Pistons

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Reuse And Salvage Guidelines

Procedures and Specifications for Pistons{1214}
Media Number -SEBF8059-15 Publication Date -03/04/2007 Date Updated -03/04/2007
i02736130
Procedures and Specifications for Pistons{1214}

SMCS - 1214
Engine:Commercial All
3044C (S/N: 3441-UP)
Engine:Truck All
Industrial Engine:with Turbochargers All
Machine Engines: All
Marine Engine:with Turbochargers All
Introduction
This Reuse and Salvage Guideline contains the necessary information in order to allow a dealer to establish a
parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit
from cost reductions. Every effort has been made in order to provide the most current information that is
known to Caterpillar. Continuing improvement and advancement of product design might have caused
changes to your product which are not included in this publication. This Reuse and Salvage Guideline must
be used with the latest technical information that is available from Caterpillar.
For additional information about this guideline, consult Repair Process Engineering of the Marketing &
Product Support Division at 1 (309) 675-5434.
Summary
This guideline can be used to determine if an old piston can be reused. The piston can expect to give normal
performance if the piston meets the specifications in this guideline. The piston must also be used in the same
application.
Safety
When replacement parts are required for this product Caterpillar

recommends using Caterpillar replacement parts or parts with
equivalent specifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product

damage, personal injury or death.
mhtml:file://C:\Users\Mathura\Documents\cat reusability guide\Media Search - SEBF80... 2/2/2012

References
ReferenceCatalog, GECJ0001-01-2, "Cat Shop Supplies and Hand Tools"
ReferenceContamination Control Guideline, PEBJ0002, "CaterpillarDealer Contamination Control

Guidelines"
ReferenceReuse and Salvage Guidelines, SEBF8049, "Piston Visual Inspection"
ReferenceReuse and Salvage Guidelines, SEBF8051, "Inspection and Measuring Procedures for Piston Pins"
ReferenceSpecial Instruction, SEHS8696, "Piston Cleaning Procedure"
ReferenceSpecifications, SENR4620
ReferenceService Magazine, SEPD0360
Nomenclature
A piston with a coating that is graphite is normally 0.020 mm (0.0008 inch) thick, dull in appearance and dark
gray in color. The top of some one-piece pistons have a hard anodized layer. This layer protects the top of the
aluminum piston from the heat of combustion in high output engines. If the anodized layer is removed, the
layer cannot be replaced. The anodized layer is not present on pistons that were manufactured after 1996. The
crowns on two-piece pistons do not have the anodized layer. The oil passage, which is used for cooling, runs
along the circumference of the crown. For the location of the oil passage, look for the holes in the bottom of
the piston and the slot for lubricating the piston pin in each piston pin bore.
Note: During cleaning of the piston with glass beads, close all oil passages in order to keep debris out..
One-Piece Pistons

Illustration 1 g01275356
Features of One-Piece Pistons
(1) Crown
(2) Crater
(3) Ring band
(4) Ring grooves
(5) Ring lands
(6) Skirt
(7) Bore surface of piston pin
(8) Snap ring groove
(9) Top land
(10) Relief for cooling jet
(11) Side relief for piston
(12) FRONT
Graphite Coating
Many of the new one-piece pistons have two important characteristics. The characteristics are graphite
coating on the skirt and an oil passage inside the crown. Refer to Illustration 2. The graphite coating is not
present on pistons that were manufactured after 1996.
A one-piece piston with a skirt of graphite coating
(13) Graphite coating

(14) Passage for oil cooling of crown
(15) Vertical oil passage
The graphite coating on the skirt helps to prevent scuffing and seizure at a cold start. A piston with a graphite
coating is normally about 0.020 mm (0.0008 inch) thick, dull in appearance and dark gray in color. The
graphite coating will eventually wear off the surface of the piston. Wear occurs at the location of contact of
the piston and liner. The wear of graphite coating is normal. During cleaning, do not remove more graphite
coating. The coating can be worn on any portion of the piston, but the piston skirt must be smooth with no
deep scratches or the buildup of material.
Anodized Layers
The top of some one-piece pistons have a hard anodized layer. This layer protects the top of the aluminum
piston from the heat of combustion in high output engines. If the anodized layer is removed, the layer cannot
be replaced. The anodized layer is not present on pistons that were manufactured after 1996. The crowns on
two-piece pistons do not have the anodized layer.
Oil Passages
The oil passage, which is used for cooling, runs along the circumference of the crown. For the location of the
oil passage, look for the holes in the bottom of the piston and slot for lubricating the piston pin in each piston
pin bore.
Steel Crown and Aluminum Skirt
A steel crown can be bolted to an aluminum skirt. This is regarded as a one-piece piston assembly because
the assembly should not be separated into two pieces. Do not separate the crown from the skirt.
Section view of piston which identifies the crown, skirt and all oil passages
(1) Crown
(14) Passage for oil cooling of crown
(16) Passage for supply of cooling jet

(17) Slot for lubrication of piston pin
(18) Joint of crown and skirt
(19) Passage for center oil return
(20) Passage for lubrication of bottom oil ring
NOTICE
Never disassemble the crown from the skirt. The pistons are assembled
at the factory using special procedures and the crowns are matched
with the skirts. This procedure cannot be duplicated in the field.
Special procedures and tooling are required to tighten the bolts holding
the crown to the skirt. Do not attempt to check or retighten the bolts.
Forged Steel Pistons
Forged Steel Piston with Single Piece
Two-Piece Pistons

Features of a two-piece piston crown and skirt
(1) Crown
(2) Crater
(4) Ring grooves
(5) Ring lands
(6) Skirt
(7) Piston pin bore
(9) Topland
Cleaning Procedure
Solvent
Clean any engine piston that is made by Caterpillar with high quality, biodegradable solvents. Remove all
carbon deposits with a solvent that does not affect the aluminum in the pistons.
Glass Beads
Use this method only when the preferred method is ineffective. Cleaning the piston with glass beads requires
certain precautions. Glass beads can alter the dimensions of the piston. The beads can hide cracks during
visual inspection also.
Never clean the piston with glass beads which are larger than 230 microns (0.009 inch). Glass beads of size
10 are 88 microns (0.0035 inch) to 149 microns (0.0095 inch) and air pressure of 550 kPa (79.7720 psi) to
620 kPa (89.9248 psi) are used to achieve the desired results. Glass beads of size 9 are 125 microns (0.0049
inch) to 177 microns (0.0070 inch) and beads of size 11 are 75 microns (0.0029 inch) to 125 microns (0.0049
inch). Sizes 9 through 11 are also acceptable. Change the glass beads and check the nozzle regularly for best
results.
Follow these guidelines in order to clean pistons with glass beads.

1. Do not use aluminum oxide or an abrasive material in place of glass beads.
2. Do not use a wire brush or a wire wheel.
3. Do not use steel shot.
4. The method of using glass beads can push a small amount of material from the ring band into the ring
groove. This material can be felt with a fingernail. If the material is not removed, the ring will not move
freely in the groove. Remove this material carefully with a triangular file or a flat file. Do not put a chamfer
on either side of the ring groove.
5. Glass beads that are larger than the recommended size or driven under excessive air pressure can smear
material over cracks. The smeared material can cover cracks that cause visual inspections for cracks to be
difficult.
One-Piece Pistons
The crowns may be cleaned with glass beads. However, several areas of the piston must be protected from the
glass beads. Refer to Illustration 6.
Note: After the piston is cleaned, it is important to check the oil passages. Make sure that all passages and
other areas are free of debris or glass beads. Any foreign material on the piston can be washed into the
lubrication system. This can cause damage to other engine components.
Use an O-ring to protect the oil ring groove.
Areas which need protection from glass beads on one-piece pistons
(7) Piston pin bore
(21) Sharp edge of crater
(22) Outer edge of piston crown
(23) Oil ring groove
(24) Oil passages
ReferenceRefer to the section ""Storage Procedures" " at the end of this document.

Piston Skirt with Graphite Coating
Clean the graphite coating on the piston skirt with a solution of liquid detergent and water. The graphite
coating can be cleaned with water and a solution of liquid detergent which contains little chlorine content.
174-6885 Cat Citra Soap is a good detergent. Mix eight ounces of liquid with every two gallons of water (240
mL per 3.8 liters).
Put the piston into this solution with enough time in order to loosen carbon and oil deposits. Remove the
piston when the piston is clean. To clean the skirt faster, heat the solution to a temperature near 55 °C (131 °
F).
Note: If the graphite coating is removed during the process of cleaning and the piston meets all other
acceptable criteria, the piston is reusable.
Never use glass beads to clean the skirt (Illustration 7) or the oil ring groove. Use a small brush to brush the
oil ring groove with previously used soap and water.
Damage of the skirt below the oil ring groove may be caused by glass beads.
Put a protective cover over the skirt (protection for the graphite coating) and the oil ring groove (protection
for the top edge of the graphite coating). Illustrations 8, 9, 10, and 11 show the areas that need protection
from glass beads. (Glass beads must not get into the oil passages.)

