Liners

Inspection and Reuse Guideline of Cylinder Liners in Cat Engines {0761, 1201, 1213,
2020/09/15
1216, 1216} (SEBF8068)
SMCS - 0761,1201,1213,1216 i08234666

Caterpillar Products
All 3300 Engines
All 3400 Engines
All 3500 Engines
All 3600 Engines
All C10 Engines
All C11 Engines
All C12 Engines

All C13 Engines
All C15 Engines
All C16 Engines
All C175 Engines
All C18 Engines
All C27 Engines
All C280 Engines
All C32 Engines
All C9 Engines
All C9.3 Engines
All G3300 Engines

All G3400 Engines
All G3500 Engines
All G3600 Engines

Engine D-Series
D-Series
Introduction
Revision Summary of Changes in SEBF8068
33 Removed duplicated part number in table8, and added serial number prefixes.
32 Corrected standard conversion for diameter of 454-9920 liner bore.
31 Added new serial number prefixes.
30 Corrected effectivity to reflect only engines with liners.
29 Updated specifications in Tables 7 and 8 and added liner sleeve dimensions.
27-28 Updates to data on Tables 7 and 8.
26 Added new serial number prefixes and C175 Cuffed Liner information.
25 Photos added to show allowable liner pitting.
Combined information from SEBF8164, SEBF8247, SEBF8817, SEBF9122,
24
SEBF9194, added 60 part numbers and repaired 9 pixelated illustrations.
Table 1
© 2020 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only.
Unauthorized use of this document or the proprietary processes therein without permission may be
violation of intellectual property law.
Information contained in this document is considered Caterpillar: Confidential Yellow.
This Reuse and Salvage Guideline contains the necessary information to allow a dealer to
establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers
and customers to benefit from cost reductions. Every effort has been made to provide the most
current information that is known to Caterpillar. Continuing improvement and advancement of
product design might have caused changes to your product which are not included in this
publication. This Reuse and Salvage Guideline must be used with the latest technical information
that is available from Caterpillar.
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keyword=2929252.&ieSystemControlNumber=SEBP43010124&componentId=00000249&tab=3&serialNumber=R5K&infoType=43&serviceMediaNumber=SEBF8
For technical questions when using this document, work with your Dealer Technical Communicator
(TC). Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning
additional repair options or modifications to reuse and salvage techniques and/or methods. To
report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for
feedback in the Service Information System (SIS Web) interface.
Canceled Part Numbers and Replaced Part

Numbers
This document may not include canceled part numbers and replaced part numbers. Use NPR on
SIS for information about canceled part numbers and replaced part numbers. NPR will provide the
current part numbers for replaced parts.
Important Safety Information
Illustration 1 g02139237
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by
failure to observe basic safety rules or precautions. An accident can often be avoided by
recognizing potentially hazardous situations before an accident occurs. A person must be alert to
potential hazards. This person should also have the necessary training, skills, and tools to perform
these functions properly. Safety precautions and warnings are provided in this instruction and on
the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or
to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a
potential hazard. Therefore, the warnings in this publication and the warnings that are on the
product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is
not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use.
Ensure that the product will not be damaged or the product will not be made unsafe by the
operation, lubrication, maintenance, or the repair procedures that are 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. The "WARNING" safety alert symbol is shown below.
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, you must determine that the operation,
lubrication, maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on
information which was available at the time of publication. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes
can affect the service that is given to the product. Obtain the complete, most current information
before you start any job. Caterpillar dealers can supply the most current information.
Summary
NOTICE
Due to a change in honing techniques, Caterpillar can
no longer recommend re-honing as a salvage
procedure.
Improvements in emissions strategy have included a proprietary

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

inspected, measured, and reused if they meet all the
criteria in this guideline.
Replacing cylinder liners is not always necessary during an engine rebuild. The installation of used
cylinder liners can result in a large decrease in the cost of the rebuild. This guideline incorporates
information on cleaning and inspecting cylinder liners. Use the criteria in this guideline and other
applicable guidelines to determine the reusability of a liner.
Follow the cleaning and inspection information in this guideline completely. This information can be
used to determine reusability. Never reuse a cylinder liner this guideline recommends should not
be used again. If a cylinder liner has damage not shown in this guideline, then do not use the
cylinder liner again. Liners that meet these guidelines are expected to give normal performance
until the next overhaul.
Information in this guideline is based on the liner removed from the engine. With the liner out of the
engine, a thorough inspection of all liner and cylinder block surfaces can be performed. Also, the
liner seals must be replaced as a measure for preventive maintenance.
If the liners have cuff rings the rings should be replaced at overhaul. Cuff rings that are still tight in
the bore may be reused if the cylinder is being inspected prior to overhaul.
Service Letters and Technical Information

