Parts Reuse Guidelines

Bulletin No 3810303
 Table of Contents

1. Introduction

2. Bearing Reuse Guidelines

3. Counterbore Reuse Guidelines

4. Cylinder Liner Reuse Guidelines

5. Piston Reuse Guidelines

2
 1. Introduction.
Significant savings can be realized by reusing parts during engine
repair. Visual inspection of many of the parts is adequate to
determine if the component can be reused without compromising
the quality of a repair.

The visual criteria published in these guidelines, when properly

applied, meet all technical requirements and are endorsed by CMI
for the repair of Cummins products.

Cummins Distributors are encouraged to use their technical

expertise to implement these guidelines for low cost, high quality
repair of Cummins engines.

3
2. Bearing Reuse Guidelines
 Contents of this section

• Loss of overlay / copper exposure.

• Abrasions or scratches from coarse particles.
• Embedded material.
• Bearing wiping.
• Cold start seizure.
• Fatigue damage.
• Corrosion.
• Fuel/coolant dilution.
• Overlay fatigue.
• Overlay cavitation.
• Installation damage.

5
 Loss of overlay / copper exposure

A loss or wearing away of the coating (overlay) of

lead/tin or lead/indium does not make the bearing
unusable. Excessive copper exposure increases the
possibility of bearing failure due to corrosion caused by
excessively acidic oil.

The geometry of the connecting rods, cylinder block,

crankshaft and bearing often results in small amount of
copper exposure early in the life of bearing. Therefore, it
is not practical to discard every bearing that has copper
exposure regardless of how small the area.

6
 Loss of overlay / copper exposure

This photograph illustrates Light copper exposure near Slightly more copper
a loss of overlay. The the edges of the bearing. exposure but the bearing
bearing material is not This bearing is acceptable is still acceptable for
visible. This bearing is for reuse. reuse.
acceptable for reuse.

7
 Loss of overlay / copper exposure

The bearing in this The bearing in this This photograph illustrates

photograph is acceptable photograph is acceptable acceptable copper exposure.
for reuse. for reuse.
With good maintenance
practices the life of a bearing
with significant copper
exposure is nearly unlimited

8
 Loss of overlay / copper exposure

This bearing exhibits This bearing is not

excessive copper acceptable for reuse.
exposure and is not
acceptable for reuse.

9
 Abrasions or scratches from coarse
particles
Bearing shell inspection can show a variety of types and
severity of abrasions or scratches.

The abrasions or scratches can be caused by built-in

contamination, abnormal component wear or poor
filtration.

10
 Abrasions or scratches from coarse
particles

This photograph illustrates Do not routinely discard all This photograph illustrates
bearings with scratches. Light
light, smooth scratches. scratches that are visible only or
a bearing with heavier
The scratches expose the that can be felt with fingernail but scratches. The scratches
copper but are not deep. do not have raised or ragged do not have raised or
The bearing is acceptable edges are acceptable for reuse. ragged edges and are not
for reuse. This photograph illustrates a deep. The bearing is
bearing with several light acceptable for reuse.
scratches. The bearing is
acceptable for reuse.
11
 Abrasions or scratches from coarse
particles

Deeper scratches or the This photograph illustrates This photograph illustrates

raised or ragged edges a bearing with deep a bearing with a scratch
will cause a disruption of scratches. The bearing is that has started to fatigue
oil film. The edges can not acceptable for reuse. along edges. The bearing
also cause a fatigue is not acceptable for
failure. These bearings are reuse.
not acceptable for reuse.

12
 Embedded material

Material embedded in a bearing is usually a result of

failure debris circulated through the lubricating system.
In many cases, debris from a main bearing failure will
pass through the crankshaft drillings and become
embedded into the rod bearing.

If small amounts of soft material are embedded, such as

from the lead/tin overlay, the bearing can be acceptable
for reuse.

13
 Embedded material

The bearing illustrated in This bearing exhibits If large amounts of soft material or
an abrasive material is embedded,
this photograph is slightly more scratches and the bearing is not acceptable for
acceptable for reuse. embedded particles, but reuse. Abrasive material
still acceptable for reuse. embedded in the bearing may cut
scratches or grooves in the
crankshaft.
This photograph illustrates a
bearing that has an unacceptable
amount of embedded material.
This bearing is not acceptable for
reuse.

14
 Embedded material

This photograph illustrates

a large amount of debris
embedment. The bearing
is not acceptable for
reuse.

15
 Bearing wiping

Wiping is the term applied to the initial stages of damage

caused by a momentary lack of lubrication. The metal to
metal contact of the bearing and journal will show as
smearing or heavy rubbing on the bearing surface.

