Inspection Procedures and Specifications For Pistons and Piston Pins

1/30/24, 3:26 PM SIS 2.
Inspection Procedures and Specifications for Pistons and Piston Pins {1214, 1214} (SEBF8059-58)
SMCS - 1214 i09949529

Caterpillar Products
All Cat Engines
Revision History:
Table 1
PIP
-
202 1046
Revision Summary of Changes in SEBF8059
Added pistons 579-0210, 599-0756, 599-0757, and 618-0617 to Table 6.
Updated the piston ring gage part number for aluminum 3500 Series pistons in Table 6..
4 4
Corrected the groove width of piston 581-6443 in Table 6.
58
12: 01/3 666

/
Added a note to the "Procedure for Measurement of Pistons and Pistons Pins" Section regarding measurement of pin bores with manganese
phosphate coating.
Updated Illustration 299.
57
56
55
Added piston 494-7164 to Table 6.
Added 575-0686 to Table 6.
Added 7 new part numbers.
2
SEB 6:35+ 0
© 2 F805 03:00
Added piston 481-5615.
54
Added piston 578-8865.
Introduction
0
Cat 4 C 2 9
© 2024 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes
e
therein without permission may be violation of intellectual property law.
r
Con illa terpi
p a
Information contained in this document is considered Caterpillar: Confidential Yellow.
fide r: llar
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
Inc
that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not
ntia
included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.
.
l Ye
For technical questions when using this document, work with your Dealer Technical Communicator (TC).
llow
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
https://sis2.cat.com/#/print-preview/service/4d1724e8-d402-4252-97a6-9ada97feccf0 1/130
1/30/24, 3:26 PM SIS 2.0
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:
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
This document will aid the technician in the visual inspection of multiple types of pistons and piston pins. It also covers multiple locations of pistons with
many different wear and failure patterns. Life will vary depending on application, load, lubrication, and environment.
This guideline contains the latest standards of engineering, which will help minimize owning and operating costs. Parts are expected to reach the next
Planned Component Rebuild (PCR) if the parts meet the specifications within this guideline and are intended for similar applications.
Use this guideline to determine whether a part should be reused. Do not install a part that is not reusable. During reconditioning, correct any condition
that might have caused the original failure.
The dimensions and tolerances provided are to return a part / component to specification. The dimensional information alone is not solely used to
condemn a part from reuse.
References
1/30/24, 3:26 PM SIS 2.0
Table 2
References
Media Number Publication Type & Title

"Why Reuse and Salvage Parts"
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
Channel1
"How to Measure a C175 Piston Bore"
https://channel1.mediaspace.kaltura.com/media/How+to+Measure+a+C175+Piston+Bore/1_06ro1gl7
Cat Inspect https://catinspectweb.cat.com/
Special Publication
PERJ1017
"Dealer Service Tools Catalog"
Reuse and Salvage Guidelines
SEBF8148
, "General Salvage and Reconditioning Techniques"
SEBF8187 "Standardized Parts Marking Procedures"
SEBF8357 "General Cleaning Methods"
Service Advisories, Service Letters, and Technical Service Bulletins
NOTICE
The most recent Service Advisories, Service Letters, and
Technical Service Bulletins that are related to this component
should be reviewed before beginning work. Often Service
Advisories, Service Letters, and Technical Service Bulletins
contain upgrades in repair procedures, parts, and safety
information which pertain to the components being repaired.
Tooling and Equipment

Note: The Tooling and Equipment in Table3 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

— (1)
Personal Protective Equipment (PPE)
— (2) Clevis/ Shackle
1P-3537 Dial Bore Gauge Kit
1U-7234 Feeler Gauge
1U-9029 Piston Ring Groove Gauge
1U-9030 Piston Ring Groove Gauge
3P-1568 Dial Indicator
Thread Tap
4C-4997
1/2 inch - 13 NC
4C-8164 Piston Ring Groove Gauge
4C-3654 Piston Ring Groove Gauge
— Loctite® Solvo Rust® LB 8713 Super Penetrating Oil (4)
— Loctite® Solvo Rust® LB 8040 Super Penetrating Oil (3)
4C-8995
Ring Expander Group
318-4874
4S-9405 Caliper
5P-1720 Seal Pick
5P-2170 Dial Bore Gauge Group
5P-3920 Steel Ruler
1/30/24, 3:26 PM SIS 2.0
5P-7414 Seal Pick

6V-2032 Adapter
— Loctite® Graphite 50 LB 8504 Anti-Seize Lubricant (4)
— Loctite® Graphite 50 LB 8009 Anti-Seize Lubricant (5)
6V-5067 O-ring
6V-6167 Contact Point
8H-8577 Hammer
8H-8581 Feeler Gauge
8T-3033
271-0505 Ring Expander Group
318-3117
8S-2328
Dial Indicator Group
8T-5096
8T-7748 Deburring Wheel
8T-7765 Surface Reconditioning Pad
8H-8581 Feeler Gauge
9A-1593 Comparison Gauge
9S-8903 Indicator Contact Point
162-5791 Shop Towels
— Bonderite® C-AK 319 mm, Alkaline Cleaner (6)
— Loctite®LB 8012 Moly Paste (7)
Socket
194-3514
22 mm 1/2 inch Drive
197-3710 Ring Groove Gauge
247-9763 Gage
288-4209
Paper Towel
605-2193
329-2411 Parts Kit
Ring groove gauge (Second/Intermediate Ring)
and
327-8645
Ring groove gauge (Oil Control Ring)
342-6241 Piston Gauge
367-9109 Digital Caliper
Micrometer Tool Set, External
385-4008
1524 mm (60 inch)
Micrometer Extensions,
Internal
385-9422
50 - 609 mm
(2 - 24 inch)
386-3364 Straight Edge
Digital Caliper
423-4373
0.0 - 203.2 mm (0.00 - 8.00 inch)
Micrometer, External
431-4150
25 mm (1 inch)
448-0722 17 mm Sideview Camera Borescope Probe
448-0723 5.5 mm HD Camera Borescope Probe
448-0724 Video Borescope - Wired Tool Group
448-0725 Video Borescope - Wireless Tool Group
459-0184 UV Lamp Group
Inside Micrometer
473-8688 2.00 - 12.00 inch
or
473-8689 Inside Micrometer
50 - 300 mm
Outside Micrometer
473-8690
0.00 - 4.00 inch
1/30/24, 3:26 PM SIS 2.0
Outside Micrometer
473-8691
2.00 - 6.00 inch
Outside Micrometer
473-8692
6.00 - 12.00 inch
Inside Micrometer
474-3709 8.00 - 32.00 inch
or
474-3710 Inside Micrometer
200 - 800 mm
491-3146 Air Gage Regulator Column Amplifier
491-3253 Piston Pin Bore Plug Gage Assembly
510-5864 Ring groove gauge (Top Ring)
— Loctite® PC 9660Maxi-Coat Rust Inhibitor (8)
— Loctite® SF 7803Maxi-Coat Rust Inhibitor (9)
— Loctite® SF 9660Maxi-Coat Rust (Aerosol) (10)
SPX/OTC J36660 Tool
486-1525 Lubricant
Automatic Tape Measure
1U-9367 1-inch X 26- ft
25.4- mm x 8- m
8S-2257 Magnifying Glass
9U-6182 Mirror (Telescoping)
9U-7231 Flashing Lights Conversion Kit
4C-9442 Light
— (2)
Bright Incandescent Light
— Reflective Surface for Inspection
Microscope (40-Power)
262-8390
Pocket
Brush
1U-9915
Curved Handle Wire
— Developer
— Penetrating Oil
— Solvent Cleaner
Fluid
505-8671
Ultrasonic Wear Indicator
415-4055 Tool Group(Ultrasonic)
(1) Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety
standards.
(2) Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for suitable tooling.
(3) Available in Europe, Africa, and the Middle East.
(4) Available in North America and Australia.
(5) Available in Europe, Africa, the Middle East, Asia Pacific, and South America.
(6) Available in North America and China.
(7) Available in North America, Europe, Africa, the Middle East, Asia Pacific, and South America.
(8) Available in North America, Asia Pacific, and South America.
(9) Available in Europe, Africa, and the Middle East.
(10) Available in Australia.
Preparation Recommendations
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.
1/30/24, 3:26 PM SIS 2.0
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 valve covers and cylinder heads 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.
Replacement Parts
Consult the applicable Parts Identification manual for your engine.
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.
Measurement Techniques
NOTICE
Precise measurements shall be made when the component and
measurement equipment are at 20° C (68° F). Measurements
shall be made after both the component and measurement
equipment have had sufficient time to soak at 20° C (68° F). This
will ensure that both the surface and core of the material are at
the same temperature.
Nomenclature of Pistons and Pistons Pins

Single Piece Forged Steel Piston Disassembly and Assembly Procedures
1/30/24, 3:26 PM SIS 2.0
Piston and pin marking for orientation.
Before removing the piston pin and the piston, make sure to mark the piston, the pin, and the connecting rod with the corresponding rod number if the
piston is being used again. The markings should be made so that the piston and the piston pin can be assembled exactly as taken apart. Mark the piston
and the piston pin as shown in Illustration 3. When the piston and the piston pin are installed, the markings should line up again as before disassembly.
Straight piston pin
Piston pin with barrel shaped ends.
There are three types of piston pins: a straight pin (Illustration 4), a barrel shaped pin (Illustration 5), and a tapered pin (not shown). The ends of a barrel
shaped pin has a cross section that resembles that of a barrel. The barrel end can easily be confused with a wear step. A tapered pin has a slight taper
from the middle of the pin to the outside edge.
Disassembly Procedures for 3600, G3600, and C280 Piston

Note: Caterpillar does not recommend disassembly and subsequent assembly of the 3618 piston or gas piston. Disassembly and subsequent assembly
should only apply to the diesel engine that has three and four piston rings.
1/30/24, 3:26 PM SIS 2.0
Piston with single bolt
Piston with four studs and nuts
There are two basic styles of pistons. The current design for diesel engines incorporates a single bolt that retains the piston crown to the piston skirt. The
former design for diesel engines incorporates four studs that are used to retain the piston crown to the piston skirt. The current design and original design
for the gas engines incorporates four studs that are used to retain the piston crown to the piston skirt. There was a design for the gas engines that
incorporated a single bolt to retain the piston crown to the skirt. Both of these types of pistons have two important characteristics that include a graphite
coating on the nodular iron or on the aluminum skirt and an oil passage inside the steel crown.
Prior to the disassembly of the piston, permanently mark the crown and the skirt of each piston with an identification number or the identification numbers
of the crown and skirt should be documented. Identification numbers are stamped on the outer rim of the crown and on the underside of the boss for the
skirt. If pistons are marked, then the crowns should be marked on the top of the outer rim. Skirts should be marked on the bottom of the rim of the boss for
the skirt. These steps will ensure that reusable crowns and skirts can be matched before placing the piston assembly in the engine. Refer to Reuse and
Salvage Guideline, SEBF8187 , "Standardized Parts Marking Procedures" for additional information.
Avoid hard contact on the piston skirts.
Do not use a mallet that is rubber or plastic to loosen the skirt from the crown.
Do not hammer on the piston skirt.
Remove the hardware that is on the underside of the skirt which is either one bolt or four nuts according to the piston design.
Suspend the piston upside-down with a lifting strap.
Use the brass rod by inserting the end through the central drain hole, and disassemble the piston with the aid of a hammer.
Disassembly Procedure For Single Bolt Three Ring Piston

1. Set the piston upside down on the crown. Clean the area around the bolt.
1/30/24, 3:26 PM SIS 2.0
PIP
-
202 1046
4
12: 01/3 666
/ 4
2
SEB 6:35+ 0
© 2 F805 03:00
Illustration 8
0
Cat 4 C2 9
2. Mark the skirt, spacer, and bolt head with a straight line across all of them.
g06468517
e
Con rpilla aterpi
3. Use a 32.0 mm (1.25 inch) socket to remove the bolt.
Note: If the bolt was loose prior to the removal, the piston cannot be reused.
4. Separate the skirt from the crown.
fide r: llar
5. Visually inspect the abutment faces for excessive wear. If no excessive wear is found, continue to the cleaning procedure.
ntia Inc
l Ye .
llow
Section view of the piston using depth micrometer
(A) Inner edge measurement
(B) Middle measurement
6. Measure the wear step on the outer abutment joint in four places. The measurements should be taken 90° apart. Use a depth micrometer to measure
down from the bottom of the crown to the inner edge of the abutment surface and then the middle of the surface. Be sure that all surfaces are cleaned
with a non-abrasive procedure. If the difference between the two measurements is less than 0.10 mm (0.004 inch), the crown can be reused.
1/30/24, 3:26 PM SIS 2.0
Measure the length (X) of the bolt to make sure that it has not stretched. The length of the bolt should be less than 81.4 mm (3.20 inch). If the length of the
bolt exceeds the specification, use the 329-2411 Parts Kit to replace the bolt.
One-Piece Pistons
The graphite coating on the skirt helps to prevent scuffing and seizure during cold starting. The coating is dull, dark gray and the thickness is
approximately 0.020 ± 0.004 mm (0.0008 ± 0.0002 inch). The purpose of the coating is similar to the lead tin overlay of a main bearing or a connecting rod
bearing. The coating is put on the piston during the manufacturing process. There are no replacement coatings that can be applied outside of
manufacturing. Be extra careful not to damage the coating during disassembly, cleaning, inspection, and assembly. It is important not to remove more of
the graphite coating during the operation of cleaning.
The graphite coating will eventually wear off the surface of the piston during normal engine operation. This wear is normal and the wear will not create
operational problems. Graphite coating can be worn from any portion of the piston but the coating is not typically worn from an area that is ± 40 degrees of
the axis of the piston pin. The piston skirt must be smooth and free of any deep scratches and material built up.
The tops 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. The location of the oil passage can be found by locating the holes in the bottom of the piston. The slot for lubricating the piston pin in each piston
pin bore is also an oil passage.
Note: During cleaning of the piston with glass beads, close all oil passages to keep out debris.
Aluminum one piece direct injection piston with a single compression ring.
(1) Crown
(2) Crater
(3) Ring Band
(4) Ring Grooves
(5) Ring Lands
1/30/24, 3:26 PM SIS 2.0
(6) Skirt
(7) Pin Bore
(8) Snap Ring Groove
(9) Top Land
(10) Skirt Relief
Aluminum one piece direct injection piston with a double ring land.
(1) Crown
(2) Crater
(3) Ring Band
(4) Ring Grooves
(5) Ring Lands
(6) Skirt
(7) Pin Bore
(9) Top Land
(10) Cooling Jet Relief
(11) Skirt Relief
Aluminum one piece direct injection piston with a single ring land.
(1) Crown
(2) Crater
(3) Ring Band
(4) Ring Grooves
(5) Ring Lands
(6) Skirt
(7) Pin Bore
(9) Top Land
(11) Skirt Relief
1/30/24, 3:26 PM SIS 2.0
Aluminum one piece piston from a 3500 series engine.
(1) Crown
(2) Crater
(3) Ring Band
(4) Ring Grooves
(5) Ring Lands
(6) Skirt
(7) Pin Bore
(9) Top Land
The piston from a typical precombustion chamber engine
(1) Crown
(2) Crater
(3) Ring Band
(4) Ring Grooves
(5) Ring Lands
(6) Skirt
(7) Pin Bore
(9) Top Land
(11) Skirt Relief
(12) Relief for Valve
(13) Heat Plug
Forged Steel Pistons
1/30/24, 3:26 PM SIS 2.0
Forged Steel Piston with Single Piece
Graphite Coating
Some 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 18
(7) Bore surface of piston pin
(13) Graphite coating
(14) Passage for oil cooling of crown
(15) Vertical oil passage
One piece piston with a coating of graphite
Refer to "Graphite Coated Pistons" later on in this document for more information.
(1) Crown
(2) Crater
(3) Ring Grooves
(4) Top Land
(5) Ring Lands
(6) Piston Pin Bushing
(7) Skirt
1/30/24, 3:26 PM SIS 2.0
(8) Pin Bore in Skirt
(9) Piston Side Relief
Note: The piston and piston pin must be identified and marked with the cylinder number and orientation in reference to the front of the engine.
Note: Do not mix and match pistons and piston pins from different cylinders. Ensure that the pistons and piston pins are oriented properly to the front of
the engine upon reassembly.
NOTICE
Piston and piston pins wear together, mixing the parts may
cause pin seizures.
This color coded piston shows the risk/stress areas of the piston. Illustration 20 is a one piece graphite coated piston but applies to all pistons.
(1) Red - High risk/stress area of the piston.
(2) Yellow - Medium risk/stress area of the piston.
(3) Green - Low risk/stress area of the piston.
Anodized Layers
The tops 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. The holes for the oil passage can be found in the bottom of the
piston. The holes can also be found in the slot for lubricating the piston pin in each piston pin bore.
Steel Crown and Aluminum Skirt

This style 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. It has two important characteristics: a graphite coating on the aluminum skirt and a separate steel crown.
1/30/24, 3:26 PM SIS 2.0
Section view of piston identifying crown, skirt, and all oil passages.
(1) Crown
(2) Crown oil cooling passage
(3) Center oil return passage
(4) Bottom oil ring lube passage
(5) Piston pin lube spot
(6) Cooling jet supply passage
(7) Crown and skirt joint
(A) Graphite coating
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.
The graphite coating on the skirt helps to prevent cold start scuffing and seizure. The coating is approximately 0.020 ± 0.004 mm (0.0008 ± 0.0002 inch)
thick, dull (not shiny) and dark gray. The coating has a purpose like the lead-tin overlay on an engine bearing. The coating is put on the piston during
manufacture. There are no replacement coatings that can be applied in the field. Be extra careful not to damage any of the coating during cleaning and
inspection.
The graphite coating will eventually wear off the piston surface where the piston contacts the liner. This wear is normal and will not create problems. Do
not remove more of the graphite coating during the cleaning operation. The coating can be worn on any portion of the piston. The piston skirt must be
smooth and free of any deep scratches and material build-up.
Two-Piece Pistons
1/30/24, 3:26 PM SIS 2.0
Features of a two-piece piston crown and skirt
(1) Crown
(2) Crater
(3) Ring grooves
(4) Top land
(5) Ring lands
(6) Piston Pin Bushing
(7) Skirt
(8) Piston pin bore
(9) Side relief for piston
Cleaning Procedure of Pistons and Piston Pins

