Check/repair connecting rod

AR03.10-B-6111B

Check/repair connecting rod

09.01.2020

Engine

457.9 in model 382.15, 634.0

Engine

904.9, 906.9 (except 906.999), 924.9 (except 924.92), 926.9 (except 926.942) in model 368, 382.17 (except 382.171/176), 382.18, 384.06/07, 634.0, 685.282/284/289/290, 979.2

I

Connecting rod for engines 904.9, 906.9, 924.9, 926.9

1

Connecting rod

2

Connecting rod bearing cap

3

Connecting rod bearings

4

Connecting rod bolts

5

Connecting rod bushing

II

Connecting rod for engine 457.9

1

Connecting rod

2

Connecting rod bearing cap

3

Connecting rod bearings

4

Connecting rod bolts

5

Connecting rod bushing

1

Connecting rod

3

Connecting rod bearings

5

Connecting rod bushing

6

Dial indicator

7

Measuring device for internal diameters (Sudden)

A

Connecting rod length (bearing shells housing center to the bushing housing center)

B

Parallelism runout and maximum torsion between the bearing shells and bushing housings center lines

C

Measurement distance



Remove

1

Remove the piston

Engine 457.9

AR03.10-B-7021C

Engine 904.9, 906.9, 924.9, 926.9

AR03.10-B-7021B



Check

2

Check the condition of the connecting rod (1)

 Replace the connecting rod when it appears bluish (as a result of overheating due to seizure), cracks, transverse ribs or damage to the coupling faces (connecting rod bearing cap/connecting rod).

3

Check the connecting rod (1) for deformation and differences in the control measures

 Straightening the connecting rods is not allowed.

 Installation: Replace the connecting rod if it shows any faults:

Engine 904.9, 906.9, 924.9, 926.9Sleeves housing diameter in the connecting rod

*BE03.10-B-1002-01C

Engine 457.9Connecting rod shells (bearings) lodging diameter

*BE03.10-B-1003-01G

Engine 904.9, 906.9, 924.9, 926.9Maximum roundness and tapper allowed in the sleeves housing and the connecting rod bushing

*BE03.10-B-1005-01C

Engine 457.9Admissible out-of-round of the lodging (basic) of the connecting rod (bearing) shell

*BE03.10-B-1004-01G

Engine 904.9, 906.9, 924.9, 926.9Maximum allowed deviation for parallelism and torsion (B) between the center lines of the sleeves housing and the connecting rod bushing, in the distance (C)

*BE03.10-B-1004-01C

Engine 457.9Maximum permissible parallelism and torsion (B) deviation between the center lines of connecting rod bearing bore and center of wrist pin bore, at distance (C)

*BE03.10-B-1012-01G

Engine 904.9, 906.9, 924.9, 926.9Connecting rod length (A), center of the sleeves housing to the center of the bushing housing

*BE03.10-B-1006-01C

Engine 457.9Connecting rod length (A), from the center of the bearing shell housing to the center of the bushing housing

*BE03.10-B-1011-01G

4

Check the bore of the bushing (5) on the connecting rod (1)

I
Engine 904.9, 906.9, 924.9, 926.9

AR03.10-B-6111-03B

IEngine 457.9

AR03.10-B-6111-03D

 Installation: Replace the bushing (5) if the bore does not meet the specification.

Engine 904.9, 906.9, 924.9, 926.9Connecting rod bushing internal diameter

*BE03.10-B-1011-01C

Engine 457.9Internal diameter of the bushing mounted on the connecting rod (final finishing)

*BE03.10-B-1005-01G

 Dial gage

*001589532100

Use:



Measuring device for internal diameters from 35 to 60 mm

5

Install the bearing shells (3) on the connecting rod (1) and check the dimensions

.