Protect oil holes from damage by glass beads. These holes are indicated by the arrows.
Protect oil holes from damage by glass beads on forged steel pistons. These holes are indicated by the arrows.
Test the strength of the plates in the cooling gallery. If either plate becomes loose, do not use the piston again.

Areas that need protection from glass beads
(17) Slot for lubrication of piston pin
Areas on the forged steel piston with single piece that need protection from glass beads
Use an O-ring as protection for the oil ring groove and the top of the graphite coating. Refer to Illustration 12.

O-ring in position
Fabricated fixture for cleaning
(25) O-ring for protection of oil ring land
(26) Cylinder liner
(27) Base plate
For maximum protection, fabricate a fixture for cleaning (Illustration 13). In addition to the O-ring, the two
other items that make up the fixture for cleaning are an old liner and a cover plate that can be welded to the
liner. Illustration 14shows an alternate fixture that makes cleaning pistons faster and easier.

This alternate fixture for cleaning has an angled design with rotating capability which makes cleaning pistons faster and easier.
(25) O-ring for protection of oil ring land
(26) Cylinder liner
(27) Base plate
(28) Bearing for air compressor
(29) Tubing
(30) Bottom plate for liner
After cleaning the piston with glass beads, use air pressure to remove debris that entered the oil passages of
the piston. Refer to Illustration 15. Wash the piston again with the solution for cleaning. Apply a rust
preventive to the iron ring band in order to prevent rusting.

ReferenceRefer to the section""Storage Procedures" " at the end of this document.
Piston Crown with Anodized Layer
Some one-piece pistons have a hard, anodized layer on top of the pistons. This layer protects the top of the
aluminum piston from the heat of combustion. The layer will last as long as the life of the piston during
normal operating conditions. If the layer is removed, the layer cannot be replaced. On one-piece pistons, the
glass beads cannot be used to clean the top of the piston or the skirt. Cover the top of the piston when glass
beads are used to clean the ring grooves. Refer to Illustration 16.
Protect the skirt and top of piston from glass beads.
Due to structural improvements to the oil gallery and the piston crown, the anodized layer is no longer
necessary. The piston has a coating which is a mixture of phosphate and graphite which has been shown to be
ineffective by data from the field and laboratory.
The new piston without the anodized layer and phosphate and graphite coating can be interchanged with the
earlier made piston that contains these two features. The pistons with the coating and the pistons without the
coating can be distinguished only by a difference in color. Refer to Illustration 17 and 18. The difference in
color has no effect on the ability to use the pistons.
Pistons without the anodized layer can be cleaned without the cap that is required for the anodized piston.
Follow all these guidelines for cleaning the pistons without the anodized layer. Anodized Pistons must follow
the same guidelines for protection of the anodized layer and coating of a mixture of phosphate and graphite.

Old style of a anodized piston with coatings of a mixture of phosphate and graphite
New piston with no anodized layer or coating of a mixture of phosphate and graphite
To clean the tops of pistons with an anodized layer, use a solution of hot water and soap in the same way as
cleaning the skirts. The solution of 174-6885 Cat Citra Soap and water may be used to clean the piston crown.
The same solution was used to clean the skirt.
Protect the anodized layer of the piston with a plastic cap when you clean the piston with glass beads. The
size of the cap is determined by the diameter of the piston and the depth of protection needed.
Refer to Catalog, GECJ0001-01-2, "Cat Shop Supplies and Hand Tools " for a list of caps and plugs.
Additional caps and plugs may be found by contacting Caplugs:
Caplugs
2150 Elmwood Ave.
Buffalo, New York 14207 (USA)
Website: www.caplugs.com
Email: info@caplugs.com

Telephone: (888) 227-5847
Pistons with Steel Crown and Aluminum Skirt
Four ring grooves are located at the top of the piston assembly. The top two ring grooves are machined in the
steel crown. The bottom two ring grooves are machined in the aluminum skirt. Be sure to use different
methods and procedures to clean each material (steel and aluminum). Clean the steel crown with a chemical
solution in order to remove carbon buildup. Clean the aluminum skirt with a solution of liquid detergent and
water in order to prevent damage to the graphite coating.
Protect Oil Passages
Tape the oil passages or plug the oil passages when you use glass beads. These passages are used to feed the
crown and the oil ring on the bottom. The oil passages are located at the following places:
z The hole on the bottom of the piston skirt that feeds the piston pin
z The four cross-drilled holes from the bottom ring groove to the inside diameter of the piston
z The hole in the center of the bottom side of the piston crown
z The spot for lubrication for the piston pin in one bore for the piston pin
Pistons that were produced earlier may have four slots for lubrication in the pin bore.
Protection for the Graphite Coating
Protect the graphite coating on the skirt and the oil ring grooves (bottom grooves) when you clean the skirt
with glass beads. There will be a small open joint approximately 0.5 mm (0.0197 inch) at the separation line
of the crown and the skirt. Permit the protective cover to slightly overlap the joint of the crown and skirt. The
cover prevents the opening from being clogged with glass beads.
Several methods can be used to protect the graphite coating on the bottom of the aluminum skirt.
z Tape
z Shim stock with band clamp
z Rubber tubing
Use an old liner or an old cylinder which is the same size as the piston to protect the graphite coating. Expose
only the top two ring grooves above the surface of the joint. Use a stop to hold the piston in the proper
position.
Cleaning The Aluminum Skirt
The aluminum surface of the skirt with graphite coating can be cleaned with water and a solution of liquid
detergent which contains little chlorine content. 174-6885 Cleaner is a good detergent to use. Refer to
Catalog, GECJ0001-01-2, "Cat Shop Supplies and Hand Tools ".
Submerge the piston in the solution for one to two hours in order to loosen carbon and oil deposits.
Remember that leaving the piston in the solution for too much time may cause damage to the graphite
coating. When the piston is clean, remove the piston from the solution. To clean the skirt faster, heat the
solution of water and detergent to 55 °C (131 °F). Flush the oil passages with a pressure washer.

NOTICE
Never use glass beads to clean the graphite-coated skirt and the bottom
two piston ring grooves. Clean the bottom two ring grooves in the
aluminum skirt with a small brush that has nylon bristles and the same
solution of soap and water.
Cleaning The Steel Crown
The steel crown can be cleaned with a chemical solution or glass beads. Clean the oil passages with 1U-5490
Cleaner and a high pressure washer in order to remove contaminants. Refer to Catalog, GECJ0001-01-2, "Cat
Shop Supplies and Hand Tools ".
Cleaning with glass beads requires protection of the graphite coating, the surface of the bore of the piston pin
and the slot for lubrication in the bore of the piston pin from damage. Tape all surfaces and oil passages in
order to prevent damage to the piston or prevent beads from entering the passages.
Two-Piece Pistons
The two-piece piston crowns may be cleaned with glass beads. However, several areas of the piston must be
protected from the glass beads. Refer to Illustration 19.
Areas which need protection from glass beads on two-piece pistons
(21) Sharp edge of crater
(22) Outer edge of piston crown
(31) Lower edge of crown
Use an O-ring to protect the oil ring groove.

After cleaning the piston with glass beads, use air pressure to remove debris that entered the oil passages of
the piston. Wash the piston again after cleaning with glass beads. Apply the rust preventive to the crown of
the two-piece piston.
Procedure for Measurement and Inspection of Pistons

Inspect Ring Grooves
The ring groove gauge can be used on all pistons to inspect the keystone ring grooves. This gauge is
recommended over former methods of checking ring groove wear because of the tool's increased accuracy.
This gauge works on both one and two-piece pistons. Refer to Table 1 for the correct gauge part number.
Gauge is aligned with the center of the piston and the gauge has no side play.
USE AGAIN

Gauge does not slide far enough in order to align with the center of the piston.
USE AGAIN
Gauge is aligned with the center of piston and the gauge has side play. Any amount of side play is not
acceptable.
DO NOT USE AGAIN
Inspect the Pin and the Bore for the Piston Pin
One-Piece Aluminum Pistons
Some one-piece pistons have circular pin bores. Other one-piece pistons have oval pin bores. This wear
pattern is formed by a side relief on both ends of the horizontal diameter. Refer to Illustration 23. The vertical

diameter must be within specifications in Table 1 but the horizontal diameter must only be larger than the
vertical diameter.
Pistons with a side relief should be measured at location 32 only.
(33) Dimension 33 will be larger than dimension 32 by 0.030 mm (0.0012 inch) to 0.045 mm (0.0018 inch).
Note: The pin bore diameter of newer one-piece pistons are elliptical. You must be sure that dimension (33)
is larger than dimension (32) .
Two-Piece Pistons and One-Piece Steel Pistons
Piston pin bore diameter (32) on all two-piece piston crowns is in Table 1. You must measure pin bore
diameter (34). Illustration 24 shows the location of the dimensions.
Measurement locations for the new piston crown pin bore diameter.

