Inspection and Reuse Guideline of Cylinder Liners in Cat Engines

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Inspection and Reuse Guideline of Cylinder Liners in Cat Engines {0761, 1201, 1213, 1216, 1216} (SEBF8068-37)
SMCS - 0761, 1201, 1213, 1216 i09943779

Caterpillar Products
All 3300 Engines
All 3400 Engines

All 3500 Engines
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All 3600 Engines
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All C10 Engines
All C11 Engines
All C12 Engines
All C13 Engines 4

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All C15 Engines
All C16 Engines

All C175 Engines
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All C18 Engines
All C27 Engines

All C280 Engines
All C32 Engines 0
Cat 4 C 2 8
All C9 Engines
All C9.3 Engines e r
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All G3300 Engines
All G3400 Engines

All G3500 Engines
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All G3600 Engines
Engine D-Series
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D-Series
Revision History:
Table 1
Revision Summary of Changes in SEBF8068

Added 2 part numbers to Table 5.
37
Added 1 part number to Table 6.
Changed part number 1P-9788 to 1U-9788 in Table 3
Added part number 586-3377.
36
Updated Table 2.
Added new serial numbers for NPI.
35 Added notice of no reuse for 516-9693.
Corrected specifications for 10 part numbers and added 523-8663 to Table 5.
34 Corrected specifications for 5 part numbers and added 469-5315 to Table 6.
Added new serial number prefixes.
Removed duplicated part number in Table 6.
33
Added new serial number prefixes.
Revision 24 of this document was the result of the combination of SEBF8164, SEBF8247, SEBF8817, SEBF9122, and SEBF9194.
Introduction
© 2023 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes
therein without permission may be violation of intellectual property law.
Information contained in this document is considered Caterpillar: Confidential Yellow.
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This Reuse and Salvage Guideline contains the necessary information 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 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 technical questions when using this document, work with your Dealer Technical Communicator (TC).
Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning additional repair options or modifications to reuse and salvage
techniques and/or methods.
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS web)
interface.
Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service Information System
website 2.0 (SIS web 2.0) for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced
parts.
Important Safety Information
Illustration 1 g02139237
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An
accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this
instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot
anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the
product are not all inclusive. Ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or the repair
procedures that are used. Ensure that the product will not be damaged or made unsafe by any operation, lubrication, maintenance, or the repair
procedures used.
Improper operation, lubrication, maintenance or repair of this

product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair

on this product, until you have read and understood the
operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could
occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. Refer to
Illustration 2 for an example of a “WARNING” Safety Alert Symbol.
This safety alert symbol means:
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Pay Attention!
Become Alert!
Your safety is Involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and
the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are
safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the
operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication.
The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the
service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current
information.
Summary
NOTICE
Due to a change in honing techniques, Caterpillar can
no longer recommend rehoning as a salvage procedure.
Improvements in emissions strategy have included a proprietary

honing technique known as plateau honing. Plateau honing
requires specialized tooling and multiple stage honing process
to complete. In a salvage situation, the material removal needed
to reestablish the hone pattern on a worn liner will make the
liner bore oversized and the wall too thin for reuse.
Caterpillar does allow for liners to be cleaned,

inspected, measured, and reused if they meet all the
criteria in this guideline.
Replacing cylinder liners is not always necessary during an engine rebuild. The installation of used cylinder liners can result in a large decrease in the cost
of the rebuild. This guideline incorporates information on cleaning and inspecting cylinder liners. Use the criteria in this guideline and other applicable
guidelines to determine the reusability of a liner.
Follow the cleaning and inspection information in this guideline completely. This information can be used to determine reusability. Never reuse a cylinder
liner this guideline recommends should not be used again. If a cylinder liner has damage not shown in this guideline, then do not use the cylinder liner
again. Liners that meet these guidelines are expected to give normal performance until the next overhaul.
Information in this guideline is based on the liner removed from the engine. With the liner out of the engine, a thorough inspection of all liner and cylinder
block surfaces can be performed. Also, the liner seals must be replaced as a measure for preventive maintenance.
If the liners have cuff rings the rings should be replaced at overhaul. Cuff rings that are still tight in the bore may be reused if the cylinder is being
inspected prior to overhaul.
References
Note: Refer to the appropriate Remove and Install (R&I), Disassembly and Assembly (D&A), and Operation and Maintenance Manual (OMM) for the part
or machine of focus before initiating this inspection or procedure.
Table 2
References
Media Number Title

"Why Reuse and Salvage Parts"
Channel1
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
Cat Inspect https://catinspectweb.cat.com/
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Special Instruction
GMG00981
, "Using 1P-3537 Dial Bore Gauge Group to Check Cylinder Bore Size"
Tool Operating Manual
NEHS0632
, "Procedures For Using the 250-6597 Cylinder Wash Tank Group"
Special Publication
PERJ1017
"Dealer Service Tools Catalog"
Reuse and Salvage Guidelines
SEBF8148
, "General Salvage and Reconditioning Techniques"
Special Instruction
SMHS8253
, "Use of 6V-7898 Dial Bore Gauge"
Special Instruction
SMHS8254
, "Using the 6V-7899 Size Setting Fixture Group"
Tooling and Equipment