AR03.10-B-6111-06B

Engine 904.9, 906.9, 924.9, 926.9Sleeves internal diameter (assembled in the connecting rod)

*BE03.10-B-1001-01C

Engine 904.9, 906.9, 924.9, 926.9Connecting for play (with sleeves) in the crankshaft neck

*BE03.10-B-1003-01C

Engine 457.9Radial play of the connecting rod bearing

*BE03.10-B-1002-01G

Engine 904.9, 906.9, 924.9, 926.9Connecting rod bolt

*BE03.10-B-1013-01C

Engine 457.9Connecting rod cap bolt

*BE03.10-B-1001-01G

.Diameter of connecting rod journal on crankshaft

*BE03.20-B-1003-02C

 Engine 904.9, 906.9, 924.9, 926.9Attachment bolt for the connecting rod cover

*BA03.10-B-1001-01B

 Engine 457.9Connecting rod cap fastening bolts

*BA03.10-B-1001-01C

 Dial gage

*001589532100

Use:



External micrometer, 50 to 75 mm

External micrometer, from 75 to 100 mm

Measuring device for internal diameters (sudden) 50 to 100 mm

6

Check the connecting rod end play in the crankshaft neck

Engine 904.9, 906.9, 924.9, 926.9Connecting for play (with sleeves) in the crankshaft neck

*BE03.10-B-1003-01C

Engine 457.9Axial play of the connecting rod shell (bearing)

*BE03.10-B-1008-01G

Engine 904.9, 906.9, 924.9, 926.9Connecting rod width, in the sleeves housing

*BE03.10-B-1007-01C

Engine 457.9Connecting rod width in the shell seat

*BE03.10-B-1013-01G

.Connecting rod bearing journal width

*BE03.20-B-1011-02C



Install

7

Install the piston

Engine 457.9

AR03.10-B-7021C

Engine 904.9, 906.9, 924.9, 926.9

AR03.10-B-7021B

Connecting rod test values

Number

Designation

Engine 904.9, 906.9 to 456372

Engine 904.9, 906.9 from 456373

BE03.10-B-1001-01C

Sleeves internal diameter (assembled in the connecting rod)

Normal

mm

70,054...70,093

70,054...70,093

Normal I

mm

69,954...69,993

69,954...69,993

Repair I

mm

69,804...69,843

69,804...69,843

repair II

mm

69,554...69,593

69,554...69,593

repair III

mm

69,304...69,343

69,304...69,343

repair IV

mm

69,054...69,093

69,054...69,093

Connecting rod test values

Number

Designation

Engine 924.9, 926.9 without Code MS5

Engine 924.9 and 926.9 with Code MS5

BE03.10-B-1001-01C

Sleeves internal diameter (assembled in the connecting rod)