Bulletins
NOTICE
The most recent Service Letters and Technical Information
Bulletins that are related to this component shall be reviewed
before beginning work. Often Service Letters and Technical
Information Bulletins contain upgrades in repair procedures,
parts, and safety information that pertain to the parts or
components being repaired.
References
References
Media
Title
Number
Special Instruction, "Using 1P-3537 Dial Bore Gauge Group to Check Cylinder
GMG00981
Bore Size"
Tool Operating Manual, "Procedures For Using the 120-9143 Cylinder Wash
, NEHS0632
Tank Gp"
, SMHS8253 Special Instruction, "Use of the 6V-7898 Dial Bore Gauge"
, SMHS8254 Special Instruction, "Using the 6V-7899 Size Setting Fixture Group"
Table 2
Tooling and Equipment
NOTICE
Failure to follow the recommended procedure or the specified
tooling that is required for the procedure could result in damage
to components.
To avoid component damage, follow the recommended

procedure using the recommended tools.
Tooling and Equipment
Part Number Description

1P-3537 Dial Bore Gauge
Nylon Bristle Brush
1P-7429
114.3 mm (4 ½ inch)
Nylon Bristle Brush
1P-9788
127.0 mm (5.0 inch)
1U-8869 Dial Indicator
2S-5658 M16 Washer
3P-1568 Dial Indicator
4C-4707 Dial Gauge
Nylon Bristles
4C-5552
57.2 mm (2 ¼ inch)
Nylon Bristle Brush
4C-6343
101.6 mm (4 inch)
Nylon Bristle Brush
4C-6344
139.7 mm (5 ½ inch)
Nylon Bristle Brush
4C-6345
152.4 mm (6 inch)
Nylon Bristle Brush
4C-6346
165.1 mm (6 ½ inch)
Nylon Bristle Brush
4C-6347
177.8 mm (7 inch)
Nylon Bristle Brush
4C-6348
190.5 mm (7 ½ inch)
Nylon Bristle Brush
4C-6349
203.2 mm (8 inch)
Nylon Bristle Brush
4C-6350
241.3 mm (9 ½ inch)
4C-9442 Flashlight
5P-4156 Indicator Base
5P-4160 Indicator Contact Point
5P-6518 Dial indicator Fixture
6V-2012 Micrometer Depth Gauge
6V-2032 Adapter
6V-7059 Micrometer
6V-7898 Dial Bore Gauge
6V-7899 Size Fixture
6V-7926 Dial Indicator
6V-7926 Dial Indicator
7K-1977 Washer
7X-2558 M16 x 2 Bolt
8S-2251 Sac Hole Drill
8S-2257 Eye Loupe
8S-3158 Indicator Gauge
8T-0447 Dial Caliper
8T-5096 Dial Indicator Group
8T-7765 Scotch Brite Pad
9U-6182 Inspection Mirror
9U-7237 Brush Extension
120-9143 Cylinder Wash Tank
Nylon Bristle Brush
135-7628
304.8 mm (12.0 inch)
151-0968 Cordless Drill
222-3061 Air Drill
Microscope, Pocket
262-8390
40x
263-7184 Crack Detection Kit
288-4209 Paper Towel
362-4253 Depth Micrometer Kit
367-9109 Digital Caliper
384-2804 Indicator Gauge Group
386-3364 Straight Edge Ruler
415-4055 Ultrasonic Tool Group
420-5317 Suitable Cribbing
Digital Caliper
423-4373 0.0 - 203.2 mm
(0.00 - 8.00 inch)
Micrometer, External
431-4150
25 mm (1 inch)
441-0714 Spring Tester
459-0184 UV Lamp Group
Micrometer, Outside
473-8690
0.00 - 4.00 inch
Micrometer, Outside
473-8691
2.00 - 6.00 inch
Micrometer, Outside
473-8691 50.8 - 152.4 mm
(2.00 - 6.00 inch)
Micrometer, Outside
473-8692
152.4 - 304.8 mm (6.00 - 12.00 inch)
486-1526 Degreaser
FT-1711 Light Table
Table 3
Nomenclature
Top Mounted Liners
Illustration 3
https://sis2.cat.com/#/detail? g06290127
(1) Fire dam
(2) Inside surface
(3) Outside surface
(4) O-ring seal grooves
(5) Filler band groove
(6) Flange
Mid Mounted Liners
(1) Liner Sleeve
(2) Inside surface
(3) Outside Surface
(4) O-ring seal grooves
Procedure to Clean Liners

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

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

One method of cleaning is to use the 120-9143 Cylinder Wash Tank to clean inside the
cylinder liners. This wash tank group is typically used for the internal cleaning of
hydraulic cylinders. The washer uses a rotating head that has both fluid nozzles
directing the cleaning solution at the bore and brushes to scrub the inner surface. The
machine also has a system for filtering that cleans the solution before recirculating the
solution back through the nozzles.
Follow the instructions that are contained in the Tool Operating Manual. Refer to Tool
Operating Manual, NEHS0632, "Procedures For Using the 120-9143 Cylinder Wash
Tank Gp".
b. Use detergent and nylon brush.

