKING ROD LENGTH, TWIST, AND BORE PARALLELISM CONNECTING ROD BEARINGS. DESCRIPTION CHECKING BEARINGS SERVICE DATA SPECIFICATIONS EQUIPMENT LISTMANUAL PISTON ASSEMBLY DESCRIPTION The piston assembly, Fig. 3-1, consists of a cast iron atloy piston, four compression rings, and two oil control tings. A “trunnion” type piston car rier, Fig. 3-2, is used with the piston assembly to PISTON ASSEMBLY AND CONNECTING RODS SECTION ENGINE MAINTENANCE 3 allow the piston to rotate or "Boat" during engine operation. The carrier supports the piston at the internal piston platform. A thrust washer, Pig, 3-2, 45 used between the platform and the catrier, The carrier is held in position inthe piston by a snap ring inside the piston. Oil taken up by the two oil control rings passes through the oil holes at the bottom of the piston Fig. 341 ~ nena 10526 Piston AssemblySection 3 Fig, 3-2 ~ Piston Carrier And Thrust Washer A. bearing insert, Fig. 33, is applied in a broached slot in the carrier. Tangs at each end of the bearing insert are bent into 2 counterbore on the carrier to prevent endwise movement. The highly polished piston pin, Fig 3-3, is applied in the carrier in contact with the bearing insert, and the assembly is bolted to the upper end of the connecting rod. Internal parts of the piston are lubricated and cooled by the piston cooling oil. Cooling oil is directed through a drilled passage in. the piston carrier, circulates about the piston crows urea, and then drains through two holes in the cartier located at the taper as shown in Fig, 3 il Drain Hole Insert inverted To Show Bearing PISTON PISTON PIN CARRIER Step To Hold Insert (Each Side) Fig, 3-3 ~ Piston Pin Insert And Carrier MAINTENANCE PISTON AND ROD INSPECTION Piston and connecting rod assemblies, Fig. 34, can be inspected while installed in an engine provided the engine is shut down and the air box and oil pan inspection covers are removed. Precautions should be taken, before proceeding. to prevent the engine from being started. Open all cylinder test valves to facilitate rotation of the crankshaft, using the turning, jack. | Rotate crankshaft_until piston of cylinder being inspected is at bottom center, nd -—— Compression Rings Theust Wash Bearing Insert Piston Pin Piston Carrier Snap Ring oil Rings Hotes SN _— tnne Searing het “Basket 8 Bearing . ~ Locatingbowels | wer Bearing She Locating Dowels Lower Bearing Shel “Fork Rod Basket Dp ~ Piston And Conneet CrossSection, Rod Assembly, a sezSection 3 2. Inspect eylinder wall and top of piston. A Replace these rings when the condition wet piston crown would indicate a leaky becomes severe. injector. Check cylinder walls to make sure there is no scoring and inspect for water 4, Inspe leaks, piston skirt for scoring or scuffing. 5. Inspect air box for foreign materia, and any 3. Visually inspect for the following ring condi- Signs of water or oll leakage ions at the liner ports. A ring in good condition will be bright OFL PAN INSPECTION and free in its groove. 1. Inspect back of upper sonnecting rod bearing, b. Broken ring, The ring tace will normally for cutting or signs of everheating, be black if broken opposite the gap. Milling may also be evident above and 2. To check for thrust washer, piston pin bear below the liner ports ing, and connecting rod bearing wear, take a lead reading of piston to cylinder head clear c. Worn ring. Replace all rings when chrome: e. Any increase sino previous fead reading plating is worn through on first. ring will indicate wear. While the ductile cast iron used in the 3. With piston at top center, inspect lower liner chrome plated top ring will function satis- walls for scoring, vison factorily in contact with the liner, the degree to which a ring is allowed to wear 4, Inspect oil pan for foreign matter. before replacement should be governed to some extent by the severity of the service. ‘An engine which seldom runs at full pigtoN AND ROD DISASSEMBLY power is more (olerant of ring condition than an engine which usually operates at or near