Normal

mm

70,054...70,093

70,054...70,093

Normal I

mm

69,954...69,993

69,954...69,993

Repair I

mm

69,804...69,843

69,804...69,843

repair II

mm

69,554...69,593

69,554...69,593

repair III

mm

69,304...69,343

69,304...69,343

repair IV

mm

69,054...69,093

69,054...69,093

Connecting rod test values

Number

Designation

Engine 457.9 except for Code MS5

BE03.10-B-1001-01G

Connecting rod cap bolt

Thread diameter

mm

16x1,5

Length of new conditions rod

mm

67,2...67,5

Rod admissible length

mm

68,5

Connecting rod test values

Number

Designation

Engine 904.9, 906.9 to 456372

Engine 904.9, 906.9 from 456373

BE03.10-B-1002-01C

Sleeves housing diameter in the connecting rod

mm

75,000...75,019

75,000...75,019

Connecting rod test values

Number

Designation

Engine 924.9, 926.9 without Code MS5

Engine 924.9 and 926.9 with Code MS5

BE03.10-B-1002-01C

Sleeves housing diameter in the connecting rod

mm

75,000...75,019

75,000...75,019

Connecting rod test values

Number

Designation

Engine 457.9 except for Code MS5

BE03.10-B-1002-01G

Radial play of the connecting rod bearing

mm

0,060...0,120

Connecting rod test values

Number

Designation

Engine 904.9, 906.9 to 456372

Engine 904.9, 906.9 from 456373

BE03.10-B-1003-01C

Connecting for play (with sleeves) in the crankshaft neck

radial

mm

0,029...0,088

0,029...0,088

axial

mm

0,170...0,470

0,170...0,470

Connecting rod test values

Number

Designation

Engine 924.9, 926.9 without Code MS5

Engine 924.9 and 926.9 with Code MS5

BE03.10-B-1003-01C

Connecting for play (with sleeves) in the crankshaft neck

radial

mm

0,029...0,088

0,029...0,088

axial

mm

0,170...0,470

0,170...0,470

Connecting rod test values

Number

Designation

Engine 457.9 except for Code MS5

BE03.10-B-1003-01G

Connecting rod shells (bearings) lodging diameter

mm

95,000...95,022

Connecting rod test values

Number

Designation

Engine 904.9, 906.9 to 456372

Engine 904.9, 906.9 from 456373

BE03.10-B-1004-01C

Maximum allowed deviation for parallelism and torsion (B) between the center lines of the sleeves housing and the connecting rod bushing, in the distance (C)

Deviation B

mm

0,025

0,025

distance of measurement C

mm

50

50

Connecting rod test values

Number

Designation

Engine 924.9, 926.9 without Code MS5

BE03.10-B-1004-01C

Maximum allowed deviation for parallelism and torsion (B) between the center lines of the sleeves housing and the connecting rod bushing, in the distance (C)

Deviation B

mm

0,025

distance of measurement C

mm

50

Connecting rod test values

Number

Designation

Engine 457.9 except for Code MS5

BE03.10-B-1004-01G

Admissible out-of-round of the lodging (basic) of the connecting rod (bearing) shell

mm

0,008

Connecting rod test values

Number

Designation

Engine 904.9, 906.9 to 456372

Engine 904.9, 906.9 from 456373

BE03.10-B-1005-01C

Maximum roundness and tapper allowed in the sleeves housing and the connecting rod bushing

sleeves housing

mm

0,01

0,01

busing housing

mm

0,006

0,006

Connecting rod test values

Number

Designation

Engine 924.9, 926.9 without Code MS5

BE03.10-B-1005-01C

Maximum roundness and tapper allowed in the sleeves housing and the connecting rod bushing

sleeves housing

mm

0,01

busing housing

mm

0,006

Connecting rod test values

Number

Designation

Engine 457.9 except for Code MS5

BE03.10-B-1005-01G

Internal diameter of the bushing mounted on the connecting rod (final finishing)

mm

52,05...52.07

Connecting rod test values

Number

Designation

Engine 904.9, 906.9 to 456372

Engine 904.9, 906.9 from 456373

BE03.10-B-1006-01C

Connecting rod length (A), center of the sleeves housing to the center of the bushing housing

mm

214,075...215,025

214,075...215,025

Connecting rod test values

Number

Designation

Engine 924.9, 926.9 without Code MS5

BE03.10-B-1006-01C

Connecting rod length (A), center of the sleeves housing to the center of the bushing housing

mm

214,075...215,025

Connecting rod test values

Number

Designation

Engine 904.9, 906.9 to 456372

Engine 904.9, 906.9 from 456373

BE03.10-B-1007-01C

Connecting rod width, in the sleeves housing

mm

33,730...33,830

33,730...33,830

Connecting rod test values

Number

Designation

Engine 924.9, 926.9 without Code MS5

Engine 924.9 and 926.9 with Code MS5

BE03.10-B-1007-01C

Connecting rod width, in the sleeves housing

mm

33,730...33,830

33,730...33,830

Connecting rod test values

Number

Designation

Engine 457.9 except for Code MS5

BE03.10-B-1008-01G

Axial play of the connecting rod shell (bearing)