Note: The Tooling and Equipment in Table 3 is not an all inclusive list of Tooling required to perform every task within this document. Tooling needs may
vary for the scope of work to be performed for each specific rebuild.
Table 3
Required Tooling and Equipment
Part Number Description

1P-3537 Dial Bore Gauge
Nylon Bristle Brush
1P-7429
114.3 mm (4 ½ inch)
Nylon Bristle Brush
1U-9788
127.0 mm (5.0 inch)
1U-8869 Dial Indicator
2S-5658 M16 Washer
3P-1568 Dial Indicator
4C-4707 Dial Gauge
4C-4426 Drill Extension
Nylon Bristles
4C-5552
57.2 mm (2 ¼ inch)
Nylon Bristle Brush
4C-6343
101.6 mm (4 inch)
Nylon Bristle Brush
4C-6344
139.7 mm (5 ½ inch)
Nylon Bristle Brush
4C-6345
152.4 mm (6 inch)
Nylon Bristle Brush
4C-6346
165.1 mm (6 ½ inch)
Nylon Bristle Brush
4C-6347
177.8 mm (7 inch)
Nylon Bristle Brush
4C-6348
190.5 mm (7 ½ inch)
Nylon Bristle Brush
4C-6349
203.2 mm (8 inch)
Nylon Bristle Brush
4C-6350
241.3 mm (9 ½ inch)
4C-9442 Flashlight
5P-4156 Indicator Base
5P-4160 Indicator Contact Point
5P-6518 Dial indicator Fixture
6V-2012 Micrometer Depth Gauge
6V-2032 Adapter
6V-7059 Micrometer
6V-7898 Dial Bore Gauge
6V-7899 Size Fixture
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6V-7926 Dial Indicator

6V-7926 Dial Indicator
7K-1977 Washer
7X-2558 M16 x 2 Bolt
8S-2251 Sac Hole Drill
8S-2257 Eye Loupe
8S-3158 Indicator Gauge
8T-0447 Dial Caliper
8T-5096 Dial Indicator Group
8T-7765 Scotch Brite Pad
9U-6182 Inspection Mirror
9U-7237 Brush Extension
120-9143
Cylinder Wash Tank
250-6597
Nylon Bristle Brush
135-7628
304.8 mm (12.0 inch)
151-0968
Cordless Drill
532-8958
222-3061 Air Drill
Microscope, Pocket
262-8390
40x
263-7184 Crack Detection Kit
288-4209
Paper Towel
605-2193
362-4253 Depth Micrometer Kit
367-9109 Digital Caliper
384-2804 Indicator Gauge Group
386-3364 Straight Edge Ruler
415-4055 Ultrasonic Tool Group
420-5317
Suitable Cribbing
524-0008
Digital Caliper
423-4373 0.0 - 203.2 mm
(0.00 - 8.00 inch)
Micrometer, External
431-4150
25 mm (1 inch)
441-0714 Spring Tester
459-0184 UV Lamp Group
Micrometer, Outside
473-8690
0.00 - 4.00 inch
Micrometer, Outside
473-8691
2.00 - 6.00 inch
Micrometer, Outside
473-8691 50.8 - 152.4 mml
(2.00 - 6.00 inch)
Micrometer, Outside
473-8692
152.4 - 304.8 mm (6.00 - 12.00 inch)
486-1526 Degreaser
FT-1711 Light Table
Preparation Recommendations
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Personal injury can result when using cleaner solvents.
To help prevent personal injury, follow the instructions and

warnings on the cleaner solvent container before using.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure.

When using pressure air, wear a protective face shield and
protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa
(30 psi) for cleaning purposes.
Note: Clean exterior of the engine prior to disassembly to minimize cross-contamination.
Before you inspect a part, clean the part thoroughly to ensure that all components are free from rust, oil, burrs, and debris prior to inspection. A
surface irregularity can hide the indication of an unacceptable defect.
Use a proper lifting device to provide safety to the operator. Also, use a proper lifting device to prevent damage to the part when you lift the part.
During cleaning, do not damage machined surfaces.
Do not use pressurized air to dry internal components. Compressed air has moisture and contaminants that can cause premature failure of internal
components.
Put hydraulic oil on all machined surfaces to prevent rust or corrosion if inspection is not done immediately after cleaning. Carefully store the parts in a
clean container.
Inspect all flange mating surfaces for fretting. Ensure that flange mating surfaces are true and free from raised material resulting from rust, nicks, and
dents.
Use appropriate thread taps to chase all threaded holes.
Refer to SEBF8148 Reuse and Salvage Guidelines , "General Salvage and Reconditioning Techniques" for available Crack Detection Methods.
Nomenclature
Top Mounted Liners
(1) Fire dam
(2) Inside surface
(3) Outside surface
(4) O-ring seal grooves
(5) Filler band groove
(6) Flange
Mid Mounted Liners

