Guideline For Reusable Parts And Salvage Operations

Procedure and Specifications to Inspect and Measure Piston Pins

Media Number -SEBF8051-03 Publication Date -23/03/2004 Date Updated -24/03/2004

SEBF80510001

Procedure and Specifications to Inspect and Measure Piston

Pins
SMCS - 1214

ILLAR®

INE FOR
BLE PARTS
LVAGE OPERATIONS
and Specifications to Inspect
ure Piston Pins

Summary of Revisions

Page Description

9-10 Revised part number information.

Introduction

This guideline enables dealers and their customers to benefit from cost reductions made possible
through an established parts reusability and salvage program. Every effort has been made to provide
the most current and relevant information known to Caterpillar Inc. Since the Company makes
ongoing changes and improvements to its products, this guideline must be used with the latest
technical information available from Caterpillar to ensure such changes and improvements are
incorporated where applicable.

For questions or additional information concerning this guideline, contact Caterpillar Service
Support Division, Dealer Support (309) 494-1934.

Summary

This guideline provides procedures for visual inspection of piston pins.

The information given in this guideline can be used to determine if a piston pin can be used again.
If a piston pin meets these specifications and other applicable specifications, it can be expected to
give normal performance until the next overhaul, when used again in the same application.

Piston Pins

There are two types of piston pins. One is a straight pin (Illustration 1) and the other has barrel
shaped ends (Illustration 2).

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Illustration 1

Typical straight piston pin.

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Illustration 2

Typical barrel shaped piston pin. (Barrel shaped ends have been exaggerated for illustration
purposes. The actual barrel shape on the pin is almost unnoticeable.)

Generally, a piston pin can be used again if:

-it has no signs of scratches, grooves or nicks; see Illustrations 3 and 4.

-it has no indication of smearing (a shift in material caused by friction) or metal transfer (movement
of material, like aluminum, from a different part); see Illustrations 5 and 6.

-its surface finish is .125 micrometers (5 microinches) or smoother and there are no wear steps
larger than 0.005 mm (0.0002 inch); see Illustrations 7 and 8.

Note: Discoloration (change of color) on the piston pin has no effect on its performance.

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Illustration 3

Scratch or groove on the surface of the pin. Scratches or grooves are not acceptable.

Do not use again

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Illustration 4

A nick on one end of the pin. NO nicks are acceptable in any area of the pin.
Do not use again

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Illustration 5

Damage caused by smearing.

Do not use again

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Illustration 6

Indications of aluminum transfer.

Do not use again

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Illustration 7

Rough surface finish---more than 0.125 micrometers (5 microinches).

Do not use again

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Illustration 8

Typical wear steps.

Visual Inspection

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Illustration 9

Pin is smooth, no grooves or wear step can be felt.

Use again
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Illustration 10

Pin surface is smooth.

Use again

Note: The dark horizontal lines on the pin (shown by the arrows in Illustration 10) are photography
shadows. These lines will not be found on pins checked in the field. Most of the photos in this
Guideline have these black lines in various forms and should be ignored.

Discoloration

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Illustration 11

Pin is discolored due to hot engine oil.

Use again
View Image

Illustration 12

Pin is discolored due to hot engine oil.

Use again

if pin surface is smooth, and scratches cannot be felt.

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Illustration 13

Pin has been polished, but stains remain. There are no rust pits.

Use again

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Illustration 14

Pin with discoloration to the pin surface. Dark vertical lines are photography shadows.

Use again

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Illustration 15

Staining from engine oil.

Use again

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Illustration 16

Staining from engine oil.

if, after polishing, pin surface is smooth and scratches cannot be felt.

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Illustration 17

Discoloration. Dark vertical lines are photography shadows.

Use again

even if discoloration did not polish out, but pin is smooth and meets surface finish requirements.

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Illustration 18

Discoloration.

Use again

Handling Damage

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Illustration 19

Handling damage on ends.

Do not use again

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Illustration 20

Nicks in rod eye bearing area.

Do not use again

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Illustration 21

Small nick (A) in rod eye bearing area. (B) Stain on pin (this alone would be acceptable).

Do not use again

Rust Pitting

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Illustration 22

Polishing has removed the stains, but rust pits still remain.

Do not use again

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Illustration 23

Polishing has removed the stains, but rust pits still remain.

Do not use again

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Illustration 24

Rust pits present after polishing.

Do not use again

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Illustration 25

One large and several small rust pits in rod eye bushing wear area.

Do not use again

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Illustration 26

The damaged area looks like a stain. Using an 8S-2257 Loupe, light pitting is visible.