full load. The chrome ring wear classifications shown in Fig. 3-5, used in NOTE: Procedures for disassembly and quali- fication of piston and connecting rod assembly components are contained in Sra wear re eee ee oe this Section. Procedures for removal, Guring ring inspection, assembly, and installation of the piston and connecting rod assembly, and of a d. Ring blow-by. Vertical brown streaks on complete cylinder power assembly are the face of the ring indicate blow-by. contained in Section 5. | 2361272 33Section 3 ‘A. new oF like new ring. This classifica tion will only be evidenced during the New or Like New fiest phase of top ring life, On a shallow groove ring, these classi cations will be evident on the top ring for @ relatively short time, On a deep groove ring, these classifications will be feuident for the major portion of ring Tite, Chrome grooves are completely wor away, showing only a smooth chrome. Type 2A face, Thee will exist for the major portion of shallow groove ring fe. It bill be-evident for a short time on only 3 small percentage of deep groove rings. No Grooves in Chrome ings are starting to woor imo the cast iron, except for the grooves, which still contain chrome, CAUTION: To. prevent liner scoring, stainless steel rings should be replaced at this time. Chrome is completely wom off and wear is concentrated on the cast iron Ringe. inthis classification are to be considered worn out and should be replaced NOTE: When classifying chrome plated stainless stee) sings, substitute references t@ “east Iron” with "stainless steal”. In addition, stainless steel rings have five grooves instead of seven Fig. 3-5 ~ Chrome Ring Wear Classification 34 23612721. Place piston and rod assembly on a wooden topped work bench and remove piston snap ring, Fig. 3-6, using snap ring remover. Care should be taken in handling piston assembly to avoid nicking or scraping the piston skirt ‘Snap Ring Remover 202690 Fig, 3-6 ~ Removing Piston Snap Ring 2. Place rod and cartier in holding fixture, Fig. 3-7, and remove piston pin bolts, This fixture has’ two mandrels which enter the piston pin bore to hold the pin while the cod bolls are removed. [t must be securely moumed on a work surface. If fixture is tnavailable, a vise having copper protected jaws may be used to Fig, 3-7 » Carrier Holding Fixture 2ge1272 Section 3 hold the connecting rod, Clamp rod hori- zontally with pin clos to vise so pin bolts may be removed without twisting rod, 3. Remove pin from carrier. At the time of piston and rod disassembly, check that the thickness of the thrust washer exceeds the minimum dimension listed in the Service Data, CLEANING Cleaning procedures should be in accord with accepted practice or as recommended by the supplier of cleaning material. Pistons 1. Remove the piston rings using ring expander as shown in Fig. +8, and discard the old rings. alkaline solvent n ualil the carbon 2. Immerse the piston in solution and allow to remy deposits are loosened. Wash the piston using steam or hot water and blow dry using compressed air. 4, Remove any carbon deposits from the com- pression ring grooves. Light grit blasting oF a piece of compression ring can be used for this, purpose, Expander 17880 Fig. 3-8 — Removing Piston RingsSection 3 5, Using 3/32" and 5/32" drills in the respective holes, clan the oil passages in the oil ring. grooves, Piston Pin And Carrier CAUTION: Abrasive matecial, including steel wool, should not be used to clean piston pins or bearing inserts. 1.1t is recommended that the piston pin and carrier assemblies be cleaned using a high flash point petroleum solvent, such as Stoddards solvent (140° F, Mash point) or equal, These parts should never be washed in an alkaline or caustie solution Clean the carbon from the oil grooves in the insert with a suitably pointed wooden stick. Embedded particles do no harm it they do not project above the bearing surface: no attempt should be made to remove them. Parts of the assembly should be adequately protected against rust and corrosion at all times. INSPECTION Piston 1. The phosphate treated surface of the piston skirt should be inspected for satisfactory con- dition, 1 the coating is worn through and bare metal in excess of approximately three square inches is exposed, the piston should be re-coated. 