Another procedure is to use a strong detergent solution, water, and a nylon brush with
a hand drill. Refer to Illustration 6 for an example of a cylinder liner cleaning brush.
Typically a brush size 25.40 mm (1.00 inch) larger than the inside diameter of the liner
bore, will provide the best cleaning results.
Refer to Tables 7 and 8 to find the appropriate sized brush needed.
Mix a fresh solution of water and a liquid cleaner such as Hydrosolv 4165. Place the
liner in a large container of cleaning solution. Support the cylinder liner so that the
cylinder liner is open at the bottom. Clamp the large nylon brush into the hand drill to
scrub the inside of liner for 1 to 2 minutes. Run the brush up and down through the liner
in an aggressive manner to clean the inner surface. Do not allow the brush to contact
the bottom of the container.
Note: A liquid detergent without chlorine content, that is mixed in hot water is a good
cleaning solution. 486-1526 5 gal Cleaner HYDROSOLV 4165 will produce the same
cleaning action as liquid soap. For liners with a heavy coating of lacquer, add butyl
cellusolv to the soap solution.
c. For protection of the surface that will last for two to three weeks against rust, do not
rinse the part after using Hydrosolv 4165. If Hydrosolv 4165 is not used, then rinse the
liner. Rinse the cylinder liner with clean, hot water, and treat the cylinder liner with rust
preventive or a thin film of engine oil. Do not allow the liner to air dry slowly after
rinsing. Use pressurized air to dry the liner immediately.
Use a white cloth to see if the liner is clean. A gray color is an indication that dirt or debris is still present.
2. Check the cylinder liner for cleanliness by wiping the bore of the cylinder liner with a clean
white cloth or a paper towel that is free of lint. If there are any signs of dirt or residue, clean
the liner again.
Note: Failure to remove all debris from a liner bore will result in decreased life of the piston
ring and lack of adequate control of oil.
3. Freshly cleaned surfaces will begin to rust if the surfaces are not protected. Put a thin layer
of engine oil or other rust preventive over the clean, dry liner immediately. Without protection,
a clean liner can show rust in minutes. Prior to storage, protect the cylinder liner from other
contaminants such as dust or dirt after treating the cylinder liner with rust preventive.
Remove the rust preventive only if further inspection is necessary or the liner is being
installed into an engine.
Cleaning Exterior Surfaces

Remove any rust or foreign deposits from the outside surface of the liner. To clean the outside
surface of the liner, use glass beads and a bead cabinet or a brass or nylon brush. Take caution
not to damage the inside of the liner, the top of the flange, and the bottom of the flange when
cleaning the outside of the liner.
NOTICE
Prefered use of glass or soda blast should only be done on the
outside of the liner. It is not allowed to use Abrasive media like
Sand, Silica in blasting cabinets. Do not blast the inside of
the liner including the cuff counterbore
Visual Inspection
To perform an accurate inspection, the cylinder liner must be cleaned thoroughly prior to
inspecting.
Outside Surface
Rust and deposits must be removed before the visual inspection.
Clean the liner again.
O-Ring Groove Area
There is a small chip in the area between the grooves.
Reuse the liner if the chip is not extended across the complete area and any burrs or sharp edges are removed
with a file.
If the liner has pits between the seal grooves and the filler band groove and the pits are deeper
than 2.3 mm (0.09 inch), do not reuse the liner.
Reuse the liner.
The exception would be if the outside of the liner has pits or erosion that goes into either of the lower two seal grooves.
(1) Light erosion
(2) Pits
Cracking
Crack
Do not reuse the liner.
Cracking that occurs on the cylinder cuff
Pitting
Used liners will generally have some minor pitting caused by the coolant as it flows from the front
to the rear of the engine.
Small pits are acceptable only if the pits are limited to one or two sides.
Small pits are acceptable only if the pits are limited to one or two sides.
Reuse the liner if there are pits on only one side.
C175 Liner Pitting in Seal Grooves, minor pitting is allowed. Measure pitting depth as shown in the
Pitting Measurement section in this document for reference.
C175 Liner Pits shown on lower section of O-Ring groove
Small pits are also acceptable if the liner was removed with the pits toward the front or rear of the
engine. If the liner is to be reused, then rotate the liner 90° so the non-pitted parts of the liner face
the coolant flow.
Deep pits
Do not reuse liners with deep pits.
Deep pits
Do not reuse liners with deep pits.
Pitting Measurement
To check the depth of a pit, grind an 8S-2251 Drill or a 1.01600 mm (0.04 inch) drill bit as shown in
Illustration 10. If the bit goes into a pit to lip (3) in Illustration 10, the pit is too deep.
Modified 8S-2251 Drill
(3) Lip
(4) Radius
(A) Depth of section to grind
Dimensions of the Modified Drill
(A) (4)
2.30 mm (0.091 inch) 0.51 mm (0.020 inch)
Table 4
Flange Area
Visible crack extending from inside liner into flange area
Pits and erosion in the filler band groove.
Reuse the liner.
There are pits and fretting under the liner flange. Large pits or groups of pits are not acceptable.
Circumferential fretting is the only acceptable fretting. The fretting must not prevent the liner from
sealing. Measure flange thickness.
Small pits
Reuse the liner.
Crack in the flange.
Do not reuse any liner that has circumferential cracks under the area of the liner flange. Do not
reuse any liner with cracks in the flange fillet.
Damage to the fire dam.
Reuse the liner.
The damage must not extend across the fire dam. Burrs or sharp edges must be removed.
Damage in the surface area of the gasket
Nick in the vertical flange
Reuse the liner.
Remove any sharp edges or high areas with a file.
Chip in the seal edge of the flange.
Inside Surface Inspection