Make a quick visual inspection of the piston before cleaning. If no obvious defects are found, clean the piston.
Solvent
Clean any 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 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.
1/30/24, 3:26 PM SIS 2.0
One-Piece Pistons
PIP
-
202 1046
The crowns may be cleaned with glass beads. However, several areas of the piston must be protected from the glass beads. Refer to Illustration 23.
Note: After the piston is cleaned, check the oil passages. Make sure that all passages and other areas are free of debris or glass beads. Foreign material
Use an O-ring to protect the oil ring groove. 4

12: 01/3 666
/ 4
on the piston can be washed into the lubrication system and can damage other engine components.
2
SEB 6:35+ 0
© 2 F805 03:00
0
Cat 4 C2 9
e
Con rpilla aterpi
fide r: llar
Illustration 23
ntia
g01275647
Areas which need protection from glass beads on one-piece pistons
Inc
.
(7) Piston pin bore
l Ye
(21) Sharp edge of crater
(22) Outer edge of piston crown
(23) Oil ring groove
llow
(24) Oil passages
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.
Put the piston into this solution with enough time 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 more than 50% of the graphite coating is missing from the skirt, the piston is not reusable
Never use glass beads to clean the skirt (Illustration 24) 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.
Protect any graphite coating. Place a protective cover over the skirt and the oil ring groove. Illustrations 25,26,27, and 28 show the areas that need
protection from glass beads. (Glass beads must not get into the oil passages.)
1/30/24, 3:26 PM SIS 2.0
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
1/30/24, 3:26 PM SIS 2.0
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 29.
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 30). 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 31 shows an alternate fixture that makes cleaning pistons faster and easier.
1/30/24, 3:26 PM SIS 2.0
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 32. Wash the
piston again with the solution for cleaning. Apply a rust preventive to the iron ring band to prevent rusting.
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 33.
1/30/24, 3:26 PM SIS 2.0
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. This mixture 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 34 and
Illustration 35. 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 an 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. Water may be used to
clean the piston crown.
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.
Pistons with Steel Crown and Aluminum Skirt

The piston has four ring grooves at the top of the 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 to remove carbon build-up. Clean the aluminum skirt with a solution of liquid detergent and water to prevent damage to the graphite
coating.
Protect Oil Passages

Tape or plug the oil passages, used for feeding the crown area and the bottom oil ring, when using glass beads. The locations of the oil passages are:
The hole on the bottom of the piston skirt which feeds the piston pin
1/30/24, 3:26 PM SIS 2.0
The four cross drilled holes from the bottom ring groove to the inside diameter of the piston
The hole in the center of the bottom side of the piston crown and the piston pin lube slot in one piston pin bore
For 3600 pistons check the holes that are in the top of the piston as the threads might need to be lightly tapped due to carbon or debris buildup. This
will ensure that the lifting hole threads will not be damaged. Use a Thread Tap that is 1/2 inch 13 NC to tap the lifting holes.
Earlier production pistons may have four lube slots in the pin bore.
Protection for the Graphite Coating

During glass bead cleaning, protect the graphite coating on the skirt and the bottom two ring grooves. Let the protective cover slightly overlap the crown
and skirt joint. There will be a small open joint approximately 0.5 mm (0.02 inch) at the parting line of the crown and the skirt. This cover will eliminate the
possibility of glass beads becoming lodged in this opening.
Several methods can be used to protect the graphite coating on the bottom of the aluminum skirt. The methods are:
Tape
Shim stock with band clamp.
Rubber tubing
O-ring for the oil ring groove
A used liner or cylinder the size of the piston with a stop to position the piston with only the top two ring grooves exposed above the mating joint surface of
the crown and skirt.
Cleaning The Aluminum Skirt

The aluminum surface of the graphite-coated skirt can be cleaned with a solution of liquid detergent, with little or no chlorine content, and water.
Bonderite® C-AK 319 mm, Alkaline Cleaner is recommended for cleaning aluminum parts. Mix Bonderite® C-AK 319 mm, Alkaline Cleaner to the
recommended concentration for aluminum parts. Caterpillar recommends testing and evaluating the recommended concentration of Bonderite® C-AK 319
mm, Alkaline Cleaner on your specific parts, with your specific equipment. Extreme cases of carbon buildup may require a slightly higher concentration
and longer soak time to remove.
Let the piston stand in this solution, normally one to two hours, to loosen carbon and oil deposits. Remove the piston when the piston looks clean. To clean
the skirt faster, heat the detergent water solution to a safe temperature. Flush the oil passages with a pressure washer.
Note: If more than 50% of the graphite coating is missing from the skirt, the piston is not reusable.
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. Use the same solution of soap and water.
Cleaning The Steel Crown

The steel crown can also be cleaned with a chemical solution, or glass beads. Flush the oil passages with a high-pressure washer and Bonderite® C-AK
319 mm, Alkaline Cleaner to remove any contaminates from oil passages.
When using glass beads to clean pistons, protect the following from bead damage: the graphite coating, the pin bore surface, and the lube slot in the
piston pin bore. Tape all surfaces and oil passages to prevent damage or beads from entering the passages.
When using glass beads to clean the crown and ring grooves, follow these requirements:
Use size 10 glass beads, 88 to 149 microns (0.0035 to 0.0059 inch) under 620 kPa (80 to 90 psi) air pressure to provide the best results.
Never use glass beads larger than 230 microns (0.0091 inch) to clean any part of the piston.
Change the glass beads and check the condition regularly for best results.
NOTICE
1. Do not use aluminum oxide or any other abrasives instead of
(or mixed with) glass beads.
1/30/24, 3:26 PM SIS 2.0
2. Do not use steel shot.
3. The glass bead method may force a small amount of material
into the ring groove. If this material can be felt with the
fingernail, remove the material with a triangular file. Failure to
do this, will prevent the ring from moving freely in the groove.
Do not put a chamfer on either side of the ring groove.
Oil Passage Holes In The Piston

Flush all oil passages and outside ring surfaces with clean engine oil before storage or installation into the engine. Store the pistons by covering them with
sheets of plastic after cleaning.
NOTICE
It is important to check all the oil passages after the piston is
cleaned, making sure that the passages are free of debris or
glass beads. Any foreign material left in the oil passages will be
washed out later into the engine lubrication system and damage
engine components.
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 36.
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.
Piston Pins
Prior to conducting a visual inspection, the piston pins must be cleaned. A good solvent can normally remove deposits of dirt and oil, but the solvent will
not remove discoloration. While discoloration is acceptable for reuse, some discoloration can be removed with the 8T-7748 Deburring Wheel. Refer to
Illustrations 37,38, and 39.
Note: Do NOT use this type of cleaning on coated piston pins.
Note: Piston pins do not need to be cleaned if the surfaces of the pins are smooth and the surfaces have an acceptable surface texture.
1/30/24, 3:26 PM SIS 2.0
Use only 8T-7748 Deburring Wheel to clean the discoloration from the piston pins. If 8T-7748 Deburring Wheel is used properly, then the surface texture
will not be damaged.
Use only the 8T-7748 Deburring Wheel that is installed with two 6V-2032 Adapters to clean the piston pin.
The discoloration around the circumference of the piston pin is acceptable if the surface is still smooth.
Note: Do not use the 6V-2033 Polishing Brush which looks like the 8T-7748 Deburring Wheel. See Illustration 37.
If the deburring wheel is used correctly, metal will not be removed and the correct surface texture of 0.125 µm (5.0000 µinch) will be maintained.
The 8T-7748 Deburring Wheel has an outer diameter of 203.2 mm (8.00 inch). The inner diameter is 76.2 mm (3.00 inch). The width is 25.4 mm
(1.00 inch). If necessary, the 12.7 mm (0.50 inch) pilot hole on 6V-2032 Adapter can be made larger. Two wheels can be installed together for more width.
Use a piece of 76.0 mm (3.00 inch) tubing to hold the wheels together. Check the information on the wheel for the correct maximum revolutions per minute
1/30/24, 3:26 PM SIS 2.0
(RPM) for operation. Then check the RPM of the grinder. It is important to turn the piston pin slowly against the wheel. Do not hold the piston pin in the
same position for more than five seconds. The finish must be even in smoothness around the piston pin.
Initial Inspection
Follow the instructions in this guideline to determine if a piston is reusable.
1. Make a visual check of the overall condition of the piston.
2. Reinspect the piston after cleaning for the following.
Cracks
Scuffing
Holes
Additional visible damage from poor handling
Imbedded material
Excessive wear of the graphite coating
3. The following areas of the piston should be inspected before reusing.
Crater
Crown
Pin Bore
Ring Groove
Ring Lands
Skirt
Snap Ring Groove
Structure
Fuel Erosion and Pitting in the Crater
Signs of carbon buildup from fuel deposits but no pitting is present. This piston may be used again after proper cleaning. USE AGAIN
1/30/24, 3:26 PM SIS 2.0
PIP
-
202 1046
12: 4 / 0 4 666
2 1 / 3
Illustration 41
SEB :35+ 0
6 g02776921
Signs of carbon buildup from fuel deposits but no pitting is present. This piston may be used again after proper cleaning. USE AGAIN
© 2 F805 03:00
Cat 024 C 9
e r
Con illa terpi
p a
fide r: llar
ntia Inc
l Ye .
Illustration 42
llow g02776920
Heavy carbon deposits, but no pitting in the metal is visible. Clean the piston and inspect again. USE AGAIN
Signs of carbon buildup from fuel deposits but no pitting is present. No damage to the crown is visible and no cracks are visible. This piston may be used again after proper cleaning. USE
AGAIN
1/30/24, 3:26 PM SIS 2.0
Minimal fuel erosion is visible after the piston has been cleaned. USE AGAIN
Fuel erosion is slightly deeper and can be felt with fingernail after cleaning. This is acceptable if the erosion does not spread across 25% of the piston. USE AGAIN
The crater of the piston shows deep erosion that is caused by fuel. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0
Deep uneven erosion caused by fuel. DO NOT USE AGAIN
The crater of the piston is showing multiple points of deep erosion that is caused by fuel. DO NOT USE AGAIN
Light pitting in a low stress area of the piston. USE AGAIN
1/30/24, 3:26 PM SIS 2.0
Minimal pitting that is consistent across the piston. USE AGAIN
Fuel erosion has caused visible pitting in the crater but the pitting is minimal. USE AGAIN
Small concentration of light pitting in a low stress area of the piston. USE AGAIN
1/30/24, 3:26 PM SIS 2.0
Heavy deep pits. DO NOT USE AGAIN
This piston shows excessive pitting that exhibits increased intensity from left to right. DO NOT USE AGAIN
Deep aggressive pits in the spray pattern. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0
Multiple points of erosion in a high stress area of the piston. DO NOT USE AGAIN
Concentrated deep pits and erosion. DO NOT USE AGAIN
Deep erosion and pitting in one centralized location. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0
Deep erosion and pitting in one centralized location. This is a close up view of Illustration 58 DO NOT USE AGAIN
Multiple deep pits across the entire piston. DO NOT USE AGAIN
Erosion and pitting across the entire piston. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0
Multiple pits and erosion across the entire piston. DO NOT USE AGAIN
The piston has heavy erosion on the crown. Any piston that is displaying this severity of erosion anywhere on the crown should not be reused. DO NOT USE AGAIN
Crown
Light pitting. USE AGAIN
Light concentration of pitting on one location of the piston. USE AGAIN
1/30/24, 3:26 PM SIS 2.0
PIP
-
202 1046
4
12: 01/3 666
/ 4
2
SEB 6:35+ 0
© 2 F805 03:00
Cat 024 C 9
Light pitting in one area of the piston. USE AGAIN
e r
Con illa terpi
p a
fide r: llar
ntia Inc
l Ye .
llow
The piston crown is showing numerous deep pits and distinct pits.
DO NOT USE AGAIN
This piston shows multiple deep and shallow pits that extend near the bowl rim. Pits on the edge of the combustion bowl are not allowed. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0
A large concentration of small and larger pits in one area of the piston. These pits are too close to the bowl. DO NOT USE AGAIN
Concentration of shallow pitting transferring into deep pitting. DO NOT USE AGAIN
Deep pitting on the crown. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0
Deep pitting over a large area of crown and into the crater. DO NOT USE AGAIN
Mild impact damage with no imbedded material. No cracks are present and no damage is on corners of crown. This piston can be reused after salvage and inspection. USE AGAIN
Mild impact damage with no imbedded material. No cracks are present. This piston can be reused after salvage and inspection. USE AGAIN
Mild impact from valve with no imbedded material and no cracks are present. USE AGAIN
Mild impact from valve with no imbedded material and no cracks are present. USE AGAIN
1/30/24, 3:26 PM SIS 2.0
Mild impact from valve. USE AGAIN
Impact damage from valve with light raised material. The impact does not show the impression of the entire valve. This piston can be reused after salvage and inspection. USE AGAIN
Impact damage from valve. Do not reuse any piston showing the entire valve impression with raised material. DO NOT USE AGAIN
Heavier impact damage from valve that runs out to the bowl. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0
Heavy impact damage from multiple valves. DO NOT USE AGAIN
Heavy impact damage with raised material. DO NOT USE AGAIN
Heavy impact damage with raised material. DO NOT USE AGAIN
Heavy impact damage with deep pits and imbedded material. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0
Heavy impact damage with deep pits. DO NOT USE AGAIN
Heavy impact damage with deep pits. DO NOT USE AGAIN
Single Bolt Three Ring Piston for 3600, G3600, and C280
Reuse the piston.
Reuse the piston.
1/30/24, 3:26 PM SIS 2.0
Reuse the piston.
Reuse the piston.
Four Ring Piston for 3600, G3600, and C280

Pilot Diameter Of The Piston Skirt
Marks due to machining
Reuse the piston skirt.
Burrs
Do not reuse the piston.
Use the piston again after the burrs are removed.
1/30/24, 3:26 PM SIS 2.0
Too much fretting and smearing
Burrs
Reuse the piston.
Use the piston again after the burrs are removed.
Main Abutment Of The Piston Skirt
Use the piston again if the nuts were tight during the disassembly of the piston.
Reuse the piston.
1/30/24, 3:26 PM SIS 2.0
Too much fretting and smearing
This is a typical appearance.
Reuse the piston.
Remove any burrs.
Reuse the piston.
Excessive fretting
Outer Abutment Of The Piston Skirt

Initial stages of a piston that is cracking with material that is being torn from the inner edge of the outer abutment are for the joint.
1/30/24, 3:26 PM SIS 2.0
PIP
-
202 1046
12: 4 / 0 4 666
2 1 / 3
SEB :35+ 0
6
© 2 F805 03:00
Remove any burrs before reassembling the piston.
Reuse the skirt.
0
Cat 4 C2 9
e
Con rpilla aterpi
fide r: llar
ntia Inc
l Ye .
llow
Acceptable level of fretting
Reuse the piston.

The outer abutment has too much fretting. The main abutment has fretting that is advanced too much, even though the fretting is localized.
Piston Crown
1/30/24, 3:26 PM SIS 2.0

Too much fretting

The piston in this example has fretting that is excessive, damage from debris, damaged bolt holes, and heavy contact on the outside of the outer abutment.

Excessive fretting

A wear pattern that is acceptable
Reuse the piston.

A wear step that is worn into the outer abutment with contact outside the outer abutment and excessive deposits under the crown
1/30/24, 3:26 PM SIS 2.0

Contact of the edge is evident at the outside diameter of the piston.

Excessive deposits under the crown, contact at the outside diameter at six to eight o'clock and excessive fretting of the outer abutment
Pin Bore
During the visual inspection of the piston pin bore, carefully inspect the snap ring groove of the piston for damage or wear. Do not use the piston again if
the groove is excessively worn or damaged. Pistons should be checked in the snap ring groove for undetected wear by comparing the fit of the snap ring
in the old piston and in a new piston. The piston should not be reused if the effort to turn the snap ring in the used piston is significantly less than the new
piston.
Note: Orientation of the piston and piston pin is critical especially with one piece graphite coated pistons. Keep the pins orientated exactly how the pins
were removed from the pistons. Failure to do so may lead to pin seizure and engine failure.

Slight wear in retaining ring groove. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Small damage to the ring groove. USE AGAIN

Slight wear to pin bore. USE AGAIN

Slight wear in the ring groove from installation or removal of the snap ring. USE AGAIN
1/30/24, 3:26 PM SIS 2.0
The machining grooves are no longer visible in the ring groove. This piston pin bore is worn. DO NOT USE AGAIN

The piston has light wear on the edge of the bore, but the measurements of the bore are correct. USE AGAIN

The piston has discoloration on the bottom of the piston. Measure the piston pin bores to make sure that there is no distortion. USE AGAIN
Use the piston again.

The piston has a wear pattern inside the pin bore. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

The piston shows wear and light scratches in the pin bore that cannot be felt with a fingernail. USE AGAIN

Slight wear/discoloration on bushing. USE AGAIN

Slight discoloration on bushing. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Small scratch to bushing that can be felt with a fingernail. DO NOT USE AGAIN

Chaining abrasive wear to bushing. DO NOT USE AGAIN

Tempering to the bushing. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Polishing to the bushing. DO NOT USE AGAIN

Slight tempering and polishing to the bushing. DO NOT USE AGAIN
Note: If piston pin bushing has worn through the phosphate coating, it is possible to be reused again only if the pin bores still meet dimensional reuse then
they are deemed acceptable to reuse.

Phosphate coating worn, check dimensional specification. If in spec, this is acceptable reuse. If out of spec, replace the piston.
1/30/24, 3:26 PM SIS 2.0
PIP
202 -1046
12: 4 / 0 4 666
2 1 / 3
SEB :35+ 0
6
© 2 F805 03:00
0 9
2
Cat 4 C
e r
Con illa terpi
p a
fide r: llar
ntia Inc
l Ye .
llow
If the piston has a bushing and is showing wear like aboveDO NOT USE AGAIN


1/30/24, 3:26 PM SIS 2.0


One-Piece Aluminum Pistons

Some one-piece pistons have circular pin bores. Other one-piece pistons have elliptical pin bores. This wear pattern is formed by a side relief on both ends
of the horizontal diameter. Refer to Illustration 134. The vertical diameter must be within specifications in Table 7 but the horizontal diameter must only be
larger than the vertical diameter.