Do not use again

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Illustration 27

Rust pits in rod eye bushing wear area.

Do not use again

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Illustration 28

Rust pits still present after polishing.

Do not use again

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Illustration 29

Rust pits (A) present after polishing. If the rust pits are removed and discoloration (B) remains, the
pin can be used again.

Do not use again

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Illustration 30

Rust pits (A) are still present after polishing. Without closer examination, some stains (B) can
appear to be rust pits.

Do not use again

Wear Step

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Illustration 31

Wear step can be felt after polishing.

Do not use again

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Illustration 32

Wear step (A) can be felt. Pitting (B) would also make the pin unusable.

Do not use

Procedure To Clean

NOTE: Piston pins need not be cleaned at all if their surfaces are smooth and have an acceptable
surface finish. See Illustrations 33 and 34 and "Procedure To Check Surface Finish."

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Illustration 33

Use only the 8T-7748 Deburring Wheel to clean discoloration from piston pins to keep the correct
surface finish.

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Illustration 34

Pin with discoloration; the dark areas around the circumference of the ring are acceptable if the pin
surface is still smooth.

Use again

A good solvent can normally remove dirt or oil deposits, but not discoloration. While discoloration
is acceptable, it can be removed with the 8T-7748 Deburring Wheel if desired. See Illustrations 34
and 35.

Use only the 8T-7748 Deburring Wheel installed with two 6V-2032 Adapters to clean the pin. See
Illustration 33. Used correctly, the 8T-7748 Deburring Wheel will not remove metal and will keep a
0.125 micrometer (5 microinch) or smoother surface finish on the pins.

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Illustration 35

Typical pin after it has been cleaned. (It is not necessary to remove all discoloration or visual dark
areas.)

Used correctly, the 8T-7748 Deburring Wheel will not remove metal and will keep a 0.125
micrometer (5 microinch) or smoother surface finish on the pins.

NOTICE

Do not use the 6V-2033 Polishing Brush, which

looks like the 8T-7748 Deburring Wheel.

The 8T-7748 Deburring Wheel is 203.2 mm OD x 76.2 mm ID x 25.4 mm wide (8 inch OD x 3 inch
ID x 1 inch wide). Each 6V-2032 Adapter has a 12.7 mm (0.50 inch) pilot hole that can be made
larger, if necessary. Two wheels can be installed together for more width. Use a piece of 76 mm
(3.0 inch) tubing to hold the wheels together. Check the information on the wheel for the correct
maximum revolutions per minute (RPM) for operation; then check the RPM of the grinder. It is
important to turn the pin slowly against the wheel. Do not hold the pin in the same position for more
than five seconds. The finish must be even in smoothness around the pin.

Procedure To Check Surface Finish

Pins must have a surface finish of 0.125 micrometers (5 microinches) or smoother. See Guideline
For Reusable Parts, SEBF8034, "Valves And Valve Springs Specifications", for a list of suppliers of
surface finish analyzers. (If the pin feels smooth, like a new pin, measurement is not necessary.)

Procedure To Measure Wear Step

Piston pins can be checked for wear steps by hand, as shown in Illustration 36. But if a wear step is
felt, (Illustration 37) it must be inspected more carefully. Normally, if a wear step can be felt at all,
the step is more than 0.005 mm (0.0002 inch).

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Illustration 36

No wear step can be felt and the surface finish is 0.125 micrometers (5 microinches) or smoother.

Use again

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Illustration 37

The wear steps on this pin can be seen and felt.

Do not use again

To be acceptable, a wear step must be no larger than 0.005 mm (0.0002 inch). Measurement is
possible with a V-block, a
3P-1568 Indicator, a 6V-6167 Contact Point and parts from an 8S-2328 Dial Indicator Group. See
Illustration 38.

Note: The back of the 3P-1568 Indicator must be replaced with a vertical center lug back. See
Illustration 39. Order the vertical center lug back from the manufacturer of the indicator. (The
name of the manufacturer is normally shown on the indicator face.) See the end of this guideline for
lists of manufacturers of V-blocks and dial indicator lug backs.

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Illustration 38

The wear step must be no larger than 0.005 mm (0.0002 inch).

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Illustration 39

3P-1568 Indicator with a vertical lug back and a 6V-6167 Contact Point.

Pin Plugs

Piston plugs can be reused if there are no signs of cracking, pitting, or scratches. This applies to all
surfaces. Carefully check the fillet area of the pin for cracking (Illustration 40).

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Illustration 40

Check for pitting, scratches or cracking. Carefully check the fillet area (indicated by arrow) for
cracking.