(34) Refer to Table 1 for this Dimension.
Inspect Bushings of Crown for Two-Piece Pistons and for One-Piece

Steel Pistons
Inspect the bushing of two-piece piston crowns for rotation. If the bushing has damage from debris or if there
is rotation of the bushing, the crown cannot be reused. See Illustration 25as an example for rotation of the
bushing.
The bushing of a two-piece piston crown has rotated.
DO NOT USE AGAIN
Enlarged view of Illustration 25 which shows rotation of bushing

DO NOT USE AGAIN
Inspect the Iron Band

Some one-piece pistons use an iron band for the top and intermediate ring grooves. The iron band is bonded
to the piston during the manufacturing process. High potential exists for damage to the bonding for the iron
band in applications that the engine encounters cold starts of 10 °C (50 °F) or colder. The result will be a
loose iron band. If the iron band is loose or free, the piston cannot be used again. It is very difficult to visually
identify a loose iron band.
Ultrasonic inspection is the only reliable method in order to determine if the iron band is correctly bonded to
the piston body. The manufacturer uses the ultrasonic method to verify the retention of the iron band. For
questions and additional information on the ultrasonic inspection of retention of the iron band, contact the
Dealer Service Support Group at (309) 675-5434.
Use an ultrasonic flaw detection unit to determine if the band has separated.

Display of Ultrasonic Flaw Detection Unit
The display of the ultrasonic flaw detection unit will show if the piston can be used again. Illustrations 29 and
30 show readings of bands. The readings can determine if the piston can be used again.
Correctly bonded bands should give a similar reading to the one above.
USE AGAIN
Bands that are incorrectly bonded will give a similar reading to the one above.
DO NOT USE AGAIN
Visual inspection of the bond of the iron band requires looking for a gap or space between the edge of the
iron band and the piston body.

NOTICE
When the iron band bond is only visually inspected, there is a very high
risk of reusing a piston with a loose iron band. This may result in a
major failure.
Checking Ring Gap

Recommendations state replacement of the piston rings whenever the piston is removed. However, the piston
rings may be reused only if the following stringent criteria are met:
z The engine must have operated with the original piston less than 8,000 hours.
z There must be no visual defects on the piston ring.
z Reuse the piston ring with the same liner or a new liner.
Storage Procedures
Proper protection of the piston from corrosion is very important. Corrosion will start in as little as one hour
after the piston has been cleaned.
When the piston will not be inspected for one hour or less the piston should be coated with a rust or corrosion
inhibitor or coated with clean engine oil. The piston should be individually wrapped in order to prevent
contamination, and the piston should be stored in a protected area in order to avoid damage.
Example of protection for a component that is stored for shorter term
When the piston will not be inspected in two days or more the piston should be coated with a rust or corrosion
inhibitor or coated with clean engine oil and the piston should be individually wrapped. The wrapped piston
should be placed in a container which is clean and structurally solid. The container should be covered or
wrapped in plastic in order to prevent damage and contamination to the piston.

Example of protection for a component that is stored for a longer term
Specifications of Pistons
Table 1
Specifications of Pistons
Part Number of
Top Ring Groove
Piston
Engine Pin Bore Width Tapered Pin for Tapered Ring
Model Two-Piece Diameter of Ring Groove
One Straight /
Straight Groove
Piece Tapered Measurement
Crown Skirt Groove Gauge Size
150- 238-
- 4621 2726 40.031 ± T - -
104.709 ±
0.007 2.540
0.040 mm
mm mm
165- 238- (4.1224 ±
(1.5760 ± (0.1000
- 4265 2726 T - - 0.0016 inch)
0.0003 inch)
inch)
40.012 ±
109.810
0.003 3.162
238- ± .100 mm
- - mm T - - mm
2698 (4.3232 ±
(1.5753 ± (0.1245
0.0039 inch)
0.0001 inch)
inch)
40.038 ±
108.664 ±
0.010 3.000
C7 238- 0.080 mm
- - mm T - - mm
ACERT 2720 (1.5763 ± (0.1181
(4.2781 ±
0.0031 inch)
0.0004 inch)
inch)
46.015 ±
0.003
262- 110.189 ±
- - mm T - - 3.200
7330 0.075 mm
(1.8116 ± mm
0.0001 (4.3381 ±
(0.1260
inch) 0.0030 inch)
inch)
262-
- - T - -
9288
40.012 ±
0.003
mm 2.900
278- (1.5753 ± 107.830 ±
- - T - - mm 0.080 mm
0574 0.0001 (0.1142 (4.2453 ±
inch) inch) 0.0031 inch)

40.071 ±
108.664 ±
0.010 3.000
280- 0.080 mm
- - mm T - - mm
7281 (4.2781 ±
(1.5776 ± (0.1181
0.0031 inch)
0.0004 inch)
inch)
110.340 ±
197- 238- 2.540
0.100 mm
- 9297 2736 T - - mm
(4.3441 ±
(0.1000
46.020 ± 0.0039 inch)
inch)
0.005
C-9 mm
197- 238-
(1.8118 ±
- 9345 2709 T - - 113.059 ±
0.0002 3.300
inch) 0.100 mm
mm
238- 238- (4.4511 ±
(0.1299
- 2701 2709 T - - 0.0039 inch)
inch)
197- 158-
- 9303 0451 T - -
197- 238-
- 9345 2709 T - -
46.020 ±
113.059 ±
C9 238- 238- 0.005 3.300
0.100 mm
ACERT - 2701 2709 mm T - - mm
(4.4511 ±
(1.8118 ± (0.1299
0.0039 inch)
0.0002 inch)
265- 238- inch)
- 1401 2709 T - -
272- 238-
- 2312 2709 T - -
133- 238-
- 7098 2710 T -
50.815 ±
123.530 ±
197- 238- 0.005 3.500
4C- 0.097 mm
C-10 - 9358 2710 mm T - mm
8165 (4.8634 ±
(2.0006 ± (0.1378
0.0038 inch)
0.0002 inch)
4P- 238- inch)
- 5852 2710 T -
197-
9381 - - 53.220 ± T - - 128.530 ±
C11 0.010 3.500 0.097 mm
ACERT mm mm (5.0602 ±

(2.0953 ± (0.1378 0.0038 inch)

265-
- - 0.0004 T - - inch)
1111
inch)
144- 238-
- 2948 2712 53.190 ± T -
128.530 ±
0.005 3.500
208- 0.097 mm
C-12 mm mm
7632 (5.0602 ±
197- 238- (2.0941 ± (0.1378
- 9328 2712 T - 0.0038 inch)
0.0002 inch)
inch)
53.190 ±
128.530 ±
C12 144- 238- 0.005 3.500
208- 0.097 mm
ACERT - 2948 2712 mm T - mm
7632 (5.0602 ±
(2.0941 ± (0.1378
0.0038 inch)
0.0002 inch)
inch)
53.220 ± 128.530 ±
265- 3.50
0.01 mm 208- 0.097 mm
C-13 1313 - - T - mm
(2.0953 ± 7632 (5.0602 ±
(0.1378
0.0004 0.0038 inch)
inch)
inch)
53.220 ±
128.530 ±
C13 265- 0.010 3.500
208- 0.097 mm
ACERT 1313 - - mm T - mm
7632 (5.0602 ±
(2.0953 ± (0.1378
0.0038 inch)
0.0004 inch)
inch)
53.190
144- 161- ± .005 128.53 ± .097
3.5 mm
- 2948 8416 mm T - - mm (5.0602 ±
(0.1378
(2.0941 ± 0.0038 inch)
inch)
0.0002
inch)
180- 132-
- 7351 6663 55.019 T -
± .045 134.82 ± .1
132- 3.3 mm
mm mm (5.3079 ±
180- 132- 4389 (0.1299
C-15 (2.1661 ± 0.0039 inch)
- 7352 6663 T - inch)
0.0018
inch)
55.020
192- 158- ± .005 137.436 ± .1
3.3 mm
- 8810 0446 mm T - - mm (5.4109 ±
(0.1299
(2.1661 ± 0.0039 inch)
inch)
0.0002
inch)
197- 132-