Finding Elliptical Tolerance
(11) Side relief for piston
(33) Major Diameter
(32) Minor Diameter
Note: The pin bore diameter of certain one-piece pistons are elliptical. Be sure that dimension (33) is larger than dimension (32).
Table 4
Acceptable Dimensions and Tolerances for Pistons with Elliptical Pin Bores
Part Pin Bore Minor Elliptical Tolerance Top Ring Groove

Number Diameter
Straight Width of Straight Ring Pin for Tapered Ring Groove
or Groove Groove
1/30/24, 3:26 PM SIS 2.0
Tapered Gauge B A
Pin Measurement
Diameter Over Pins
Major Diameter = Minor
7C-2431
70.003 ± 0.005 mm Diameter + 3.500 mm 168.630 ± 0.097 mm
9Y-2100 T N/A 9U-7360
(2.7560 ± 0.00020 inch) 0.040 ± 0.008 mm (0.1378 inch) (6.6390 ± 0.0038 inch)
9Y-4124
(0.0016 ± 0003 inch)
7E-8656 Major Diameter = Minor
50.814 ± 0.004 mm 3.302 mm 134.341 ± 0.097 mm
7E-8700 Diameter + 0.008 mm T N/A 4C-8169
(2.0005 ± 0.0002 inch) (0.1300 inch) (5.2890 ± 0.0038 inch)
(1)
(0.0003 inch)
212-7596
346-2096
376-4141
69.975 ± 0.033 mm Diameter + 3.63 ± 0.01 mm
455-7266 S 510-5864 N/A N/A
(2.7549 ± 0.0013 inch) 0.040 ± 0.008 mm (0.14291 ± 0.00039 inch)
478-7471
(0.0016 ± 0003 inch)
478-7472
495-5305
6I-4609
7E-7600
101-4140
133-9375 Major Diameter = Minor
192-3896 70.003 ± 0.005 mm Diameter + 3.63 ± 0.01 mm
S 510-5864 N/A N/A
197-3765 (2.7560 ± 0.0002 inch) 0.040 ± 0.008 mm (0.14291 ± 0.00039 inch)
280-3213 (0.0016 ± 0003 inch)
342-9847
376-7655
486-0883
107–3565
154-8087 Major Diameter = Minor
43.188 ± 0.004 mm 2.540 mm 117.455 ± 0.097 mm
165-4262 Diameter + 0.007 mm T N/A 4C-8168
(1.7003 ± 0.0002 inch) (0.1000 inch) (4.6242 ± 0.0038 inch)
168-4531 (0.0003 inch)
514-7396
129-0358 43.188 ± 0.004 mm 3.233 ± 0.013 mm
Diameter + 0.007 mm S N/A N/A N/A
164-6560 (1.7003 ± 0.0002 inch) (0.1273 ± 0.0005 inch)
(0.0003 inch)
233-2431 75.98 ± 0.02 mm 0.4 ± 0.007 mm 3.500 mm 168.35 ± 0.111 mm
T N/A 9U-7360
(2)
(2.9913 ± 0.0008 inch) (0.01575 ± 0.00028 inch) (0.1378 inch) (6.62794 ± 0.00437 inch)
165-4262 43.188 ± 0.004 mm Major Ø = Minor Ø + 2.540 mm 117.455 ± 0.097 mm
T N/A 4C-8168
168-4531 (1.7003 ± 0.0002 inch) 0.007 mm (0.0003 inch) (0.1000 inch) (4.6242 ± 0.0038 inch)
(1) These part numbers have elliptical piston pin bores. Tolerance between major and minor diameters is 0.008 mm or 0.0003 inch.
(2) This part number was canceled and replaced by part number 278–0247, then again by 299–5204. The elliptical pin bore feature was removed in these part number.
Two-Piece Pistons and One-Piece Steel Pistons

Piston pin bore diameter (32) on all two-piece piston crowns is in Table 7. The pin bore diameter (34) must be measured. Illustration 135 shows the
measurement locations.

Measurement locations for the new piston crown pin bore diameter.
(34) Refer to Table 7 for this dimension.
Inspect Bushings of Crown for Two-Piece Pistons and for One-Piece Steel Pistons
1/30/24, 3:26 PM SIS 2.0
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 136 as an example for rotation of the bushing.

The bushing of a two-piece piston crown has rotated.
Do not use the piston again.

Enlarged view of Illustration 136 which shows rotation of bushing
Procedure to Measure Piston Pin Bores for C175 Pistons
NOTICE
Precise measurements shall be made when the
component and measurement equipment are at 20 °C
(68 °F). Measurements shall be made after both the
component and measurement equipment have had
sufficient time to soak at 20 °C (68 °F). This will ensure
that both the surface and core of the material is at the
same temperature.
1/30/24, 3:26 PM SIS 2.0

View of Piston Pin Bore Plug Gage Assembly 491-3253 and Air Gage Regulator Column Amplifier 491-3146.
An air gage is the only method for measuring pin bore.
It is not necessary to check the piston pin bore diameter if the piston pin has been found with rotation that was easy during disassembly. If a piston has
been in an engine event which has caused force against the piston, check the pin bore for distortion.
Refer to manufactures operating manual for step-by-step instructions setup and measuring the pin bore.
To provide addition clarification and details, a Caterpillar Channel 1 video has been created outlining the critical steps in measuring the piston bore.
Reviewing the videos is recommended prior to starting the measuring process.
Note: A CWS login is required to access Caterpillar Channel 1 Videos.
Table 5
Caterpillar Channel 1
Title: "How to Measure a C175 Piston Bore"
https://channel1.mediaspace.kaltura.com/media/How+to+Measure+a+C175+Piston+Bore/1_06ro1gl7
Ring Grooves
Note: Measuring ring grooves can consume a considerable amount of time. Make sure that the piston is reusable by all other measurements and criteria
before performing the procedure to measure piston ring grooves.
Note: All piston ring grooves that show any wear steps must be measured.

Identification of piston ring grooves
(12) Top piston ring
(13) Intermediate piston ring
(14) Oil control piston ring
1/30/24, 3:26 PM SIS 2.0

Small wear step. USE AGAIN

Large wear step. DO NOT USE AGAIN

Carbon in the ring groove. Clean the piston again and reinspect. This piston is reusable if the carbon can be removed. USE AGAIN

Corrosion on the top ring grove. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Pitting in the bottom ring groove. DO NOT USE AGAIN
The ring groove gauge can be used on all pistons to inspect the grooves for the keystone ring. This gauge is recommended over former methods of
checking ring groove wear because of increased tool accuracy. This gauge works on both one and two-piece pistons. Refer to Table 7 for the correct
gauge part number.
Gauge is aligned with the center of the piston and the gauge has no side play.
Gauge does not slide far enough to align with the center of the piston.
1/30/24, 3:26 PM SIS 2.0
Gauge is aligned with the center of piston and the gauge has side play. Any amount of side play is not acceptable.
Table 7 provides specifications for the piston and specifications for the piston ring.

Correct use of the ring groove gauge. The gauge should not go in the groove past the gauge line that is on the top of the gauge.
Follow this procedure to determine ring groove wear.
1. Ensure that the piston is clean.
2. Visually inspect the piston before proceeding further.
3. Select the proper Ring Groove Gauge from Table 7 and use the proper Ring Groove Gauge to measure the piston ring grooves.
4. Check the ring grooves in two locations at 90 degrees from the pin bores. If the gauge goes into a groove past the gauge line near the end of the
gauge, do not use the piston again. Never use force to push the gauge into the groove.
5. The gauges have a gauge line across the width of the gauge for determining the maximum penetration of the gauge.
6. Reference Table 7 for the applicable specifications for piston ring grooves.
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 when the engine encounters cold starts of 10° C (50° F) or less. The result will
be a loose iron band. If the iron band is loose or free, the piston cannot be used again. Identifying a loose iron band is difficult with a visual inspection.
Ultrasonic inspection is the only reliable method 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.
1/30/24, 3:26 PM SIS 2.0

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. Illustration 151 and Illustration 152 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.
1/30/24, 3:26 PM SIS 2.0
PIP
-
202 1046
4
12: 01/3 666
/ 4
Illustration 152 2
SEB 6:35+ 0 g01276076
Bands that are incorrectly bonded will give a similar reading to the one above.
© 2 F805 03:00
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.
0
Cat 4 C2
NOTICE
9
e
Con rpilla aterpi
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.
fide r: llar
Ring Lands
ntia Inc
l Ye .
llow

Slight scuffing/adhesive wear. A narrow patch of scuffing is not acceptable for reuse. DO NOT USE AGAIN

Slight scuffing/adhesive wear. This is a close up photo of Illustration 153. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Slight scuffing/adhesive wear on the second land. This contact pattern is too wide for reuse of the piston. DO NOT USE AGAIN

Adhesive wear on ring lands. DO NOT USE AGAIN

Polishing of the entire middle ring land is not allowed. USE AGAIN

Slight pitting in the top ring land. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

The piston shows normal carbon scratches. The scratches are common on piston with offset pin bores.
USE AGAIN

Example of light carbon scratches on the piston.
USE AGAIN

The piston is displaying heavy carbon scratches in the top ring land.
DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0

The piston has light carbon scratches in the top ring land.
USE AGAIN
Use the piston again after the raised areas are removed with a file and the piston is properly cleaned.

Slight pitting on the bottom land. USE AGAIN

Small nicks without raised material. USE AGAIN

Slight wear to bottom land with no raised metal and the machining marks still visible. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Small ding to middle ring land that does not extend into the ring groove. This piston can be reused after salvage and inspection. USE AGAIN

Small ding on top of crown. USE AGAIN

Handling damage with slight raised material. This piston can be reused after salvage and inspection. USE AGAIN

Light handling damage with no raised material. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Handling damage with raised material across the entire land. DO NOT USE AGAIN

Handling damage that runs across the lands. DO NOT USE AGAIN

Handling damage with raised material that extends into the ring groove. DO NOT USE AGAIN

Light handling damage. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Ding in top ring land that has no raised material. USE AGAIN

Dent that is present across more than one land and also has raised material into the ring groove. DO NOT USE AGAIN

Small dent in bottom land with no raised material. USE AGAIN

Small dent in the top land with light raised material. This piston can be reused after salvage and inspection. USE AGAIN
Skirt
1/30/24, 3:26 PM SIS 2.0

The horizontal marking is discoloration and does not affect the reusability of the piston. USE AGAIN

The horizontal markings are the result of the manufacturing process and are not a defect. USE AGAIN

Discoloration is due to the cleaning solution. USE AGAIN
1/30/24, 3:26 PM SIS 2.0
PIP
-
202 1046
4
12: 01/3 666
/ 4
2
SEB 6:35+ 0
Illustration 181
© 2 F805 03:00
g02840281
0 9
A buffed and polished skirt that is ready for reuse. USE AGAIN
Cat 4 C2
e
Con rpilla aterpi
fide r: llar
ntia Inc
l Ye .
llow
Polishing marks with the original machining marks still showing after polishing. USE AGAIN

Small dings with no raised metal. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Slight ding on edge and side surface with no raised metal. USE AGAIN

Slight pitting. USE AGAIN

Slight pitting with no raised areas. USE AGAIN
1/30/24, 3:26 PM SIS 2.0
Light scratches on the bottom of the skirt. USE AGAIN

Minor scratches in the bottom of skirt. USE AGAIN

Light handling damage with no raised material. USE AGAIN

Light scratches in the skirt. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Steel piston with a scratch in the skirt that shows no raised material. USE AGAIN

This piston has been buffed and still shows a long deep scratch. DO NOT USE AGAIN

Deep horizontal scratch with raised material. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0

The scratches on this skirt are deeper than the machining marks and is quite large. DO NOT USE AGAIN

Large scratches deeper than machining marks and also with raised material. DO NOT USE AGAIN

Light scratch on the skirt. USE AGAIN

Scratch that still shows after polishing the skirt. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Light scuffing. USE AGAIN

Two dings in the skirt with light raised material. This piston can be reused after salvage and inspection. USE AGAIN

Deep gouges in the skirt. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0
Large gouge above the pin bore. DO NOT USE AGAIN

Damage on top surface of the skirt. This damage is at the joint between the skirt and the crown on two-piece pistons. No damage is allowed in this area.
DO NOT USE AGAIN

Scuffing on the skirt with transferred material. DO NOT USE AGAIN

1/30/24, 3:26 PM SIS 2.0


Severe scuffing due to seizure. DO NOT USE AGAIN

1/30/24, 3:26 PM SIS 2.0

Note: No embedded material is allowed. Embedded material appears as dark hard specks in the skirt surface that can scratch the cylinder wall. Do not
reuse any piston skirt that has embedded material.

Material is embedded into the surface.
DO NOT USE AGAIN

Material is embedded into the surface.
DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0
PIP
-
202 1046
4
12: 01/3 666
/ 4
Small amounts of embedded material are unacceptable.
DO NOT USE AGAIN
2
SEB 6:35+ 0
© 2 F805 03:00
Cat 024 C 9
e r
Con illa terpi
p a
fide r: llar
ntia Inc
l Ye .
llow
This example shows heavy concentration of embedded particles.
DO NOT USE AGAIN

A single large embedded particle is unacceptable, even if scratches are light.
DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Scratches are not deep and no embedded material is visible.
USE AGAIN

Scratches are not deep and no embedded material is visible.
USE AGAIN
Structure

Clean underside of piston. No discoloration or any other defects seen. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Clean underside of piston. No discoloration or any other defects seen. USE AGAIN

Slight Pitting. USE AGAIN

Slight Pitting. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Heavy Pitting. DO NOT USE AGAIN
Graphite Coated Pistons

Note: If a piston has severe scoring, material transfer, embedded material, or other obvious damage the piston should not be used again.
If the lower cover plates of the cooling gallery are found to be loose, the piston cannot be used again. Great care should be taken to inspect the inside of
the cooling gallery for debris. The use of a borescope may aid in inspecting the gallery.

Mild wear of graphite coating with no scratches. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Mild wear to graphite with scratch not penetrating the graphite coating. USE AGAIN

Mild wear to graphite coating with no scratches. Slight polishing to upper skirt area. USE AGAIN
Note: Do not use the piston again if the loss of coating on the skirt exceeds half the area of the skirt. The piston should not be reused if the wear is from
hard contact.

No deep scratches but over half of graphite coating is worn away. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Polishing should not go out to the edge of the skirt. DO NOT USE AGAIN

Minor scratches/coating wear/handling damage. USE AGAIN

Scratches with over half of the graphite coating worn. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Over half of the graphite coating is worn. DO NOT USE AGAIN


1/30/24, 3:26 PM SIS 2.0

Debonding of the graphite coating. DO NOT USE AGAIN

Debonding of the graphite coating. DO NOT USE AGAIN
Cracks in the Piston

Small cracks around the heat plug are normal. To measure these cracks, use a 34 gauge wire that has a diameter of 0.15 mm (0.006 inch) as a gauge. A
262-8390 Microscope can also be used.

If necessary, use a 262-8390 Microscope to measure the size of the cracks around the heat plug.
1/30/24, 3:26 PM SIS 2.0
PIP
-
202 1046
4
12: 01/3 666
/ 4
2
SEB 6:35+ 0
Illustration 235
© 2 F805 03:00 g06297503
0 9
View the cracks through the eyepiece of the 262-8390 Microscope. This crack is wider than 0.15 mm (0.006 inch).
Cat 4 C 2
e r
Con illa terpi
p a
fide r: llar
ntia Inc
l Ye .
llow
Small cracks that are less than 0.15 mm (0.006 inch) wide around the heat plug. USE AGAIN

The arrows show cracks that are wider than 0.15 mm (0.006 inch). DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Large cracks connected to each other. DO NOT USE AGAIN

The crack goes across the area between the relief for the valves. DO NOT USE AGAIN

Cracks in the crater that are not wider than 0.15 mm (0.006 inch). USE AGAIN
Note: Direct injection aluminum pistons have a sharp edge at the edge of the crater bowl to ensure good engine performance for emissions and fuel
economy. Fine cracks can begin at this sharp edge due to thermal fatigue and mechanical fatigue. Although some fine cracking may be normal, larger
cracks can be a sign of severe engine load factor. The pistons with crater cracks that are less than 6.00 mm (0.236 inch) long may be reused. The piston
can be reused if the cracks are on the edge of the crater rim of the piston. The cracks in the piston should not be within 30 degrees of the centerline of the
piston pin bore.
1/30/24, 3:26 PM SIS 2.0

Cracks that are less than 6.00 mm (0.236 inch) long are allowed within the shaded area.
(A) 30 degrees
(B) 6.00 mm (0.236 inch)

The cracks are in the crater area of an aluminum direct injection piston. Measure the length and angle of the crack in relation to the pin bore. Use the piston again if the crack is less than
6.00 mm (0.236 inch) long and the crack is not within 30 degrees of the pin bore. This crack is over 6.00 mm (0.236 inch). DO NOT USE AGAIN

The crack in the piston is outside of the allowable area for cracks.
DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0

A crack in the top land of the piston. DO NOT USE AGAIN

The crack is in the ring land of the piston. DO NOT USE AGAIN

The piston is showing heavy damage to the skirt. A piston with cracks in any area of the skirt make the piston unusable. DO NOT USE AGAIN
Note: Illustration 247,248, and 249 are the same piston. There is wear on the outside of the skirt but closer inspection shows a crack on the inside of the
skirt.
1/30/24, 3:26 PM SIS 2.0
No cracks are permitted. DO NOT USE AGAIN
1/30/24, 3:26 PM SIS 2.0

The piston has a crack in the web area. There is also damage near the pin bore of the piston. DO NOT USE AGAIN
Damage from Improper Handling

Top skirt damage. This piston can be reused after salvage operation and reinspect piston. USE AGAIN

Small ding in crown. This piston can be reused after salvage operation and inspection. USE AGAIN

Small dent in very edge of crown. USE AGAIN
1/30/24, 3:26 PM SIS 2.0

Small dent in crown. This piston can be reused after salvage operation and inspection. USE AGAIN

Large dent in very edge of crown. DO NOT USE AGAIN


1/30/24, 3:26 PM SIS 2.0

Nick in the pin bore. DO NOT USE AGAIN
Reconditioning Procedure
There are several methods for reconditioning minor damage to the piston crown and the piston skirt. Use the method for cleaning that is least aggressive
during the process for reconditioning of the piston.
A depression results when a part is scratched, nicked, or dented. The scratch, the nick, or the dent can also result in an area that is raised.

