Page 341 - CTS - Mechanic Diesel - TP

MECHANIC DIESEL - CITS

iii Connecting Rod and Cross head
1 Remove the side and rear covers from the power end.

2 Remove the plunger clamps and push the plungers into the fluid end
3 Remove the extension rods.
4 Using strong internal snap ring pliers, remove the snap rings from the from the cross head pin.
5 Using a slide hammer or partially threaded rod, remove the pin from the cross head.
6 Remove one cross head and connecting rod at a time. The middle crosshead pin can not be removed until the
outer crosshead is removed.
7 Remove the two locknuts from each rod cap of the rod to be removed.
8 Remove the rod cap, labelling each for correct re-assembly.
9 Remove the studs in the connecting rod by the locking two nuts onto the stud. Remove the stud by loosening
the inner nut against the outer nut.
10 Remove the main bearing retainers (bolt, nut and washers) opposite the crank throw.
11 Rotate the crankshaft to the back stroke of the rod to be removed and push the rod forward till it clears the
throw and lower it to the bottom of the power end.
12 Rotate the crankshaft till the throw is on top (90 degrees from the back position) and remove the connecting
rod out the back of the power end, being careful not to damage the crank throw
13 Clean and inspect all bearings and bearing surfaces. Replace any defective or worn parts.
14 Clean the oil port in the centre of the connecting rod
15 When replacing the wrist pin bushing in a connecting rod, make sure the oil grooves are placed toward the rear
(crank end of the rod)

Use a hydraulic press to replace the wrist pin bushing, as hammering will destroy the bushing
If a hydraulic press is not available, place the bushing in a freezer overnight to allow the bushing to
slip easily into the connecting rod

16 When re-installing the crossheads and connecting rods, start with the centre assembly.

17 Install the non-grooved rod bearing into the connecting rod.
18 With the crank throw at the top position, feed the connecting rod into the power end and place as far forward
as possible.
19 Rotate the crank throw to the back stroke position, Lift and pull the connecting rod back until it is in place on
the crank throw
20 Hand tighten the two studs into the connecting rod. Apply thread seal to the stud threads engaged in the rod.
Make sure the studs are fully seated in the connecting rod.
21 Install the grooved rod bearing into the cap.
22 Install the rod cap with bearing onto the connecting rod
23 Install and torque the rod cap locknuts by applying correct torque as per manufacturers recommendation.
24 Lift the front of the connecting rod and slide the crosshead back until the wrist pin bores align

25 Install the wrist pin.
26 Install the snap ring into the groove in the crosshead.
27 Re-install the main bearing retainers.
28 Check the crosshead guide clearances prior to operation
iv Crosshead Guides

1 Remove the connecting rod and crosshead of the guides to be serviced.

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CITS : Automotive - Mechanic Diesel - Exercise 18.5