9317 6663
- T -
197- 132-
- 9329 6663 55.019 ± T -
134.820 ±
0.045 3.300
132- 0.100 mm
221- 132- mm mm
4389 (5.3079 ±
- 2305 6663 (2.1661 ± T - (0.1299
0.0039 inch)
0.0018 inch)
inch)
225- 132-
- 0115 6663 T -
229-
2861 - - T -
232-
- - T -
6557
60.093 ±
247- 134.820 ±
C15 - - 0.008 T - 3.300
132- 0.100 mm
ACERT 6123 mm mm
4389 (5.3079 ±
248- (2.3658 ± (0.1299
- - T - 0.0039 inch)
5514 0.0003 inch)
inch)
252-
- - T -
0656
284-
- - T -
8983
55.020 ±
137.436 ±
139- 238- 0.005 3.300
208- 0.100 mm
- 8500 2715 mm T - mm
7636 (5.4109 ±
(2.1661 ± (0.1299
0.0039 inch)
0.0002 inch)
inch)
53.190 ±
128.530 ±
144- 161- 0.005 3.500
0.097 mm
- 2948 8416 mm T - - mm
(5.0602 ±
(2.0941 ± (0.1378
0.0038 inch)
C-16 0.0002 inch)
inch)
55.020 ±
139.910 ±
192- 238- 0.005 2.900
0.100 mm
- 8810 2715 mm T - - mm
(5.5083 ±
(2.1661 ± (0.1142
0.0039 inch)
0.0002 inch)
inch)
55.019 ± 134.820 ±
221- 132- 0.045 132- 3.300 0.100 mm

2305 6663 mm 4389 mm (5.3079 ±

(2.1661 ± (0.1299 0.0039 inch)
- T -
0.0018 inch)
inch)
143.500 ±
219- 2.540
0.100 mm
8102 - - T - - mm
(5.6496 ±
60.093 ± (0.1000
0.0039 inch)
0.008 inch)
C-18 mm
(2.3658 ±
0.0003 142.250 ±
3.300
235- inch) 0.100 mm
- - T - - mm
8098 (5.6004 ±
(0.1299
0.0039 inch)
inch)
143.500 ±
219- 2.540
0.100 mm
8102 - - T - - mm
(5.6496 ±
(0.1000
0.0039 inch)
inch)
234-
- - 60.093 T - -
C18 5858
± .008
ACERT
235- mm
- - (2.3658 ± T - -
8098
0.0003 142.250 ±
3.300
239- inch) 0.100 mm
- - T - - mm
7844 (5.6004 ±
(0.1299
0.0039 inch)
247- inch)
- - T - -
7745
283-
- - T - -
3550
247-
7791 - - 60.093 T - - 134.820 ±
C27 ± .008 3.300
0.110 mm
ACERT mm mm
(5.3079 ±
(2.3658 ± (0.1299
247- 0.0043 inch)
- - 0.0003 T - - inch)
7792 inch)
60.093
143.500 ±
C30 235- ± .008 2.540
0.100 mm
ACERT 6257 - - mm T - - mm
(5.6496 ±
(2.3658 ± (0.1000
0.0039 inch)
0.0003 inch)
inch)
247-
7789 - - 60.093 T - -
C32 ± .008 3.300 142.250 ±
ACERT mm mm 0.100 mm

(2.3658 ± (0.1299 (5.6004 ±

247-
- - 0.0003 T - - inch) 0.0039 inch)
7790
inch)
234-
4814 - - 30.005 ± T - - 95.112 ±
0.005 2.550
3044C 0.210 mm
mm mm
(3.7445 ±
(1.1813 ± (0.1004
239- 0.0082 inch)
- - 0.0002 T - - inch)
8506 inch)
107-
0984 - - T - -
107-
- - T - -
8366
128-
- - 30.005 ± T - -
2952 95.112 ±
0.005 2.550
0.210 mm
3046 128- mm mm
- - T - - (3.7445 ±
3295 (1.1813 ± (0.1004
0.0082 inch)
0.0002 inch)
160- inch)
- - T - -
6600
200-
- - T - -
7904
234-
- - T - -
4815
178-
6546 - - T - -
34.007 ±
212- 102.336 ±
- - 0.005 T - - 3.000
3064 8484 0.241 mm
mm mm
3066 (4.0290 ±
233- (1.3389 ± (0.1181
- - T - - 0.0095 inch)
1162 0.0002 inch)
inch)
5I-
- - T - -
7537
9Y-
7452 - - T -
40.005 ±
0.005
7E- mm
- - T -
1298 (1.5750 ±
102.250 ±
0.0002 2.540
105- 4C- 0.076 mm
3114 - - inch) T - mm
1710 8164 (4.0256 ±
(0.1000
0.0030 inch)
inch)
100- 4P-
- 4300 1549 T -
40.031 ±
107- 107- 0.007

7553 7791 mm
- T -
(1.5760 ±
0.0003
7E- 4P- inch)
- 3226 1546 T -
105-
1710 - - T -
40.005 ±
102.250 ±
0.005 2.540
4C-8164 0.076 mm
3116 107- mm mm
- - T - (4.0256 ±
7563 (1.5750 ± (0.1000
0.0030 inch)
0.0002 inch)
115- inch)
- - T -
4124
4P-
1550 - - T -
6I-
- - T -
1144
7C-
- - T -
5668
7E-
- - T -
1298
100- 4P-
- 4300 1549 T -
105- 107-
-- 1720 7791 T -
40.031 ±
107- 107- 2.540 102.250 ±
0.007
- 7545 7791 T - 4C-8164 mm 0.076 mm
3116 mm
(0.1000 (4.0256 ±
(1.5760 ±
inch) 0.0030 inch)
0.0003
107- 107-
inch)
- 7553 7791 T -
107- 107-
- 7852 7791 T -
142- 107-
- 7307 7791 T -
6I- 107-
- 1512 7791 T -
6I- 107-
- 4248 7791 T -

7E- 4P-
- 3226 1546 T -
113- 187-
- 6119 1513 T -
126- 115-
- 0502 4083 T -
133- 187-
- 4983 1513 T -
133- 187-
- 5044 1513 40.031 ± T - 104.709 ±
0.007 2.540
186- 0.040 mm
3126 mm mm
144- 187- 0190 (4.1224 ±
(1.5760 ± (0.1000
- 3444 1513 T - 0.0016 inch)
0.0003 inch)
inch)
150- 187-
- 4621 1513 T -
164- 187-
- 6556 1513 T -
175- 187-
- 3671 1513 T -
150- 115-
- 4621 4083 T -
40.031 ±
104.709 ±
3126B 150- 187- 0.007 2.540
186- 0.040 mm
3126E - 4621 1513 mm T - mm
0190 (4.1224 ±
(1.5760 ± (0.1000
0.0016 inch)
0.0003 inch)
150- 238- inch)
- 4621 2726 T -
40.038 ±
104.709 ±
165- 187- 0.010 2.540
186- 0.040 mm
- 4265 1513 mm T - mm
0190 (4.1224 ±
(1.5763 ± (0.1000
0.0016 inch)
3126B 0.0004 inch)
3126E inch)
177- 109.660 ±
- - T - - 0.100 mm
7498
40.012 ± (4.3173 ±
0.003 3.162 0.0039 inch)

mm mm
(1.5753 ± (0.1245
0.0001 inch)
inch) 109.81 ± .1
238-
- - T - - mm (4.3232 ±
2729
0.0039 inch)
38.118 ± 3.277 ±
9I- 0.005 0.013
3160 7737 - - mm S mm - - -
(1.5007 ± (0.1290
0.0002 ± 0.0005
inch) inch)
4P- 7E-
- 5852 6876 T -
50.830 ±
123.530 ±
7C- 7C- 0.008 3.500
4C- 0.097 mm
3176 - 4197 4197 mm T - mm
8165 (4.8634 ±
(2.0012 ± (0.1378
0.0038 inch)
0.0003 inch)
7E- 7E- inch)
- 6875 6876 T -
50.830 ±
123.530 ±
4P- 101- 0.008 3.500
3176B 4C- 0.097 mm
- 5852 2042 mm T - mm
8165 (4.8634 ±
(2.0012 ± (0.1378
0.0038 inch)
0.0003 inch)
inch)
133- 101-
- 7098 2042 T -
50.830 ±
123.530 ±
133- 238- 0.008 3.500
3176C 4C- 0.097 mm
- 7098 2710 mm T - mm
8165 (4.8634 ±
(2.0012 ± (0.1378
0.0038 inch)
0.0003 inch)
4P- 238- inch)
- 5852 2710 T -
144- 161-
- 2948 8416 53.205 ± T -
128.530 ±
0.010 3.500
208- 0.097 mm
mm mm
197- 161- 7632 (5.0602 ±
(2.0947 ± (0.1378
- 9328 8416 T - 0.0038 inch)
0.0004 inch)
3196 inch)
4P- 101- 50.830 ± 4C-