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(1) Liner Sleeve
(2) Inside surface
(3) Outside Surface
(4) O-ring seal grooves
Procedure to Clean Liners

Prior to inspecting the cylinder liners, the liners must be cleaned thoroughly inside and out. Cleaning the liner requires a strong cleaning solvent or
detergent, a nylon brush, and rust preventative.
Note: The following information applies to cylinder liners that are being prepared for inspection. Never store liners in a dirty condition as corrosion or
rusting of machined surfaces may occur. Always store liners upright, storing the liners on their side will cause liners to deform into an out of round state.
If Using Cat Nylon Bristle Brushes
(A) Nylon Brush
(B) 4C-4426 Drill Extension
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Nylon brush used to clean liners
If Cat nylon bristle brushes are used to clean a bores, a 305 mm (12.0 inch) 4C-4426 Drill (Extension) (B) is required to attach the brushes to the
extension. Select the appropriately sized brush, based on the bore size.
1. To use the 4C-4426 Drill (Extension) (B), cut the twisted wire handle off nylon bristle brush (A) to the length needed to perform the task.
2. Slide the twisted wire handle into extension .
3. Use the two set screws to hold the brush in place.
Cleaning Interior Surfaces
Personal injury can result when using cleaner solvents.
To help prevent personal injury, follow the instructions and

warnings on the cleaner solvent container before using.
1. Remove all O-ring seals that may still be on the liner. Clean all the surfaces that held the seals with a nonmetallic material for reconditioning surfaces,
such as a soft abrasive pad or nylon brush that does not contain iron oxide. All deposits of material such as scale or rust must be removed from the
areas of the seals. There are two acceptable methods of cleaning a cylinder liner. The use of either a hydraulic cylinder wash tank with rotating
nozzles and brush or a solution of water and cleaner with a nylon cylinder brush.
a. Use a hydraulic wash tank.

One method of cleaning is to use the 250-6597 Cylinder Wash Tank to clean inside the cylinder liners. This wash tank group is typically used for
the internal cleaning of hydraulic cylinders. The washer uses a rotating head that has both fluid nozzles directing the cleaning solution at the bore
and brushes to scrub the inner surface. The machine also has a system for filtering that cleans the solution before recirculating the solution back
through the nozzles.
Follow the instructions that are contained in the Tool Operating Manual. Refer to Tool Operating Manual, NEHS0632 , "Procedures For Using the
250-6597 Cylinder Wash Tank Gp".
b. Use detergent and nylon brush.