2 Inspect the piston seoring. or other na reject the piston. wface for excessive which would Check all points of measurement as shown in . Discard any pistons that exceed the Retr e Service Datta ond of setion fr applicable dimensions, 1 Piston Skirt Diaeter 2 Paton Piaform Bore 3 Pieton see Digmeter 4 Paton To Cari Pilot Clearance 5 Paton Platform To Bottom OF SSeap Ring Groove 6. Compression Ring Groove Width 7. ston To Cylinder Head Clearance 8B. Compresion Ring To Land Clearance 3, Piston To Liner Clearance, 10, oi1 Ring Gronve win 11. Gil Ring To Land Crees Fig, 3-9 ~ Piston Measurement Points 3-64, Check piston ring groove wear step. Check wear step in top ring groove, Fig. 3-10, Top ting breakage ean be caused by excessive wear step. NOTE: Reworked ring groowos should have 1/32" top land edges. 19829 Fig, 3-10 ~ Typical Piston Ring Groove Wear Step A piston ring groove gauge, Fig. 311, is available to make the wear step measurement. Gauges also are available for measuring wear step in oversize ring grooves. Each gauge consists of 4 number of separate width in cators precise to .001", Standard ring groove gauge has indicators from .194"" through Fig, 3-11 — Piston Ring Groove Gauge e278 Section 3 203", See Tool Catalog for ove: gauge numbers. To measure wear step, it is first necessary to determine the original ring groove width, be- cause it may Vary from. ,[94"" 10.197". Insert gauge blocks in ring groove, and by trail, determine the largest one which enters its full depth, This will indicate the original width of the ring groove being measured. Then insert the largest block that will enter the groove up to the wear step. The size of the wear step is determtined by subtracting the small block dimension from the large block dimension, ize ring When a wear step, in excess of maximum allowable, is found in the top compression ring groove, the groove may be weut to remove the Wear step, provided the finished width does not execed .201" for use with a standard ring. If the ring groove is worn beyond a width of 261", it is possible 10 machine the top ring groove to use oversize ring. See Service Data for limits When performing either of the preceding operations, care must be taken to keep the ring groove faces parallel to each other and at right angles to the centerline of the piston. ‘The surface finish must be smooth to avoid excessive wear, Inspect the piston for cracks using magnaflux procedure. Remove have been undercrown deposits. Pistons that found dimensionally and struc turally satisfactory for reuse, should also have the heat dam area thoroughly cleaned of undercrown deposits, Undercrown cleaning should be accomplished using a sand or grit blast cleaning in conjunction with liquid cleaning. Carrier In this assembly, Fig. 3-3, a broached slot or recess in the cartier, receives a precision bearing insert. A hardened polished piston pin runs against the bearing insert Normal bearing wear does not affect the carrier. Maximum permissible wear on the insert piston pin, and carrier pilots are listed in Service Data. Used parts in good condition should not be interchanged. A new bearing insert should beSection 3 used when a new piston pin is used. The piston pin should always be applied in the same relative position to the bearing insert. The small hole in the piston pin should be matched with the piston cooling. oil inlet hole ia the carrier as a con- Venient means of keeping the pin and insert in the same relative position for maximum perform= ance. Except in extraordinary cases of pilot wear, carriers may be expected to have un indefinitely Jong file, Also, the bearing insert need not be removed for measurement unless its appearance is, questionable and/or the wear on the piston pin is well advanced, Measure the carrier to determine that the di sions do not exceed the limits shown in Service Data, the Piston Pin n. The bearing surface should be Toughness and have a mirror I. Inspect the free of any finish. . Fretting on the pin, only where it contacts the connecting rod, may be removed using a fine stone. 