- 5852 2042 0.008 T - 3.500 123.530 ±
8165
mm mm 0.097 mm
(2.0012 ± (0.1378 (4.8634 ±

0.0003 inch) 0.0038 inch)

inch)
2W-
4831 - - 38.118 ± S 3.276 ± - - -
0.005 0.013
3204 mm mm
(1.5007 ± (0.1290
7C- 0.0002 ± 0.0005 -
- - S - -
1146 inch) inch)
101-
0812 - - T -
38.128 ±
111.087 ±
0.005 2.540
4C-8166 0.076 mm
118- mm mm
- - T - (4.3735 ±
2285 (1.5011 ± (0.1000
0.0030 inch)
0.0002 inch)
125- inch)
- - T -
3208 8143
2W-
- - S - - -
4831 38.118 ± 3.276 ±
0.005 0.013
2W-
- - mm S mm - - -
8412
(1.5007 ± (0.1290
7C- 0.0002 ± 0.0005
- - inch) S inch) - - -
3558
7E-
4729 - - 38.128 ± T - 111.087 ±
0.005 2.540
4C-8166 0.076 mm
mm mm
(4.3735 ±
(1.5011 ± (0.1000
7E- 0.0030 inch)
- - 0.0002 T - inch)
9937 inch)
7W-
- - S - - -
3846
7W-
- - S - - -
8111
9L-
- - S - - -
3208 7737
9L-
- - 38.118 ± S 3.276 ± - - -
7827
0.005 0.013
9N- mm mm
- - (1.5007 ± S (0.1290 - - -
1356
0.0002 ± 0.0005
9N- inch) inch)
- - S - - -
1357
9N-
- - S - - -
5326
9N-
- - S - - -
5327

9N-
- - S - - -
5405
9N-
- - S - - -
5406
9N-
- - S - - -
5407
3.233 ±
164- 0.013
6560 - - S mm - - -
43.188 ± (0.1273
0.004 ± 0.0005
mm inch)
(1.7003 ±
0.0002 117.455 ±
inch) 2.540
165- 4C- 0.097 mm
- - T - mm
4262 8168 (4.6242 ±
(0.1000
0.0038 inch)
inch)
43.182 ±
0.005
2P-
- - mm S - - -
6270
(1.7001 ±
0.0002
inch) 3.233 ±
0.013
3304 8N- mm
- - 38.128 S - - -
3180 (0.1273
± .005
± 0.0005
mm
inch)
8N- (1.5011 ±
- - 0.0002 S - - -
3184
inch)
9N-
- - S - - -
5250
43.182 ±
0.005
mm 117.455 ±
2.540
9N- (1.7001 ± 4C- 0.097 mm
- - T - mm
5403 0.0002 8168 (4.6242 ±
(0.1000
inch) 0.0038 inch)
inch)
38.128 ± 3.233 ±
0.005 0.013
9S-
- - mm S mm - - -
4148
(1.5011 ± (0.1273
0.0002 ± 0.0005
inch) inch)
43.118 ± 3.233 ±
164- 0.004 0.013

6560 mm mm
3304B (1.6976 ± (0.1273
- - S - - -
0.0002 ± 0.0005
inch) inch)
165-
4262 - - 43.118 ± T - 117.455 ±
0.004 2.540
3304B 4C- 0.097 mm
mm mm
8168 (4.6242 ±
(1.6976 ± (0.1000
168- 0.0038 inch)
- - 0.0002 T - inch)
4531 inch)
4P-
2654 - - S 3.230 ± - - -
0.010
mm
(0.1272
4P- 38.128 ± ± 0.0004 -
- - S - -
2655 0.005 inch)
3304
mm
GAS
(1.5011 ±
0.0002 3.233 ±
inch) 0.013
8L-
- - S mm - - -
5277
(0.1273
± 0.0005
inch)
165-
4262 - - 43.118 ± T - 117.455 ±
0.004 2.540
4C- 0.097 mm
mm mm
8168 (4.6242 ±
(1.6976 ± (0.1000
168- 0.0038 inch)
- - 0.0002 T - inch)
4531 inch)
2P-
- - 43.195 ± S 3.233 ± - - -
6270
0.008 0.013
mm mm
7S- (1.7006 ± (0.1273
- - 0.0003 S ± 0.0005 - - -
6791
inch) inch)
3306
8N-
- - 38.128 ± S - - -
3180
0.005 3.233 ±
mm 0.013
8N- (1.5011 ± mm
- - 0.0002 S - - -
3184 (0.1273
inch) ± 0.0005
9N- inch)
- - S - - -
5250
43.195 ±
0.008
9N- mm 4C- 117.455 ±
- - T -
5403 (1.7006 ± 8168 2.540 0.097 mm
0.0003 mm (4.6242 ±

inch) (0.1000 0.0038 inch)

inch)
38.128 ± 3.233 ±
0.005 0.013
9S-
mm S mm - - -
4148
(1.5011 ± (0.1273
0.0002 ± 0.0005
inch) inch)
165-
4262 - - 43.118 ± T -
0.004
mm
(1.6976 ±
168- 0.0002
- - T - 117.455 ±
4531 inch) 2.540
3306B 4C-8168 0.097 mm
mm
(4.6242 ±
(0.1000
0.0038 inch)
43.195 ± inch)
0.008
9N-
- - mm T -
5403
(1.7006 ±
0.0003
inch)
107-
3565 - - 43.188 ± T - 117.455 ±
0.004 2.540
3306C 4C-8168 0.097 mm
mm mm
(4.6242 ±
(1.7003 ± (0.1000
154- 0.0038 inch)
- - 0.0002 T - inch)
8087 inch)
3.230 ±
4P- 0.010
2655 - - S mm - - -
(0.1272
38.128 ± ± 0.0004
0.005 inch)
3306
mm
GAS
(1.5011 ±
0.0002 3.233
inch) ± .013
8L-
- - S mm - - -
5277
(0.1273
± 0.0005
inch)
50.815 ± 3.864 ±
112- 0.005 0.010
3406 4585 - - mm S mm - - -
(2.0006 ± (0.1521
0.0002 ± 0.0004
inch) inch)

3.864 ±
0.010
4P-
mm
8996 - - S - - -
(0.1521
± 0.0004
inch)
133.932 ±
2.540
6N- 0.097 mm
- - T - - mm
4080 (5.2729 ±
(0.1000
0.0038 inch)
inch)
50.815 ± 3.864 ±
0.005 0.01
7E-
3406 - - mm S mm - - -
3888
(2.0006 ± (0.1521
0.0002 ± 0.0004
inch) inch)
7N-
- - T - - 133.932 ±
3633 2.540
0.097 mm
mm
(5.2729 ±
8N- (0.1000
- - T - - 0.0038 inch)
1601 inch)
134.341 ±
3.302
9Y- 4C-8169 0.097 mm
- - T - mm
4004 (5.2890 ±
(0.1300
0.0038 inch)
inch)
50.814 ±
100- 0.004 3.302
4C-8169
7403 - - mm T - mm
(2.0005 ± (0.1300
0.0002 inch) 134.341 ±
inch) 0.097 mm
(5.2890 ±
55.021 ± 0.0038 inch)
0.004
101-
- - mm T - -
0016
(2.1662 ±
0.0002
inch) 3.300
mm
(0.1299
55.047 ± inch)
125- 130- 0.008 134.820 ±
132-
- 8869 0241 mm T - 0.100 mm
4389
(2.1672 ± (5.3079 ±
0.0003 0.0039 inch)
inch)

50.814 ±
0.004
160-
- - mm T - 3.302
1131 4C-8169
(2.0005 ± mm 134.341 ±
0.0002 (0.1300 0.097 mm
inch) inch) (5.2890 ±
0.0038 inch)
1W-
- - T -
9372
2W- 50.815 ±
- - T - -
0865 0.008
mm 3.300
(2.0006 ± mm
0.0003 134.639 ±
7C- (0.1299 0.097 mm
- - inch) T - -
0473 inch) (5.3007 ±
0.0038 inch)
3406B 7E-
- - 55.021 ± T -
0292
0.004 3.300
mm mm
7E- (2.1662 ± (0.1299
- - 0.0002 T - inch)
0539
inch)
50.814 ±
134.341 ±
0.004
7E- 4C-8169 0.097 mm
- - mm T -
8885 (5.2890 ±
(2.0005 ±
0.0038 inch)
0.0002
inch) 3.302
mm
9Y- (0.1300
- - 50.815 ± T - inch)
4004
0.008
mm
9Y- (2.0006 ±
- - 0.0003 T -
9889
inch)
50.814 ±
100- 0.004 3.302
4C-8169
7403 - - mm T - mm
(2.0005 ± (0.1300
0.0002 inch) 134.341 ±
3406C inch) 0.097 mm
(5.2890 ±
55.021 ± 0.0038 inch)
0.004 3.300
101-
- - mm T - - mm
0016
(2.1662 ± (0.1299
0.0002 inch)
inch)