Use the FT1711 Light Table to check for scratches and pits on the inside surface of the liner bore.
The fluorescent light will work better than the incandescent light when you inspect the bore.
If the pits or light spots of rust that occur on the inside of the cylinder liner are directly opposite to
the pits on the outside surface, then the liner should not be used again. This type of pitting can go
through the walls of the cylinder liner and into the bore.
Light Table
Example of good clean cross hatch.
Pits on the inside surface
Crack on the inside surface
Deep grooves on the inside surface
Heavy rust on the inside surface
Do not reuse the liner .
Water spots on the inside surface.
Do not reuse the liner
Shiny areas on the inside surface, no visible cross hatch remains.
Water rings and spots on the inside surface.
Deep double wear step on the inside surface
Crack Detection Methods

After cleaning and a visual inspection, liners should be checked for cracks that may not be readily
visible. If a cylinder liner is cracked at any location, then do not use the cylinder liner again.
NOTICE
Regardless of which crack detection method is used, it is
important that the instructions furnished with the detection
equipment are followed closely when checking any component.
Failure to do so may cause inaccurate results or may cause
injury to the operator and/or surroundings.
Crack detection methods or Non-Destructive Testing (NDT) are utilized for examining components
for cracks without damaging the component. Visual inspection (VT), Liquid Penetrant Testing (PT),
Magnetic Particle Inspection (MT), Ultrasonic Testing (UT), Radiographic Testing (RT) and Eddy-
Current Testing (ET) are recommended methods. There may be more than one acceptable crack
detection method for the inspection of a given part, though the liquid penetrant is the most
versatile. For example, the liquid penetrant method can be used when inspecting smooth
machined components such as shafts, gear teeth, and splines, but using the Wet Magnetic
Particle Inspection is more accurate. Refer to Table 5 for advantages and disadvantages and Table
6 for standards and requirements for these NDT methods.
Crack Inspection Method Advantages vs. Disadvantages
Inspection
Advantages Disadvantages
Method
- Least expensive
Visual - Detects most damaging - Limited to surface-only defects
Surface defects - Requires inspectors to have broad knowledge of
Inspection - Immediate results welding and fabrication in addition to non-destructive
(VT) - Minimum part testing
preparation
- Inexpensive
Liquid - Minimal training - Least sensitive
Penetrant - Portable - Detects surface cracks only
(PT) - Works on nonmagnetic - Rough or porous surfaces interfere with test
material
- Portable
Dry Magnetic - Fast/Immediate Results - Works on magnetic material only
Particle (MT) - Detects surface and - Less sensitive than Wet Magnetic Particle
subsurface discontinuities
- More sensitive than
- Requires Power for Light
Liquid Penetrant
Wet Magnetic - Works on magnetic parts only
- Detects subsurface as
Particle (MT) - Liquid composition and agitation must be
much as 0.13 mm
monitored
(0.005 inch)
- Most sensitive
- Detects deep material
defects - Most expensive
Ultrasonic
- Immediate results - Requires operator training and certification
Testing (UT)
- Wide range of materials - Surface must be accessible to probe
and thickness can be
inspected
- Surface and near surface
flaws detectable - Difficult to interpret
Eddy-Current -Moderate - Only for metals
Testing (ET) speed/Immediate results -Rough surfaces interfere with test
-Sensitive to small - Surface must be accessible to probe
discontinuities
-Detects surface and
internal flaws - Not for porous materials
Radiographic - Minimum part - Radiation protection needed
Testing (RT) preparation - Defect able to be detected is limited to 2% of
- Can inspect hidden thickness
areas
Table 5
Applicable Crack Detection Standards
Required
Inspection Acceptance
Standard Personnel
Method Criteria
Qualifications
EN-ISO 9712 - Level 2
Visual Surface EN-ISO 5817 EN-ISO 5817 - Level B
ANSI-ASNT SNT-TC-
Inspection (VT) AWS D1.1 AWS D1.1 - Table 6.1
1A Level 2
Liquid Penetrant EN-ISO 3452 EN-ISO 23277
ANSI-ASNT SNT-TC-
Testing (PT) ASTM E165 AWS - D1.1
1A Level 2
Magnetic Particle EN-ISO 17638 EN-ISO 23278 - Level 1
ANSI-ASNT SNT-TC-
Testing (MT) ASTM E709 AWS D1.1 - Table 6.1
1A Level 2
EN-ISO 11666 Technique
EN-ISO 17640 - EN-ISO 9712 - Level 2
Ultrasonic Testing 2 - Level 2
Level B ANSI-ASNT SNT-TC-
(UT) AWS D1.1 - Class A -
AWS D1.1 1A Level 2
Table 6.3
Eddy-Current Testing EN-ISO 15549
EN-ISO 20807 ANSI-ASNT SNT-TC-
(ET) ASTM E426
1A Level 2
Radiographic Testing EN-ISO 5579
EN-ISO 10657-1 ANSI-ASNT SNT-TC-
(RT) ASTM E94
1A Level 2
Table 6
Visual Surface Inspection (VT)
Example of Visual Inspection Tools
(A) Flashlight or adequate light source
(B) Magnifying eye loupe
(C) Tape measure or other measuring device
(D) Inspection mirror
(E) Weld size inspection gauges
Components and welds that are to be inspected using PT, MT, or UT shall first be subject to Visual
Surface Inspection (VT). Visual Inspection is often the most cost-effective inspection method and
requires little equipment as seen in Illustration 42. It is suggested that at a minimum personnel
performing Visual Inspection are either trained to a company standard or have sufficient
experience and knowledge with regard to the components being inspected. It is also suggested
that personnel performing visual inspections take some type of eyesight test regularly.
Liquid Penetrant Testing (PT)
Personal injury can result from improper handling of chemicals.
Make sure you use all the necessary protective equipment

