e. Install.

9-21. CONNECTING ROD BEARINGS REPLACEMENT

Figure 9-32. Using Plastigage to Determine Bearing Clearance

TM-9-6115-604-34 Generator Set Diesel Engine Driven Tactical Skid Mtd 5 Kw. 1 Phase-2 Wire 1 Phase -3 Wire 3 Phase -4 Wire 120. 120/240 and 120/208 Volts Manual
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TM 9-6115-604-34 NAVFAC P-8-633-34 (2) Visually inspect each bearing shell for defects and signs of uneven wear. Interpret bearing shell appearance as follows: (a) Bearing shells that have been operating at the correct clearance and with adequate lubrication will have a dull gray color. Bearing shells having a black surface, or showing varnish build-up, have been running at excessive clearance and shall be replaced. (b) Bearing shells that show bright shiny spots or areas have been running at insufficient clearance and shall be replaced. If bright areas appear along one edge of the bearing shell misalignment exists. Check the connecting rod for alignment in accordance with paragraph 9-20. (c) Bearing shells that are flaked, scored, galled, or show visible embedded dirt particles shall be replaced. (3) Using a micrometer having a ball anvil, measure each bearing shell. Minimum thickness for connecting rod bearing shells shall be in accordance with Table 1-4. If either shell of a bearing set is under the minimum thickness, replace both shells. (4) Inspect the crankshaft journal as follows: (a) Visually inspect the journal for cracks, nicks, pitting, scoring, or grooving. Replace the crankshaft in accordance with paragraph 9-27 if cracked. Rebuild the crankshaft in accordance with paragraph 9-28 if surface defects are over 0.003 inch (0.08 mm) deep. (b) Using an outside micrometer, check the journal for wear, out-of-round, and taper. Rebuild the crankshaft in accordance with paragraph 9-28 if is worn more than the limits specified in Table 1-4, out-of-round more than 0 .002 inch (0.005 mm), or tapered more than 0.0005 inch (0.013 mm) over the full length of the journal. (c) Visually inspect the thrust surfaces for cracks, nicks, pitting, scoring, or grooving. Rebuild the crankshaft in accordance with paragraph 9-28 if surface defects are over 0.003 inch (0.008 mm) deep. e. Install. CAUTION During bearing shell Installation procedures, be sure all parts are kept dean and free of dirt or other foreign materials Be especially careful when Installing the bearing shells in the connecting rod and cap. Even a small amount of foreign matter trapped between the bearing shells and the rod or cap, will decrease bearing shell-to-journal clearance and result in premature wear or burned bearIng shells. NOTE Bearing shells must be replaced in sets only. (1) Remove all traces of oil and foreign material from the mating and bearing surfaces of the connecting rod (4) and cap (3). (2) Install serviceable or replacement bearing shells (11) in the connecting rod (4) and cap (3). Be sure the bearing shells are firmly seated in the rod and cap. (3) Pull the connecting rod into position on the journal, and remove the guide pins 3375098 from the connecting rod. NOTE Plastigage is available in three clearance ranges: Type PG-1 (green) for a clearance range of 0.001 to 0.003 inch (0.025 to 0.076 mm); Type PR-1 (red) for a clearance range of 0.002 to 0.006 inch (0.051 to 0.152 mm); Type PB1 (blue) for a clearance range of 0.004 to 0.009 inch (0.102 to 0.229 mm). Select the range needed for the clearance being checked in accordance with Table 1-4. (4) Place a strip of Plastgage across the full width of the bearing shell in the rod cap (A, Figure 9-32). NOTE Before installing the connecting rod bolts (1, Figure 9-24) and washers (2), coat the bolt threads, under side of bolt heads, and washers with dean lubricating oil MIL-L-2104. (5) Being careful not to dislodge the Plastigage, install the bearing cap (3, Figure 9-24) on the connecting rod (4) and retain with washers (2) and bolts (1). Tighten the bolts in accordance with Table 1-3. 9-59

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