Carefully remove the raised metal area that is caused by nicks, dents, and scratches. Illustration 248 shows examples of the various types of damage to the piston. In order for the piston to
be reused, the piston must be cleaned and the area of metal that is raised must be removed from the surface.
(A) Scratch
(B) Raised Metal
The raised areas of the piston can be removed by several methods. The most common methods of removing raised metal are a file, a polishing wheel, or
an abrasive disc. The file is the most aggressive method for removing raised material. The file is recommended for small areas on the surface for material
that has been raised more than 0.20 mm (0.008 inch). Use caution to ensure that only the raised material is removed. Be sure that no indentations are left
behind from the reconditioning procedure.
The polishing wheel and the abrasive disc are used to remove small scratches in larger areas. The piston skirt is made from aluminum. To reduce the risk
of damage to the piston, manual buffing is preferred to a polishing wheel to remove scratches and imperfections. Illustration 181 and Illustration 182 show
an example of a skirt that was buffed with an abrasive disc.
Piston Pins that are Reusable

A piston pin can usually be used again if the following specifications are met.
The piston pin does not have visible signs of scratches, grooves, or nicks.
The piston pin does not have indication of smearing or metal transfer.
The surface texture is within the specification of 0.125 µm (5.00 µinch). Refer to "Procedure to Check Surface Texture" within this document.
The piston pin does not have a wear step that is larger than 0.005 mm (0.0002 inch). Refer to the section "Wear Step" within this document.
The piston pin is within the diameter specifications listed in Table 29.
1/30/24, 3:26 PM SIS 2.0
Note: Discoloration on the piston pin has no effect on the performance.
Visual Inspection
A through visual inspection is the first step in determining the reusability of a piston pin. Inspect the pin for nicks, dings, cracks, grooves, and overall
abuse. The following are some examples of light wear, however the piston pin is still reusable.

Reuse the Pin
The piston pin is smooth. Grooves or wear steps cannot be felt on this pin.
Note: The dark horizontal lines on the piston pin are dark spots in the picture. These lines will not be found on piston pins that are checked in the field.
Most of the photos in this guideline have these black lines in various forms. The black lines should be ignored.

Reuse the Pin
The surface of the piston pin is smooth.
Discoloration
Hot engine oil can discolor the piston pin through normal operation. Normally discoloration alone does not affect the pins hardness or heat treatment.
Discoloration alone is not a reason to discard a piston pin. The following section shows some examples of common discoloration that can occur and still
reuse the piston pin.

Reuse the Pin
The piston pin is discolored from hot engine oil.
1/30/24, 3:26 PM SIS 2.0
PIP
202 -1046
Illustration 263
Reuse the Pin
g01248382
12: 4 / 0 4 666
2 1 / 3
The piston pin is discolored from hot engine oil. Use the pin again if the surface is smooth and scratches cannot be felt.
SEB :35+ 0
6
© 2 F805 03:00
Cat 024 C 9
Illustration 264
e r
Con illa terpi
p
g01248386
a
fide r: llar
Reuse the Pin
The piston pin has been polished but the stains remain. No pits of rust exist.
ntia Inc
l Ye .
llow
Reuse the Pin
The piston pin is discolored on the surface.

Reuse the Pin
The piston pin is discolored from the engine oil.
1/30/24, 3:26 PM SIS 2.0

Reuse the Pin
The piston pin is discolored from the engine oil. Use the pin again if the surface is smooth and scratches cannot be felt with a fingernail.

Reuse the Pin
The piston pin is discolored. The discoloration may remain on the pin. Use the pin again if the surface is smooth and the pin meets the requirements for
the surface texture.

Reuse the Pin
The piston pin is discolored.
Piston Pins that are not Reusable

A piston pin cannot usually be used again if the following specifications are met.
The piston pin has distinct signs of scratches, grooves, or nicks.
The piston pin has indication of smearing or metal transfer.
The surface texture is beyond specifications. Refer to Table 29 within this document.
The piston pin has wear steps that are larger than specifications. Refer to the section "Wear Step" within this document.
The piston pin is not within the diameter specifications listed in Table 29.
Visual Inspection
A through visual inspection is the first step in determining the reusability of a piston pin. Inspect the pin barrel, end and chamfer area for nicks, dings,
cracks, grooves, and overall abuse. The following are some visual indicators that would render a piston pin unusable.
1/30/24, 3:26 PM SIS 2.0

Do Not Reuse the Pin
The piston pin has a scratch or a groove on the surface. Scratches or grooves are not acceptable.

The piston pin has a nick on the end of the pin. Nicks are not acceptable in any area of the piston pin.

The piston pin has damage from smearing.
1/30/24, 3:26 PM SIS 2.0

The piston pin shows indications of aluminum transfer.

The piston pin has a rough surface texture. When the surface texture is more than 0.125 µm (5.00 µinch), the surface texture is considered rough and
unacceptable.

The piston pin shows wear of the coating on the pin. Do not reuse piston pins with the coating that is worn off.
Handling Damage
Care must be taken during the disassembly process. The following are some examples of damage that was created in handling the piston pin after
disassembly.
1/30/24, 3:26 PM SIS 2.0

The piston pin has damage from handling on both ends.

The piston pin has nicks near the area for the rod eye bushing.

The piston pin has a small nick (A) near the area for the rod eye bushing and a stain (B). The stain is acceptable, but the nicks are unacceptable.
Rust Pitting
Rust will occasionally occur on the piston pin. When the rust is deep and begins to eat into the metal with a pit, then the pin would not be reusable. The
following are some examples of piston pins that had surface rust, were cleaned and polished, and the rust pits remained.

The piston pin has been polished to remove the stains, but the pits of rust remain on the piston pin.
1/30/24, 3:26 PM SIS 2.0

The piston pin has been polished to remove the discoloration, but pits of rust remain on the piston pin.

The piston pin still has pits of rust after being polished.

The piston pin has one large pit of rust and several small pits of rust near the area of wear for the rod eye bushing.

The piston pin has a damaged area that looks like a stain. However, light pitting can be seen by using 8S-2257 Eye Loupe As.
1/30/24, 3:26 PM SIS 2.0

The piston pin has pits of rust in the area for the rod eye bushing.

The piston pin has pits of rust that are still present after polishing.
The piston pin has pits of rust (C) after being polished.
Note: If the pits of rust are removed and the stains (B) remain, then the piston pin can be reused.

The piston pin has pits of rust (C) that are present after polishing. Some stains (B) can appear to be pits of rust without close examination.
Wear Step
1/30/24, 3:26 PM SIS 2.0
A wear step is formed as the piston runs in the engine. If a piston pin has wear steps that can be felt with a fingernail or measured beyond the
specification, then the piston pin should not be reused. This section details how to measure a wear step in a piston pin.

Detail of an unacceptable wear step on a pin.
(A) Wear step
(B) Height of wear step
The wear step (A) can be felt with a fingernail. The height of the wear step (B) measures larger than 0.005 mm (0.0002 inch).

Excessive wear step. The wear step can be felt after polishing.

(A) Wear step
(C) Pitting
The wear step (A) can be felt with a fingernail after polishing. Pitting (C) also makes the piston pin unusable.
Barrel Shaped Pins and Wear Steps

Some piston pins have a barrel shape near the ends of the pin (Illustration 291). This barrel shape can be mistaken for a wear step. Table 29 shows which
piston pins have barrel shaped ends.
1/30/24, 3:26 PM SIS 2.0
PIP
202 -1046
12: 4 / 0 4 666
2 1 / 3
SEB :35+ 0
6
Detail of the barrel shape found on certain piston pins.
© 2 F805 03:00
The height of the lip of barrel shaped pins is shown in Illustration 291. This lip in the pin can often be confused for a wear step, check Table 29 to see
which pins are barrel shaped, and use good judgment when looking for a wear step.
Cat 024 C 9
Procedure to Measure Wear Steps
e r
Con illa terpi
p a
fide r: llar
ntia Inc
l Ye .
llow
The piston pins can be checked for wear steps by hand. Refer to Illustration 292. If a wear step can be felt, the piston pin must be inspected more
carefully. If a wear step can be felt and the wear step is more than 0.005 mm (0.0002 inch), then the pin is unacceptable.

An example of excessive wear steps on a piston pin.
To be acceptable for reuse, a wear step must be no larger than 0.005 mm (0.0002 inch).Pins with wear steps larger than 0.005 mm (0.0002 inch) cannot
be reused. Measuring the wear step is possible with a V-block, a 3P-1568 Dial Indicator, a 6V-6167 Contact Point, and parts from a 8T-5096 Dial Indicator.
Refer to Illustration 294 and Illustration 295.
Note: The back of the 3P-1568 Dial Indicator must be replaced with a back that has a vertical center lug. Refer to Illustration 295.
1/30/24, 3:26 PM SIS 2.0

3P-1568 Dial Indicator with a back that has a vertical lug (A) and a 6V-6167 Contact Point (B)
Reusing 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 for cracking. Refer
to Illustration 296.
1/30/24, 3:26 PM SIS 2.0
Any wear on the plug must be evenly distributed around the top of the plug. Refer to Illustration 297. Normal wear will appear as a polished surface and no
material will be removed. If the top of the plug shows signs of wear on the material, do not reuse the plug.
NOTICE
If the plug or pin assembly is dropped, do not use it again.
Dropping can cause impact loading which can cause a crack in
the plug. The crack may not be visible during inspection. These
cracks can then cause the parts to fail which will result in
engine damage.
Piston Plug Assembly

When assembling the piston plug, take note of the following special assembly instructions.
1. Apply Loctite Hysol 9434 epoxy in a continuous bead where indicated in 298 on each pin plug.
2. Insert the plug into the wrist pin.
3. Do not allow any visible adhesive to remain on the outside of the plug after assembly.
4. Allow five days to cure at room temperature.
Retaining Rings
The retaining rings for piston pins cannot be reused once the engine has been run. A retaining ring must always be replaced with a new ring after being
removed from a piston.
Procedure for Measurement of Pistons and Pistons Pins

Note: Pin bore dimensions refer to the diameters before a manganese phosphate coating is applied. Allow 2.00 µm (78.7402 µinch) to 10.00 µm
(393.7008 µinch) when measuring pin bores with manganese phosphate coating.
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:
The engine must have operated with the original piston less than 8,000 hours.
There must be no visual defects on the piston ring.
Reuse the piston ring with the same liner or a new liner.
Specifications of Pistons
1/30/24, 3:26 PM SIS 2.0

Measurement Over Pins (MOP) and Groove example.
Table 6
One-Piece Piston Specifications
Top Ring Groove
Piston Pin for Tapered Rin

Piston Body Bore Pin Bore Diameter Straight Ring
Part Width of Straight
Diameter (Bearing Inside Diameter) or Groove A B
Number Groove
Tapered Gauge Pin Measu
Diameter Over P
38.118 ± 0.005 mm 3.276 ± 0.013 mm
1N-3064 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
1W-2064 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
1W-2066 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
1W-2071 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
1W-2072 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
1W-5792 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
2W-4831 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
2W-8411 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.128 ± 0.005 mm 3.230 ± 0.010 mm
3S-4028 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
38.128 ± 0.005 mm 3.230 ± 0.010 mm
4N-4029 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
40.020 ± 0.008 mm 2.540 mm 10
4P-1550 N/A T N/A 4C-8164
(1.5756 ± 0.0003 inch) (0.1000 inch) (4.0
38.128 ± 0.005 mm 3.230 ± 0.010 mm
4P-2654 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
38.128 ± 0.005 mm 3.230 ± 0.010 mm
4P-2655 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
40.020 ± 0.008 mm 2.540 mm 10
4P-2990 N/A T N/A 4C-8164
(1.5756 ± 0.0003 inch) (0.1000 inch) (4.0
50.815 ± 0.005 mm 2.525 ± 0.010 mm
4P-7187 N/A S N/A N/A
(2.0006 ± 0.0002 inch) (0.0994 ± 0.0004 inch)
50.815 ± 0.005 mm 3.864 ± 0.010 mm
4P-8996 N/A S N/A N/A
(2.0006 ± 0.0002 inch) (0.1521 ± 0.0004 inch)
38.128 ± 0.005 mm 3.230 ± 0.010 mm
5S-9017 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
40.020 ± 0.008 mm 2.540 mm 10
6I-1144 N/A T N/A 4C-8164
(1.5756 ± 0.0003 inch) (0.1000 inch) (4.0
6I-4609 70.003 ± 0.005 mm N/A S 3.630 ± 0.010 mm N/A N/A
1/30/24, 3:26 PM SIS 2.0
(2.7560 ± 0.0002 inch) (0.1429 ± 0.0004 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
6N-4220 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
6N-4340 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
6N-4350 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
6N-8648 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
6N-9087 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
6N-9088 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
50.815 ± 0.008 mm 3.300 mm 13
7C-0473 N/A T N/A 325-8422
(2.0006 ± 0.0003 inch) (0.1299 inch) (5.3
38.118 ± 0.005 mm 3.276 ± 0.013 mm
7C-0893 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
7C-1146 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
70.003 ± 0.005 mm 3.500 mm 16
7C-2431 N/A T N/A 9U-7360
(2.7560 ± 0.00020 inch) (0.1378 inch) (6.6
38.118 ± 0.005 mm 3.276 ± 0.013 mm
7C-2553 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
50.808 ± 0.004 mm 3.300 mm 13
7C-3496 N/A T N/A 325-8423
(2.0003 ± 0.0002 inch) (0.1299 inch) (5.3
38.118 ± 0.005 mm 3.276 ± 0.013 mm
7C-3858 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
40.020 ± 0.008 mm 2.540 mm 10
7C-5668 N/A T N/A 4C-8164
(1.5756 ± 0.0003 inch) (0.1000 inch) (4.0
55.021 ± 0.004 mm 3.300 mm 13
7E-0292 N/A T N/A 4C-8169
(2.1662 ± 0.0002 inch) (0.1299 inch) (5.2
50.814 ± 0.004 mm 3.302 mm 13
7E-0305 N/A T N/A 4C-8169
(2.0005 ± 0.0002 inch) (0.1300 inch) (5.2
50.814 ± 0.004 mm 3.302 mm 13
7E-0539 N/A T N/A 4C-8169
(2.0005 ± 0.0002 inch) (0.1300 inch) (5.2
40.020 ± 0.008 mm 2.540 mm 10
7E-1298 N/A T N/A 4C-8164
(1.5756 ± 0.0003 inch) (0.1000 inch) (4.0
40.020 ± 0.008 mm 2.540 mm 10
7E-3428 N/A T N/A 4C-8164
(1.5756 ± 0.0003 inch) (0.1000 inch) (4.0
50.815 ± 0.005 mm 2.527 ± 0.013 mm
7E-3888 N/A S N/A N/A
(2.0006 ± 0.0002 inch) (0.0995 ± 0.0005 inch)
38.128 ± 0.005 mm 2.540 mm 11
7E-4729 N/A T N/A 4C-8166
(1.5011 ± 0.0002 inch) (0.1000 inch) (4.3
50.815 ± 0.005 mm 2.527 ± 0.013 mm
7E-8335 N/A S N/A N/A
(2.0006 ± 0.0002 inch) (0.0995 ± 0.0005 inch)
50.814 ± 0.004 mm 3.302 mm 13
7E-8885 N/A T N/A 4C-8169
(2.0005 ± 0.0002 inch) (0.1300 inch) (5.2
38.128 ± 0.005 mm 2.540 mm 11
7E-9937 N/A T N/A 4C-8166
(1.5011 ± 0.0002 inch) (0.1000 inch) (4.3
50.815 ± 0.008 mm 2.540 mm 13
7N-3510 N/A T N/A 574-6683
(2.0006 ± 0.0003 inch) (0.1000 inch) (5.2
50.815 ± 0.008 mm 2.540 mm 13
7N-3511 N/A T N/A 574-6683
(2.0006 ± 0.0003 inch) (0.1000 inch) (5.2
38.128 ± 0.005 mm 3.230 ± 0.010 mm
7S-9366 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
7W-3846 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
7W-3847 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
7W-8111 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (0.1290 ± 0.0005 inch)
1/30/24, 3:26 PM SIS 2.0
38.128 ± 0.005 mm 3.230 ± 0.010 mm

8L-4165 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
38.128 ± 0.005 mm 3.230 ± 0.010 mm
8L-4166 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
38.128 ± 0.005 mm 3.230 ± 0.010 mm
8L-5277 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
38.128 ± 0.005 mm 3.230 ± 0.010 mm
8N-3181 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
38.128 ± 0.005 mm 3.230 ± 0.010 mm
8N-3184 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9L-6979 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9L-9298 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9L-9299 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9L-9300 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9L-9361 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9L-9362 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9L-9363 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9L-9670 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9L-9671 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9L-9672 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9L-9299 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9N-0579 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9N-0580 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
43.195 ± 0.008 mm 3.233 ± 0.013 mm
9N-5249 N/A S N/A N/A
(1.7006 ± 0.0003 inch) (0.1273 ± 0.0005 inch)
43.195 ± 0.008 mm 2.540 mm 11
9N-5402 N/A T N/A 4C-8168
(1.7006 ± 0.0003 inch) (0.1000 inch) (4.6
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9N-5405 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9N-5406 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9N-5407 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9N-5407 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9N-5631 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9N-5754 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.128 ± 0.005 mm 3.230 ± 0.010 mm
9S-8913 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9Y-1219 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
70.003 ± 0.005 mm 3.500 mm 16
9Y-2100 N/A T N/A 9U-7360
(2.7560 ± 0.00020 inch) (0.1378 inch) (6.6
50.815 ± 0.008 mm 3.302 mm 13
9Y-3116 N/A T N/A 4C-8169
(2.0006 ± 0.0003 inch) (0.1300 inch) (5.2
70.003 ± 0.005 mm 3.500 mm 16
9Y-4124 N/A T N/A 9U-7360
(2.7560 ± 0.00020 inch) (0.1378 inch) (6.6
1/30/24, 3:26 PM SIS 2.0
38.118 ± 0.005 mm 3.276 ± 0.013 mm