16
 Bearing wiping

This photograph illustrates Wiping damage occurs quickly This photograph illustrates
an early indication of and the bearings will be the maximum amount of
wiping as shown by destroyed if the conditions wiping that is acceptable
exists for more than a few
polishing at the center and for reuse.
revolutions of the crankshaft.
edges of the bearing. This
bearing is acceptable for This photograph illustrates a
reuse. slightly heavier amount of
polishing, but the bearing is
acceptable for reuse.
17
 Bearing wiping

This photograph illustrates This photograph illustrates

a rod bearing that had bearing damage. The bearing
started to seize and the is not acceptable for reuse.
surface material has
smeared. This bearing is
not acceptable for reuse.

18
 Cold start seizure

The seizure is caused by running the engine at high

speed immediately after starting before the lubricating oil
can flow through the bearing. The lubrication film is not
sufficient to prevent adhesive contact between bearing
and crank when acceleration occurs.

These bearings are not acceptable for

reuse.

19
 Fatigue damage

Fatigue of the copper/lead bearing material can be

caused by bearing overloads. The overload can be
caused by crank, connecting rod or bearing geometry,
scratches or grooves with raised edges or external
conditions such as overfueling.

20
 Fatigue damage

Bearing that show any This photograph illustrates Fatigue of the steel back
amount of fatigue damage fatigue that has been of the bearing will show as
are not acceptable for initiated at the edge of the cracking of the steel back.
reuse. deep scratches. This This type of failure can be
bearing is not acceptable the result of low bearing
for reuse. crush or connecting rod or
main bearing bore
geometry.
21
 Fatigue damage

The bearing in this

photograph has an
indication of fatigue near
the edge. Look for other
cracks coming out from
the defective area of the
bearing. Not acceptable
for reuse.
22
 Corrosion

Corrosion attacks the bearing when the acid content of

the oil becomes excessive. A bearing with deep wear
and exposed copper is more vulnerable to corrosive
attack. The acid will attack and remove the pure lead
from the copper bearing material. The fatigue strength of
the remaining structure will then be greatly reduced.

23
 corrosion

Corrosive attack on Pitting due to corrosion This photograph illustrates

exposed copper will may be more numerous a bearing with major
usually show a deeper and smaller pitting from corrosion. If kept in
orange to brown color. ordinary fatigue. Usually, service, this bearing would
Bearing with corrosion there will be more fail in a short period of
damage are not uniformity of damage in the time.
acceptable for reuse. connecting rod bearing.

24
 Fuel/coolant dilution

Bearings that have been operated with coolant in the oil

will have a milky gray edge around exposed copper and
black discoloration of the overlay. This can be caused by
contaminated oil, leaking liner seals, leaking oil cooler
seals, etc.

25
 Fuel/coolant dilution

This bearing exhibits black This bearing has a broad Bearings that have been operated
with fuel in the oil will have a
discoloration of the band of black discoloration slightly green or brown hue. The
overlay, but is acceptable of the overlay at both condition can be caused by
for reuse. edges of the loaded overfueling, excessive idle
bearing area. The bearing periods, injector o-ring leakage or
incomplete combustion.
is acceptable for reuse.
This bearing is acceptable for
reuse.

26
 Fuel/coolant dilution

This photograph illustrates

a bearing that have been
exposed to fuel in the lube
oil. The bearing is
acceptable for reuse.

27
 Overlay fatigue
Overlay fatigue occurs in the loaded area of the bearing.
It shows as a series of irregular and sometimes inter-
connecting dark lines. Overlay fatigue is not detrimental
to the function of the bearing and does not extend
deeper than the lead/tin or lead/indium coating.

. Both bearings are

acceptable for reuse.

28
 Overlay cavitation
Overlay cavitation is caused by the dynamics of the oil
film as it moves around the crank and bearing joint. This
condition appears only on the unloaded half of the
bearing set. The area of cavitation will vary in size and
outline and is normally appears only in the bearing
overlay material.
. These bearings are
acceptable for reuse.

Bearing in this photograph

has slightly larger areas of
cavitation but is still
acceptable for reuse

29
 Installation damage

During bearing removal you might find examples of

incorrect bearing installation. These bearing are not
acceptable for reuse.

30
 Installation damage

This photograph illustrates This photograph shows the This photograph illustrates
that an object was reverse side of the bearing a bearing that was
between the bearing back previously illustrated. incorrectly installed. The
and the bore for the tang was not correctly
bearing thus causing aligned with the slot in the
deflection of the bearing. connecting rod.

31
 Installation damage

This photograph shows the This photograph illustrates

reverse side of the bearing bearing deformation caused
previously illustrated. by using a sharp tool against
the back of the bearing during
disassembly. The condition of
the bearing was acceptable
before it was damaged during
disassembly.

32
3. Block Counterbore Reuse
Guidelines
 Contents of this section

• Counterbore inside diameter wear.