Another procedure is to use a strong detergent solution, water, and a nylon brush with a hand drill. Refer to Illustration 6 for an example of a
cylinder liner cleaning brush. Typically a brush size 25.40 mm (1.00 inch) larger than the inside diameter of the liner bore, will provide the best
cleaning results.
Refer to Tables 5 and 6 to find the appropriate sized brush needed.
Mix a fresh solution of water and a liquid cleaner such as Hydrosolv 4165. Place the liner in a large container of cleaning solution. Support the
cylinder liner so that the cylinder liner is open at the bottom. Clamp the large nylon brush into the hand drill to scrub inside the liner for 1 to 2
minutes. Run the brush up and down through the liner in an aggressive manner to clean the inner surface. Do not allow the brush to contact the
bottom of the container.
Note: A liquid detergent without chlorine content, that is mixed in hot water is a good cleaning solution. 486-1526 5 gal Cleaner HYDROSOLV
4165 will produce the same cleaning action as liquid soap. For liners with a heavy coating of lacquer, add butyl cellusole to the soap solution.
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c. For protection of the surface that will last for two to three weeks against rust, do not rinse the part after using Hydrosolv 4165. If Hydrosolv 4165
is not used, then rinse the liner. Rinse the cylinder liner with clean, hot water, and treat the cylinder liner with rust preventive or a thin film of
engine oil. Do not allow the liner to air dry slowly after rinsing. Use pressurized air to dry the liner immediately.
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Use a white cloth to see if the liner is clean. A gray color is an indication that dirt or debris is still present.
2. Check the cylinder liner for cleanliness by wiping the bore with a clean white cloth or a paper towel that is free of lint. If there are any signs of dirt or
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residue, clean the liner again.
Note: Failure to remove all debris from a liner bore will result in decreased life of the piston ring and lack of adequate control of oil.
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3. Freshly cleaned surfaces will begin to rust if the surfaces are not protected. Put a thin layer of engine oil or other rust preventive over the clean, dry
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liner immediately. Without protection, a clean liner can show rust in minutes. Prior to storage, protect the cylinder liner from other contaminants such
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as dust or dirt after treating the cylinder liner with rust preventive. Remove the rust preventive only if further inspection is necessary or the liner is
being installed into an engine.
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Cleaning Exterior Surfaces
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Remove any rust or foreign deposits from the outside surface of the liner. To clean the outside surface of the liner, use glass beads and a bead cabinet or
a brass or nylon brush. Do not damage the inside of the liner, the top of the flange, or the bottom of the flange when cleaning the outside.
NOTICE
Preferred use of glass or soda blast should only be done on the
outside of the liner. It is not allowed to use Abrasive media like
Sand, Silica in blasting cabinets. Do not blast the inside of
the liner including the cuff counterbore
Visual Inspection
To perform an accurate inspection, the cylinder liner must be cleaned thoroughly prior to inspecting.
Outside Surface
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Rust and deposits must be removed before the visual inspection.
Clean the liner again.
O-Ring Groove Area
There is a small chip in the area between the grooves.
Reuse the liner if the chip is not extended across the complete area and any burrs or sharp edges are removed with a file.
If the liner has pits between the seal grooves and the filler band groove and the pits are deeper than 2.3 mm (0.09 inch), do not reuse the liner.
Reuse the liner.
The exception would be if the outside of the liner has pits or erosion that goes into either of the lower two seal grooves.
(1) Light erosion
(2) Pits
Cracking
Refer to , SEBF8148 Reuse and Salvage Guidelines , "General Salvage and Reconditioning Techniques" for available Crack Detection Methods.
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Crack
Do not reuse the liner.
Cracking that occurs on the cylinder cuff
Pitting
Used liners will generally have some minor pitting caused by the coolant as it flows from the front to the rear of the engine.
Small pits are acceptable only if the pits are limited to one or two sides.
Small pits are acceptable only if the pits are limited to one or two sides.
Reuse the liner if there are pits on only one side.
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C175 Liner Pitting in Seal Grooves, minor pitting is allowed. Measure pitting depth as shown in the Pitting Measurement section in this document for
reference.
C175 Liner Pits shown on lower section of O-Ring groove
Small pits are also acceptable if the liner was removed with the pits toward the front or rear of the engine. If the liner is to be reused, then rotate the liner
90° so the non-pitted parts of the liner face the coolant flow.
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Deep pits
Do not reuse liners with deep pits.
Deep pits
Do not reuse liners with deep pits.
Pitting Measurement
To check the depth of a pit, grind an 8S-2251 Drill or a 1.01600 mm (0.04 inch) drill bit as shown in Illustration 20. If the bit goes into a pit to lip (3), the pit
is too deep.
Modified 8S-2251 Drill
(3) Lip
(4) Radius
(A) Depth of section to grind
Table 4
Dimensions of the Modified Drill
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A 4
2.30 mm (0.091 inch) 0.51 mm (0.020 inch)
Flange Area
Visible crack extending from inside liner into flange area
Pits and erosion in the filler band groove.
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Reuse the liner.
There are pits and fretting under the liner flange. Large pits or groups of pits are not acceptable. Circumferential fretting is the only acceptable fretting. The
fretting must not prevent the liner from sealing. Measure flange thickness.
Small pits
Reuse the liner.
Crack in the flange.
Do not reuse any liner that has circumferential cracks under the area of the liner flange. Do not reuse any liner with cracks in the flange fillet.
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Damage to the fire dam.
Reuse the liner.
The damage must not extend across the fire dam. Burrs or sharp edges must be removed.
Damage in the surface area of the gasket
Nick in the vertical flange
Reuse the liner.
Remove any sharp edges or high areas with a file.
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Chip in the seal edge of the flange.
Inside Surface Inspection

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Use the FT–1711 Light Table to check for scratches and pits on the inside surface of the liner bore. The fluorescent light will work better than the
incandescent light when you inspect the bore.
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If the pits or light spots of rust that occur on the inside of the cylinder liner are directly opposite to the pits on the outside surface, then the liner should not
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be used again. This type of pitting can go through the walls of the cylinder liner and into the bore.
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Light Table
Example of good clean cross hatch.
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Pits on the inside surface
Crack on the inside surface
Deep grooves on the inside surface
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Heavy rust on the inside surface
Do not reuse the liner .
Water spots on the inside surface.
Do not reuse the liner
Shiny areas on the inside surface, no visible cross hatch remains.
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Water rings and spots on the inside surface.
Deep double wear step on the inside surface
Cylinder Liner Specifications