Any wear on the plug must be evenly distributed around the top of the plug (refer to Illustration 41).
Normal wear will appear as a polished surface and no material will be removed. If the top of the
plug shows signs of material wear, do not use the plug again.

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Illustration 41

Top of plug shows area of normal wear. This area should have a polished appearance.

NOTICE
 If the plug or pin/plug assembly is dropped, do
not use it again. Dropping can cause impact
loading, which can cause a crack in the plug, not
visible during inspection. These cracks can then
cause the parts to fail, resulting in engine
damage.

Retaining Rings

NOTICE

Piston Pin Retaining Rings are one time use

items. Anytime a retaining ring is removed
from a piston it should be scrapped and replaced
with a new ring.

Chart A - Piston Pin Specifications1

Engine Piston Pins Minimum Reuse
New Pin Diameter Tolerance Wear Step
Model Part Number Diameter
C7
197-9371 39.973 (1.5737) 39.988 (1.5743) .005 (.000197) .005 (.000197)
C7 ACERT
197-9371 39.973 (1.5737) 39.988 (1.5743) .005 (.000197) .005 (.000197)
C9
166-3648 45.985 (1.8104) 46.000 (1.8110) .005 (.000197) .005 (.000197)
C9 ACERT
166-3648 45.985 (1.8104) 46.000 (1.8110) .005 (.000197) .005 (.000197)
C10
168-7276 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)
C11 ACERT
197-9327 53.140 (2.0921) 53.155 (2.0927) .005 (.000197) .005 (.000197)
C12
168-7296 53.155 (2.0927) 53.17 (2.0933) .005 (.000197) .005 (.000197)

168-7276 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

C12 ACERT
168-7296 53.155 (2.0927) 53.17 (2.0933) .005 (.000197) .005 (.000197)
C13 ACERT
197-9327 53.140 (2.0921) 53.155 (2.0927) .005 (.000197) .005 (.000197)
C15
168-7246 54.985 (2.1648) 55.000 (2.1654) .005 (.000197) .005 (.000197)

180-7350 59.960 (2.3606) 59.975 (2.3612) .005 (.000197) .005 (.000197)

C15 ACERT
180-7350 59.960 (2.3606) 59.975 (2.3612) .005 (.000197) .005 (.000197)
 Chart A - Piston Pin Specifications1
Engine Piston Pins Minimum Reuse
New Pin Diameter Tolerance Wear Step
Model Part Number Diameter
C16
168-7246 54.985 (2.1648) 55.000 (2.1654) .005 (.000197) .005 (.000197)
C18
180-7350 59.960 (2.3606) 59.975 (2.3612) .005 (.000197) .005 (.000197)
C18 ACERT
180-7350 59.960 (2.3606) 59.975 (2.3612) .005 (.000197) .005 (.000197)
C30 ACERT
197-9291 59.930 (2.3594) 59.945 (2.3600) .005 (.000197) .005 (.000197)
3114
7C-3901 39.985 (1.5742) 40.000 (1.5748) .005 (.000197) .005 (.000197)

7C-0115 39.985 (1.5742) 40.000 (1.5748) .005 (.000197) .005 (.000197)

3116
7C-3901 39.985 (1.5742) 40.000 (1.5748) .005 (.000197) .005 (.000197)

7C-0115 39.985 (1.5742) 40.000 (1.5748) .005 (.000197) .005 (.000197)

3126
101-3210 39.985 (1.5742) 40.000 (1.5748) .005 (.000197) .005 (.000197)

164-6555 39.985 (1.5742) 40.000 (1.5748) .005 (.000197) .005 (.000197)

168-7226 39.978 (1.5739) 39.993 (1.5745) .005 (.000197) .005 (.000197)

8Q-1665 39.978 (1.5739) 39.993 (1.5745) .005 (.000197) .005 (.000197)

3160
7N-9803 38.082 (1.4993) 38.097 (1.4999) .005 (.000197) .005 (.000197)
3176
7W-9710 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)
3196
168-7276 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

168-7296 53.155 (2.0927) 53.17 (2.0933) .005 (.000197) .005 (.000197)

3204
7N-9803 38.082 (1.4993) 38.097 (1.4999) .005 (.000197) .005 (.000197)
3208
7N-9803 38.082 (1.4993) 38.097 (1.4999) .005 (.000197) .005 (.000197)

9L-9889 38.082 (1.4993) 38.097 (1.4999) .005 (.000197) .005 (.000197)

3304
7N-9804 38.093 (1.4997) 38.108 (1.5003) .005 (.000197) .005 (.000197)

7N-9805 43.160 (1.6992) 43.175 (1.6998) .005 (.000197) .005 (.000197)