3. Check the 7/8"-14 bolt threads in the pin by retapping. If the threads are damaged, replace the pin. 4. Check the pin diameter. CONNECTING ROD ASSEMBLY DESCRIPTION The “trunnion lype" connecting rods, Fig. 3-12, are interlocking, blade and fork construction. The blade rod moves back and forth on the back of the upper crankpin bearing and is held in place by a counterbore in the fork rod. One end of the blade rod slipper foot is longer than the other and is known as the “tong toe." The blade rods are installed in the right bank’ with the long toe toward the center of the engine. The fork rods are installed in the lelt bank. Serrations on the sides of the rod at the bottom - od To Piston Pin Botts Fork Rod Upper Basket ° “~~ Blade Rod Bolts ig wel : [Fm vove Barna St Lover Bearing Sha eS TM os eas Bolt Nuts _ ~ Lower Basket Boils Fork Rod Gasket Fig, 3-12 ~ Connecting Rods, Bearing Shells, ‘And Basket match similar serrations on the fork rod basket, Fig. 3-12. The rod basket consists of two halves, held together at the bottom by thiee bolts and selflacking nuts, The fork rod and basket are bolted together at the serrations. Fork rods and baskets are not interchangeable since they are line bored as an assembly. Both the fork rod and basket are stamped with an identical assembly serial number for matching and identification purposes. MAINTENANCE CLEANING Cleaning procedures should be in accord with accepted practice or as recommended by the supplier of cleaning material, The glazed finish and the bearing pattern oil stain usually found on the bade rod slipper surface is considered normal, and removal should not be attempted. CAUTION: Abrisive material, including steel wool, should not be used to clean connecting rods or bearing shells. 38 266873INSPECTION Fork Rod 1. After all parts are clean, check the tapped holes in the fork rod. I threads are wom, the bolts holding the basket may loosen during operation and damage the engine Plug gauge, Fig. 3-13, is available to check the Fork rod bolt threads. One end of the gauge is marked "GO" and the opposite end "HI", ‘The gauge should be used according 10 the following procedure, a. Thread the "GO" portion of the gauge into cach of the holes, Fig, 3-13, and check for binding, which may indicate damaged Uireads. Normally, this gauze should enter the holes freciy and a sl shake or wobble is permissible. An attempt should then be made to screw the "HE" portion of the gauge into each " gauge, Fork Rod “HiI" Portion (Thread Protector Installed) Fig, 3:13 ~ Checking Fork Rod Bolt Threads ‘6873 Section 3 therefore, rods may be entirely satis: factory even though the gauge may be screwed in the threads, even to the extent of bottoming Normally, in rods having little wear, this gauige will be difficult to thread into the holes more than a couple of turns. In many cases, however, the gauge can be threaded into the rod but will be snug and tight. While threaded in, check for shake or wobble taking care that the gauge is not bottomed in the hole, which would cause binding and a false reading. ‘The fork rod should be serapped if shake or wobble 8 experienced with the "HI" gauge, To further ensure proper torque values, it is recommended that new holts be used However, old bolts may be used if they are qualified by careful inspection, Dis- card any that may be bent or have threads showing signs of galling, wear, or other imperfections. 2. Fork rod serrations should be checked for nicks, burrs, and cleanliness, Check tightness of upper bearing locating dowels. Step dowels ure available in the event oversize dowels are required. Inspect for cracks in serrations and rod visually and by magnaflus. 