Note: Cylinder liners with dimensions that are outside the ranges that are shown in Tables 5 and 6 should not be reused.
Liners that have passed all the "Visual Inspection" criteria must be measured to ensure they can be reused. Use precise gauges of known accuracy to
measure the cylinder liner bore to check if the cylinder liner is worn beyond the specification. Critical dimensions for cylinder liners are listed in Tables 5
and 6. If the liner has the specified dimensions and the crosshatched pattern is still visible throughout the liner bore, then the liner may be reused.
The following specifications are for cylinder liners at a temperature of 20 °C (68.0 °F). Dimensions of the bore will be slightly higher if measurements are
taken immediately after cleaning with hot water or if the liner is at a higher ambient temperature.
Bore diameters should be measured with a dial bore gauge that has been accurately calibrated with a master ring or a fixture for setting the gauge.
Record the part number of the cylinder liner and the sequence numbers for the inspection process. Keep a log of history or a permanent record by
sequence number of the cylinder liner for any measurements that are taken for future reference.
Critical Dimensions for Top Mounted Liners
Typical dimensions for top mounted liners. Some liners will not have all these features.
(A) Thickness of Liner Flange
(B) Height of Fire Dam
(C) Diameter of Liner Sleeve Bore
(D) Height of Liner Sleeve Bore
(E) Diameter of Liner Bore
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Example of a bore cooled liner.
(F) Width of the top Seal Ring Groove
NOTICE
Do not reuse 516-9693. Replace with 556-0701.
Table 5
Critical Dimensions for Top Supported Liners
Part
A B Diameter C D Diameter E F
Number
33.00 ± 0.03 mm 3.50 ± 0.03 mm 280.025 ± 0.025 mm
1W-7900 N/A N/A N/A
(1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.0246 ± 0.0010 inch)
33.00 ± 0.03 mm 3.50 ± 0.03 mm 280.025 ± 0.025 mm 7.00 ± 0.13 m
7C-4981 N/A N/A
(1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.0246 ± 0.0010 inch) (0.276 ± 0.005 in
33.00 ± 0.03 mm 3.50 ± 0.03 mm 300.025 ± 0.025 mm
7C-5044 N/A N/A N/A
(1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.8120 ± 0.0010 inch)
33.00 ± 0.03 mm 3.50 ± 0.03 mm 280.025 ± 0.025 mm
7E-8268 N/A N/A N/A
(1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.0246 ± 0.0010 inch)
33.00 ± 0.03 mm 3.50 ± 0.03 mm 280.025 ± 0.025 mm 7.00 ± 0.13 m
7E-8298 N/A N/A
(1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.0246 ± 0.0010 inch) (0.276 ± 0.005 in
10.282 ± 0.020 mm 1.02 ± 0.13 mm 120.675 ± 0.037 mm
110-5800 N/A N/A N/A
(0.4048 ± 0.0008 inch) (0.040 ± 0.005 inch) (4.7510 ± 0.0015 inch)
33.00 ± 0.03 mm 3.50 ± 0.03 mm 280.025 ± 0.025 mm 7.00 ± 0.13 m
111-1656 N/A N/A
(1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.0246 ± 0.0010 inch) (0.276 ± 0.005 in
12.65 ± 0.02 mm 1.06 ± 0.08 mm 170.025 ± 0.025 mm
123-8206 N/A N/A N/A
(0.498 ± 0.001 inch) (0.042 ± 0.003 inch) (6.6939 ± 0.0010 inch)
8.89 ± 0.02 mm 1.12 ± 0.05 mm 139.685 ± 0.025 mm
132-6881 N/A N/A N/A
(0.350 ± 0.001 inch) (0.044 ± 0.002 inch) (5.4994 ± 0.0010 inch)
33.00 ± 0.03 mm 3.50 ± 0.03 mm 290.025 ± 0.025 mm 57.50 ± 0.10 mm 280.025 ± 0.025 mm
179-3167 N/A
(1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.4183 ± 0.0010 inch) (2.264 ± 0.004 inch) (11.0246 ± 0.0010 inch)
33.00 ± 0.03 mm 3.50 ± 0.03 mm 290.025 ± 0.025 mm 57.50 ± 0.10 mm 280.025 ± 0.025 mm
179-3168 N/A
33.00 ± 0.03 mm 3.50 ± 0.03 mm 290.025 ± 0.025 mm 53.50 ± 0.10 mm 279.985 ± 0.025 mm
195-3507 N/A
8.89 ± 0.02 mm 1.12 ± 0.05 mm 139.685 ± 0.037 mm
197-9348 N/A N/A N/A
(0.350 ± 0.001 inch) (0.044 ± 0.002 inch) (5.4994 ± 0.0015 inch)
8.89 ± 0.02 mm 1.04 ± 0.13 mm 137.185 ± 0.025 mm
197-9322 N/A N/A N/A
(0.350 ± 0.001 inch) (0.041 ± 0.005 inch) (5.4010 ± 0.0010 inch)
12.65 ± 0.02 mm 1.06 ± 0.08 mm 170.025 ± 0.025 mm
211-7826 N/A N/A N/A
(0.498 ± 0.001 inch) (0.042 ± 0.003 inch) (6.6939 ± 0.0010 inch)
33.00 ± 0.03 mm 3.50 ± 0.03 mm 290.025 ± 0.025 mm 53.50 ± 0.10 mm 279.955 ± 0.025 mm
259-1046 N/A
1/30/24, 3:06 PM SIS 2.0
8.89 ± 0.02 mm 1.04 ± 0.13 mm 145.000 ± 0.025 mm

