Engineering

Standards
Engineering Standard Number
Name TUBES, METALLIC

INSPECTION SPECIFICATION 16454

Identifier
(ITEM)

1. Scope
This specification defines the inspection guidelines for metallic tubing. The specification includes
acceptance criteria for wall distortion (kinks, wrinkles, flattening, nicks, dents, and clamping
marks etc.) resulting from the manufacturing process or unintentional handling damage.

2. Applicable Documents
Applicable documents listed below may be obtained from the respective organizations listed in
CES 10054.

a. CES 10054, Standard Organization Addresses

b. CES 10056, General Glossary

3. Definitions
Terms used in this standard that have a general definition for usage in Cummins Engineering
Standards are defined in CES 10056, General Glossary.

3.1. Bend Zone

The area of a tube between the start of a radius and the end of that same radius.
3.2. Clamping Marks

Surface blemishes produced in the tube bending process by the tooling used to hold the tube as it
is bent.

3.3. Dent

A surface blemish, whose width is large in comparison to its depth, resulting from unintentional
processing or handling errors. A dent will not generally produce raised metal around its edges.

3.4. Flattening

A distortion in the roundness of a tube, usually resulting in an oval shape.

3.5. Kink

An unintentional bend which develops in the creation, processing, or application of a tube.

Current Release Number Std. Revision Level

941914-000 001 Page 1 of 7
PROPRIETARY: Information contained within this document is not to be disclosed to third
parties, or used for any purpose other than the manufacture for Cummins or its subsidiaries.
 Engineering
Standards
Engineering Standard Number
Name TUBES, METALLIC

INSPECTION SPECIFICATION 16454

Identifier
(ITEM)

3.6. Nick

A shallow V shaped depression or indentation in a surface resulting from unintentional processing

or handling error. A nick may produce raised metal around its edges.

3.7. Wrinkle

Waviness most commonly found within the bend zone just behind the tangent point (or start of the
bend).

4. Specification
4.1. Wall Distortion

4.1.1. Wall distortion includes flattening, kinks, wrinkles, nicks, dents, and clamping marks
etc., as defined in Section 3.

4.1.2 For the purpose of evaluating wall distortion, metallic tubing is divided into four types
based on the internal fluid pressure of the application.

4.1.3. Type I

Type I tubing contains atmospheric pressure or is not used for fluid passage. Examples of Type I
tubing are listed below:

a. Air Inlet Tube

b. Battery Drain Tube
c. Bleed Tube
d. Breather Tube
e. Compressor Oil Drain Tube
f. Corrosion Resistor Tube
g. Cpr Air Discharge
h. Fuel Drain Tube
i. Lub Oil Drain Tube
j. Muffler Drain Tube
k. Oil Filler Tube
l. Oil Gage Tube
m. Radiator Fill Tube
n. Spark Plug Adapter Tube

Current Release Number Std. Revision Level

941914-000 001 Page 2 of 7
PROPRIETARY: Information contained within this document is not to be disclosed to third
parties, or used for any purpose other than the manufacture for Cummins or its subsidiaries.
 Engineering
Standards
Engineering Standard Number
Name TUBES, METALLIC

INSPECTION SPECIFICATION 16454

Identifier
(ITEM)

4.1.3. Type I (Continued)

o. Tank Fill Tube

p. Turbo Oil Drain Tube
q. Vac Pump Water Drain Tube
r. Var Timing Drain Tube
s. Vent Tube
t. Water Drain Tube

4.1.4. Type II

Type II tubing is used for fluid passage with a pressure from atmospheric up to and including 100
pounds per square inch (689.4 kilopascals). Examples of Type II tubing are listed below:

a. Aftercooler Tube
b. Aneroid Tube
c. Burner Tube
d. Coupling Tube
e. Cpr Water Inlet Tube
f. Cpr Water Outlet Tube
g. Expansion Tank Tube
h. Filter Tube
i. Flexible Tube
j. Governor Tube
k. Grease Tube
l. Hand Pump Tube
m. Heat Exchanger Tube
n. Heater Tube
o. Intercooler Tube
p. Lub Oil Bypass Tube
q. Lub Oil Supply Tube
r. Lub Oil Transfer Tube
s. Oil Cooler Tube
t. Oil Manifold Tube
u. Piston Cooling Tube
v. Radiator Inlet Tube

Current Release Number Std. Revision Level

941914-000 001 Page 3 of 7
PROPRIETARY: Information contained within this document is not to be disclosed to third
parties, or used for any purpose other than the manufacture for Cummins or its subsidiaries.
 Engineering
Standards
Engineering Standard Number
Name TUBES, METALLIC

INSPECTION SPECIFICATION 16454

Identifier
(ITEM)

4.1.4. Type II (Continued)

w. Radiator Outlet Tube

x. Scavenger Inlet Tube
y. Scavenger Outlet Tube
z. Sea Water Pump Tube
aa. Shutoff Valve Tube
ab. Starting Aid Tube
ac. Tur Oil Supply Tube
ad. Var Timing Supply Tube
ae. Vehicle Heater Tube
af. Water Bypass Tube
ag. Water Inlet Tube
ah. Water Makeup Tube
ai. Water Outlet Tube
aj. Water Transfer Tube