3.To ensure proper clamping between the piston pin and rod saddle, protrusions in the saddle caused by nicks or fretting must be removed. Use grade 150 abrasive paper or a fine eylindrical stone. 4. Check fork rod bore by fastening basket securely in place using 175 ft-lbs torque on upper basket bolts, Fig. 3-12. (Nonnal upper basket bolt torque is 190 Feths on assembly.) Torque value of lower basket (split line) bolts is 75 felbs, Measure bore at points 60° apart 4s indicated in Fig. 3-14. The average of these dimensions must not exceed the specified maximum, I bose is beyond this dimension. the tod and basket should be reworked.Section 3 Fig, 3-14 ~ Checking Fork Rod Bore 5. Fork rod rework will be required for any of the following conditions: a. Average of three GO" measurements across fork rod and basket bore exceeds speci fied maxinvum, b. Nicks, burrs, or fretting on fork and basket serrations. Damaged threads in bolt kofes (sec Step 1), oF loose dowels. d. Damaged or distorted basket €. Outof-parallel in excess of limit in tength of saddle. £, Length of rod between bore centers is less than the minimum g. Fork oxoeeds, depth. counter bore, maximum 6, Fork rod assembly should be serapped if any fone or more of the following conditions exist a. Patigue eracks throtigh basket serrations and rejectable magnatlux indications, b, Heat diseoloration in basket or fork c Rod ovisted, bent, outof-parallel, or damaged beyond repair, d. Length of rod between bore centers is less than minimum. Blade Rod 1. The blade rod is checked on a 7.692" diam- ter mandrel to observe slipper surface for ‘open or “closed cnds, Blade surface should be smooth. Rod should be scrapped if this surface shows heat discolorations. NOTE: The flaine hardening process, produces a blue black color on the top side of the blade rod slipper foot. This discoloration is normal and has not been caused by overheating during operation. The slipper surface, however, should show no dis: coloration, 2. To ensure proper clamping between the piston pin and rod saddle, protrusions in the saddle caused by nicks or fretting must be removed. Use grade 150 abrasive paper or & fine cylindrical stone. 3. Blade rod rework will be required for any of the following conditions. a Scarred, pitted, rustetched slipper surface. or deeply b. End of slipper closed in beyond limit, ©. End of slipper opened beyond limit, 4. Ontof-parallel exceeds limit along. saddle length. ©. Length of rod between bore centers is tess than minimum allowable 4. Blade rod should be scrapped if any one or more of the following conditions exist a. Rejectable magnaflux indications. 310 286873b. Heat discoloration on slipper surface. ¢. Less than minimum flange thickness on slipper shoulder. d. Rod twisted, bent, outoFparatel, or damage beyond repair c. Length of rod between bore centers is less than minimurn, CHECKING ROD LENGTH, TWIST, AND BORE PARALLELISM The connecting rod checking fixture, Fig. 3-15, is available for accurate inspection of the connect- ing rod length, twist, and parallelism of piston pin saddle to bearing bore. Fig, 3:15 = Checking Connecting Rods e873 Section 3 1.Place connecting rod on checking fixture, being sure bearing bore is clean and centered on -mandreh Slide dial indicator into top pin saddle of connecting rod. Sweep left hand side of saddle radius and adjust knurled thumb screw on back of sweep indicating bracket until @ consistent reading is achieved while sweeping complete left hand side of saddle radius. Do Note not_adjust_dial_face_on_diat indicator, the reading on dial indicator and record. Any deviation between this readiay and ing recorded when the checking fixture was set up would indicate a longer or shorter distance between bore centerlines, See Service Data for limits Check slipper surface for open ends by trying 4 003" feeler gai Jv toc end, between slipper surface and mandrel. Blade tods with open ends may be used providing a .003" feeler be inserted more’ than two inches from each end of slipper when rod is mounted