required to do the job.
Make sure that you read and understand all directions and
hazards described on the labels and material safety data sheet
of any chemical that is used.
Observe all safety precautions recommended by the chemical

manufacturer for handling, storage, and disposal of chemicals.
Refer to Tooling and Equipment Table 3 for part numbers.
Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to
wipe the surface clean.
Penetrant: This solution is highly visible, and will seep into openings at the surface of a part
with capillary action.
Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and
providing a contrasting background to increase the visibility of the penetrant indications.
Brush: Removes dirt and rust.
Cloth or Wipes: Use with cleaner and for other miscellaneous uses.
Typical example of pre-cleaning area.
1. Preclean inspection area. Spray on cleaner / remover to loosen any scale, dirt, or any oil.
Wipe the area to inspect with a solvent dampened cloth to remove remaining dirt and allow
the area to dry. If there is visible crack remove paint using paint remover or wire brush.
Typical example of applying penetrant.
2. Apply penetrant by spraying to the entire area to be examined. Allow 10 to 15 minutes for
penetrant to soak. After the penetrant has been allowed to soak, remove the excess
penetrant with clean, dry wipe.
Typical example of removing excess penetrant oil.
3. The last traces of penetrant should be removed with the cleaner solvent dampened cloth or
wipe. Allow the area to dry thoroughly.
Typical example of applying developer.
4. Before using Developer, ensure that it is mixed thoroughly by shaking can. Holding can
approximately 203.20 - 304.80 mm (8.00 - 12.00 inch) away from part, apply an even, thin
layer of developer over the area being inspected. A few thin layers are a better application
method than one thick layer.
Typical example of cracks found during a liquid penetrant testing.
5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks.
Defects will show as red lines in white developer background, refer to Illustration 47. Clean
the area of application of the developer with solvent cleaner.
Dry Magnetic Particle Testing (MT)

(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke.
(C) Dry powder bulb.
1. Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes
and shapes to produce magnetic particle indications. The powder shall be of a color that will
provide adequate contrast with the background of the surface being inspected.
2. Dry magnetic particles shall be stored in suitable containers to resist contamination such as
moisture, grease, oil, non-magnetic particles such as sand, and excessive heat.
Contaminants will manifest in the form of particle color change and particle agglomeration.
The degree of contamination will determine further use of the powder.
3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation
of System Performance/Sensitivity) when not performing.
4. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable
magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing
current to impose a localized longitudinal magnetic field into the part. The magnetizing force
of the yoke is related to the electromagnetic strength and can be tested by determining the
lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).
5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like
coating of the dry magnetic particles. Blower should also have sufficient force to remove
excess particles without disturbing those particles that are evidence of indications.
6. All equipment shall be inspected at a minimum of once a year or when accuracy is

questionable.
1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale,
paint, and other contaminants.
2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.
3. Simultaneously apply the dry powder using the dry powder blower.
4. Remove excess powder by lightly blowing away the dry particles.
5. Continue around the entire circumference of each bore. Position the yoke twice in each area
at 1.57 rad (90°) to ensure that multiple directions of the magnetic field are created.
6. Observe particles and note if any clusters of particles appear revealing an indication.
7. Record the size and shape of any discontinuities or indications found.
Wet Magnetic Particle Testing (MT)

(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke.
(D) UV Lamp used in wet magnetic particle inspection process.
Pear Shaped Centrifuge Tube
1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given
concentration that will allow application to the test surface by spraying.
2. Concentration:
a. The concentration of the suspended magnetic particles shall be as specified by the

manufacturer and be checked by settling volume measurements.
b. Concentrations are determined by measuring the settling volume by using an ASTM

pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL (0.0017 oz)
1.0 mL (0.034 oz) divisions, refer to Illustration 50. Before sampling, the suspension
shall be thoroughly mixed to assure suspension of all particles, which could have
settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and allowed to
settle for 30 minutes. The settling volume should be between 0.1 mL (0.0034 oz) and
0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.
c. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.
d. The oil shall have the following characteristics:
Low viscosity not to exceed 50 mSt (5.0 cSt) at any temperature at which the
vehicle is to be used.
Low inherent fluorescence and be non-reactive.
e. The conditioning agents used in the conditioned water shall have the following
characteristics:
Impart good wetting characteristics and good dispersion.
Minimize foaming and be non-corrosive.
Low viscosity shall not exceed a maximum viscosity of 50 mSt (5.0 cSt) at 38° C
(100° F).
Non-fluorescent, non-reactive, and odorless.
Alkalinity shall not exceed a pH of 10.5.
3. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable
magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing
current to impose a localized longitudinal magnetic field into the part. The magnetizing force
of the yoke is related to the electromagnetic strength and can be tested by determining the
lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).
1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale,
paint, and any other contaminants.
2. Apply the magnetic field using the yoke against the surface in the area to be inspected.
3. For case hardened and ground surfaces:
Due to the sensitivity required to locate the grinding cracks, inspection of case
hardened and ground surfaces require that the yoke is applied so that the magnetic
field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the
increased sensitivity resulting when the yoke is energized, the yoke is not moved until
the evaluation is completed in the first direction. An AC yoke shall be used.
4. Visually inspect for indications of discontinuities using the proper illumination.
5. Record the size and shape of any discontinuities found.
Ultrasonic Testing (UT)