4.1.5. Type III

Type III tubing is used for fluid passage with a pressure of over 100 pounds per square inch (689.4
kilopascals). Examples of Type III tubing are listed below:

a. Air Tube
b. Air Balance Tube
c. Air Crossover Tube
d. Air Fuel Control Tube
e. Air Transfer Tube
f. Compressor Air Inlet Tube
g. Exhaust Outlet Tube
h. Fuel Bypass Tube
i. Fuel Supply Tube
j. Fuel Transfer Tube
k. Injector Fuel Supply Tube
l. Manifold Pressure Tube
m. Pressure Sensing Tube
n. Supercharger Tube
o. Vac Pump Air Discharge Tube

Current Release Number Std. Revision Level

941914-000 001 Page 4 of 7
PROPRIETARY: Information contained within this document is not to be disclosed to third
parties, or used for any purpose other than the manufacture for Cummins or its subsidiaries.
 Engineering
Standards
Engineering Standard Number
Name TUBES, METALLIC

INSPECTION SPECIFICATION 16454

Identifier
(ITEM)

4.1.6. Type IV

Type IV tubing is used for fluid passage with a pressure less than atmospheric. An example of Type
IV tubing is a Lub Oil Suction Tube.

4.1.7. Acceptance Limits

4.1.7.1. Kinks

4.1.7.1.1. The presence of kinks shall be determined by nonmagnified visual examination.

4.1.7.1.2. Kinks are not permitted in either the straight or tube bend zones for any of the four
types.

4.1.7.2. Wrinkles

4.1.7.2.1. Measurement of wrinkles is the largest O.D. within a bend zone minus the smallest
O.D. in that same bend zone (crest to valley of wrinkle).

4.1.7.2.2. Wrinkles shall be measured using a dial test indicator measuring parallel to the axis
of the tube.

4.1.7.2.3. Wrinkles are not acceptable in the straight sections of tubing.

4.1.7.2.4. Wrinkles are acceptable within the bend zone of tubing as indicated below:

a. Type I 0.03 inch (0.8 millimeter) maximum

b. Type II for tubes with bend radii smaller than 3 times the tube O.D.: 0.03 inch (0.8
millimeter) maximum.
c. Type II for tubes with bend radii 3 times the tube O.D. or larger: 0.01 inch (0.3 millimeter)
maximum.
d. Type III 2 percent of tube nominal O.D. maximum.
e. Type IV for tubes with bend radii smaller than 3 times the tube O.D.: 0.03 inch (0.8
millimeter) maximum.
f. Type IV for tubes with bend radii 3 times the tube O.D. or larger: 0.01 inch (0.3 millimeter)
maximum.

Current Release Number Std. Revision Level

941914-000 001 Page 5 of 7
PROPRIETARY: Information contained within this document is not to be disclosed to third
parties, or used for any purpose other than the manufacture for Cummins or its subsidiaries.
 Engineering
Standards
Engineering Standard Number
Name TUBES, METALLIC

INSPECTION SPECIFICATION 16454

Identifier
(ITEM)

4.1.7.3. Flattening

4.1.7.3.1. Flattening is defined by the formula:

Flattening = (Maximum O.D. - Minimum O.D.) X 100%

Nominal O.D.

4.1.7.3.2. To determine flattening, maximum and minimum O.D.’s shall be measured using
outside calipers or micrometers.

4.1.7.3.3. Flattening is not acceptable in the straight sections of tubing.

4.1.7.3.4. Flattening in the tube bend zone is acceptable within the following limits:

a. Type I for tubes with bend radii smaller than 1.5 times the tube O.D.: 20 percent maximum.
b. Type I for tubes with bend radii 1.5 times the tube O.D. or larger: 15 percent maximum.
c. Type II for tubes with bend radii smaller than 1.5 times the tube O.D.: 15 percent
maximum.
d. Type II for tubes with bend radii 1.5 times the tube O.D. or larger: 10 percent maximum.
Type III 10 percent maximum.
e. Type IV for tubes with bend radii smaller than 1.5 times the tube O.D.: 15 percent
maximum.
f. Type IV for tubes with bend radii 1.5 times the tube O.D. or larger: 10 percent maximum.

4.1.7.4. Standardized Tube Tolerances

Tolerances for various types of tubing has been standardized. The following tolerance values are
applicable to any tube unless stated otherwise on the face of the drawing.

a. Bend Angle Tolerance plus/minus 1/2 degrees

b. Tolerance Between Bends plus/minus 0.03" (plus/minus 0.8 millimeter)
c. Tolerance from either tube end to start of the bend plus/minus 0.03" plus/minus 0.8
millimeter)
d. Rotation angle tolerance plus/minus 1/2 degrees.

Current Release Number Std. Revision Level

941914-000 001 Page 6 of 7
PROPRIETARY: Information contained within this document is not to be disclosed to third
parties, or used for any purpose other than the manufacture for Cummins or its subsidiaries.
 Engineering
Standards
Engineering Standard Number
Name TUBES, METALLIC

INSPECTION SPECIFICATION 16454

Identifier
(ITEM)

4.1.7.5. Acceptance Limits for Other Defects

The following limits are applicable for nicks, dents, and clamping marks etc., in B and C Series
Type III fuel tubes.

4.1.7.5.1. Deformation due to nicks, dents, and clamping marks etc., may be up to 2 percent
maximum for fuel tube outer diameter.

4.1.7.5.2. Length or width of nicks, dents, or clamping marks etc., may be up to 3 millimeters.

4.1.7.5.3. The number of defects on a fuel tube may be up to a maximum of five (5).

Current Release Number Std. Revision Level

941914-000 001 Page 7 of 7
PROPRIETARY: Information contained within this document is not to be disclosed to third
parties, or used for any purpose other than the manufacture for Cummins or its subsidiaries.