on the mandrel. A’ closed in slipper is evidenced by the ends having no clearance and the sfipper surface being open, Rods with a closed in slipper surface may be used providing a clearance less shan the limit is obtained when measured any place between ends of slipper on mandrel ate After adjusting indicator, set contact point at top inside edge of saddle, and run indicator along length of saddle. Indicator deflection shows rod twist in the length of the saddle which should not exceed limit shown in the Service Data, Place indicstor al one end of dottom of saddle and note indjextor reading. Check along length of saddle bottom, circumventing bolt holes, to check outof-parallel, Indicator must not show more than maximum deflee- tion along length of saddle CONNECTING ROD BEARINGS DESCRIPTION Connecting rod beatings consist of upper and lower shells, Fig, 3-12. ‘They are semicircifar in shape and have a steel back with a layer of lead bronze beating material covered by a lead tin coating. on the inside diameter. The upper bearingSection 3 has, in addition, a bearing surface in the center of the outer diameter consisting of a layer of bronze bearing material with a pure tead-flash overlay. This provides a bearing surface for the slipper of the blade connecting rod. Dowels in the fork rod and basket hold the bearing shells in proper position. Two dowels in the fork rod locate the upper shell and one dowel in the basket locates the lower shell. There is no provision for connecting rod bearing adjustment, When bearing clearance exceeds the limit given in Service Data, they should be re- placed. After bearing shells are once used on a crankpin and have accumulated numerous dirt scratches, they must not be used on any other cerankpin. MAINTENANCE CHECKING CONNECTING ROD BEARINGS The connecting rod bearings should be checked whenever the piston and rod assembly is removed from the engine. To make this check, apply bearings to fork rod and basket in which they are to be used. Tighten basket bolts to 175 ftbs torque and measure across the bearing bore at points 60° apart. This is similar to the procedure used when checking fork rod basket bore, Fig. 3-14. The average of these three readings must not be less than is necessary to ensure a clearance between erankpin journal and bearing within the 31 specified limits, After operation, rod bearings may give indication of being tight across the split, line ‘when toose on the crankpin, However, rod bearings intended for use should be mounted in the fork rod and then checked. NOTE: After bearings have once been sed, they should not be used on any other journal Check upper bearing step thickness as shown. in Fig. 3-16. This will indicate blade rod bearing surface wear. Step thickness should not be less than minimum limit. Bearing shells will usually be dirt scratched to some degree, but unless condition is severe, the Ddeatings can be reused. 9575 Fig, 3-16 ~ Checking Rod Upper Bearing Shell E1273HM SOUTH AFRICAN RAILWAYS Section 3 SERVICE DATA PISTON ASSEMBLY AND CONNECTING RODS SPECIFICATIONS Connecting Rod iecting rod basket bore (See text) — New . eee es 7,624"7.625" Max. 22... bec feces 7.626" Blade rod bearing seat diameter (See text) = New. nee ces 7.692'-7,693" Clearance between shoulder on blide rod and counterbore in fork rod ~ New . .008"..013" Max. 025" (This clearance measured by plicing feeler auge between biade rod | and top of upper bearing.) Depth of counterbore in fork rod for slipper on blade rod ~ New 385".3805" *Limit : : : tee ~ 400" (Provided the preceding maximum .025" clearance is held.) Blade rod shoulder thiekness New 3445"..346" “Limit : : (*Provided the preceding maxim Connecting rod length = New . (Generated bore centerline dimension) ~ Rework Limit’... 