Note: Crack depth cannot be accurately determined by UT, only full depth cracking can be
consistently determined. For cracks that are not full depth, an indication of a partial depth cracks
can be detected by an experienced technician.
NOTICE
All personnel involved in ultrasonic testing shall be qualified to
Level 2 in accordance to standards stated in Table 6.
1. Ultrasonic Testing (UT) is a method of Non-Destructive Testing (NDT) using short ultrasonic
pulse waves (with frequencies from 0.1-15 MHz up to 50 MHz) to detect the thickness of the
object. Ultrasonic testing consists of an ultrasound transducer connected to a diagnostic
machine and passed over the object being inspected.
2. There are two methods of receiving the ultrasound waveform from the transducer: reflection
and attenuation.
a. Reflection - Ultrasonic pulses exit the transducer and travel throughout the thickness of
the material. When the sound waves propagate into an object being tested, the waves
return to the transducer when a discontinuity is discovered along the sonic path. These
waves continue and reflect form the back surface of the material to project the
thickness of the material.
b. Attenuation - A transmitter sends ultrasound through one surface, and a separate

receiver detects the amount that has reached it on another surface after traveling
through the medium. Any discontinuities or other conditions within the medium will
reduce the amount of sound transmitted, revealing the presence of the imperfections.
Eddy-Current Testing (ET)

NOTICE
All personnel involved in Eddy-Current Testing shall be qualified
to Level 2 in accordance to standards stated in Table 6.
Eddy-Current Testing
Eddy-Current Testing (ET) is a Non-Destructive Testing (NDT) method in which eddy-current flow
is induced in the test object. Changes in the flow caused by variations in the specimen are
reflected in to a nearby coil or coils for subsequent analysis by suitable instrumentation and
techniques. Major applications of eddy-current testing are surface inspection and tubing
inspections.
Radiographic Testing (RT)

Note: CAUTION: This process is dangerous. Only qualified personnel and test equipment should
be appointed to perform this type of testing.
NOTICE
All personnel involved in radiographic testing shall be qualified
to Level 2 in accordance to standards stated in Table 6.
Radiographic Testing
Radiographic Testing (RT) is a Non-Destructive Testing (NDT) method in which short wavelength
of electromagnetic radiation is used to penetrate materials to find hidden discontinuities such as
cracks. In radiographic testing, the test object is placed between the radiation source and the film,
or x-ray detector. The electromagnetic radiation will penetrate the thickness of the test object and,
when all the way through, will project onto the film any indications that have been in the path of the
radiation waves.
Cylinder Liner Specifications