322-1126 N/A N/A N/A
(0.350 ± 0.001 inch) (0.041 ± 0.005 inch) (5.7087 ± 0.0010 inch)
33.00 ± 0.03 mm 3.50 ± 0.03 mm 300.025 ± 0.025 mm
343-4443 N/A N/A N/A
(1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.8120 ± 0.0010 inch)
33.00 ± 0.03 mm 3.50 ± 0.03 mm 290.025 ± 0.025 mm 57.50 ± 0.10 mm 280.025 ± 0.025 mm
343-4444 N/A
33.00 ± 0.03 mm 3.50 ± 0.03 mm 290.025 ± 0.025 mm 57.50 ± 0.10 mm 280.025 ± 0.025 mm
343-4445 N/A
12.65 ± 0.02 mm 1.06 ± 0.08 mm 174.077 ± 0.031 mm 19.55 ± 0.1 mm 170.025 ± 0.025 mm
350-0074 N/A
10.282 ± 0.020 mm 1.02 ± 0.13 mm 120.675 ± 0.037 mm
371-5941 N/A N/A N/A
(0.4048 ± 0.0008 inch) (0.040 ± 0.005 inch) (4.7510 ± 0.0015 inch)
12.65 ± 0.02 mm 1.06 ± 0.08 mm 174.077 ± 0.031 mm 19.55 ± 0.1 mm 170.025 ± 0.025 mm
374-3576 N/A
33.00 ± 0.03 mm 3.50 ± 0.03 mm 290.025 ± 0.025 mm 57.50 ± 0.10 mm 280.025 ± 0.025 mm
377-6887 N/A
33.00 ± 0.03 mm 3.50 ± 0.03 mm 280.025 ± 0.025 mm 7.00 ± 0.13 m
385-3468 N/A N/A
(1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.0246 ± 0.0010 inch) (0.276 ± 0.005 in
33.00 ± 0.03 mm 3.50 ± 0.03 mm 290.025 ± 0.025 mm 53.50 ± 0.10 mm 279.955 ± 0.025 mm
385-3469 N/A
33.00 ± 0.03 mm 3.50 ± 0.05 mm 290.025 ± 0.025 mm 53.50 ± 0.10 mm 279.985 ± 0.025 mm
385-3470 N/A
8.89 ± 0.02 mm 1.12 ± 0.05 mm 139.685 ± 0.037 mm
420-2631 N/A N/A N/A
(0.350 ± 0.001 inch) (0.044 ± 0.002 inch) (5.4994 ± 0.0015 inch)
12.65 ± 0.02 mm 1.18 ± 0.02 mm 174.077 ± 0.031 mm 7.09 ± 0.05 mm 170.025 ± 0.025 mm
447-3915 N/A
12.65 ± 0.02 mm 1.18 ± 0.02 mm 174.50 ± 0.02 mm 19.52 ± 0.10 mm 170.025 ± 0.025 mm
454-9920 N/A
8.89 ± 0.02 mm 1.12 ± 0.05 mm 139.685 ± 0.025 mm
473-9034 N/A N/A N/A
(0.350 ± 0.001 inch) (0.044 ± 0.002 inch) (5.4994 ± 0.0010 inch)
8089 ± 0.02 mm 1.04 ± 0.13 mm 145.00 ± 0.025 mm
504-6997 N/A N/A N/A
(318.4639 ± 0.0008 inch) (0.0409 ± 0.0051 inch) (5.7087 ± 0.001 inch)
516-9693
(1) N/A N/A N/A N/A N/A N/A
12.65 ± 0.02 mm 1.06 ± 0.08 mm 170.025 ± 0.025 mm

523-8663 N/A N/A N/A
(0.498 ± 0.001 inch) (0.042 ± 0.003 inch) (6.6939 ± 0.0010 inch)
8.89 ± 0.02 mm 1.04 ± 0.13 mm 145.000 ± 0.025 mm
556-0701 N/A N/A N/A
(0.350 ± 0.001 inch) (0.041 ± 0.005 inch) (5.7087 ± 0.0010 inch)
8.89 ± 0.020 mm 10.2 ± 0.25 mm 14.20 ± 0.25 mm 137.185 ± 0.025 mm
586-3377 N/A N/A
(0.350 ± 0.0008 inch) (0.4016 ± 0.0098 inch) (0.5591 ± 0.0098 inch) (5.40097 ± 0.00098 inch)
12.65 ± 0.02 mm 1.18 ± 0.02 mm 174.077 ± 0.031 mm 7.09 ± 0.05 mm 170.025 ± 0.025 mm
602-6440 N/A
(1) Do not reuse, replace with 556-0701.
Critical Dimensions for Mid Mounted Liners
1/30/24, 3:06 PM SIS 2.0
Typical dimensions for mid mounted liners. Some liners will not have all of these features.
(C) Diameter of Liner Sleeve Bore
(D) Height of Liner Sleeve Bore
Table 6
Critical Reuse Dimensions for Mid Supported Liners in order of bore size
Part Number A B Diameter C D Diameter E