9Y-4187 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
38.118 ± 0.005 mm 3.276 ± 0.013 mm
9Y-6773 N/A S N/A N/A
(1.5007 ± 0.0002 inch) (1) (0.1290 ± 0.0005 inch)
50.815 ± 0.008 mm 3.302 mm 13
9Y-7212 N/A T N/A 4C-8169
(2.0006 ± 0.0003 inch) (0.1300 inch) (5.2
40.020 ± 0.008 mm 2.540 mm 10
9Y-7452 N/A T N/A 4C-8164
(1.5756 ± 0.0003 inch) (0.1000 inch) (4.0
50.815 ± 0.008 mm 3.302 mm 13
9Y-9889 N/A T N/A 4C-8169
(2.0006 ± 0.0003 inch) (0.1300 inch) (5.2
50.814 ± 0.004 mm 3.302 mm 13
100-7403 N/A T N/A 4C-8169
(2.0005 ± 0.0002 inch) (0.1300 inch) (5.2
55.021 ± 0.004 mm 3.300 mm 13
101-0016 N/A T N/A 4C-8169
(2.1662 ± 0.0002 inch) (0.1299 inch) (5.2
38.128 ± 0.005 mm 2.540 mm 11
101-0812 N/A T N/A 4C-8166
(1.5011 ± 0.0002 inch) (0.1000 inch) (4.3
38.128 ± 0.005 mm 3.230 ± 0.010 mm
109-5845 N/A S N/A N/A
(1.5011 ± 0.0002 inch) (1) (0.1272 ± 0.0004 inch)
40.020 ± 0.008 mm 2.540 mm 10
105-1710 N/A T N/A 4C-8164
(1.5756 ± 0.0003 inch) (0.1000 inch) (4.0
30.005 ± 0.005 mm 2.550 mm 95
107-8366 N/A T N/A 4C-8164
(1.1813 ± 0.0002 inch) (0.1004 inch) (3.7
30.005 ± 0.005 mm 2.550 mm 95
107-0984 N/A T N/A 4C-8164
(1.1813 ± 0.0002 inch) (0.1004 inch) (3.7
50.815 ± 0.005 mm 3.864 ± 0.010 mm
107-1704 N/A S N/A N/A
(2.0006 ± 0.0002 inch) (0.1521 ± 0.0004 inch)
40.020 ± 0.008 mm 2.540 mm 10
107-7563 N/A T N/A 4C-8164
(1.5756 ± 0.0003 inch) (0.1000 inch) (4.0
50.815 ± 0.005 mm 3.864 ± 0.010 mm
112-4585 N/A S N/A N/A
(2.0006 ± 0.0002 inch) (0.1521 ± 0.0004 inch)
55.021 ± 0.004 mm 3.300 mm 13
117-5063 N/A T N/A 4C-8169
(2.1662 ± 0.0002 inch) (0.1299 inch) (5.2
38.128 ± 0.005 mm 2.540 mm 11
121-4695 N/A T N/A 4C-8166
(1.5011 ± 0.0002 inch) (0.1000 inch) (4.3
50.815 ± 0.005 mm 3.864 ± 0.010 mm
127-5723 N/A S N/A N/A
(2.0006 ± 0.0002 inch) (0.1521 ± 0.0004 inch)
30.005 ± 0.005 mm 2.550 mm 95
128-2952 N/A T N/A 4C-8164
(1.1813 ± 0.0002 inch) (0.1004 inch) (3.7
30.005 ± 0.005 mm 2.550 mm 95
128-3295 N/A T N/A 4C-8164
(1.1813 ± 0.0002 inch) (0.1004 inch) (3.7
50.815 ± 0.005 mm 3.864 ± 0.010 mm
136-6007 N/A S N/A N/A
(2.0006 ± 0.0002 inch) (0.1521 ± 0.0004 inch)
130.059 ± 0.009 mm 6.175 ± 0.015 mm
136-9360 N/A S 197-3710 N/A
(5.12042 ± 0.00035 inch) (0.24311 ± 0.00059 inch)
50.814 ± 0.004 mm 3.302 mm 13
160-1131 N/A T N/A 4C-8169
(2.0005 ± 0.0002 inch) (0.1300 inch) (5.2
30.005 ± 0.005 mm 2.550 mm 95
160-6600 N/A T N/A 4C-8164
(1.1813 ± 0.0002 inch) (0.1004 inch) (3.7
50.815 ± 0.005 mm 3.864 ± 0.010 mm
160-7992 N/A S N/A N/A
(2.0006 ± 0.0002 inch) (0.1521 ± 0.0004 inch)
50.815 ± 0.005 mm 3.864 ± 0.010 mm
160-7994 N/A S N/A N/A
(2.0006 ± 0.0002 inch) (0.1521 ± 0.0004 inch)
50.814 ± 0.004 mm 3.302 mm 13
172-3280 N/A T N/A 4C-8169
(2.0005 ± 0.0002 inch) (0.1300 inch) (5.2
50.814 ± 0.004 mm 3.302 mm 13
174-6102 N/A T N/A 4C-8169
(2.0005 ± 0.0002 inch) (0.1300 inch) (5.2
50.814 ± 0.004 mm 3.302 mm 13
174-6103 N/A T N/A 4C-8169
(2.0005 ± 0.0002 inch) (0.1300 inch) (5.2
50.858 ± 0.008 mm 3.300 mm 13
192-2208 N/A T N/A 325-8423
(2.0023 ± 0.0003 inch) (0.1299 inch) (5.3
50.858 ± 0.008 mm 3.300 mm 13
192-2209 N/A T N/A 325-8423
(2.0023 ± 0.0003 inch) (0.1299 inch) (5.3
1/30/24, 3:26 PM SIS 2.0
40.0115 ± 0.0025 mm 3.162 mm 10

197-9340 N/A T N/A 325-8420
(1.5753 ± 0.0001 inch) (0.1245 inch) (4.3
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
197-9381 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
197-9383 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
30.005 ± 0.005 mm 2.550 mm 95
200-7904 N/A T N/A 4C-8164
(1.1813 ± 0.0002 inch) (0.1004 inch) (3.7
65.635 ± 0.01 mm 60.0925 ± 0.0075 mm 2.54 mm
219-8102 T N/A 325-8418
(2.5841 ± 0.0004 inch) (2.3658 ± 0.0003 inch) (0.100 inch) (5.6
30.005 ± 0.005 mm 2.550 mm 95
225-4284 N/A T N/A 4C-8164
(1.1813 ± 0.0002 inch) (0.1004 inch) (3.7
75.980 + 0.02 - 0.00 mm 69.962 + 0.113 / +0.098 mm 3.50 mm 16
233-2430 T N/A 9U-7360
(2.9913 + 0.0008 - 0.00 inch) (2.75440 + 0.0045 / + 0.0039 inch) (0.1378 inch) (6.6
30.005 ± 0.005 mm 2.550 mm 95
234-4814 N/A T N/A 4C-8164
(1.1813 ± 0.0002 inch) (0.1004 inch) (3.7
65.635 ± 0.01 mm 60.0925 ± 0.0075 mm 2.54 mm
235-6257 T N/A 325-8418
(2.5841 ± 0.0004 inch) (2.3658 ± 0.0003 inch) (0.100 inch) (5.6
65.635 ± 0.01 mm 60.0925 ± 0.0075 mm 3.300 mm 14
235-8098 T N/A N/A
(2.5841 ± 0.0004 inch) (2.3658 ± 0.0003 inch) (0.1299 inch) (5.6
40.012 ± 0.003 mm 3.162 mm 10
238-2698 N/A T N/A 325-8420
(1.5753 ± 0.0001 inch) (0.1245 inch) (4.3
57.367 ± 0.01 mm 53.220 ± 0.01 mm 3.500 mm 12
238-2713 T N/A 574-6685
(2.2585 ± 0.0004 inch) (2.0953 ± 0.0004 inch) (0.1378 inch) (5.0
43.808 ± 0.01 mm 40.038 ± 0.01 mm 3.000 mm 10
238-2720 T N/A 325-8420
(1.7247 ± 0.0004 inch) (1.5763 ± 0.0004 inch) (0.1181 inch) (4.2
40.0115 ± 0.0025 mm 3.162 mm 10
238-2729 N/A T N/A 325-8420
(1.5753 ± 0.0001 inch) (0.1245 inch) (4.3
65.635 ± 0.01 mm 60.0925 ± 0.0075 mm 3.300 mm 14
239-7844 T N/A N/A
(2.5841 ± 0.0004 inch) (2.3658 ± 0.0003 inch) (0.1299 inch) (5.6
30.005 ± 0.005 mm 2.550 mm 95
239-8506 N/A T N/A 4C-8164
(1.1813 ± 0.0002 inch) (0.1004 inch) (3.7
65.635 ± 0.01 mm 60.0925 ± 0.0075 mm 3.300 mm 13
247-6123 T N/A 325-8423
(2.5841 ± 0.0004 inch) (2.3658 ± 0.0003 inch) (0.1299 inch) (5.3
60.0925 ± 0.0075 mm 3.300 mm 13
247-7791 N/A T N/A 325-8423
(2.3658 ± 0.0003 inch) (0.1299 inch) (5.3
60.0925 ± 0.0075 mm 3.300 mm 13
247-7792 N/A T N/A 325-8423
(2.3658 ± 0.0003 inch) (0.1299 inch) (5.3
60.0925 ± 0.0075 mm 3.300 mm 13
248-5516 N/A T N/A 325-8423
(2.3658 ± 0.0003 inch) (0.1299 inch) (5.3
60.0925 ± 0.0075 mm 3.300 mm 13
252-0656 N/A T N/A 325-8423
(2.3658 ± 0.0003 inch) (0.1299 inch) (5.3
46.015 ± 0.003 mm 3.200 mm 110
262-7330 N/A T N/A 325-8420
(1.8116 ± 0.0001 inch) (0.1260 inch) (4.3
50.013 ± 0.003 mm 3.270 mm 11
262-7331 N/A T N/A 418-9826
(1.9690 ± 0.0001 inch) (0.1287 inch) (4.5
40.0115 ± 0.0025 mm 3.200 mm 110
262-9288 N/A T N/A 325-8420
(1.57525 ± 0.00010 inch) (0.1260 inch) (4.3
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
265-1111 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
57.367 ± 0.01 mm 53.220 ± 0.01 mm 3.500 mm 12
265-1313 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0953 ± 0.0004 inch) (0.1378 inch) (5.0
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
267-2068 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
75.98 ± 0.02 mm 70.0705 ± 0.0075 mm 3.500 mm 16
278-0247 T N/A 9U-7360
(2.9913 ± 0.0008 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.62
43.808 ± 0.008 mm 40.038 ± 0.01 mm 2.900 mm 10
278-0574 T N/A 325-8420
(1.72472 ± 0.00031 inch) (1.5763 ± 0.0004 inch) (0.1142 inch) (4.24
57.347 ± 0.01 mm 53.260 ± 0.01 mm 3.500 mm 12
280-7098 T N/A 208-7632
(2.2578 ± 0.0004 inch) (2.0969 ± 0.0004 inch) (0.1378 inch) (5.0
75.980 + 0.02 - 0.00 mm 69.962 + 0.113 / +0.098 mm 3.50 mm 16
282-0644 T N/A 9U-7360
(2.9913 + 0.0008 - 0.00 inch) (2.75440 + 0.0045 / + 0.0039 inch) (0.1378 inch) (6.6
1/30/24, 3:26 PM SIS 2.0
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12

286-7208 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
50.815 ± 0.008 mm 3.302 mm 13
290-0017 N/A T N/A 4C-8169
(2.0006 ± 0.0003 inch) (0.1300 inch) (5.2
34.007 ± 0.005 mm 3.000 mm 10
297-7750 N/A T N/A 4C-8164
(1.3389 ± 0.0002 inch) (0.1181 inch) (4.0
34.007 ± 0.005 mm 3.000 mm 10
297-7751 N/A T N/A 4C-8164
(1.3389 ± 0.0002 inch) (0.1181 inch) (4.0
34.007 ± 0.005 mm 3.000 mm 10
297-7752 N/A T N/A 4C-8164
(1.3389 ± 0.0002 inch) (0.1181 inch) (4.0
34.007 ± 0.005 mm 3.000 mm 10
297-7753 N/A T N/A 4C-8164
(1.3389 ± 0.0002 inch) (0.1181 inch) (4.0
75.98 ± 0.02 mm 70.0705 ± 0.0075 mm 3.500 mm 16
299-5204 T N/A 9U-7360
(2.9913 ± 0.0008 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.62
60.0925 ± 0.0075 mm 3.300 mm 13
306-7460 N/A T N/A 325-8423
(2.3658 ± 0.0003 inch) (0.1299 inch) (5.3
75.980 + 0.02 mm 70.0705 ± 0.0075 mm 3.500 mm 16
314-5005 T N/A 246-1176
(2.9913 + 0.0008 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.6
75.980 + 0.02 mm 70.0705 ± 0.0075 mm 3.500 mm 16
314-5006 T N/A 246-1176
(2.9913 + 0.0008 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.6
75.980 + 0.02 mm 70.0705 ± 0.0075 mm 3.500 mm 16
314-5007 T N/A 246-1176
(2.9913 + 0.0008 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.6
65.635 ± 0.01 mm 60.0925 ± 0.0075 mm 3.300 mm 14
319-6715 T N/A N/A
(2.5841 ± 0.0004 inch) (2.3658 ± 0.0003 inch) (0.1299 inch) (5.6
65.635 ± 0.01 mm 60.0925 ± 0.0075 mm 3.300 mm 14
319-6716 T N/A N/A
(2.5841 ± 0.0004 inch) (2.3658 ± 0.0003 inch) (0.1299 inch) (5.6
65.635 ± 0.01 mm 60.0925 ± 0.0075 mm 3.300 mm 14
319-6717 T N/A N/A
(2.5841 ± 0.0004 inch) (2.3658 ± 0.0003 inch) (0.1299 inch) (5.6
50.013 ± 0.003 mm 3.270 mm 11
319-7886 N/A T N/A 418-9826
(1.9690 ± 0.0001 inch) (0.1287 inch) (4.5
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
322-0329 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
322-3146 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
322-3148 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
57.347 ± 0.01 mm 53.260 ± 0.01 mm 3.500 mm 12
322-3149 T N/A 208-7632
(2.2578 ± 0.0004 inch) (2.0969 ± 0.0004 inch) (0.1378 inch) (5.0
75.121 ± 0.015 mm 3.6 ± 0.01 mm
323-4017 N/A N/A 510-5864 N/A
(2.9575 ± 0.0006 inch) (0.1417 ± 0.0004 inch)
75.121 ± 0.015 mm 3.6 ± 0.01 mm
323-4018 N/A N/A 510-5864 N/A
(2.9575 ± 0.0006 inch) (0.1417 ± 0.0004 inch)
60.095 ± 0.010 mm 3.400 mm 135
325-9492 N/A T N/A 325-8423
(2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
65.635 ± 0.01 mm 60.0925 ± 0.0075 mm 3.300 mm 14
329-4509 T N/A N/A
(2.5841 ± 0.0004 inch) (2.3658 ± 0.0003 inch) (0.1299 inch) (5.6
65.635 ± 0.01 mm 60.0925 ± 0.0075 mm 3.300 mm 14
329-4510 T N/A N/A
(2.5841 ± 0.0004 inch) (2.3658 ± 0.0003 inch) (0.1299 inch) (5.6
65.635 ± 0.01 mm 60.0925 ± 0.0075 mm 3.300 mm 14
329-4511 T N/A N/A
(2.5841 ± 0.0004 inch) (2.3658 ± 0.0003 inch) (0.1299 inch) (5.6
65.635 ± 0.01 mm 60.0925 ± 0.0075 mm 3.300 mm 14
330-6090 T N/A N/A
(2.5841 ± 0.0004 inch) (2.3658 ± 0.0003 inch) (0.1299 inch) (5.6
60.095 ± 0.010 mm 3.400 mm 135
330-7762 N/A T N/A 325-8423
(2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
75.99 ± 0.01 mm 70.0705 ± 0.0075 mm 3.500 mm 16
331-9822 T N/A 574-6686
(2.9917± 0.0004 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.4
60.095 ± 0.005 mm 3.8 mm 14
338-3641 N/A T N/A 574-6687
(2.3659 ± 0.0002 inch) (0.150 inch) (5.7
75.99 ± 0.01 mm 70.0705 ± 0.0075 mm 3.500 mm 16
339-3027 T N/A 574-6686
(2.9917± 0.0004 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.4
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
339-8174 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
1/30/24, 3:26 PM SIS 2.0
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12

339-8176 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
339-8177 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
53.250 ± 0.01 mm 3.500 mm 12
PIP
342-6357 N/A T N/A 208-7632
(2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
60.095 ± 0.010 mm 3.400 mm 135
-
342-6359 N/A T N/A 325-8423
202 1046
(2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
75.99 ± 0.01 mm 70.0705 ± 0.0075 mm 3.500 mm 16
343-7301 T N/A 574-6686
(2.9917± 0.0004 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.4
346-6615
60.095 ± 0.010 mm
(2.3659 ± 0.0004 inch)
60.095 ± 0.010 mm
4
12: 01/3 666
/ 4 N/A T N/A 325-8423
3.400 mm
(0.1339 inch)
3.400 mm
135
(5.34
135
2
346-6616 N/A T N/A 325-8423
(2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
SEB 6:35+ 0
60.095 ± 0.010 mm 3.400 mm 135
346-6617 N/A T N/A 325-8423
(2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
60.095 ± 0.010 mm 3.400 mm 135
© 2 F805 03:00
346-6618 N/A T N/A 325-8423
(2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
60.095 ± 0.010 mm 3.400 mm 135
347-3241 N/A T N/A 325-8423
(2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
348-5356
75.980 + 0.02 mm
(2.9913 + 0.0008 inch)
75.99 ± 0.01 mm
0
Cat 4 C2 9 70.0705 ± 0.0075 mm
(2.7587 ± 0.0003 inch)
70.0705 ± 0.0075 mm
T N/A 246-1176
3.500 mm
(0.1378 inch)
3.500 mm
16
(6.6
16
e
Con rpilla aterpi
348-5357 T N/A 574-6686
(2.9917± 0.0004 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.4
75.99 ± 0.01 mm 70.0705 ± 0.0075 mm 3.500 mm 16
349-8473 T N/A 574-6686
(2.9917± 0.0004 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.4
352-4981
60.095 ± 0.010 mm
fide r:
(2.3659 ± 0.0004 inch)
llarN/A T N/A 325-8423
3.400 mm
(0.1339 inch)
135
(5.34
ntia Inc
60.095 ± 0.010 mm 3.400 mm 135
356-4787 N/A T N/A 325-8423
(2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
356-9946
60.095 ± 0.010 mm
(2.3659 ± 0.0004 inch)
l Ye N/A
. T N/A 325-8423
3.400 mm
(0.1339 inch)
135
(5.34
llow
50.013 ± 0.003 mm 3.270 mm 11
357-0447 N/A T N/A 418-9826
(1.9690 ± 0.0001 inch) (0.1287 inch) (4.5
60.125 ± 0.005 mm 3.6 mm 14
361-5742 N/A T N/A 325-8425
(2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
60.125 ± 0.005 mm 3.6 mm 14
361-5744 N/A T N/A 325-8425
(2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
60.125 ± 0.005 mm 3.8 mm 14
362-9350 N/A T N/A 574-6687
(2.3671 ± 0.0002 inch) (0.150 inch) (5.7
60.125 ± 0.005 mm 3.8 mm 14
362-9351 N/A T N/A 574-6687
(2.3671 ± 0.0002 inch) (0.150 inch) (5.7
60.125 ± 0.005 mm 3.6 mm 14
367-5160 N/A T N/A 325-8425
(2.3671 ± 0.0002 inch) (0.1417 inch) (5.70
60.095 ± 0.005 mm 3.6 mm 14
367-5181 N/A T N/A 325-8425
(2.3659 ± 0.0002 inch) (0.1417 inch) (5.70
50.858 ± 0.008 mm 3.300 mm 13
367-5183 N/A T N/A 325-8423
(2.0023 ± 0.0003 inch) (0.1299 inch) (5.3
60.125 ± 0.005 mm 3.6 mm 14
368-7815 N/A T N/A 325-8425
(2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
60.125 ± 0.005 mm 3.6 mm 14
368-7816 N/A T N/A 325-8425
(2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
60.125 ± 0.005 mm 3.6 mm 14
368-7817 N/A T N/A 325-8425
(2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
60.125 ± 0.005 mm 3.6 mm 14
368-7818 N/A T N/A 325-8425
(2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
60.125 ± 0.005 mm 3.6 mm 14
368-8179 N/A T N/A 325-8425
(2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
75.99 ± 0.01 mm 70.0705 ± 0.0075 mm 3.500 mm 16
369-1284 T N/A 574-6686
(2.9917± 0.0004 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.4
50.013 ± 0.003 mm 3.270 mm 11
369-5326 N/A T N/A 418-9826
(1.9690 ± 0.0001 inch) (0.1287 inch) (4.5
1/30/24, 3:26 PM SIS 2.0
60.125 ± 0.005 mm 3.6 mm 14

