5.
Middle Packing
a. Install packing cup with O-ring. Install segmented
packing set (tangent, tangent) with pin side towards
the cylinder followed by the packing backup ring.
b. Install purge packing cup with O-ring. Install
biased packing set (tangent, tangent with springs
towards cylinder) with pin side towards crankcase.
c. Install O-ring on a packing spacer and install both
into crankcase side of the packing cartridge body
with O-ring side first.
d. For both Specification Codes G and H, install the
packing cartridge adapter onto the crankcase
side of the packing cartridge body such that the
cup spacer slides into the crankcase side of the
packing cartridge adapter and engages the middle
packing set to retain it in the packing cartridge
body. Attach the packing cartridge adapter to the
packing cartridge body with the four small socket
head screws.
6.
Outer Packing
a. Install an O-ring on a packing spacer and install
both into cylinder side of packing cartridge body
O-ring towards cylinder.
b. Install biased packing set (tangent, tangent with
spring towards cylinder) with pin side towards
cylinder followed by purge packing cup with
O-ring.
c. Install a back-up ring, segmented packing set
(tangent-tangent [TT]) and packing cup with O-ring
into the cylinder side of packing cartridge body.
d. Install a back-up ring, segmented packing set
(radial-tangent [RT]) and packing cup with O-ring
into the cylinder side of packing cartridge body.
Repeat this process for remaining RT packing sets
e. Install a pressure breaker ring (not included on 6"
and 8" cylinders) and final packing cup with O-ring
into the cylinder side of packing cartridge body
f. Install a new O-ring on the outside of the packing
cartridge adapter and inside the adapter
g. Install a packing installation cone (Part no. 3905)
on the threaded end of the piston rod.
h. Carefully install the completed packing cartridge
assembly on the piston rod and insert into the
adapter. Be sure the mark previously made on the
packing cartridge body is oriented up because
most packing cartridge bodies can only be
installed in one position.
i. Install the packing cartridge cap in the adapter.
Be sure the mark previously made on the packing
cartridge cap is oriented up because the packing
cartridge cap can only be installed in one position.
On 2-3/4", 3-1/4" and 4" Cylinders only, insure
that the pin extending from the outer end of the
packing box cartridge fits into the corresponding
hole in the packing cartridge cap.
j. Attach the packing cartridge cap to the adapter
with the four socket head bolts
k. Remove the packing installation cone.
7. Replace the cylinder, pistons and cylinder head (along
with adjustable head components, if any).
8. Rotate unit by hand to insure proper assembly.
5 .7 Bearing Replacement for
Crankcase and Connecting Rod
1. To replace the crankcase roller bearings, wrist
pin bushing and connecting rod bearings, begin
by removing the head (or head, adjustable cap
and adjustable cup—applies to adjustable head
configuration only), cylinder, pistons, adapter, distance
piece (THG600 only) and crosshead and connecting
rod assemblies.
2. Drain the crankcase and remove the inspection plates.
3. Choose and mark one connecting rod and the
corresponding connecting rod cap to identify them. DO
NOT MIX CONNECTING RODS AND CAPS. Loosen
and remove the connecting rod nuts in order to remove
the crosshead and connecting rod assemblies.
5 .7 .1 Wrist Pin Bushing Replacement
1. To replace the wrist pin bushing, remove the retainer
rings that position the wrist pin in the crosshead.
2. Press out the wrist pin so the crosshead and
connecting rod may be separated. Inspect the wrist
pin for wear and damage and replace if necessary.
3. Press out the old wrist pin bushing and press a
new bushing into the connecting rod. DO NOT
MACHINE THE O.D. OR I.D. OF THE BUSHING
BEFORE PRESSING INTO CONNECTING ROD.
4. Make sure the lubrication hole in the bushing
matches the oil passage in the connecting rod. If the
holes do not align, drill out the bushing through the
connecting rod lubricant passage with a long drill.
Bore the wrist pin bushing I.D. as indicated. See
Appendix D for details. Over boring the bushing can
lead to premature failure of the wrist pin bushing
and/or wrist pin.
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