8M-6487 43.160 (1.6992) 43.175 (1.6998) .005 (.000197) .005 (.000197)

9H-4016 38.093 (1.4997) 38.108 (1.5003) .005 (.000197) .005 (.000197)

3304B
7N-9805 43.160 (1.6992) 43.175 (1.6998) .005 (.000197) .005 (.000197)
3306
7N-9804 38.093 (1.4997) 38.108 (1.5003) .005 (.000197) .005 (.000197)

7N-9805 43.160 (1.6992) 43.175 (1.6998) .005 (.000197) .005 (.000197)

8M-6487 43.160 (1.6992) 43.175 (1.6998) .005 (.000197) .005 (.000197)

9H-4016 38.093 (1.4997) 38.108 (1.5003) .005 (.000197) .005 (.000197)

7N-9805 43.160 (1.6992) 43.175 (1.6998) .005 (.000197) .005 (.000197)

 Chart A - Piston Pin Specifications1
Engine Piston Pins Minimum Reuse
New Pin Diameter Tolerance Wear Step
Model Part Number Diameter
3306B
7N-9805 43.160 (1.6992) 43.175 (1.6998) .005 (.000197) .005 (.000197)
3406
7N-9806 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

7N-9807 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

8N-1608 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

3406B
168-7246 54.985 (2.1648) 55.000 (2.1654) .005 (.000197) .005 (.000197)

7E-1749 54.985 (2.1648) 55.000 (2.1654) .005 (.000197) .005 (.000197)

8N-1608 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

3406C
102-9796 54.985 (2.1648) 55.000 (2.1654) .005 (.000197) .005 (.000197)

168-7246 54.985 (2.1648) 55.000 (2.1654) .005 (.000197) .005 (.000197)

7E-1749 54.985 (2.1648) 55.000 (2.1654) .005 (.000197) .005 (.000197)

8N-1608 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

3406E
102-9796 54.985 (2.1648) 55.000 (2.1654) .005 (.000197) .005 (.000197)

168-7246 54.985 (2.1648) 55.000 (2.1654) .005 (.000197) .005 (.000197)

7E-1749 54.985 (2.1648) 55.000 (2.1654) .005 (.000197) .005 (.000197)

3408
7N-9806 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

7N-9807 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

8N-1608 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

3408B
7N-9806 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

7N-9807 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

8N-1608 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

3408C
7N-9807 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

8N-1608 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

3408E
173-0148 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

8N-1608 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

3412
7N-9807 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

8N-1608 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

3412C
7N-9807 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

8N-1608 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

3412D
197-9291 59.930 (2.3594) 59.945 (2.3600) .005 (.000197) .005 (.000197)
 Chart A - Piston Pin Specifications1
Engine Piston Pins Minimum Reuse
New Pin Diameter Tolerance Wear Step
Model Part Number Diameter
3412E
173-0148 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

8N-1608 50.780 (1.9992) 50.795 (1.9998) .005 (.000197) .005 (.000197)

3508
138-8506 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

138-8507 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

197-0560 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

4W-8484 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

7C-8610 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

3508B
138-8507 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

197-0560 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

3512
138-8506 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

138-8507 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

197-0560 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

4W-8484 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

7C-8610 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

7N-2393 69.950 (2.7539) 69.965 (2.7545) .005 (.000197) .005 (.000197)

3512B
138-8507 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

138-8508 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

197-0560 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

3516
138-8506 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

138-8507 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

197-0560 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

4W-8484 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

7C-8610 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

3516B
138-8507 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

138-8508 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

197-0560 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

230-8154 69.915 (2.7526) 69.930 (2.7531) .005 (.000197) .005 (.000197)

3524B
138-8508 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)
3606
7C-1412 119.978 (4.7235) 119.994 (4.7242) .006 (.000236) .005 (.000197)
 Chart A - Piston Pin Specifications1
Engine Piston Pins Minimum Reuse
New Pin Diameter Tolerance Wear Step
Model Part Number Diameter
3608
138-8506 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

138-8507 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

4W-8484 69.947 (2.7538) 69.962 (2.7544) .005 (.000197) .005 (.000197)

7C-1412 119.978 (4.7235) 119.994 (4.7242) .006 (.000236) .005 (.000197)

3612
7C-1412 119.978 (4.7235) 119.994 (4.7242) .006 (.000236) .005 (.000197)
3616
7C-1412 119.978 (4.7235) 119.994 (4.7242) .006 (.000236) .005 (.000197)
3618
141-6063 129.928 (5.1153) 129.944 (5.1159) .006 (.000236) .005 (.000197)

1
Dimensions are in mm(in)

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