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INSTALLATION - TM-5-4210-229-14P_420
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TM-5-4210-229-14P Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Cylinder sleeve removal.
TM5-4210-229-14&P 6-12.  PISTON AND CONNECTING ROD MAINTENANCE. This task cover:     a.  Removal b.  Inspection c.  Installation INITIAL SET-UP Tools Universal Wet Sleeve Puller (PLT-502-3) Arbor Press Dial Indicator Piston Ring Expander Piston and Piston Ring Compressor (SE-1680) General Mechanics Tool Kit Equipment Condition Para.  Condition Description 4-92   Oil Pan Removed 6-6     Cylinder Head and Valves Removed Materials/Parts Piston Sleeve (682720C1) Piston and Sleeve Kit (1802581C91) Piston Ring Set (687429C91) Piston Pin (670675C1) Connecting Rod (688923C91) Cleaning Solvent (Appendix D, Item 54) Lubricating Oil (Appendix D, Item 37) Molykote (Appendix D, Item 35) Plastigage (Appendix D, Item 40a) REMOVAL NOTE Check crankshaft bearing bolt torque on the main bearing and connecting rod bolts anytime the oil pan is removed. a.  Main bearing and connecting rod bolt torques check. (1) Using a direct reading torque wrench (not a clicker type) place the socket over the bolt head and gently pull the wrench in the tightening direction to remove slack.  Mark the bolt and rod with the marks in align- ment.  For mains, mark the cap and the socket. (2) Loosen bolts 1/4 turn.  Torque with a slow steady motion and read the torque at the moment the marks are once again aligned. (3) On the main bearing bolts if torque is found to be below 115 ft-lb (155 N.m), and cap is not to be removed, back off 1/4 turn and retorque to 115 ft-lb (155 N.m).  Those at 115 ft-lb (155 N.m) or higher should be left with marks aligned. (4) For connecting rod bolts if the torque of both bolts is 130 ft-lb (175 N.m) or higher, and rod is not to be removed, they may be left with the marks aligned. (5) If the torque of either bolt is found to be less than 110 ft-lb (150 N.m), the rod should be removed and inspected. (6) If the torque of both connecting rod bolts is found to be at least 110 ft-lb (150 N.m), but either or both less than 130 lb-ft (175 N.m), the cap should be removed and the bear- ing inspected. NOTE If bearing distress is noted or bearings are not a tight fit in rod and cap, new inserts should be used and the cap reinstalled.  If no bearing dis- tress is noted, reinstall the bearings and cap. CAUTION Before proceeding with piston and connecting rod removal, inspect the sleeves at the upper end of the ring travel for the presence of a ridge.  This ridge must be removed with a fine emery cloth and a carbon scraper before the piston is removed.  This prevents damage to the piston ring lands during removal and also prevents damage to new piston rings when installing the piston.  When removing a piston from the crank-case, do not allow the piston skirt to strike the crankcase or the connecting rod to strike the piston sleeve, as severe damage to the sleeve could result. 6-28

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