• Counterbore seat wear.
• Head deck wear.
• Counterbore ledge cracks.
• Capscrew hole cracks.
• Water passage cracks.

34
 Counterbore inside diameter wear

The press fit (A) between the The machining marks left Wear areas are indicated by
counterbore inside diameter and polishing on the inside
the liner flange helps prevent
in the counterbore can be
used to determine if the diameter (ID) surface.
movement (B) of the liner and
Significant wear is indicated
subsequent wear of the flange counterbore is acceptable
ledge and counterbore seat (C). by a lack of machining marks
for reuse. on the surface of the inside
If there is wear, it usually occurs in diameter in the press fit area.
line with the crankshaft.
This block is acceptable for
A worn counterbore seat will allow reuse, no appreciable wear
coolant leak. evident.
35
 Counterbore inside diameter wear

The degree of wear is The ID of this counterbore The wear (no machining
visually detectable by the has a small polished area marks) on the ID of this
absence of machining which is less than ½ inch in counterbore exceeds ½
marks in the polished width. inch.
area.
This counterbore is This block is not
The limit for worn away acceptable for reuse. acceptable for reuse
marks is ½ inch. without a re-machining the
counterbore ID.

36
 Counterbore seat wear

Leaks path are created by This close-up view of the The degree of wear is visually
detectable by absence of
both seat wear (polishing) damage area reveals the machining marks in the polished
and pitting. pitting. area.

Pitting on the liner seat is This cylinder block requires NOTE: The tool marks (if any) on
previously re-machined seats will
not acceptable. counterbore machining be radial instead of concentric
before it can be reused. ridges.

The limit for worn away marks is

1/2 inch.
37
 Head deck wear

Head gasket to block wear does not contribute to

counterbore leakage.

38
 Counterbore ledge cracks

Hairline cracks on the Open cracks require

counterbore seat are not counterbore machining and
detrimental. re-evaluation.

Cracks which remain after If the cracks are closed

machining for an oversize after machining, the
liner or salvage sleeve are counterbore is acceptable
acceptable. for reuse

39
 Capscrew hole cracks / Water passage cracks

Cracks which extend from Cracks which extend into Cracks which extends
the counterbore wall to the the threaded portion of the horizontally from
capscrew hole are hole require salvage with a counterbore ledge to the
acceptable for reuse if it blind end thread insert. water passage require
does not extend into sleeving of the water
threaded portion of hole. passage.

40
4. Cylinder Liner Reuse
Guidelines
 Contents of this section

• Bore wear.
 Liner bore scoring.
 Liner bore scratches.
• Crevice seal groove erosion.
• Flange crack.
• Flange wear (Ledge).
• Flange wear (Outside diameter).
• Liner corrosion.
• Liner pitting.

42
 Bore wear

Liner are manufactured with a This liner has only a small amount This liner exhibits limited
very straight, round cylinder bore of light polish. moderate polish.
to provide a sealing surface for the
piston ring. Light polish is defined as a bright, Moderate polish is defined as a
shiny worn area with a gray hue. A bright, mirror finish in the ring
Wear of the bore is detectable by light amount of Lubrite coating will travel area and has very light
the degree of polishing visible in remain in the heavy etch pattern traces of the hone marks.
the bore. will be gone. The hone marks are
still intact. This liner is acceptable for reuse.
This is a new liner.
This liner is acceptable for reuse.
43
 Bore wear / Liner bore scoring

This liner has heavy polish In addition to the obvious heavy This liner has severe
polish, this liner has scoring
present in over 20 percent indicated by the dark spots in the
scoring. Liners with any
of the piston of the piston upper ring reversal area. indication of scuffing or
ring travel area. scoring are not acceptable
A scored surface interrupts ring for reuse.
sealing. If the damaged surface
The liner is not contains embedded carbon, it will
acceptable for reuse cause new ring to wear rapidly. This liner is not
acceptable for reuse.
This liner is not acceptable for
reuse.
44
 Liner bore scratches

Minor vertical scratches in This liner has deep scratches in the

ring travel area sufficient to hang
the liner bore are not the fingernail during inspection.
detrimental to piston ring
sealing. Severe scratches can have raised
material at the edges of scratch
which affect ring sealing and
This liner is acceptable accelerate ring wear.
for reuse.
This liner is not acceptable for
reuse.