100.120 ± 0.03 mm 1.10 ± 0.08 mm 125.037 ± 0.037 mm
6I-3550 N/A N/A
(3.9417 ± 0.001 inch) (0.043 ± 0.003 inch) (4.9227 ± 0.0015 inch)
100.120 ± 0.025 mm 1.13 ± 0.05 mm 125.037 ± 0.037 mm
148-2125 N/A N/A
(3.9417 ± 0.0010 inch) (0.045 ± 0.002 inch) (4.9227 ± 0.0015 inch)
100.120 ± 0.025 mm 1.13 ± 0.05 mm 130.037 ± 0.037 mm
148-2130 N/A N/A
(3.9417 ± 0.0010 inch) (0.045 ± 0.002 inch) (5.1196 ± 0.0015 inch)
130.000 ± 0.025 mm 1.13 ± 0.05 mm 112.025 ± 0.025 mm
190-3562 N/A N/A
(5.1181 ± 0.0010 inch) (0.045 ± 0.002 inch) (4.4104 ± 0.0010 inch)
100.120 ± 0.025 mm 1.13 ± 0.05 mm 130.025 ± 0.025 mm
197-9330 N/A N/A
(3.9417 ± 0.0010 inch) (0.045 ± 0.002 inch) (5.1191 ± 0.0010 inch)
130.000 ± 0.025 mm 1.13 ± 0.05 mm 115.025 ± 0.025 mm
267-6686 N/A N/A
(5.1181 ± 0.0010 inch) (0.045 ± 0.002 inch) (4.5285 ± 0.0010 inch)
114.70 ± 0.10 mm 185.50 ± 0.025 mm 23.85 ± 0.13 mm 175.025 ± 0.025 mm
313-7141 N/A
114.70 ± 0.10 mm 185.50 ± 0.025 mm 25.35 ± 0.13 mm 175.025 ± 0.025 mm
377-8485 N/A
130.000 ± 0.025 mm 1.13 ± 0.05 mm 112.025 ± 0.025 mm
385-7276 N/A N/A
(5.1181 ± 0.0010 inch) (0.045 ± 0.002 inch) (4.4104 ± 0.0010 inch)
114.70 ± 0.10 mm 185.50 ± 0.025 mm 23.85 ± 0.13 mm 175.025 ± 0.025 mm
471-4230 N/A
130.000 ± 0.025 mm 1.13 ± 0.05 mm 112.025 ± 0.025 mm
469-5312 N/A N/A
(5.1181 ± 0.0010 inch) (0.045 ± 0.002 inch) (4.4104 ± 0.0010 inch)
130.000 ± 0.025 mm 1.13 ± 0.05 mm 115.025 ± 0.025 mm
469-5313 N/A N/A
(5.1181 ± 0.0010 inch) (0.045 ± 0.002 inch) (4.5285 ± 0.0010 inch)
100.125 ± 0.025 mm 1.13 ± 0.05 mm 125.037 ± 0.037 mm
469-5314 N/A N/A
(3.9419 ± 0.0010 inch) (0.045 ± 0.002 inch) (4.9227 ± 0.0015 inch)
100.120 ± 0.025 mm 1.13 ± 0.05 mm 130.025 ± 0.025 mm
469-5315 N/A N/A
(3.9417 ± 0.0010 inch) (0.045 ± 0.002 inch) (5.1191 ± 0.0010 inch)
Table 7
Liner Sleeve Dimensions
Sleeve Liner Outside Diameter Inside Diameter Height
259-1046 289.975 ± 0.025 mm 279.025 ± 0.050 mm 53.3 mm
137-4017
385-3469 (11.4163 ± 0.0010 inch) (10.9852 ± 0.0020 inch) (2.10 inch)
313-7141 185.450 ± 0.025 mm 174.045 ± 0.050 mm 25.50 ± 0.10 mm
381-3969
377-8485 (7.3012 ± 0.0010 inch) (6.8522 ± 0.0020 inch) (1.004 ± 0.004 inch)
174.42 mm 169.52 ± 0.02 mm 19.35 ± 0.05 mm
516-1856 454-9920
(6.867 inch) (6.674 ± 0.001 inch) (0.762 ± 0.002 inch)
Measuring Flange Thickness

Flange Thickness for Top Supported Liners
Measure the thickness of the flange with a micrometer. Thickness of the flange must meet the dimensions in Table 5 for reuse.
1/30/24, 3:06 PM SIS 2.0
Flange Thickness for Mid-Supported Liners