372-4884 N/A T N/A 325-8425
(2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
60.125 ± 0.005 mm 3.6 mm 14
372-4970 N/A T N/A 325-8425
(2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
75.980 + 0.02 mm 70.0705 ± 0.0075 mm 3.500 mm 16
374-2082 T N/A 246-1176
(2.9913 + 0.0008 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.6
75.980 + 0.02 mm 70.0705 ± 0.0075 mm 3.500 mm 16
374-2083 T N/A 246-1176
(2.9913 + 0.0008 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.6
60.125 ± 0.005 mm 3.6 mm 14
375-8134 N/A T N/A 325-8425
(2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
60.125 ± 0.005 mm 3.6 mm 14
375-8261 N/A T N/A 325-8425
(2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
60.095 ± 0.010 mm 3.400 mm 135
376-7362 N/A T N/A 325-8423
(2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
75.99 ± 0.01 mm 70.0705 ± 0.0075 mm 3.500 mm 16
376-8090 T N/A 574-6686
(2.9917± 0.0004 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.4
50.815 ± 0.008 mm 3.302 mm 13
378-0509 N/A T N/A 4C-8169
(2.0006 ± 0.0003 inch) (0.1300 inch) (5.2
50.815 ± 0.008 mm 3.302 mm 13
378-1441 N/A T N/A 4C-8169
(2.0006 ± 0.0003 inch) (0.1300 inch) (5.2
60.095 ± 0.010 mm 3.400 mm 135
381-9249 N/A T N/A 325-8423
(2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
60.095 ± 0.010 mm 3.400 mm 135
381-9250 N/A T N/A 325-8423
(2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
70.0705 ± 0.0075 mm 3.6 ± 0.01 mm
384-2884 N/A S N/A N/A
(2.7587 ± 0.0003 inch) (0.142 ± 0.0004 inch)
53.250 ± 0.01 mm 3.500 mm 12
384-3698 N/A T N/A 208-7632
(2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
388-2310 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
388-9353 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
60.095 ± 0.010 mm 60.095 ± 0.010 mm 3.400 mm 135
388-9354 T N/A 325-8423
(2.3659 ± 0.0004 inch) (2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
388-9355 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
57.367 ± 0.01 mm 53.250 ± 0.01 mm 3.500 mm 12
388-9356 T N/A 208-7632
(2.2585 ± 0.0004 inch) (2.0965 ± 0.0004 inch) (0.1378 inch) (5.0
65.650 ± 0.01 mm 60.125 ± 0.005 mm 3.6 mm 14
394-3591 T N/A 325-8425
(2.5846 ± 0.0004 inch) (2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
65.650 ± 0.01 mm 60.125 ± 0.005 mm 3.6 mm 14
396-0368 T N/A 325-8425
(2.5846 ± 0.0004 inch) (2.3671 ± 0.0002 inch) (0.1417 inch) (5.6
50.013 ± 0.003 mm 3.270 mm 11
396-1539 N/A T N/A 418-9826
(1.9690 ± 0.0001 inch) (0.1287 inch) (4.5
70.0705 ± 0.0075 mm 3.500 mm 16
418-9359 N/A T N/A 246-1176
(2.7587 ± 0.0003 inch) (0.1378 inch) (6.6
28.0 + 0.005 - 0.001 mm 2.05 mm 84
423-8419 N/A S 2.0 mm (0.0787 inch) N/A
(1.1024 + 0.0002 - 0.00004 inch) (0.08071 inch) (3.3
75.99 ± 0.01 mm 70.0705 ± 0.0075 mm 3.50 mm 16
432-0023 T N/A 246-1176
(2.9917 ± 0.0004 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.6
60.095 ± 0.010 mm 3.400 mm 135
432-1858 N/A T N/A 325-8423
(2.3659 ± 0.0004 inch) (0.1339 inch) (5.34
50.013 ± 0.003 mm 3.270 mm 11
437-7099 N/A T N/A 418-9826
(1.9690 ± 0.0001 inch) (0.1287 inch) (4.5
50.10 ± 0.01 mm 3.2 mm 115
444-6465 N/A T N/A 574-6684
(1.9724 ± 0.0004 inch) (0.1260 inch) (4.5
39.715 ± 0.003 mm
445-2942 N/A T N/A N/A N/A
(1.5636 ± 0.0001 inch)
75.99 ± 0.01 mm 70.0705 ± 0.0075 mm 3.50 mm 16
453-2335 T N/A 246-1176
(2.9917 ± 0.0004 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.6
75.980 + 0.02 mm 70.0705 ± 0.0075 mm 3.500 mm 16
458-7308 T N/A 246-1176
(2.9913 + 0.0008 inch) (2.75868 ± 0.00030 inch) (0.13780 inch) (6.62
1/30/24, 3:26 PM SIS 2.0
75.121 ± 0.015 mm 3.6 ± 0.01 mm

477-2235 N/A S 510-5864 N/A
(2.95751 ± 0.0006 inch) (0.1417 ± 0.0004 inch)
75.121 ± 0.015 mm 3.6 ± 0.01 mm
477-2237 N/A S 510-5864 N/A
(2.95751 ± 0.0006 inch) (0.1417 ± 0.0004 inch)
75.98 ± 0.01 mm 70.0705 ± 0.0075 mm 3.6 ± 0.01 mm
481-5615 S 510-5864 N/A
(2.9913 ± 0.0004 inch) (2.7587 ± 0.0003 inch) (0.1417 ± 0.0004 inch)
75.99 ± 0.01 mm 70.0705 ± 0.0075 mm 3.50 mm 16
481-5617 T N/A 246-1176
(2.9917 ± 0.0004 inch) (2.7587 ± 0.0003 inch) (0.1378 inch) (6.6
39.715 ± 0.003 mm
486-6201 N/A T N/A N/A N/A
(1.5636 ± 0.0001 inch)
60.125 ± 0.005 mm 60.125 ± 0.005 mm 3.60 mm 14
494-7164 T N/A 325-8423
(2.3671 ± 0.00020 inch) (2.3671 ± 0.00020 inch) (0.1417 inch) (5.7020
70.0705 ± 0.0075 mm 3.50 mm 16
535-9617 N/A T N/A 246-1176
(2.7587 ± 0.0003 inch) (0.1378 inch) (6.6
50.013 ± 0.003 mm 3.270 mm 11
546-4573 N/A T N/A 418-9826
(1.9690 ± 0.0001 inch) (0.1287 inch) (4.5
50.013 ± 0.003 mm 3.270 mm 11
551-0841 N/A T N/A 418-9826
(1.9690 ± 0.0001 inch) (0.1287 inch) (4.5
75.121 ± 0.015 mm 3.6 ± 0.01 mm
556-5879 N/A S 510-5864 N/A
(2.95751 ± 0.0006 inch) (0.1417 ± 0.0004 inch)
75.121 ± 0.015 mm 3.6 ± 0.01 mm
556-5880 N/A S 510-5864 N/A
(2.95751 ± 0.0006 inch) (0.1417 ± 0.0004 inch)
50.10 ± 0.01 mm 3.2 mm 115
557-5686 N/A T N/A 574-6684
(1.9724 ± 0.0004 inch) (0.1260 inch) (4.5
75.121 ± 0.015 mm 3.6 ± 0.01 mm
565-3631 N/A S 510-5864 N/A
(2.95751 ± 0.0006 inch) (0.1417 ± 0.0004 inch)
75.121 ± 0.015 mm 3.6 ± 0.01 mm
565-3632 N/A S 510-5864 N/A
(2.95751 ± 0.0006 inch) (0.1417 ± 0.0004 inch)
50.10 ± 0.01 mm 3.2 mm 115
566-9196 N/A T N/A 574-6684
(1.9724 ± 0.0004 inch) (0.1260 inch) (4.5
50.10 ± 0.01 mm 3.2 mm 115
567-1478 N/A T N/A 574-6684
(1.9724 ± 0.0004 inch) (0.1260 inch) (4.5
28.0055 ± 0.0025 mm
575-0685 N/A T N/A N/A N/A
(1.10258 ± 0.00010 inch)
28.003 mm (1.1025 inch)
575-0686 to N/A S 2.05 mm (0.0807 inch) N/A N/A
28.008 mm (1.1027 inch)
75.980 + 0.02 mm 70.0705 ± 0.0075 mm 3.50 + 0.11 mm
578-8865 S N/A N/A
(2.9913 + 0.0008 inch) (2.7587 ± 0.0003 inch) (0.13780 + 0.00433 inch)
70.0705 ± 0.0075 mm 3.60 ± 0.01 mm
579-0210 N/A S N/A N/A
(2.7587 ± 0.0003 inch) (0.1417 ± 0.0004 inch)
75.980 + 0.02 mm 70.0705 ± 0.0075 mm 3.60 ± 0.01 mm
581-6443 S 510-5864 N/A
(2.9913 + 0.0008 inch) (2.7587 ± 0.0003 inch) (0.1417 ± 0.0004 inch)
21.00 to 21.016 mm 2.08 ± 0.01 mm
590-0754 N/A S N/A N/A
(0.8268 to 0.8274 inch) (0.0819 ± 0.0004 inch)
60.10 ± 0.01 mm 3.40 mm 14
599-0756 N/A T N/A 325-8425
(2.3661 ± 0.0004 inch) (0.1339 inch) (5.6
60.10 ± 0.01 mm 3.40 mm 14
599-0757 N/A T N/A 325-8425
(2.3661 ± 0.0004 inch) (0.1339 inch) (5.6
60.10 ± 0.01 mm 3.40 mm 14
618-0617 N/A T N/A 325-8425
(2.3661 ± 0.0004 inch) (0.1339 inch) (5.6
(1) This piston does not use a pin bearing. This is the pin bore diameter.
Table 7
Specification for Two-Piece Pistons with Tapered Top Ring Grooves
Piston Top Ring Groove

Crown Pin Bore Diameter
Assembly Crown Bearing Bore Skirt Part Skirt Bearing Bore Ring Pin for Tapered Ring G
Part (Bearing Inside
Part Diameter Number Diameter Groove
Number Diameter)
Number Gauge A B
6I-2717 4P-5852 54.988 ± 0.008 mm 238-2710 50.815 ± 0.005 mm 50.830 ± 0.008 mm 4C-8165 3.500 mm 123.530
116-5371 133-7098 (2.1649 ± 0.0003 inch) (2.0006 ± 0.0002 inch) (2.0012 ± 0.0003 inch) (0.1378 inch) (4.8634 ±
197-9358
1/30/24, 3:26 PM SIS 2.0
132-3203
222-8708
6I-1211
6I-1212
6I-4765
7E-1289 6I-1210
100-4301 6I-4248
101-4569 101-4572
107-7546 105-1720 4P-1549
43.808 ± 0.008 mm 40.02 ± 0.008 mm 40.031 ± 0.007 mm 2.540 mm 102.250
107-7639 107-7545 107-7791 4C-8164
(1.7247 ± 0.0003 inch) (1.5756 ± 0.0003 inch) (1.57602 ± 0.00028 inch) (0.1000 inch) (4.0256 ±
107-7780 107-7553 238-2716
115-4081 107-7852
115-4089 115-4088
115-4234 142-7307
124-2936
126-5421
144-3449
7E-3973
119-1321 113-5999
55.420 ± 0.01 mm 50.824 ± 0.004 mm 50.848 ± 0.008 mm 3.30 mm 134.820
131-4771 123-4612 163-0930 325-8423
156-8265 197-9314
173-0139
113-6119
107-7614
115-4243
107-7788
126-0502
113-6095
133-4983
134-0765 115-4083
133-5043 43.808 ± 0.008 mm 40.02 ± 0.008 mm 40.031 ± 0.007 mm 2.540 mm 104.709
139-3530 187-1513 186-0190
133-5044 (1.7247 ± 0.0003 inch) (1.5756 ± 0.0003 inch) (1.5760 ± 0.0003 inch) (0.1000 inch) (4.1224 ±
140-7390 238-2726
136-0626
144-3445
142-7301
147-9592
144-3444
197-9255
150-4621
43.808 ± 0.008 mm 40.02 ± 0.008 mm 40.038 ± 0.010 mm 2.540 mm 104.709
165-4266 165-4265 187-1513 186-0190
107-7788
136-0604
164-6556
136-0605
172-3282
140-7390
175-3671
161-8420 115-4083
197-9320 43.808 ± 0.008 mm 40.02 ± 0.008 mm 40.031 ± 0.01 mm 2.540 mm 104.709
172-3283 187-1513 186-0190
175-3672 238-2726
393-8986
212-3660
393-8987
227-5948
393-8988
227-5949
227-5958
7C-2888
107-2198
116-1372
117-7059
126-0736
122-1678
133-7537
133-7538 60.30 ± 0.01 mm 58.150 ± 0.15 mm 55.047 ± 0.008 mm 3.300 mm 134.820
135-2837 128-2830 325-8423
135-2851 (2.3740 ± 0.0004 inch) (2.2894 ± 0.0059 inch) (2.1672± 0.0003 inch) (0.1299 inch) (5.3079 ±
136-1560
136-1562
138-1791
138-8374
176-5744
150-8238
221-2305
60.310 ± 0.01 mm 55.30 ± 0.10 mm 3.300 mm 134.860
163-0920 168-4540 130-0241 N/A 325-8423
(2.3744 ± 0.0004 inch) (2.1772 ± 0.0039 inch) (0.1299 inch) (5.3094 ±
273-5799 55.077 ± 0.008 mm 55.30 ± 0.10 mm 3.300 mm 134.820
145-6700 130-0241 N/A 325-8423
130-8841 (2.1684 ± 0.0003 inch) (2.1772 ± 0.0039 inch) (0.1299 inch) (5.3079 ±
139-8500
139-8502
192-8810 60.01 ± 0.01 mm 55.03 ± 0.005 mm 55.0505 ± 0.0055 mm 3.300 mm 137.436
134-3071 284-6039 208-7636
393-8989 (2.3626 ± 0.0004 inch) (2.1665 ± 0.0002 inch) (2.1673± 0.0002 inch) (0.1299 inch) (5.4109 ±
313-9357
393-8990
126-0736
122-1678 60.310 ± 0.01 mm 55.30 ± 0.10 mm 3.300 mm 134.820
133-7537 130-0241 N/A 325-8423
150-8238 (2.37440 ± 0.00039 inch) (2.1772 ± 0.0039 inch) (0.1299 inch) (5.3079 ±
136-1560
60.310 mm 55.30 ± 0.10 mm 3.300 mm 134.860
163-0920 168-4540 130-0241 N/A
(2.3744 inch) (2.1772 ± 0.0039 inch) (0.1299 inch) (5.30944 ±
6I-2861 133-8383 74.760 ± 0.015 mm 70.380 ± 0.10 mm 70.035 ± 0.005 mm 3.50 mm 168.630
125-2782 9U-7360
101-0829 144-0720 (2.9433 ± 0.0006 inch) (2.7709 ± 0.0039 inch) (2.7573 ± 0.0002 inch) (0.1378 inch) (6.6390 ±
75.760 ± 0.015 mm 70.380 ± 0.10 mm 70.035 ± 0.005 mm 3.50 mm 168.630
147-0617 128-9517 125-2782 9U-7360
1/30/24, 3:26 PM SIS 2.0
117-2673
130-0863
195-6595
195-6595 144-2948
57.367 ± 0.01 mm 53.190 ± 0.005 mm 53.205 ± 0.01 mm 3.500 mm 128.530
197-9252 197-9328 238-2712 208-7632
215-1421 197-9374
222-8707
224-4141
385-5519
144– 74.76 ± 0.015 mm 125– 69.983 ± 0.005 mm 70.035 ± 0.005 mm 574– 3.50 mm 168.630
101-0829
0720 (2.9433 ± 0.0006 inch) 2782 (2.7552 ± 0.0002 inch) (2.7573 ± 0.0002 inch) 6686 (0.13780 inch) (6.6390 ±
160-5910
244-8850
172-0919
249-5671 76.010 ± 0.01 mm 69.988 ± 0.005 mm 70.0525 ± 0.0075 mm 4.100 mm 169.494
249-4512 155-5271 204-8041
279-6770
283-0246
473-9076
76.010 ± 0.01 mm 69.956 ± 0.005 mm 70.0525 ± 0.0075 mm 3.50 mm 167.80
230-2517 230-9043 230-8095 204-8041
133-3360
180-7351
168-4535
180-7352
176-5745 60.310 ± 0.01 mm 55.019 ± 0.045 mm 55.047 ± 0.008 mm 3.300 mm 134.820
197-9317 132-6663 325-8423
197-9329
215-8023
221-2305
222-8709
177-7878 50.01 ± 0.01 mm 158-0451 46.020 ± 0.005 mm 46.04 ± 0.01 mm 2.540 mm 110.340
197-9297 325-8417
188-9141 (1.9689 ± 0.0004 inch) 324-7380 (1.8118 ± 0.0002 inch) (1.8126 ± 0.0004 inch) (0.1000 inch) (4.3441 ±
197-9302
197-9303
197-9385
197-9345
225-2482
197-9368 158-0451
238-2702 50.01 ± 0.01 mm 46.020 ± 0.005 mm 46.04 ± 0.01 mm 3.300 mm 113.059
238-2701 238-2709 325-8421
265-1401 324-7380
267-7269
272-2312
320-6382
385-1657
347-7908
125-8869
60.31 ± 0.01 mm 55.30 ± 0.10 mm 55.047 ± 0.008 mm 2.540 mm 133.930
130-4614 149-5566 130-0241 T
168-4540
Table 8
Specification for Two-Piece Pistons with Straight Top Ring Grooves
Pin Bore Top Ring Groove