45
 Flange wear (outside diameter)

The press fit (A) between the Wear on the OD of the flange is
The degree of wear is visually
outside diameter (OD) of the liner indicated by small polished area on
detectable by the absence of
flange and the block helps to this liner. machining marks in the
prevent movement (B) of the liner
and subsequent wear of the flange NOTE: The polished area on
polished area.
ledge and counterbore seat (C). reusable liner should be positioned
at a right angle to the crankshaft so The left side of the flange in
If there is wear, it usually occurs in an unpolished area is installed in this close-up view reveals
line with the crankshaft. line with the crankshaft. worn away machining marks.
A worn counterbore seat will allow This liner is acceptable for reuse.
coolant leak.
46
 Flange wear (outside diameter)

The limit for worn away The wear (no machining The wear on this flange is
machining marks is 1/2 marks) on this flange is greater than one half inch.
inch. less than ½ inch.
A liner with this amount of
wear is not acceptable for
A liner with this degree of reuse.
flange wear is reusable.

47
 Flange wear (ledge) / Flange cracks

Wear is indicated by absence of Wear (no machining marks) Flange cracks are
machining marks in the polished area.
and pitting on this flange ledge unacceptable. Cracks are
The limit for worn away machining is greater than ½ inch. most noticeable on the
marks is ½ inch. internal surface of the liner,
NOTE: The polished area on reusable This liner is not acceptable normally ½ inch down from
liners should be positioned at a right for reuse. the top of the liner.
angle to the crankshaft so when the
liner is installed, an unpolished area is
in line with the crankshaft. Do not reuse a liner with
flange cracks.

48
 Liner pitting

This liner has light pitting. Reused liners having light Heavy pitting is indicated
The pitting is due to improper
pitting must be installed by a depth greater than
maintenance of the cooling with the pitting positioned half liner wall thickness.
system. Light pitting is indicated in line with the crankshaft.
by a depth less than half the liner This liner is not
wall thickness.
acceptable for reuse.
This liner is acceptable for reuse.

49
 Crevice seal groove erosion / Liner corrosion

Coolant erosion of the crevice seal Erosion greater than half Corrosion is caused by
is indicated by pitting which
progresses downward from the
the crevice seal groove poor maintenance of the
top of the crevice seal groove. The width is which can caused cooling system.
limit for erosion is one-half the a coolant leak.
groove width. After all those scale is
This liner is acceptable for reuse This liner is not removed, this liner will be
providing the erosion is installed in acceptable for reuse. acceptable for reuse.
line with crankshaft.

50
5. Piston Reuse Guidelines
 Contents of this section

• Carbon damage.
• Dome cracks.
• Pin bore cracks.
• Skirt damage.

52
 Carbon damage

Carbon build up above the Damage extending into the The wear on this flange is
upper ring land can cause ring land will displace metal greater than one half inch.
metal to be removed from from the land into de
piston. Damage above the A liner with this amount of
groove causing loss of
ring land does not affect the wear is not acceptable for
function of the piston. piston ring sealing. reuse.

This piston is acceptable for This piston ring is not

reuse. acceptable for reuse.

53
 Dome cracks / Pin bore cracks

Cracks in the dome area of Cracks that are longer than The length of a crack in the
the piston area caused by one-half the rim width or pin bore can progress with
intense head of the cylinder cracks that extend over the continue use of the piston.
during engine operation.
rim toward the Ni-resist
Cracks shorter than one-half Pistons with pin bore cracks
the rim thickness do not affect insert are detrimental. are not acceptable for reuse.
the function of the piston.
This piston ring is not
This piston is acceptable for acceptable for reuse.
reuse.

54
 Ring land damage

Piston with ring groove This piston has a worn ring This piston has erosion
damage cannot be reused. groove and is not caused by non-atomized fuel.
Generally the wear will be acceptable for reuse. Pistons exhibiting any erosion
most noticeable in the second near the ring lands are not
ring groove. A worn groove acceptable for reuse.
will have a detectable step at
the back of the groove and a This piston is not acceptable
rolled edged at the surface of for reuse.
the piston.

55
 Ring land damage / Skirt damage

This photograph illustrates severe Damage to the piston skirt surface The scratch on this piston
ring land contact with the cylinder is detrimental when the damage is
liner. This is a result of either the such that it interrupts the normal
is long and deep; therefore
piston pin bore being off-center or film of oil which prevents metal-to- this piston is not
a bent connecting rod. Pistons metal contact between the piston acceptable for reuse.
exhibiting any contact damage to and the cylinder.
the ring lands are not acceptable
for reuse. The scratches on this piston
are very shallow; therefore,
Caution: Be sure to check the the piston is acceptable for
twist and bend of the connecting
rod before installing a new piston.
reuse.

56
 Skirt damage

This photograph illustrates a In addition to the long scratch, the

light rubbing condition which skirt of this piston reveals scuffing
is not detrimental. The due to severe rubbing of the
cylinder liner.
horizontal grooves machined
into the skirt for oil retention The horizontal grooves are worn
have not been worn away. away. In fact the dark, vertical line
indicates material transfer from the
This piston is acceptable for liner.
reuse.
This piston is not acceptable
for reuse.
57
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