mm

0,130...0,292

Connecting rod test values

Number

Designation

Engine 904.9, 906.9 to 456372

Engine 904.9, 906.9 from 456373

BE03.10-B-1011-01C

Connecting rod bushing internal diameter

mm

40,03...40,04

42,04...42,05

Connecting rod test values

Number

Designation

Engine 924.9, 926.9 without Code MS5

Engine 924.9 and 926.9 with Code MS5

BE03.10-B-1011-01C

Connecting rod bushing internal diameter

mm

42,04...42,05

44,05...44,06

Connecting rod test values

Number

Designation

Engine 457.9 except for Code MS5

BE03.10-B-1011-01G

Connecting rod length (A), from the center of the bearing shell housing to the center of the bushing housing

mm

250,970...251,03

Connecting rod test values

Number

Designation

Engine 457.9 except for Code MS5

BE03.10-B-1012-01G

Maximum permissible parallelism and torsion (B) deviation between the center lines of connecting rod bearing bore and center of wrist pin bore, at distance (C)

deviation B

mm

0,030

Measuring distance

mm

50

Connecting rod test values

Number

Designation

Engine 904.9, 906.9 to 456372

Engine 904.9, 906.9 from 456373

BE03.10-B-1013-01C

Connecting rod bolt

Thread

M

12 x 1,25

12 x 1,25

Length (L) - new bolt

mm

55,5...56,0

55,5...56,0

Length (L) - used bolt

mm

57,0

57,0

Connecting rod test values

Number

Designation

Engine 924.9, 926.9 without Code MS5

Engine 924.9 and 926.9 with Code MS5

BE03.10-B-1013-01C

Connecting rod bolt

Thread

M

12 x 1,25

12x1,25

Length (L) - new bolt

mm

55,5...56,0

56,0

Length (L) - used bolt

mm

57,0

57,0

Connecting rod test values

Number

Designation

Engine 457.9 except for Code MS5

BE03.10-B-1013-01G

Connecting rod width in the shell seat

mm

37,000...37,400

Crankshaft test values

Number

Designation

Engine 457.9 without Code MS5

Engine 904.9

BE03.20-B-1003-02C

Diameter of connecting rod journal on crankshaft

standard

mm

89,980...90,000

69,995...70,015

standard I

mm

89,880...89,900

69,895...69,915

repair stage I

mm

89,730...89,750

69,745...69,765

repair stage II

mm

89,480...89,500

69,495...69,515

repair stage III

mm

89,230...89,250

69,245...69,265

repair stage IV

mm

88,980...89,000

68,995...69,015

Crankshaft test values

Number

Designation

Engine 906.9; 926.9; 924.9

BE03.20-B-1003-02C

Diameter of connecting rod journal on crankshaft

standard

mm

69,995...70,015

standard I

mm

69,895...69,915

repair stage I

mm

69,745...69,765

repair stage II

mm

69,495...69,515

repair stage III

mm

69,245...69,265

repair stage IV

mm

68,995...69,015

Crankshaft test values

Number

Designation

Engine 457.9 without Code MS5

Engine 904.9

BE03.20-B-1011-02C

Connecting rod bearing journal width

standard

mm

46,0...46,1

34,0...34,2

repair

mm

-

-

Crankshaft test values

Number

Designation

Engine 906.9; 926.9; 924.9

BE03.20-B-1011-02C

Connecting rod bearing journal width

standard

mm

34,0...34,2

repair

mm

-

 Connecting rod

Number

Designation

Engine 902.9, 904.9, 906.9

Engine 924.9, 926.9

BA03.10-B-1001-01B

Attachment bolt for the connecting rod cover

1st stage

Nm

10

10

2nd stage

Nm

40...50

40...50

3rd stage

Graus

90...100

90...100

 Connecting rod

Number

Designation

Engine 457.9; 460.984

BA03.10-B-1001-01C

Connecting rod cap fastening bolts

Initial tightening

Nm

100...115

Final angular tightening

graus

90...100