Inspection and Reuse Guideline of Cylinder Liners in Cat Engines {0761, 1201, 1213, 1216, 1216} Caterpillar

Caterpillar Products

All Cat Engines

Introduction

Table 1

Revision	Summary of Changes in SEBF8068
26	Added new serial number prefixes / C175 Cuffed Liner information
25	Photos added to show allowable liner pitting
24	Combined information from SEBF8164, SEBF8247, SEBF8817, SEBF9122, SEBF9194, added 60 part numbers and repaired 9 pixelated illustrations

© 2019 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.

For technical questions when using this document, work with your Dealer Technical Communicator (TC). 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.

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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.

Illustration 2	g00008666

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

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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

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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

Table 2

References
Media Number	Title
GMG00981	Special Instruction, "Using 1P-3537 Dial Bore Gauge Group to Check Cylinder Bore Size"
, NEHS0632	Tool Operating Manual, "Procedures For Using the 120-9143 Cylinder Wash Tank Gp"
, SMHS8253	Special Instruction, "Use of the 6V-7898 Dial Bore Gauge"
, SMHS8254	Special Instruction, "Using the 6V-7899 Size Setting Fixture Group"

Tooling and Equipment

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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.

Table 3

Tooling and Equipment
Part Number	Description
1P-3537	Dial Bore Gauge
1P-7429	Nylon Bristle Brush 114.3 mm (4 ½ inch)
1P-9788	Nylon Bristle Brush 127.0 mm (5.0 inch)
1U-8869	Dial Indicator
2S-5658	M16 Washer
3P-1568	Dial Indicator
4C-4707	Dial Gauge
4C-5552	Nylon Bristles 57.2 mm (2 ¼ inch)
4C-6343	Nylon Bristle Brush 101.6 mm (4 inch)
4C-6344	Nylon Bristle Brush 139.7 mm (5 ½ inch)
4C-6345	Nylon Bristle Brush 152.4 mm (6 inch)
4C-6346	Nylon Bristle Brush 165.1 mm (6 ½ inch)
4C-6347	Nylon Bristle Brush 177.8 mm (7 inch)
4C-6348	Nylon Bristle Brush 190.5 mm (7 ½ inch)
4C-6349	Nylon Bristle Brush 203.2 mm (8 inch)
4C-6350	Nylon Bristle Brush 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
135-7628	Nylon Bristle Brush 304.8 mm (12.0 inch)
151-0968	Cordless Drill
222-3061	Air Drill
262-8390	Microscope, Pocket 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
423-4373	Digital Caliper 0.0 - 203.2 mm (0.00 - 8.00 inch)
431-4150	Micrometer, External 25 mm (1 inch)
441-0714	Spring Tester
459-0184	UV Lamp Group
473-8690	Micrometer, Outside 0.00 - 4.00 inch
473-8691	Micrometer, Outside 2.00 - 6.00 inch
473-8691	Micrometer, Outside 50.8 - 152.4 mm (2.00 - 6.00 inch)
473-8692	Micrometer, Outside 152.4 - 304.8 mm (6.00 - 12.00 inch)
486-1526	Degreaser
FT-1711	Light Table

Nomenclature

Top Mounted Liners

Illustration 3	g06290127
(1) Fire dam (2) Inside surface (3) Outside surface (4) O-ring seal grooves (5) Filler band groove (6) Flange

Mid Mounted Liners

Illustration 4	g03520081
(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

Illustration 5	g06180533
(A) Nylon Brush (B) 4C-4426 Extension

Illustration 6	g02031657
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

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Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using.

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.

   1. 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".

   2. 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.

   3. For protection of the surface that will last for two to three weeks against rust, do not rinse the part after using Hydrosolv 4165. If Hydrosolv 4165 is not used, then rinse the liner. Rinse the cylinder liner with clean, hot water, and treat the cylinder liner with rust preventive or a thin film of engine oil. Do not allow the liner to air dry slowly after rinsing. Use pressurized air to dry the liner immediately.
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   Illustration 7	g02032995
   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.

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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

Illustration 8	g02004824
Rust and deposits must be removed before the visual inspection. Clean the liner again.

O-Ring Groove Area

Illustration 9	g02006654
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.

Illustration 10	g02006694
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

Illustration 11	g02006774
Crack Do not reuse the liner.

Illustration 12	g06290408
Cracking that occurs on the cylinder cuff Do not reuse the liner.

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.

Illustration 13	g06376639
Small pits are acceptable only if the pits are limited to one or two sides.

Illustration 14	g02006857
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.

Illustration 15	g06376638
C175 Liner Pits shown on lower section of O-Ring groove

Illustration 16	g06376641
C175 Liner Pits shown on lower section of O-Ring groove

Illustration 17	g06376642
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.

Illustration 18	g03554498
Deep pits Do not reuse liners with deep pits.

Illustration 19	g02006934
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.

Illustration 20	g02007072
Modified 8S-2251 Drill (3) Lip (4) Radius (A) Depth of section to grind

Table 4

Dimensions of the Modified Drill
(A)	(4)
2.30 mm (0.091 inch)	0.51 mm (0.020 inch)

Illustration 21	g02007054

Flange Area

Illustration 22	g03566667
Visible crack extending from inside liner into flange area Do not reuse the liner.