6... - Serap Limit Saddle end for piston pin Twist in length of saddle ~ Limit Parallelism in length of saddle ~ Limit Blade rod slipper surface "Closed in” —Mimit “Opened out" = Limit Connecting Rod Bearings Bearing inside diameter (Average of three 60° measurements) ~ New Bearing to crankpin clearance — New yess eee Limit : Bearing shell thickness ~New . . . Thickness limit (Standard) = Ming 2... CBW US) = Min ee (116" US) — Min Upper connecting rod step thickness ~ Limit e974 025" clearance is held.) 22.998) 3.002" ce eee ee eee eee es 22,990" oo ne 22.979" Sete : 006" 004" bees an 007" 003" 6.5066"-6.5100" 007"-.011" eee O15" 5587"..5598" cee eee eee beens 5530" nes 5686" 5843" eee 027" 313Section 3 Piston Refer to Fig, 3-9 ~ circled number coine! Piston skirt diameter Now soe eee ee bimt Out-oFround : (Check diameter 2" below the compression ring grooves and below the oil ring grooves, take two readings 90° to cach other, at cach fo @ Piston platform bore (upper cartier pilot) — New Loe : Limit oo : (Check at two places 90° to each other.) Piston platform should be sq @ Piston inside diameter (lower cartier pilot) = New Limit @ Piston to carrier pilot clearance = New Limit @®Piston platform to bottom of snap ring groove = New Limit groove width w/standard 1 ®No. 1 compression ring New a Wear Limit W/l/64" OS. ring Remachining limit Wear limit W/1/32" OS. ring Remachining limit Wear limit. Loe Wear step ~ Max. Piston to. cylinder head clearance = New Min. New Max, Differential reading An increase in compression clearance of .030" from le with callouts oa illustration. Weation.) the assembly value at the time of installation condemns the assembly. Any sudden inerease should be investigated immediately. ® Compression ring to tand © No. 1 groove chrome ring New : Max. No. 2 and 3 groove, chrome NW lee e eee on Max. : : 314 9.049".9,081"" 3.565"3.507) 3.570 fare t0 piston O.D. within .003" total indicator reading, 7,487"-7.490) 7.494" .003"".007" oll" 6.376" 6.380 6.389" 2194) 209" sees 920" 00s" 00s" 00+ 0075"-.012" 016" 256873Section 3 SOUTH AFRICAN RAILWAYS SERVICE DATA PISTON ASSEMBLY AND CONNECTING RODS No. : wroove, taper ferrox ti ors" 011s" New ves beeen seeeeeee 113" @ Piston to liner clearance Measured 6" below liner gasket face -- New ee .0085"-.0130", Max. 022" NOTE: Maxinnan piston to liner clearance of 022" det mines the maximum weur limit of a finer at the 6" dimension. If pistons are selectively fitted to liners, a lincr at 9.073" could be used with a 9.051" piston. If pistons and liners are_not selectively fitted, then the maximum wear limit of the Jiner at the 6" dimension would be 9.068" as the minimum wear limit of a used piston is 9.046". @iit ring groove width = New 25 1".254" (Oil ring to tand clearance ~ New 002""-.006"" Piston rings Compression ring gap (new ring in 9-1/16" liner) ees. .040",050" Carrier Cartier height (top of platform to bottom of carrier) ~ New : vee 5.999"5.995" Limit : bee 5.992" Carrier top pilot diameter ~ New oe Limit Carrier bottom pilot diameter ~ New : cee : . - 7,482!'-7.484" Limit . . : . 7.480" Clearance (carrier to piston snap ting) ~ New : - - : 002".015" Limit sees e : see sees 025" Carrier bearing insert thickness — NOW ove c eee - : - ~ -150"%.151"" Min. Dene eee nnn 147" Piston Pin Diameter ~ New . . sees 3.684""-3.685"" Min, 3.668" ‘seE97« 315Section 3 Piston Thrust Washer Thickness — New Limit Thickness variation — Max. EQUIPMENT LIST Motor driven flexible shatt buffer, 115 V Motor driven Mexible shatt buffer, 230 V Piston cooling pipe cleaning tool | Wire (lead, 1/8" dia. - 50 Ib spool) Torque wrench, 3/4” drive (0-300 Ibs) Snap ring remover. . : Torque wrench extension (used with torque wrench 8157121) Piston carrier holding tixture Wire holder (has contour of piston crown to hold small lengths of lead wire for piston to head clearance) Wire (lead, 1/8" dia., used with holder 8243220 or alone ~ 5 Ib spool) Fork connecting rod basket thread gauge Piston ring groove gange Standard (194" = 203") 1/64" OS. (.210" = 219") 1/32" OS. (225" - 234") Piston ring expander Connecting rod checking fixture Iss" 188" 17s" 003" Part No, 8084282 8084283 8087086 8130471 8157121 8171633 8210136 8236589 8243220 8243661 8265955 8275503 8331113 8331043 8349892 8423236 266873