Measure the thickness of the mid-support with an outside micrometer. The thickness of the mid-support must meet the dimensions in Table 6 for reuse.
(A) Mid-support thickness
Measuring Liner Bore

Before measuring the liner bore, the liner must first have passed a complete visual inspection. The measuring of the liner bore is to determine if the liner is
out of round. Maximum reuse specifications can be found within Tables 5 and 6.
Gauges For Measuring
Typical example of dial bore gauge set.
Bore diameters should be measured with a dial bore gauge that has been accurately calibrated with a master ring or a fixture for setting the gauge.
For instructions on how to use a dial bore gauge set, refer to Special Instruction, SMHS8253 , "Use of the 6V-7898 Dial Bore Gauge". Use the 1P-3537
Dial Bore Gauge.
Record the part number of the cylinder liner and the sequence numbers for the inspection process. Keep a log of history or a permanent record by
sequence number of the cylinder liner for any measurements that are taken for future reference.
1/30/24, 3:06 PM SIS 2.0
Measuring Procedure
Typical diameter measuring locations.
Measure the bore of the cylinder liner at three points on the horizontal plane that are 45° apart. Repeat this measuring procedure three separate times on
the vertical plane. The measurements should be taken at the top end of the stroke, the middle, and the lower end of the stroke. Refer to Illustration 48.
Measure the inside diameter of the liner with a dial bore gauge.
If all the measurements of the bore are acceptable according to Tables 5 and 6, then the liner can be used again.
1. Determine the wear of the diameter of the cylinder liner bore by taking three sets of measurements. Take these measurements 45° from each other in
three different locations in the cylinder liner. One set of measurements should be taken at the upper end of the cylinder liner at the point of the
maximum wear. The second set of measurements should be taken in the middle of the liner. The last set of measurements should be taken at the
lower end of the liner. Record this information for future reference.
2. It is important to maintain the dimensions that are listed in Tables 5 and 6.
Liner Storage
Storage of the cylinder liners requires some special attention to avoid destroying a reusable liner.
Always protect the liners in storage.
Never store liners in a dirty condition as this practice will accelerate rusting and corrosion of the machined surface.
Always use a rust preventative or a light film of clean engine oil to protect the clean liner.
Never store the liner on its side. Doing so will gradually deform the liners into an out of round shape.
PIP-10464666
2024/01/30
12:06:46+03:00
i03720107
© 2024 Caterpillar Inc.
1/30/24, 3:06 PM SIS 2.0
Caterpillar:
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Inspection and Reuse Guideline of Cylinder Liners in Cat Engines

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Inspection and Reuse Guideline of Cylinder Liners in Cat Engines

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1/30/24, 3:06 PM SIS 2.

SMCS - 0761, 1201, 1213, 1216 i09943779

All 3400 Engines

All C12 Engines

All C13 Engines 4

All C16 Engines

All C27 Engines

All G3400 Engines

Revision Summary of Changes in SEBF8068

Information contained in this document is considered Caterpillar: Confidential Yellow.

Canceled Part Numbers and Replaced Part Numbers

Important Safety Information

Improper operation, lubrication, maintenance or repair of this

Do not operate or perform any lubrication, maintenance or repair

This safety alert symbol means:

Your safety is Involved.

Improvements in emissions strategy have included a proprietary

Caterpillar does allow for liners to be cleaned,

Media Number Title

Tooling and Equipment

Required Tooling and Equipment

Part Number Description

6V-7926 Dial Indicator

To help prevent personal injury, follow the instructions and

Personal injury can result from air pressure.

Personal injury can result without following proper procedure.

Note: Clean exterior of the engine prior to disassembly to minimize cross-contamination.

During cleaning, do not damage machined surfaces.

Use appropriate thread taps to chase all threaded holes.

Mid Mounted Liners

Procedure to Clean Liners

If Using Cat Nylon Bristle Brushes

2. Slide the twisted wire handle into extension .

3. Use the two set screws to hold the brush in place.

Cleaning Interior Surfaces

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and

a. Use a hydraulic wash tank.

b. Use detergent and nylon brush.

Refer to Tables 5 and 6 to find the appropriate sized brush needed.

O-Ring Groove Area

Dimensions of the Modified Drill

Remove any sharp edges or high areas with a file.

Inside Surface Inspection

Cylinder Liner Specifications

Critical Dimensions for Top Mounted Liners

Critical Dimensions for Top Supported Liners

8.89 ± 0.02 mm 1.04 ± 0.13 mm 145.000 ± 0.025 mm

12.65 ± 0.02 mm 1.06 ± 0.08 mm 170.025 ± 0.025 mm

Critical Dimensions for Mid Mounted Liners

Part Number A B Diameter C D Diameter E

Measuring Flange Thickness

Flange Thickness for Mid-Supported Liners

Measuring Liner Bore

Gauges For Measuring

2. It is important to maintain the dimensions that are listed in Tables 5 and 6.

Always protect the liners in storage.

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