Note: Cylinder liners with dimensions that are outside the ranges that are shown in Tables 7 and 8
should not be reused.
Liners that have passed all the "Visual Inspection" criteria must be measured to ensure they can
be reused. Use precise gauges of known accuracy to measure the cylinder liner bore to check if
the cylinder liner is worn beyond the specification. Critical dimensions for cylinder liners are listed
in Tables 7 and 8. If the liner has the specified dimensions and the crosshatched pattern is still
visible throughout the liner bore, then the liner may be reused.
The following specifications are for cylinder liners at a temperature of 20 °C (68.0 °F). Dimensions
of the bore will be slightly higher if measurements are taken immediately after cleaning with hot
water or if the liner is at a higher ambient temperature.
Bore diameters should be measured with a dial bore gauge that has been accurately calibrated
with a master ring or a fixture for setting the gauge.
Record the part number of the cylinder liner and the sequence numbers for the inspection process.
Keep a log of history or a permanent record by sequence number of the cylinder liner for any
measurements that are taken for future reference.
Critical Dimensions for Top Mounted Liners
Typical dimensions for top mounted liners. Some liners will not have all these features.
(A) Thickness of Liner Flange
(B) Height of Fire Dam
(C) Diameter of Liner Sleeve Bore
(D) Height of Liner Sleeve Bore
(E) Diameter of Liner Bore
Example of a bore cooled liner.
(F) Width of the top Seal Ring Groove
Use the following reference table for measuring the cylinder liners.
Critical Dimensions for Top Supported Liners in order of bore size
Liner A B C D E F
110-5800 10.282 ± 0.020 mm 1.02 ± 0.13 mm 120.675 ± 0.037 mm
N/A N/A N/A
371-5941 (0.4048 ± 0.0008 inch) (0.040 ± 0.005 inch) (4.7510 ± 0.0015 inch)
8.89 ± 0.02 mm 1.04 ± 0.13 mm 137.185 ± 0.025 mm
197-9322 N/A N/A N/A
(0.350 ± 0.001
https://sis2.cat.com/#/detail? inch) (0.041 ± 0.005 inch) (5.4010 ± 0.0010 inch)
132-6881
197-9348 8.89 ± 0.02 mm 1.12 ± 0.05 mm 139.685 ± 0.037 mm
N/A N/A N/A
420-2631 (0.350 ± 0.001 inch) (0.044 ± 0.002 inch) (5.4994 ± 0.0015 inch)
473-9034
322-1126
8.89 ± 0.02 mm 1.04 ± 0.13 mm 145.000 ± 0.025 mm
516-9693 N/A N/A N/A
(0.350 ± 0.001 inch) (0.041 ± 0.005 inch) (5.7087 ± 0.0010 inch)
556-0701
123-8206
211-7826
12.65 ± 0.02 mm 1.06 ± 0.08 mm 170.025 ± 0.250 mm
350-0074 N/A N/A N/A
(0.498 ± 0.001 inch) (0.042 ± 0.003 inch) (6.6939 ± 0.0098 inch)
374-3576
447-3915
12.65 ± 0.02 mm 1.18 ± 0.02 mm 174.50 ± 0.02 mm 19.52 ± 0.10 mm 170.025 ± 0.25 mm
454-9920 N/A
(0.498 ± 0.001 inch) (0.046 ± 0.001 inch) (6.870 ± 0.001 inch) (0.769 ± 0.004 inch) (6.6939 ± 0.0098 inch)
259-1046 33.00 ± 0.03 mm 3.50 ± 0.03 mm 290.025 ± 0.025 mm 53.50 ± 0.10 mm 279.955 ± 0.025 mm
N/A
385-3469 (1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.4183 ± 0.0010 inch) (2.106 ± 0.004 inch) (11.0218 ± 0.00010 inch)
1W-7900 33.00 ± 0.03 mm 3.50 ± 0.03 mm 280.025 ± 0.025 mm
N/A N/A N/A
7E-8268 (1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.0246 ± 0.0010 inch)
7C-4981
7E-8298 33.00 ± 0.03 mm 3.50 ± 0.03 mm 280.025 ± 0.025 mm 7.00 ± 0.13 mm
N/A N/A
111-1656 (1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.0246 ± 0.0010 inch) (0.276 ± 0.005 inch)
385-3468
179-3167
179-3168
195-3507
33.00 ± 0.03 mm 3.50 ± 0.03 mm 290.025 ± 0.025 mm 57.50 ± 0.10 mm 280.025 ± 0.025 mm
343-4444 N/A
(1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.4183 ± 0.0010 inch) (2.264 ± 0.004 inch) (11.0246 ± 0.0010 inch)
343-4445
377-6887
385-3470
7C-5044 33.00 ± 0.03 mm 3.50 ± 0.03 mm 300.025 ± 0.025 mm
N/A N/A N/A
343-4443 (1.299 ± 0.001 inch) (0.138 ± 0.001 inch) (11.8120 ± 0.0010 inch)
Table 7
Critical Dimensions for Mid Mounted Liners
Typical dimensions for mid mounted liners. Some liners will not have all of these features.
(C) Diameter of Liner Sleeve Bore
(D) Height of Liner Sleeve Bore
Critical Reuse Dimensions for Mid Supported Liners in order of bore size
Liner A B C D E
190-3562
130.000 ± 0.025 mm 1.13 ± 0.05 mm 112.025 ± 0.025 mm
385-7276 N/A N/A
(5.1181 ± 0.0010 inch) (0.045 ± 0.002 inch) (4.4104 ± 0.0010 inch)
469-5312
267-6686 130.000 ± 0.025 mm 1.13 ± 0.05 mm 115.025 ± 0.025 mm
N/A N/A
469-5313 (5.1181 ± 0.0010 inch) (0.045 ± 0.002 inch) (4.5285 ± 0.0010 inch)
100.120 ± 0.025 mm 1.10 ± 0.08 mm 125.037 ± 0.037 mm
6I-3550 N/A N/A
(3.9417 ± 0.0010 inch) (0.043 ± 0.003 inch) (4.9227 ± 0.0015 inch)
148-2125 100.120 ± 0.025 mm 1.13 ± 0.05 mm 125.037 ± 0.037 mm
N/A N/A
469-5314 (3.9417 ± 0.0010 inch) (0.045 ± 0.002 inch) (4.9227 ± 0.0015 inch)
148-2130 100.120 ± 0.025 mm 1.13 ± 0.05 mm 130.037 ± 0.037 mm
N/A N/A
197-9330 (3.9417 ± 0.0010 inch) (0.045 ± 0.002 inch) (5.1196 ± 0.0015 inch)
313-7141 114.70 ± 0.10 mm 185.545 ± 0.020 mm 23.85 ± 0.13 mm 175.025 ± 0.025 mm
N/A
377-8485 (4.516 ± 0.004 inch) (7.3049 ± 0.0008 inch) (0.939 ± 0.005 inch) (6.8907 ± 0.0010 inch)
Table 8
Liner Sleeve Dimensions
Sleeve Liner Outside Diameter Inside Diameter Height
259-1046 289.975 ± 0.025 mm 279.025 ± 0.050 mm
137-4017 53.3 mm (2.10 inch)
385-3469 (11.4163 ± 0.0010 inch) (10.9852 ± 0.0020 inch)
313-7141 185.450 ± 0.025 mm 174.045 ± 0.050 mm 25.50 ± 0.10 mm
381-3969
377-8485 (7.3012 ± 0.0010 inch) (6.8522 ± 0.0020 inch) (1.004 ± 0.004 inch)
169.52 ± 0.02 mm 19.35 ± 0.05 mm
516-1856 454-9920 174.42 mm (6.867 inch)
(6.674 ± 0.001 inch) (0.762 ± 0.002 inch)
Table 9
Measuring Flange Thickness