50.814 ±
134.341 ±
116- 0.004 3.302
4C-8169 0.097 mm
8154 - - mm T - mm
(5.2890 ±
(2.0005 ± (0.1300
0.0038 inch)
0.0002 inch)
inch)
55.021 ±
134.341 ±
0.004 3.300
117- 0.097 mm
mm T - - mm
5063 (5.2890 ±
(2.1662 ± (0.1299
0.0038 inch)
0.0002 inch)
inch)
125- 130-
- 8869 0241 55.047 ± T -
134.820 ±
0.008 3.300
132- 0.100 mm
mm mm
138- 130- 4389 (5.3079 ±
(2.1672 ± (0.1299
- 1791 0241 T - 0.0039 inch)
0.0003 inch)
inch)
50.814 ±
0.004
160-
- - mm T -
1131 3.302
(2.0005 ± 4C-8169
3406C 0.0002 mm
inch) (0.1300
inch)
1W-
- - 50.815 ± T -
9372
0.008
mm
7C- (2.0006 ±
- - 0.0003 T - -
0473
inch)
3.300 134.341 ±
55.021 ± mm 0.097 mm
0.004 (0.1299 (5.2890 ±
7E-
- - mm T - inch) 0.0038 inch)
0292
(2.1662 ±
0.0002
inch)
7E-
- - T -
0305 50.814 ±
0.004 3.302
7E-
- - mm T - mm
0539
(2.0005 ± (0.1300
7E- 0.0002 inch)
- - inch) T -
8885
50.815 ±
9Y- 0.008 2.540

4004 mm mm
(2.0006 ± (0.1000
- - T -
0.0003 inch)
inch)
50.814 ±
0.004
9Y-
- - mm T -
9156
(2.0005 ±
4C-8169
0.0002
inch) 3.302
mm
(0.1300
50.815 ± inch)
0.008
9Y-
- - mm T -
9889
(2.0006 ±
0.0003
inch)
55.021 ±
134.341 ±
108- 0.004
4C-8169 0.097 mm
2716 - - mm T -
(5.2890 ±
(2.1662 ±
0.0038 inch)
0.0002
inch)
55.047 ±
134.820 ±
136- 130- 0.008
132- 0.100 mm
- 1560 0241 mm T -
4389 (5.3079 ±
(2.1672 ±
0.0039 inch)
0.0003
inch)
55.051 ±
3.300 137.436 ±
139- 158- 0.006
3406E mm 0.100 mm
- 8500 0446 mm T - -
(0.1299 (5.4109 ±
(2.1673 ±
inch) 0.0039 inch)
0.0002
inch)
55.077 ±
145- 130- 0.008
- 6700 0241 mm T -
(2.1684 ±
0.0003
134.820 ±
inch) 132- 0.100 mm
149- 130- 4389 (5.3079 ±
- 5566 0241 55.047 ± T - 0.0039 inch)
0.008
mm
180- 132- (2.1672 ±
- 7352 6663 0.0003 T -
inch)

55.047 ±
134.820 ±
7C- 128- 0.008 3.300
3406E 132- 0.100 mm
- 2888 2830 mm T - mm
4389 (5.3079 ±
(2.1672 ± (0.1299
0.0039 inch)
0.0003 inch)
inch)
50.815 ± 3.864 ±
107- 0.005 0.010
3406
1704 - - mm S mm - - -
GAS
(2.0006 ± (0.1521
0.0002 ± 0.0004
inch) inch)
7N-
3511 - - T - -
133.932 ±
2.540
0.097 mm
7N- mm
- - T - - (5.2729 ±
3633 50.815 ± (0.1000
0.0038 inch)
0.005 inch)
8N-
3408 - - mm T - -
1607
(2.0006 ±
0.0002
inch) 134.341 ±
3.302
9Y- 4C-8169 0.097 mm
- - T - mm
7212 (5.2890 ±
(0.1300
0.0038 inch)
inch)
50.814 ±
134.341 ±
174- 0.004 3.302
4C-8169 0.097 mm
6102 - - mm T - mm
(5.2890 ±
(2.0005 ± (0.1300
0.0038 inch)
0.0002 inch)
inch)
50.815 ± 3.860 ±
0.005 0.010
4P-
- - mm S mm - - -
8996
(2.0006 ± (0.1520
3408B 0.0002 ± 0.0004
inch) inch)
2.527 ±
0.013
7E-
- - S mm - - -
8335
(0.0995
± 0.0005
inch)
7N-
- - 50.815 ± T - -
3511
0.005 133.932 ±
7N- mm 2.540 0.097 mm

3633 - - (2.0006 ± T - - mm (5.2729 ±

0.0002 (0.1000 0.0038 inch)
8N- inch) inch)
- - T - -
1607
134.341 ±
3.302
9Y- 4C-8169 0.097 mm
- - T - mm
7212 (5.2890 ±
(0.1300
0.0038 inch)
inch)
174-
6102 - - 50.814 ± T - 134.341 ±
0.004 3.302
4C-8169 0.097 mm
mm mm
(5.2890 ±
(2.0005 ± (0.1300
174- 0.0038 inch)
- - 0.0002 T - inch)
6103 inch)
7N-
- - T - - 133.932 ±
3408C 3633 2.540
0.097 mm
mm
(5.2729 ±
8N- 50.815 ± (0.1000
- - T - - 0.0038 inch)
1607 0.005 inch)
mm
(2.0006 ±
0.0002 134.341 ±
3.302
9Y- inch) 4C-8169 0.097 mm
- - T - mm
7212 (5.2890 ±
(0.1300
0.0038 inch)
inch)
50.814 ±
134.341 ±
174- 0.004 3.302
4C-8169 0.097 mm
6102 - - mm T - mm
(5.2890 ±
(2.0005 ± (0.1300
0.0038 inch)
0.0002 inch)
3408E inch)
50.858 ±
134.820 ±
0.008 3.300
192- 132- 0.100 mm
- - mm T - mm
2208 4389 (5.3079 ±
(2.0023 ± (0.1299
0.0039 inch)
0.0003 inch)
inch)
50.815 ± 3.864 ±
107- 0.005 0.010
3408
1704 - - mm S mm - - -
GAS
(2.0006 ± (0.1521
0.0002 ± 0.0004
inch) inch)
3.864 ±

0.010
160- mm
7992 - - S (0.1521 - - -
± 0.0004
50.815 ± inch)
0.005
3408
mm
GAS 2.525 ±
(2.0006 ±
0.0002 0.010
4P-
- - inch) S mm - - -
7187
(0.0994
± 0.0004
inch)
50.815 ± 3.864 ±
107- 0.005 0.010
1704 - - mm S mm - - -
(2.0006 ± (0.1521
0.0002 ± 0.0004
inch) inch)
50.848 ±
134.820 ±
123- 163- 0.009 3.300
123- 0.100 mm
- 4612 0930 mm T - mm
4389 (5.3079 ±
(2.0019 ± (0.1299
0.0039 inch)
0.0003 inch)
inch)
50.815 ± 3.864 ±
0.005 0.010
160-
- - mm S mm - - -
7992
(2.0006 ± (0.1521
0.0002 ± 0.0004
inch) inch)
3412
50.814 ±
134.341 ±
0.004 3.302
174- 4C-8619 0.097 mm
- - mm T - mm
6102 (5.2890 ±
(2.0005 ± (0.1300
0.0038 inch)
0.0002 inch)
inch)
2.525 ±
0.010
4P-
- - S mm - - -
7187
(0.0994
± 0.0004
inch)
4P-
- - S 3.864 ± - - -
8995
0.010
mm
4P- (0.1521 -
- - S - -
8996 ± 0.0004

inch)
7E-
- - S 2.527 ± - - -
3888
0.013
mm
7E- (0.0995
- - S ± 0.0005 - - -
8335
inch)
7N-
- - T - -
3633
8N-
- - T - -
1607
133.932 ±
2.540
0.097 mm
50.815 ± mm
2.527 ± (5.2729 ±
0.005 (0.1000
0.013 0.0038 inch)
8Q- mm inch)
- - S mm -
9342 (2.0006 ± (0.0995
0.0002 ± 0.0005
inch) inch)
134.341 ±
3.302
9Y- 4C-8169 0.097 mm
- - T - mm
7212 (5.2890 ±
(0.1300
0.0038 inch)
inch)
2.527 ±
0.013
9Y-
- - S mm - - -
8496
(0.0995
± 0.0005
inch)
50.848 ±
123- 163- 0.009
- 4612 0930 mm T -
(2.0019 ±
0.0003 134.820 ±
inch) 3.300
132- 0.100 mm
mm
4389 (5.3079 ±
(0.1299
50.853 ± 0.0039 inch)
inch)
3412C 155- 163- 0.008
- 4336 0930 mm T -
(2.0021 ±
0.0003
inch)
174-
- - T -
6102 50.814 ± 4C-8169 134.341 ±
0.004 3.302 0.097 mm
mm mm (5.2890 ±
174- (2.0005 ± (0.1300 0.0038 inch)

