LOCK 3C8511 - Caterpillar

Assembly Procedure
Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     139-9039     Retaining Ring Pliers     1    
B     7M-3978     Ring Expander     1    
C     5P-8639     Hydraulic Press (Connecting Rod Bearing)     1    
8F-0024 Hose Assembly     1    
1P-2375 Connecting Coupler     1    
1P-2376 Connecting Coupler     1    
5P-8651 Spacer     1    
5P-8649 Adapter     1    
5P-8650 Bushing Adapter     1    
5P-9725 Hydraulic Cylinder Gp     1    Note: Prior to removal from the engine, the pistons and connecting rod assemblies were marked. The components must be reassembled together. The components must be installed in the original location in the engine. Do not interchange any of the components.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01194442
Illustration 2 g01194444
The connecting rod must be heated for the installation of the piston pin bearing. Do not use a torch.
Heat connecting rod (7) along Length (Y) . (Y) Maximum Length for heating the connecting rod ... 89 mm (3.5 inch)
Allow the connecting rod and the bearing to cool to room temperature.
Use Tooling (C) to remove the old bearing and install new bearing (5) at the same time. The adapter of Tooling (C) should make full contact with the surfaces of connecting rod (7) .Note: Orient the bearing joint within 5 degrees of either Location (X) .
Use a pin boring machine to machine the bore of the piston pin bearing to the correct diameter.Diameter of bearing bore ... 50.830 0.008 mm (2.0012 0.0003 inch)
Illustration 3 g01194406
Install piston crown (1) in piston skirt (4) .
Position the spring for the oil control piston ring in the oil ring groove in piston crown (1) .
Use Tooling (B) to position the oil control piston ring over the spring. Position the oil control piston ring so that the gap is 180 degrees from the joint in the spring.
Use Tooling (B) to install the intermediate piston ring with the side that has the identification "UP-2" toward the top of the piston.
Use Tooling (B) to install the top piston ring with the side that has the identification "UP-1" toward the top of the piston.
Position the piston rings so the end gaps are 120 degrees from each other.
Place piston crown (1) and piston skirt (4) in position on connecting rod (7) . Apply clean engine oil to piston pin (6) and install the piston pin. Use Tooling (A) to install retainer rings (3) . Ensure that the retainer rings are fully seated in the grooves of the piston.Note: Ensure that the connecting rod bearings are installed so that the bearing tabs fit into the notch in the connecting rod and the connecting rod cap.
Install connecting rod bearings (8) in connecting rod (7) and the connecting rod cap. Install bolts (2) in the connecting rod.End By: Install the pistons and connecting rods. Refer to Disassembly