Flange Thickness for Top Supported Liners
Measure the thickness of the flange with a micrometer. Thickness of the flange must meet the
dimensions in Table 7 for reuse.
Flange Thickness for Mid-Supported Liners

Measure the thickness of the mid-support with an outside micrometer. The thickness of the mid-
support must meet the dimensions in Table 8 for reuse.
(A) Mid-support thickness
Measuring Liner Bore

Before measuring the liner bore, the liner must first have passed a complete visual inspection. The
measuring of the liner bore is to determine if the liner is out of round. Maximum reuse
specifications can be found within Tables 7 and 8.
Gauges For Measuring
Typical example of dial bore gauge set.
Bore diameters should be measured with a dial bore gauge that has been accurately calibrated
with a master ring or a fixture for setting the gauge.
For instructions on how to use a dial bore gauge set, refer to Special Instruction, SMHS8253, "Use
of the 6V-7898 Dial Bore Gauge". Use the 1P-3537 Dial Bore Gauge.
Record the part number of the cylinder liner and the sequence numbers for the inspection process.
Keep a log of history or a permanent record by sequence number of the cylinder liner for any
measurements that are taken for future reference.
Measuring Procedure
Typical diameter measuring locations.
Measure the bore of the cylinder liner at three points on the horizontal plane that are 45° apart.
Repeat this measuring procedure three separate times on the vertical plane. The measurements
should be taken at the top end of the stroke, the middle, and the lower end of the stroke. Refer to
Illustration 59.
Measure the inside diameter of the liner with a dial bore gauge.
If all the measurements of the bore are acceptable according to Tables 7 and 8, then the liner can
be used again.
1. Determine the wear of the diameter of the cylinder liner bore by taking three sets of
measurements that are 45° from each other in three different locations in the cylinder liner.
One set of measurements should be taken at the upper end of the cylinder liner at the point
of the maximum wear. The second set of measurements should be taken in the middle of the
liner. The last set of measurements should be taken at the lower end of the liner. Record this
information for future reference.
2. It is important to maintain the dimensions that are listed in Tables 7 and 8.
Liner Storage
Storage of the cylinder liners requires some special attention to avoid destroying a reusable liner.
Always protect the liners in storage.
Never store liners in a dirty condition as this practice will accelerate rusting and corrosion of
the machined surface.
Always use a rust preventative or a light film of clean engine oil to protect the clean liner.
Never store the liner on its side. Doing so will gradually deform the liners into an out of round
shape.
PIP-10181735
2021/02/12
17:10:01-08:00
i03720107
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Inspection and Reuse Guideline of Cylinder Liners in Cat Engines {0761, 1201, 1213,

SMCS - 0761,1201,1213,1216 i08234666

All 3400 Engines

All 3500 Engines

All 3600 Engines

All C10 Engines

All C11 Engines

All C12 Engines

All C15 Engines

All C16 Engines

All C175 Engines

All C18 Engines

All C27 Engines

All C280 Engines

All C32 Engines

All C9.3 Engines

All G3300 Engines

All G3500 Engines

All G3600 Engines

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

Canceled Part Numbers and Replaced Part

Important Safety Information

Improper operation, lubrication, maintenance or repair of this

Do not operate or perform any lubrication, maintenance or repair

This safety alert symbol means:

Your safety is involved.

Improvements in emissions strategy have included a proprietary

Caterpillar does allow for liners to be cleaned,

Service Letters and Technical Information

Tooling and Equipment

To avoid component damage, follow the recommended

Tooling and Equipment

Part Number Description

Mid Mounted Liners

Procedure to Clean Liners

If Using Cat Nylon Bristle Brushes

2. Slide the twisted wire handle into extension .

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

Cleaning Interior Surfaces

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and

a. Use a hydraulic wash tank.

b. Use detergent and nylon brush.

Refer to Tables 7 and 8 to find the appropriate sized brush needed.

Cleaning Exterior Surfaces

O-Ring Groove Area

Dimensions of the Modified Drill

Remove any sharp edges or high areas with a file.

Inside Surface Inspection

Crack Detection Methods

Crack Inspection Method Advantages vs. Disadvantages

Applicable Crack Detection Standards

Visual Surface Inspection (VT)

Liquid Penetrant Testing (PT)

Personal injury can result from improper handling of chemicals.

Make sure you use all the necessary protective equipment

Observe all safety precautions recommended by the chemical

Refer to Tooling and Equipment Table 3 for part numbers.

Brush: Removes dirt and rust.