6103 0.0002 inch)

- - T -
inch)
7N-
3633 - - T - - 133.932 ±
2.540
0.097 mm
mm
(5.2729 ±
50.815 ± (0.1000
8N- 0.0038 inch)
- - 0.005 T - - inch)
3412C 1607
mm
(2.0006 ±
0.0002 134.341 ±
3.302
9Y- inch) 4C-8169 0.097 mm
- - T - mm
7212 (5.2890 ±
(0.1300
0.0038 inch)
inch)
60.093 ±
142.250 ±
236- 0.008 3.300
3412D 0.100 mm
1848 - - mm T - - mm
(5.6004 ±
(2.3658 ± (0.1299
0.0039 inch)
0.0003 inch)
inch)
113- 116-
- 5999 0930 50.848 ± T -
134.820 ±
0.009 3.300
132- 0.100 mm
mm mm
155- 163- 4389 (5.3079 ±
(2.0019 ± (0.1299
0.0039 inch)
- 4336 0930 0.0003 T - inch)
inch)
50.814 ±
134.341 ±
0.004 3.302
172- 4C-8169 0.097 mm
- - mm T - mm
3280 (5.2890 ±
(2.0005 ± (0.1300
0.0038 inch)
0.0002 inch)
3412E inch)
192-
- - 50.858 ± T -
2208
0.008
mm
192- (2.0023 ±
- - 0.0003 T -
2209 134.820 ±
inch) 3.300
132- 0.100 mm
mm
4389 (5.3079 ±
(0.1299
0.0039 inch)
50.848 ± inch)
197- 160- 0.009
- 9314 0930 mm T -
(2.0019 ±
0.0003
inch)
69.983 ±
223- 0.005 3.500 168.350 ±

6362 mm mm 0.111 mm
(2.7552 ± (0.1378 (6.6279 ±
3500 - - T - -
0.0002 inch) 0.0044 inch)
inch)
69.962 ±
168.350 ±
223- 0.005 3.500
3500B 0.111 mm
6363 - - mm T - - mm
(6.6279 ±
(2.7544 ± (0.1378
0.0044 inch)
0.0002 inch)
inch)
70.003 ± 3.630 ±
101- 0.005 0.010
4140 - - mm S mm - - -
(2.7560 ± (0.1429
0.0002 ± 0.0004
inch) inch)
133- 125-
- 8383 2728 70.035 ± T -
168.630 ±
0.035 3.500
9U-7359 0.097 mm
mm mm
180- 0R- (6.6390 ±
(2.7573 ± (0.1378
- 7493 8718 T - 0.0038 inch)
0.0014 inch)
inch)
70.003 ± 3.630 ±
0.005 0.010
197-
- - mm S mm - - -
3765
(2.7560 ± (0.1429
0.0002 ± 0.0004
inch) inch)
3508
69.962 ±
168.350 ±
0.005 3.500
233- 0.111 mm
- - mm T - - mm
2430 (6.6279 ±
(2.7544 ± (0.1378
0.0044 inch)
0.0002 inch)
inch)
70.035 ±
168.630 ±
6I- 6I- 0.005 3.500
9U- 0.097 mm
- 3019 3018 mm T - mm
73559 (6.6390 ±
(2.7573 ± (0.1378
0.0038 inch)
0.0002 inch)
inch)
70.003 ± 3.630 ±
0.005 0.010
6I-
- - mm S mm - - -
4609
(2.7560 ± (0.1429
0.0002 ± 0.0004
inch) inch)

168.630 ±
7C- 70.380 ± 3.500
9U-7359 0.097 mm
2431 - - 0.100 T - mm
(6.6390 ±
mm (0.1378
0.0038 inch)
(2.7709 ± inch)
0.0039
7C- inch)
- - S - - -
3895
3.630 ±
70.003 ± 0.010
0.005 mm
7E- (0.1429 -
- - mm S - -
7600 ± 0.0004
(2.7560 ±
0.0002 inch)
3508 inch)
70.380 ±
0.100
9Y-
- - mm T -
4124
(2.7709 ±
0.0039 168.630 ±
inch) 3.500
9U-7359 0.097 mm
mm
(6.6390 ±
(0.1378
70.035 ± 0.0038 inch)
inch)
9Y- 4P- 0.005
- 7027 1658 mm T -
(2.7573 ±
0.0002
inch)
144- 125-
- 0720 2782 70.035 ± T -
168.630 ±
0.005
9U-7359 0.097 mm
mm
(6.6390 ±
180- 0R- (2.7573 ±
- 7494 8718 T - 0.0038 inch)
0.0002
inch) 3.500
3508B
mm
(0.1378
69.962 ± inch) 168.350 ±
0.005
233- 0.111 mm
- - mm T - -
2431 (6.6279 ±
(2.7544 ±
0.0044 inch)
0.0002
inch)
70.035 ±
168.630 ±
133- 125- 0.035 3.500
9U-7359 0.097 mm
- 8383 2782 mm T - mm
(6.6390 ±
(2.7573 ± (0.1378
0.0038 inch)
0.0014 inch)
inch)
69.962 ±

0.098
mm
233-
- - (2.7544 ± T - - - -
2430
0.0039
inch)
3508C
281-
- - 70.071 ± T - - - -
6140
0.008
mm
282- (2.7587 ±
- - 0.0003 T - - - -
0644
inch)
70.035 ±
133- 125- 0.035
- 8383 2728 mm T - 168.630 ±
(2.7573 ± 9U-7359 0.097 mm
0.0014 (6.6390 ±
inch) 0.0038 inch)
180- 0R-
- 7493 8718 T -
3.500
69.962 ± mm 168.350 ±
0.005 (0.1378 0.111 mm
233-
- - mm T - - inch)
2430 (6.6279 ±
(2.7544 ±
0.0044 inch)
0.0002
inch)
70.380 ±
168.630 ±
0.100
3512 7C- 9U-7359 0.097 mm
- - mm T -
2431 (6.6390 ±
(2.7709 ±
0.0038 inch)
0.0039
inch)
7C-
- - 70.003 ± S 3.630 ± - - -
3895
0.005 0.010
mm mm
7E- (2.7560 ± (0.1429
- - 0.0002 S ± 0.0004 - - -
7600
inch) inch)
69.983 ±
0.005
8N-
- - mm T -
1421 3.500
(2.7552 ± 9U-7359
0.0002 mm
inch) (0.1378
inch) 168.630 ±
0.097 mm
(6.6390 ±
70.380 ± 0.0038 inch)

0.100
mm
9Y-
- - (2.7709 ± T -
4124
0.0039
inch)
70.035 ±
168.630 ±
9Y- 4P- 0.005 3.500
9U-7359 0.097 mm
3512 - 7027 1658 mm T - mm
(6.6390 ±
(2.7573 ± (0.1378
0.0038 inch)
0.0002 inch)
inch)
70.035 ±
168.630 ±
144- 125- 0.005 3.500
9U-7359 0.097 mm
- 0720 2782 mm T - mm
(6.6390 ±
(2.7573 ± (0.1378
0.0038 inch)
0.0002 inch)
inch)
70.053 ±
169.494 ±
172- 155- 0.008 4.100
3512B 0.111 mm
- 0919 5271 mm T - - mm
(6.6730 ±
(2.7580 ± (0.1614
0.0044 inch)
0.0003 inch)
inch)
69.962 ±
168.350 ±
0.005 3.500
233- 0.111 mm
- - mm T - - mm
2431 (6.6279 ±
(2.7544 ± (0.1378
0.0044 inch)
0.0002 inch)
inch)
70.053 ±
2821- 0.008
3512C
6140 - - mm T - - - -
(2.7580 ±
0.0003
inch)
101-
4140 - - S - - -
129-
- - 70.003 ± S 3.630 ± - - -
4269
0.005 0.013
3512 197-
- - mm S mm - - -
GAS 3765 (2.7560 ± (0.1429
0.0002 ± 0.0005
6I- inch) inch)
- - S - - -
4609
7C-
- - S - - -
3895