Piston
Crown Diameter
Assembly Crown Pin Bore Skirt Part Skirt Pin Bore Straight R
Part Diameter Number Diameter (Bearing
Part or Width of Straight Groove G
Number Inside
Number Tapered G
Diameter)
4P-8959
7C-7888
118-3517
120.20 ± 0.05 mm 5.16 ± 0.01 mm
150-2512 204-4437 N/A 204-5268 N/A S
(4.7323 ± 0.002 inch) (0.20315 ± 0.00039 inch)
204-5289
205-5807
240-4644
204-6114
204-6117
205-5808
205-5809
290-2039 120.190 +0.015 mm 5.150 + 0.02 mm
240-4641 N/A 290-2038 N/A S
290-2040 (4.7319 + 0.0006 inch) (0.2028 + 0.0008 inch)
240-4642
240-4643
290-2041
290-2042
121-4068
128-5641 120.0405 ± 0.0205 mm 128-5634 120.028 ± 0.008 mm 5.16 ± 0.01 mm
241-4949 N/A S
172-7974 (4.7260 ± 0.0008 inch) 172-6773 (4.7255 ± 0.0003 inch) (0.20315 ± 0.00039 inch)
172-6772
318-2344 314-2694 N/A 314-2695 120.00 + 0.035 - 0.015 mm S 6.00 + 0.20 - 0.17 mm
319-7945 436-9030 436-9026 (4.7244 + 0.0014 - 0.0006 inch) (0.23622 + 0.00787 - 0.0067 inch)
370-8035
433-9743
436-6352
436-6353
1/30/24, 3:26 PM SIS 2.0
456-6694
467-8328
G3616 Two-Piece Pistons with Angled Bores
Table 9
Angled Pin Bore Specifications

Skirt Part Diameter Diameter
A D
Number B C
154-4318
0.534°
156-5568 46.80 mm 120.040 + 0.015 mm - 0.00 120.040 + 0.015 mm - 0.00 (4.72597 + 0.0006 - 0.00 inch)
2
204-5268 (1.8425 inch) (4.72597 + 0.0006 - 0.00 inch) + 0.180 mm (0.0071 inch)
places
290-2038
Table 10
Specifications for 2 Piece Pistons with Skirts with Angled Pin Bores
Top Ring Groove

Piston Crown Pin
Crown Part Skirt Part Skirt Pin Bore Straight Ring
Assembly Part Bore
Number
Number Diameter Diameter or Width of Groove Groove
Number
Tapered Gauge
152-3826
157-0726
157-1111 152-5875
204-5283 156-1705
204-5289 157-1114
154-4318
201-5390 204-4131 5.160 ± 0.01 mm
N/A 156-5568 See Table 9 S 4C-3654
290-2039 204-4437 (0.2032 ± 0.0004 inch)
204-5268
205-5807 204-5281
205-5809 290-2038
240-4643 359-1722
290-2042
369-3226
157-1116
156-1699
204-5281 5.150 + 0.02 - 0.00 mm
290-2041 N/A 290-2038 See Table 9 S 4C-3654
290-2036 (0.20276 + 0.00079 - 0.00 inch)
290-2040
290-2037
Two-Piece Pistons in 3054 and 3056

Table 11
Piston Pin Bore Specifications
Description Dimension
Diameter of the Bore for the Piston Pin (Naturally Aspirated Engines) 34.928 mm (1.3751 inch) to 34.934 mm (1.375 inch)
Diameter of the Bore for the Piston Pin (Turbocharged Engines) 38.103 mm (1.5001 inch) to 38.109 mm (1.5003 inch)
If the gap is larger than the dimensions shown, the ring and/or the bore may be worn.
1/30/24, 3:26 PM SIS 2.0
Table 12
Top Ring Gap Specifications

(Turbocharged Engines)
Shape of groove for top ring Tapered
Shape of top ring Wedge
Gap of top ring 0.35 mm (0.0138 inch) to 0.80 mm (0.0315 inch)
Gap of top ring with internal step 0.35 mm (0.0138 inch) to 0.70 mm (0.0275 inch)
Top Ring Gap Specifications
(Naturally Aspirated Engines)
Width of groove in piston for top ring 2.57 mm (0.101 inch) to 2.59 mm (0.102 inch)
Clearance between groove and top ring (new piston) 0.08 mm (0.003 inch) to 0.11 mm (0.004 inch)
Gap of top ring (early engines) 0.40 mm (0.016 inch) to 0.85 mm (0.033 inch)
Gap of top ring (later engines) 0.28 mm (0.011 inch) to 0.63 mm (0.025 inch)
Note: Install the word "TOP" toward the top of the piston. New top rings have a red or blue identification mark, which must be on the left of the ring gap
when the top ring is installed on an upright piston.
Table 13
Intermediate Ring Gap Specifications

Width of groove in piston for intermediate ring 2.56 mm (0.100 inch) to 2.58 mm (0.102 inch)
Clearance between the groove and the intermediate ring 0.07 mm (0.003 inch) to 0.11 mm (0.004 inch)
Gap of intermediate Ring 0.30 mm (0.011 inch) to 0.76 mm (0.030 inch)
Gap of intermediate ring with outside step 0.40 mm (0.016 inch) to 0.85 mm (0.033 inch)
Thickness of the intermediate ring 2.48 mm (0.097 inch) to 2.49 mm (0.098 inch)
Intermediate Ring Gap Specifications
Width of groove in piston for intermediate ring 2.55 mm (0.100 inch) to 2.57 mm (0.101 inch)
Clearance between the groove and the intermediate ring 0.06 mm (0.002 inch) to 0.09 mm (0.003 inch)
Gap of intermediate Ring
0.30 mm (0.011 inch) to 0.76 mm (0.030 inch)
Early Engines
Gap of intermediate Ring
0.40 mm (0.016 inch) to 0.85 mm (0.033 inch)
Later Engines
Note: Install the word "Top" toward the top of the piston. New intermediate rings have a green identification mark, which must be on the left of the ring gap
when the intermediate ring is installed on an upright piston.
Table 14
Oil Control Ring Specifications

Width of groove in piston for oil control ring 4.04 mm (0.159 inch) to 4.06 mm (0.159 inch)
Clearance between groove and oil control ring 0.05 mm (0.002 inch) to 0.08 mm (0.003 inch)
Gap of oil control ring 0.38 mm (0.015 inch) to 0.84 mm (0.033 inch)
Thickness of oil control ring 3.98 mm (0.156 inch) to 3.99 mm (0.157 inch)
Oil Control Ring Specifications
Width of groove in piston for oil control ring 4.03 mm (0.159 inch) to 4.06 mm (0.160 inch)
Clearance between groove and oil control ring 0.04 mm (0.002 inch) to 0.08 mm (0.003 inch)
Gap of oil control ring 0.38 mm (0.015 inch) to 0.84 mm (0.033 inch)
Thickness of oil control ring 3.98 mm (0.156 inch) to 3.99 mm (0.157 inch)
Information for C3.3, C4.4, C6.6 and C7.1 Pistons.

1/30/24, 3:26 PM SIS 2.0
Note: Piston size must be consistent in all cylinders. These engines do not offer a single cylinder repair option via sleeve inserts. All pistons must be
modified at the same to maintain consistent balance.
Table 15
Piston and Piston Ring Kits for C3.3 481-2990 and 481-2991 Cylinder Blocks
Piston Kits Piston Ring Kit

Model
Part Number Description Part Number Description
233-7232 Standard Piston 233-7231 Standard Piston Ring Kit
C3.3 Generator Set 288-9942 0.5 mm (0.020 inch) Oversized Piston Kit 334-1996 0.5 mm (0.020 inch) Oversized Piston Ring Kit
288-9943 1.0 mm (0.040 inch) Oversized Piston Kit 334-1997 1.0 mm (0.040 inch) Oversized Piston Ring Kit
508-1899 Standard Piston N/A N/A
C3.3 Generator Set 508-1903 (1) 0.5 mm (0.020 inch) Oversized Piston Kit N/A N/A
288-9943 (1)
1.0 mm (0.040 inch) Oversized Piston Kit N/A N/A
(1) Kit includes Retaining Rings, Piston Rings, Piston, and Pin
Table 16
Piston and Piston Ring Kits for 362-2190, 363-3907, 366-5613, 451-7736, 458-7553, and 564-8857 Cylinder Blocks

Model Part Part
Description Description
Number Number
C4.4 Tier 3 Mechanical362-2190 Cylinder 0.5 mm (0.020 inch) Oversized 0.5 mm (0.020 inch) Oversized
396-5342 334-1996
Block Piston Kit Piston Ring Kit
458-7586 N/A — —
C4.4 Tier 4 Electronic363-3907, 366-5613
Cylinder Blocks 0.5 mm (0.020 inch) Oversized 0.5 mm (0.020 inch) Oversized
396-4482 380-2065
Piston Kit Piston Ring Kit
0.5 mm (0.020 inch) Oversized 0.5 mm (0.020 inch) Oversized
447-5249 380-2065
C4.4 Tier 3 LRC451-7736 Cylinder Block Piston Kit Piston Ring Kit
447-5250 466-4849
Table 17
Piston and Piston Ring Kits for 351-8229, 351-8234, 351-8238, 351-8243, 547-6884, 547-6889, 547-6893, and 547-6897
Cylinder Blocks

Model
360-2028
360-3987 Standard Piston Standard Piston Ring Kit
558-6157
C4.4 Tier 4i and Tier 0.5 mm (0.020 inch) Oversized Piston 449-2818 0.5 mm (0.020 inch) Oversized Piston Ring
361-5409
4F Kit 558-6158 Kit
1.0 mm (0.040 inch) Oversized Piston 449-2819 1.0 mm (0.040 inch) Oversized Piston Ring
361-5410
Kit 558-6159 Kit
0.5 mm (0.020 inch) Oversized Piston 0.5 mm (0.020 inch) Oversized Piston Ring
421-7760 449-2818
C4.4 Tier 4F Kit Kit
421-7763 449-2819
Kit Kit
Table 18
Piston and Piston Ring Kits for C4.4 602-2013 Cylinder Block

Model
1/30/24, 3:26 PM SIS 2.0

C4.4 Generator Set 574-9896
PIP
0.5 mm (0.020 inch) Oversized Piston Kit 574-9873 0.5 mm (0.020 inch) Oversized Piston Ring Kit
-
Table 19
202 1046
12: 4 / 0 4 6
Piston and Piston Ring Kits for 274-4718, 277-6271, 277-6276, and 608-8024, Cylinder Blocks
6
1
Model Part Number Description
508-1899
2 / 3 6 Standard Piston
SEB 6:35+ 0
508-1903 0.5 mm (0.020 inch) Oversized Piston Kit
C4.4 Generator Set (1)
508-1898
© 2 F805 03:00
Standard Piston
0 9
(1) Kits includes Piston Rings, Oil Ring, Retaining Ring, Piston and Pin.
Table 20
Cat 4 C2
e
Con rpilla aterpi
Piston and Piston Ring Kits for 306-6845 Cylinder Block
llar
Model
fide r:
Part Part
Description Description
Number Number
ntia Inc
.
380-2062 380-2065
l Ye
C6.6 Tier 3 Electronic Kit Kit
493-3305 466-4849
llow
Kit Kit
C6.6 Tier 3 380-2063 380-2065
Kit Kit
Mechanical
493-4289 466-4849
Kit Kit
Table 21
Piston and Piston Ring Kits for C6.6 Tier 4i 363-7645 Cylinder Block

Model
C6.6 Tier 4i 361-2590 0.5 mm (0.020 inch) Oversized Piston Kit 449-2818 0.5 mm (0.020 inch) Oversized Piston Ring Kit
Table 22
Piston and Piston Ring Kits for 331-1682and 383-3581 Cylinder Blocks

Model Part Part Number
Description (1)
Description
Number
389-7188
276-7476
C7.1 Tier 0 Mechanical LRC 331-1682 0.5 mm (0.020 inch) Oversized 0.5 mm (0.020 inch) Oversized
380-4849 380-2065
Cylinder Block Piston Kit Piston Ring Kit
380-5078 466-4849
C7.1 Tier 2 Mechanical LRC 331-1682 389-7188
Cylinder Block 276-7476
415-3050 380-2065
1/30/24, 3:26 PM SIS 2.0

415-3052 466-4849
389-7188
276-7476
C7.1 Tier 2 Mechanical LRC 331-1682 0.5 mm (0.020 inch) Oversized 0.5 mm (0.020 inch) Oversized
380-4848 380-2065
Cylinder Block Piston Kit Piston Ring Kit
380-5077 466-4849
443-9543
276-7476
C7.1 Tier 2 and Tier 3 Electronic LRC 383- 0.5 mm (0.020 inch) Oversized 0.5 mm (0.020 inch) Oversized
391-3732 380-2065
3581 Cylinder Block Piston Kit Piston Ring Kit
391-3735 466-4849
(1) The most current part number is identified in bold font when multiple part numbers are in a cell.
Table 23

Model
Table 24

Model
Table 25
Piston and Piston Ring Kits for C7.1 Genset with 395-3427 Cylinder Block
Model
C7.1 Genset 421-7753 0.5 mm (0.020 inch) Oversized Piston Kit 449-2818 0.5 mm (0.020 inch) Oversized Piston Ring Kit
The projection of the piston must be measured after any of the following components are replaced or if the top deck surface is machined.
Crankshaft
Cylinder head
Connecting rod
Bearing for the piston pin
Refer to "Measuring Piston Projection" in this document for the correct procedure.
Note: The top of the piston should NEVER be machined to obtain the correct projection of the piston.
Measuring Piston Projection

When reusing the original piston, the original connecting rod should also be used in the original cylinder where the piston and rod assembly was removed.
1/30/24, 3:26 PM SIS 2.0
Table 26
Tooling
Tool Part Number Description

H 1P-2403 Dial Indicator
I 1P-2402 Gauge Body
If piston projection is not within the allowed range, a different length of connecting rod may be used to achieve the correct projection. Different lengths of
connecting rods are available to help maintain the correct projection of the piston. The length of the connecting rod is determined by offset machining the
inner bore of the piston pin bearing. The offset will move the position of the piston, making the overall length of the connecting rod shorter or longer. The
projection of the piston will determine what length of connecting rod should be used.
The other option of correcting piston projection is to purchase a new piston pin bushing. The new bushing can have the center of the inside finished
diameter offset machined to change the projection of the piston.
Use the following procedure to measure the projection of the piston. Use the top surface of the cylinder block to zero Tooling (H).
1. Rotate the crankcase until the piston is just before top dead center.
2. Position Tooling (H) and Tooling (I) and slowly rotate the crankshaft to determine when the piston is at the highest position. Record this dimension and
determine if the piston projection is within specifications.
Piston Height
3054 & 3056

The piston height above the top face of the cylinder block is controlled by different grades of height of the piston. Identification of the height grade is by the
letter that is stamped on the top of each piston. The difference between each grade of height is 0.045 mm (0.0018 inch).
Table 27
1/30/24, 3:26 PM SIS 2.0
Height Grades of the Piston
Letter on top of the Piston Height Dimension Latest Equivalent Grade

A(1) 70.334 mm (2.7690 inch) G
B(1)
70.289 mm (2.7672 inch) H
C (1)
70.244 mm (2.7655 inch) J
D(1) 70.199 mm (2.7637 inch) K
E(1) 70.154 mm (2.7619 inch) L
F 70.391 mm (2.7712 inch) N/A
G 70.345 mm (2.7694 inch) N/A
2 x 70.299 mm
H N/A
(2.7676 inch)
2X 70.253 mm
J N/A
(2.7658 inch)
2X
K 70.207 mm N/A
(2.7640 inch)
(2X)
L 70.161 mm N/A
(2.7622 inch)
(1) Earlier Engines

Piston height above top face of cylinder block
Quadram piston 0.14 mm (0.006 inch) to 0.36 mm (0.014 inch)

Piston height above top face of cylinder block
Fastram pistons 0.38 mm (0.015 inch) to 0.50 mm (0.0197 inch)
C175
When new pistons are being installed, new pistons must have the same height of compression.
Table 28
Height of Piston
Distance (K) from the

Centerline of Pin
Part Number of Piston Height of Compression
Bore to the Top of
the Piston
323-4017 Standard 120.8 ± 0.1 mm (4.756 ± 0.004 inch)
1/30/24, 3:26 PM SIS 2.0
323-4018
477-2237
477-2235 121.0 ± 0.1 mm (4.764 ± 0.004 inch)
556-5880 N/A 120.30 ± 0.10 mm (4.7362 ± 0.0039 inch)
565-3632 N/A 120.8 ± 0.1 mm (4.756 ± 0.004 inch)
565-3631 N/A 120.8 ± 0.1 mm (4.756 ± 0.004 inch)
556-5879 N/A 120.8 ± 0.1 mm (4.756 ± 0.004 inch)
Piston Pin Measuring Locations

Straight Pin Locations
Straight piston pin diameter and roughness are measured in at least three places where the bushing has contacted the pin. Within the distance (A) from
each end and the middle of the pin (B). Distance (A) on straight pins is determined by visually identifying where the piston pin bushing has contacted the
pin. Refer to Table 29 for the minimum reuse diameter of piston pin.

(A) Measurement area of contact from piston pin bushing.
(B) Measurement area of contact from piston rod bushing.
Tapered Pin Locations

Tapered Pin diameter and roughness are measured in at least three places. At least distance (A) from each end and at the middle of the pin (B). Refer to
Table 29 for distance (A) and minimum reuse diameter of piston pin.

(A) Measurement of taper.
Barrel Shaped Pin Locations

Barrel Shaped Pin diameter and roughness is measured in at least three places. At the barrel radius peak, the distance (A) from each end and at the
middle of the pin. Refer to Table 29 for distance (A) and minimum reuse diameter of piston pin.
1/30/24, 3:26 PM SIS 2.0

(A) Measurement from end of pin to peak of barrel.
Procedure to Check Surface Texture

Always check the surface texture of piston pins with adequate tooling. Do not reuse the piston pin if the surface texture is too rough. Refer to Table 29 for
the surface texture specifications.
Piston Pin Specifications

Use the following guide for measuring the specifications of the piston pin.
Table 29
Specifications for Piston Pins
Minimum Surface Shape of

Piston Acceptable
Length A Diameter for Diameter of a New Piston Pin Texture Piston
Pin Wear Step
Reuse (Ra) Pin
1M-6101
N/A
7N-9806 50.780 mm 50.795 ± 0.005 mm 0.005 mm 0.125 µm
Straight
6.10 mm (1.9992 inch) (1.9998 ± 0.0002 inch) (0.0002 inch) (4.9212 µinch)
524-7988
(0.240 inch)
69.942 mm 69.957 ± 0.005 mm 0.005 mm 0.125 µm
4W-7403 N/A Straight
(2.7536 inch) (2.7542 ± 0.0002 inch) (0.0002 inch) (4.9212 µinch)
4W-8484 20.50 ± 2.50 mm 69.947 mm 69.962 ± 0.005 mm 0.005 mm 0.125 µm
Barrel(1)
138-8506 (0.807 ± 0.100 inch) (2.7538 inch) (2.75440 ± 0.0002 inch) (0.0002 inch) (4.9212 µinch)
9.25 mm 50.780 mm 50.795 ± 0.005 mm 0.005 mm 0.125 µm
6I-2718 Tapered
(0.364 inch) (1.9992 inch) (1.9998 ± 0.0002 inch) (0.0002 inch) (4.9212 µinch)
7C-0115 9.25 mm
7C-3901 (0.364 inch) 39.985 mm 40.000 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-7980 4.80 mm (1.5742 inch) (1.57480 ± 0.0002 inch) (0.0002 inch) (4.9212 µinch)
524-7982 (0.189 inch)
119.988 mm 119.994 ± 0.006 mm 0.005 mm 0.125 µm
7C-1412 N/A Straight
7C-8610 69.957 mm 69.962 ± 0.005 mm 0.005 mm 0.125 µm
N/A Straight
138-8507 (2.7542 inch) (2.7544 ± 0.0002 inch) (0.0002 inch) (4.9212 µinch)
7E-1749 9.25 mm
168-7246 (0.364 inch) 54.985 mm 55.000 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-5613
(0.260 inch)
69.950 mm 69.965 ± 0.005 mm 0.005 mm 0.125 µm
7N-2393 N/A Straight
9L-8108
1M-6101
38.082 mm 38.097 ± 0.005 mm 0.005 mm 0.125 µm
9L-9889 N/A Straight
7N-9803
577-3581
9.25 mm 38.093 mm 38.108 mm 0.005 mm 0.125 µm Tapered
7N-9804
(0.364 inch) (1.4997 inch) (1.5003 inch) (0.0002 inch) (4.9212 µinch)
1/30/24, 3:26 PM SIS 2.0
4.60 mm
524-7984
(0.181 inch)
9.25 mm
7N-9805
(0.364 inch) 43.160 mm 43.175 mm 0.005 mm 0.125 µm
Tapered
5.20 mm (1.6992 inch) (1.6998 inch) (0.0002 inch) (4.9212 µinch)
524-7986
(0.205 inch)
7N-9807
9.25 mm
7W-9710
(0.364 inch) 50.780 mm 50.795 ± 0.005 mm 0.005 mm 0.125 µm
D 8N-1608 Tapered
D524-5564 6.10 mm
524-7990 (0.240 inch)
50.780 mm 50.795 ± 0.005 mm 0.005 mm 0.125 µm
8L-3443 N/A Straight
43.160 mm 43.175 mm 0.005 mm 0.125 µm
8M-6487 N/A Straight
(1.6992 inch) (1.6998 inch) (0.0002 inch) (4.9212 µinch)
38.093 mm 38.1076 ± 0.005 mm 0.005 mm 0.125 µm
9H-4016 N/A Straight
33.985 mm 34.000 ± 0.005 mm 0.005 mm
094-7134 N/A N/A Straight
(1.3380 inch) (1.3385 ± 0.0002 inch) (0.0002 inch)
39.985 mm 40.000 ± 0.005 mm 0.005 mm 0.125 µm
101-3210 N/A Straight
9.25 mm
102-9796
(0.364 inch) 54.985 mm 55.000 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-7819
(0.260 inch)
103-9679 29.985 mm 30.000 ± 0.005 mm 0.005 mm
N/A N/A Straight
234-4815 (1.1805 inch) (1.1811 ± 0.0002 inch) (0.0002 inch)
69.947 mm 69.962 ± 0.005 mm 0.005 mm 0.125 µm
129.929 mm 129.944 ± 0.006 mm 0.005 mm 0.125 µm
20.985 mm 21.000 ± 0.002 mm 0.005 mm
153-5540 N/A N/A N/A
(0.8262 inch) (0.8268 ± 0.0001 inch) (0.0002 inch)
27.985 mm 28.000 ± 0.004 mm 0.005 mm
154-0873 N/A N/A N/A
(1.1018 inch) (1.1024 ± 0.0002 inch) (0.0002 inch)
9.25 mm
161-8417
(0.364 inch) 50.755 mm 50.770 mm 0.005 mm 0.125 µm
Tapered
6.10 mm (1.9982 inch) (1.9988 inch) (0.0002 inch) (4.9212 µinch)
524-7841
(0.240 inch)
9.25 mm
164-6555
(0.364 inch) 39.978 mm 39.993 ± 0.005 mm 0.005 mm
N/A Tapered
4.80 mm (1.5739 inch) (1.5745 ± 0.0002 inch) (0.0002 inch)
524-7845
(0.189 inch)
9.25 mm
166-3648
(0.364 inch) 45.985 mm 46.000 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-5611
(0.21654 inch)
9.25 mm
168-7224
(0.364 inch) 39.978 mm 39.993 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-7848
(0.189 inch)
9.25 mm
168-7226
(0.364 inch) 39.978 mm 39.993 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-0480
(0.189 inch)
9.25 mm
168-7276
(0.364 inch) 50.780 mm 50.795 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-6484
(0.240 inch)
9.25 mm 53.155 mm 53.170 ± 0.005 mm 0.005 mm 0.125 µm Tapered
168-7296
524-6469 6.40 mm
1/30/24, 3:26 PM SIS 2.0
(0.252 inch)
9.25 mm
173-0148
(0.364 inch) 50.780 mm 50.795 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-7118
(0.240 inch)
9.25 mm 59.960 mm 59.975 ± 0.005 mm 0.005 mm 0.125 µm
180-7350 Tapered
15 mm 69.947 mm 69.962 ± 0.005 mm 0.005 mm 0.125 µm
197-0560 Straight
9.25 mm
197-9291
(0.364 inch) 59.930 mm 59.945 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-7850
(0.283 inch)
9.25 mm
197-9327
(0.364 inch) 53.140 mm 53.155 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-6478
(0.252 inch)
9.25 mm
197-9371
(0.364 inch) 39.973 mm 39.988 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-6492
(0.189 inch)
9.25 mm 54.960 mm 54.975 mm 0.005 mm 0.125 µm
215-5829 Tapered
(0.364 inch) (2.1638 inch) (2.1644 inch) (0.0002 inch) (4.9212 µinch)
9.25 mm
238-2731
(0.364 inch) 49.985 mm 50.000 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-5566
(0.236 inch)
9.25 mm
238-2735
(0.364 inch) 45.985 mm 46.000 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-7881
(0.217 inch)
74.985 mm 75.000 ± 0.005 mm 0.005 mm 0.125 µm
15.00 mm 69.915 mm 69.930 ± 0.005 mm 0.005 mm 0.125 µm
263-8955 Straight
9.25 mm
272-0961
(0.364 inch) 54.960 mm 54.975 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
524-7884
(0.260 inch)
23.00 mm 69.915 mm 69.930 ± 0.005 mm 0.005 mm 0.125 µm
302-3451 Tapered
9.25 mm
384-0401
(0.364 inch) 49.970 mm 49.985 ± 0.005 mm 0.005 mm 0.125 µm
Tapered
384-0401
(0.236 inch)
109.85 ± 0.25 mm 74.985 mm 75.000 ± 0.005 mm 0.005 mm 0.125 µm
392-4608 Straight
(4.325 ± 0.010 inch) (2.9522 inch) (2.9528 ± 0.0002 inch) (0.0002 inch) (4.9212 µinch)
9.25 mm 0.08 µm
469-1989
(0.364 inch) 59.960 mm 59.975 ± 0.005 mm 0.005 mm (3.1496 µinch)
Tapered
7.2 mm (2.3606 inch) (2.36122 ± 0.0002 inch) (0.0002 inch) 0.09 µm
524-5565
(0.2835 inch) (3.5433 µinch)
49.970 mm 49.985 ± 0.005 mm 0.005 mm 0.125 µm
20.985 mm 21.00 + 0.002 - 0.004 mm 0.005 mm 0.07 µm
(0.82618 inch) (0.8268 + 0.0001 - 0.0002 inch) (0.0002 inch) (2.756 µinch)
(1) Lip Height of barrel shaped piston pinch: 0.02 ± 0.005 mm (0.00079 ± 0.00020 inch)
Procedure for Assembly

Note: Caterpillar does not recommend disassembly and subsequent assembly of the 3618 piston or gas piston. Disassembly and subsequent assembly
should only apply to the diesel engine that has three and four piston rings.
1/30/24, 3:26 PM SIS 2.0
Note: Provide a clean environment for assembly and torquing, and use a nonmetallic surface for storing and handling to avoid scratching the surfaces that
are matching.
Note: Ensure that the piston components are cleaned prior to assembly.
NOTICE
Keep all parts clean from contaminants
Contaminants may cause rapid wear and shorten component

life
Pistons with a Single Bolt and Three Rings
1. Place the skirt back on the crown. The alignment pin (1) should be in the hole (2) in the skirt. The alignment pin should not be in an oil passage.

(3) Washer
(4) Spacer
(5) Washer
(6) Bolt
2. Place the washer and the spacer in the skirt. Make sure that they have the proper orientation.
3. Lubricate the bolt threads and the area under the bolt head with Loctite®LB 8012 Moly Paste.
4. Tighten the bolt to a torque of 160.0 N·m (118.01 lb ft).
1/30/24, 3:26 PM SIS 2.0
5. Loosen the bolt, and place the 342-6241 Piston Gauge on the washer around the bolt. Line up the 0° mark with the line made on the skirt during
disassembly and measure back to the line on the bolt. The line on the bolt should be around 90°.
PIP
-
202 1046
4
12: 01/3 666
/ 4
2
SEB 6:35+ 0
© 2 F805 03:00
Illustration 310
0
Cat 4 C2 9 g06468524
e
Con rpilla aterpi
6. Tighten the bolt to a torque of 40.0 N·m (29.50 lb ft) The line on the bolt should now be between 60° and 90°. If it is less than 60°, the piston is not to
be reused.
fide r: llar
ntia Inc
l Ye .
llow
7. With the line on the bolt between 60° and 90°, turn the bolt another 90°
Piston Crown to Piston Skirt for the Piston that has Four Rings
The following is a set of step-by-step instructions for reassembly of the piston. Reference the applicable Tables that accompany the steps of the procedure
for the specifications for torquing the hardware and torque and then turn specifications.
1/30/24, 3:26 PM SIS 2.0
1. Place the piston crown upside-down on a flat surface. Clean the stud holes (2) in the crown and the stud threads with a degreaser that is alcohol.
Before beginning the assembly, ensure that the bolt hole is clean and ensure that the bolt hole is dry. Assemble the studs (1) into the crown with no
lubrication, and torque the studs to 40 N·m (29.5 lb ft).
2. The new O-ring seal should be coated with P-80 Assembly Lubricant or another grease that is free from acid for ease of assembly. Make sure that all
the studs, the nuts, and the contact surface of the spacers are clean and dry. Minor scratches and minor nicks may be reworked at the discretion of
the technician.
Note: Remove all the plugs that were used during the cleaning of the piston.
3. Install the skirt onto the crown. Use a brush and apply a thin coat of Loctite® Graphite 50 LB 8504 Anti-Seize Lubridcnat or Loctite® Graphite 50 LB
8009 Anti-Seize Lubridcnat to the stud threads and to the contact surface of the hex nut.
4. To properly seat the crown to the skirt, torque all four nuts in a cross pattern to 80 N·m (59.0 lb ft).
5. Loosen all four nuts and recheck the torque for the studs. The torque should be 40 N·m (29.5 lb ft). Measure the distance from the end of the skirt to
the end of the studs and record the value.
6. Tighten the nuts until the nuts are finger tight. Measure the “inner” gap and record the “inner” gap between the steel crown and the aluminum skirt at
four points around the piston. The “inner” gap should be measured with a feeler gauge in two locations that are parallel to the pin bore and the “inner”
gap should be measured with a feeler gauge in two locations that are perpendicular to the pin bore. The measurement locations should be zero
degrees, 90 degrees, 180 degrees, and 270 degrees. The “inner” gap should not exceed 0.15 mm (0.006 inch). If the gap exceeds this measurement
the piston will not have the probability of meeting expected operating hours.
1/30/24, 3:26 PM SIS 2.0
7. Torque each nut in a cross pattern to 15 N·m (11.1 lb ft).
8. Use the SPX/OTC J36660 tool that is to torque and turn. Turn the nuts in a cross pattern to 90 degrees.
Note: There will be some clearance in the tooling that will accompany the twisting and the torque reaction that occurs during the turning portion of
torquing of the nuts and this will result in the nut that will have turned a number of degrees less than the indication on the keypad. To determine the
amount of lost turn, relax the force on the greaser bar and then pull back until all the clearance and the torque reaction is removed. Note the reading
on the keypad and offset the 90 degrees of turn by the amount of torque reaction. Normally, the clearance and the torque reaction will be
approximately 3 to 5 degrees that is dependent on the hand tools that are used.
9. Assembly Check
The retaining nuts should not turn when 55 N·m (40.6 lb ft) of torque is applied.
Note: The torque specification of the Assembly Check which is step 9 is not a replacement for the assembly procedure.
10. Remeasure the distance from the end of the skirt to the end of the studs and record the value.
11. Calculate the stretch of the stud and record the stretch of the stud. The distance is equal to 0.30 ± 0.05 mm (0.012 ± 0.002 inch). The stretch of the
stud equals the measured distance with the nuts that are loose minus the measured distance that is referred to in the previous statement. If the
stretch of the stud varies from the average stretch of the stud that is over 0.05 mm (0.002 inch) then the following steps must be repeated. Loosen the
nuts. Remeasure the distance. Tighten the nuts. Recalculate the stretch on the stud. If the variation of the stretch of the stud still exceeds 0.05 mm
(0.002 inch) then replace all the pieces for retention. The pieces for retention include the studs, the nuts, and the spacers.
12. Mark each skirt on the bottom of the rim or mark each boss that is part of the skirt to show the date that the piston was reconditioned. Refer to Reuse
and Salvage Guideline, SEBF8187 , "Standardized Parts Marking Procedures" for additional information.
Installation of the Piston Rings
NOTICE
Do not install the piston rings without the use of the piston ring
expander. Piston ring breakage and piston damage may result if
the piston ring expander is not used.
Use the following steps to install the piston rings for all engine models.
Note: Use the appropriate Ring Expander Group to install the oil ring first. Refer to Table 3 for the correct tool. The oil ring is the bottom piston ring on the
piston. A spring is on the inner diameter of the grooved oil ring. The middle of the spring is marked with a white band. Orient the ends of the spring to 180
degrees opposite side of the ring gap. The white band on the spring will be visible through the ring gap.
1. Grip the oil ring and grip the spring in the inner diameter of the ring. Separate the two ends of the spring until the oil ring is expanded enough to be
installed over the piston. After the oil ring is over the bottom groove in the piston, release the spring and allow the oil ring to contract into the groove.
Make sure that the white band on the spring is visible through the ring gap.
2. Use the appropriate Ring Expander Group to install the second compression ring. The second compression ring is the middle piston ring on the
piston. Install the compression ring with the side marked “UP 2” toward the top of the piston. Install the compression ring in the middle groove of the
piston. Orient the ring gap to 120 degrees away from the oil ring gap.
Note: Pistons with four piston rings have two Center piston rings. Use the Ring Expander Group to install the third compression ring with the side
marked “UP 3” toward the top of the piston. The ring end gap must be 120 degrees from the adjacent ring end gap. Use the Ring Expander Group to
install the second compression ring with the side marked “UP 2” toward the top of the piston. The ring end gap must be 120 degrees from the adjacent
ring end gap.
3. Use the Ring Expander Group to install the first compression ring. The first compression ring is the top piston ring on the piston (3). Install the
compression ring with the side marked “UP 1” toward the top of the piston. Orient the ring gap to 120 degrees away from the adjacent ring gap.
PIP-10464666
2024/01/30
12:25:52+03:00
i02736130
© 2024 Caterpillar Inc.
Caterpillar:
Confidential Yellow

Inspection Procedures and Specifications For Pistons and Piston Pins

Uploaded by

Copyright:

Available Formats

Inspection Procedures and Specifications For Pistons and Piston Pins

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Inspection Procedures and Specifications For Pistons and Piston Pins

Uploaded by

Copyright:

Available Formats

1/30/24, 3:26 PM SIS 2.

SMCS - 1214 i09949529

12: 01/3 666

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.

Media Number Publication Type & Title

Service Advisories, Service Letters, and Technical Service Bulletins

Tooling and Equipment

Required Tooling and Equipment

Part Number Description

5P-7414 Seal Pick

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and

Personal injury can result from air pressure.

During cleaning, do not damage machined surfaces.

Use appropriate thread taps to chase all threaded holes.

When replacement parts are required for this product Caterpillar

Failure to heed this warning can lead to premature failures,

Nomenclature of Pistons and Pistons Pins

Disassembly Procedures for 3600, G3600, and C280 Piston

Avoid hard contact on the piston skirts.

Do not hammer on the piston skirt.

Suspend the piston upside-down with a lifting strap.

Disassembly Procedure For Single Bolt Three Ring Piston

4. Separate the skirt from the crown.

Forged Steel Pistons

Steel Crown and Aluminum Skirt

Cleaning Procedure of Pistons and Piston Pins

Follow these guidelines 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.

Use an O-ring to protect the oil ring groove. 4

Piston Skirt with Graphite Coating

Piston Crown with Anodized Layer

Pistons with Steel Crown and Aluminum Skirt

Protect Oil Passages

Protection for the Graphite Coating

Shim stock with band clamp.

O-ring for the oil ring groove

Cleaning The Aluminum Skirt

Cleaning The Steel Crown

Oil Passage Holes In The Piston

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

Note: Do NOT use this type of cleaning on coated piston pins.

1. Make a visual check of the overall condition of the piston.

2. Reinspect the piston after cleaning for the following.

Additional visible damage from poor handling

Excessive wear of the graphite coating

3. The following areas of the piston should be inspected before reusing.

Snap Ring Groove

Fuel Erosion and Pitting in the Crater

Four Ring Piston for 3600, G3600, and C280

Do not reuse the piston.