7E-
- - S - - -
7600
133- 125-
- 8383 2728 70.035 ± T -
168.630 ±
0.035 3.500
9U-7359 0.097 mm
mm mm
180- 0R- (6.6390 ±
(2.7573 ± (0.1378
0.0038 inch)
- 7493 8718 0.0014 T - inch)
inch)
70.003 ± 3.630 ±
0.005 0.010
197-
- - mm S mm - - -
3765
(2.7560 ± (0.1429
0.0002 ± 0.0004
inch) inch)
69.962 ±
168.350 ±
0.005 3.500
233- 0.111 mm
- - mm T - - mm
2430 (6.6279 ±
(2.7544 ± (0.1378
0.0044 inch)
0.0002 inch)
inch)
3516
70.003 ± 3.630 ±
0.005 0.010
6I-
- - mm S mm - - -
4609
(2.7560 ± (0.1429
0.0002 ± 0.0004
inch) inch)
70.380 ±
168.630 ±
0.100 3.500
7C- 9U-7359 0.097 mm
- - mm T - mm
2431 (6.6390 ±
(2.7709 ± (0.1378
0.0038 inch)
0.0039 inch)
inch)
7C-
- - S - - -
3895 70.003 ± 3.630 ±
0.005 0.010
7E-
- - mm S mm - - -
7600
(2.7560 ± (0.1429
7E- 0.0002 ± 0.0004
- - inch) S inch) - - -
7940
70.035 ±
8Q- 6I- 0.005
- 1403 2683 mm T - 9U-7359
3516 (2.7573 ±
0.0002
inch) 168.630 ±
3.500 0.097 mm
mm (6.6390 ±

70.380 ± (0.1378 0.0038 inch)

0.100 inch)
9Y- mm
- - T -
4124 (2.7709 ±
0.0039
inch)
70.035 ±
168.630 ±
144- 125- 0.005 3.500
9U-7359 0.097 mm
- 0720 2782 mm T - mm
(6.6390 ±
(2.7573 ± (0.1378
0.0038 inch)
0.0002 inch)
inch)
70.053 ±
169.494 ±
172- 155- 0.008 4.100
204- 0.111 mm
- 0919 5271 mm T - mm
8041 (6.6730 ±
(2.7580 ± (0.1614
0.0044 inch)
0.0003 inch)
inch)
70.035 ±
168.630 ±
180- 0R- 0.005 3.500
9U-7359 0.097 mm
- 7494 8718 mm T - mm
(6.6390 ±
(2.7573 ± (0.1378
0.0038 inch)
0.0002 inch)
3516B inch)
70.053 ±
169.494 ±
230- 230- 0.008 4.100
204- 0.111 mm
- 9043 8095 mm T - mm
8041 (6.6730 ±
(2.7580 ± (0.1614
0.0044 inch)
0.0003 inch)
inch)
69.962 ±
168.350 ±
0.005 3.500
233- 0.111 mm
- - mm T - - mm
2431 (6.6279 ±
(2.7544 ± (0.1378
0.0044 inch)
0.0002 inch)
inch)
70.053 ±
169.494 ±
10R- 10R- 0.008 4.100
204- 0.111 mm
- 1468 1421 mm T - mm
8041 (6.6730 ±
(2.7580 ± (0.1614
0.0044 inch)
0.0003 inch)
inch)
2821- 70.053 ±
3516C
6140 - - 0.008 T - - - -
mm
(2.7580 ±

0.0003
inch)
172- 155-
- 0919 5271 70.053 ± T -
169.494 ±
0.008 4.100
3524B 204- 0.111 mm
mm mm
10R- 10R- 8041 (6.6730 ±
(2.7580 ± (0.1614
0.0044 inch)
- 1468 1421 0.0003 T - inch)
inch)
120.200 ± 5.160 ±
128- 128- 0.050 0.010
3606 - 5641 5634 mm S mm - - -
(4.7323 ± (0.2031
0.0020 ± 0.0004
inch) inch)
101-
4140 - - 70.003 ± S 3.630 ± - - -
0.005 0.010
mm mm
(2.7560 ± (0.1429
133- 0.0002 ± 0.0004 -
- - S - -
9375 inch) inch)
70.035 ±
168.630 ±
144- 125- 0.005 3.500
9U-7359 0.097 mm
- 0720 2782 mm T - mm
(6.6390 ±
(2.7573 ± (0.1378
0.0038 inch)
0.0002 inch)
inch)
3608
120.200 ± 5.160 ±
172- 172- 0.050 0.010
- 7974 6773 mm S mm - - -
(4.7323 ± (0.2031
0.0020 ± 0.0004
inch) inch)
197-
- - 70.003 ± S 3.630 ± - - -
3765
0.005 0.010
mm mm
212- (2.7560 ± (0.1429
- - 0.0002 S ± 0.0004 - - -
7596
inch) inch)
6I-
4609 - - 70.003 ± S 3.630 ± - - -
0.005 0.010
3608 mm mm
(2.7560 ± (0.1429
7E- 0.0002 ± 0.0004 -
- - S - -
7940 inch) inch)
128- 128-

5641 5634 120.20 ± 5.160 ±

- S - - -
0.050 0.010
mm mm
3612 172- 172- (4.7323 ± (0.2031
- 7974 6773 0.0020 S ± 0.0004 - - -
inch) inch)
120.200 ± 5.160 ±
128- 128- 0.050 0.010
3616 - 5641 5634 mm S mm - - -
(4.7323 ± (0.2031
0.0020 ± 0.0004
inch) inch)
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All Rights Reserved.
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Media Search - SEBF8059 - Procedures and Specifications for Pistons{1214} Page 1 of 53

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Reuse And Salvage Guidelines

Procedures and Specifications for Pistons{1214}

When replacement parts are required for this product Caterpillar

Failure to heed this warning can lead to premature failures, product

mhtml:file://C:\Users\Mathura\Documents\cat reusability guide\Media Search - SEBF80... 2/2/2012

ReferenceContamination Control Guideline, PEBJ0002, "CaterpillarDealer Contamination Control

ReferenceReuse and Salvage Guidelines, SEBF8049, "Piston Visual Inspection"

ReferenceSpecial Instruction, SEHS8696, "Piston Cleaning Procedure"

ReferenceService Magazine, SEPD0360

mhtml:file://C:\Users\Mathura\Documents\cat reusability guide\Media Search - SEBF80... 2/2/2012

(3) Ring band

(4) Ring grooves

(5) Ring lands

(7) Bore surface of piston pin

(8) Snap ring groove

(9) Top land

(10) Relief for cooling jet

(11) Side relief for piston

(7) Bore surface of piston pin

(13) Graphite coating

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(14) Passage for oil cooling of crown

(15) Vertical oil passage

Steel Crown and Aluminum Skirt

(13) Graphite coating

(14) Passage for oil cooling of crown

(16) Passage for supply of cooling jet

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(17) Slot for lubrication of piston pin

(18) Joint of crown and skirt

(19) Passage for center oil return

(20) Passage for lubrication of bottom oil ring

Forged Steel Pistons

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(4) Ring grooves

(5) Ring lands

(7) Piston pin bore

(11) Side relief for piston

Follow these guidelines in order to clean pistons with glass beads.

mhtml:file://C:\Users\Mathura\Documents\cat reusability guide\Media Search - SEBF80... 2/2/2012

1. Do not use aluminum oxide or an abrasive material in place of glass beads.

2. Do not use a wire brush or a wire wheel.

3. Do not use steel shot.

Use an O-ring to protect the oil ring groove.

(7) Piston pin bore

(21) Sharp edge of crater

(22) Outer edge of piston crown

(23) Oil ring groove

(24) Oil passages

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Piston Skirt with Graphite Coating

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mhtml:file://C:\Users\Mathura\Documents\cat reusability guide\Media Search - SEBF80... 2/2/2012

(7) Bore surface of piston pin

(13) Graphite coating

(17) Slot for lubrication of piston pin

(7) Bore surface of piston pin

(13) Graphite coating

mhtml:file://C:\Users\Mathura\Documents\cat reusability guide\Media Search - SEBF80... 2/2/2012

(25) O-ring for protection of oil ring land

(26) Cylinder liner

(27) Base plate