Illustration 23	g02008133
Pits and erosion in the filler band groove. Do not reuse the liner.

Illustration 24	g02008254
Do not reuse the liner.

Illustration 25	g02008298
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.

Illustration 26	g02008418
Small pits Reuse the liner.

Illustration 27	g06290417
Crack in the flange. Do not reuse the liner.

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.

Illustration 28	g02008619
Damage to the fire dam. Reuse the liner.

The damage must not extend across the fire dam. Burrs or sharp edges must be removed.

Illustration 29	g02008647
Damage in the surface area of the gasket Do not reuse the liner.

Illustration 30	g02008657
Nick in the vertical flange Reuse the liner.

Remove any sharp edges or high areas with a file.

Illustration 31	g02008696
Chip in the seal edge of the flange. Do not reuse the liner.

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 insideofthe 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.

Illustration 32	g02020854
Light Table

Illustration 33	g01842838
Example of good clean cross hatch.

Illustration 34	g02020874
Pits on the inside surface Do not reuse the liner.

Illustration 35	g02022540
Crack on the inside surface Do not reuse the liner.

Illustration 36	g02022546
Deep grooves on the inside surface Do not reuse the liner.

Illustration 37	g02022941
Heavy rust on the inside surface Do not reuse the liner .

Illustration 38	g02022949
Water spots on the inside surface. Do not reuse the liner

Illustration 39	g02023415
Shiny areas on the inside surface, no visible cross hatch remains. Do not reuse the liner.

Illustration 40	g02023523
Water rings and spots on the inside surface. Do not reuse the liner.

Illustration 41	g02023538
Deep double wear step on the inside surface Do not reuse the liner.

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.

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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.

Table 5

Crack Inspection Method Advantages vs. Disadvantages
Inspection Method	Advantages	Disadvantages
Visual Surface Inspection (VT)	- Least expensive - Detects most damaging defects - Immediate results - Minimum part preparation	- Limited to surface-only defects - Requires inspectors to have broad knowledge of welding and fabrication in addition to non-destructive testing
Liquid Penetrant (PT)	- Inexpensive - Minimal training - Portable - Works on nonmagnetic material	- Least sensitive - Detects surface cracks only - Rough or porous surfaces interfere with test
Dry Magnetic Particle (MT)	- Portable - Fast/Immediate Results - Detects surface and subsurface discontinuities	- Works on magnetic material only - Less sensitive than Wet Magnetic Particle
Wet Magnetic Particle (MT)	- More sensitive than Liquid Penetrant - Detects subsurface as much as 0.13 mm (0.005 inch)	- Requires Power for Light - Works on magnetic parts only - Liquid composition and agitation must be monitored
Ultrasonic Testing (UT)	- Most sensitive - Detects deep material defects - Immediate results - Wide range of materials and thickness can be inspected	- Most expensive - Requires operator training and certification - Surface must be accessible to probe
Eddy-Current Testing (ET)	- Surface and near surface flaws detectable -Moderate speed/Immediate results -Sensitive to small discontinuities	- Difficult to interpret - Only for metals -Rough surfaces interfere with test - Surface must be accessible to probe
Radiographic Testing (RT)	-Detects surface and internal flaws - Minimum part preparation - Can inspect hidden areas	- Not for porous materials - Radiation protection needed - Defect able to be detected is limited to 2% of thickness

Table 6

Applicable Crack Detection Standards
Inspection Method	Standard	Acceptance Criteria	Required Personnel Qualifications
Visual Surface Inspection (VT)	EN-ISO 5817 AWS D1.1	EN-ISO 5817 - Level B AWS D1.1 - Table 6.1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Liquid Penetrant Testing (PT)	EN-ISO 3452 ASTM E165	EN-ISO 23277 AWS - D1.1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Magnetic Particle Testing (MT)	EN-ISO 17638 ASTM E709	EN-ISO 23278 - Level 1 AWS D1.1 - Table 6.1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Ultrasonic Testing (UT)	EN-ISO 17640 - Level B AWS D1.1	EN-ISO 11666 Technique 2 - Level 2 AWS D1.1 - Class A - Table 6.3	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Eddy-Current Testing (ET)	EN-ISO 15549 ASTM E426	EN-ISO 20807	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Radiographic Testing (RT)	EN-ISO 5579 ASTM E94	EN-ISO 10657-1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2

Visual Surface Inspection (VT)

Illustration 42	g06085008
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)

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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.

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Illustration 43	g06107074
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.
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   Illustration 44	g06107081
   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.
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   Illustration 45	g06107088
   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.
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   Illustration 46	g06107094
   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.
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   Illustration 47	g06084042
   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)

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 48	g06085930
(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)

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 49	g06085937
(A) Indications shown by magnetic particle testing. (B) Typical electromagnetic yoke. (D) UV Lamp used in wet magnetic particle inspection process.

Illustration 50	g06003178
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:

   1. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.

   2. 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.

   3. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.

   4. 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.

   5. 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.

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NOTICE
All personnel involved in ultrasonic testing shall be qualified to Level 2 in accordance to standards stated in Table 6.

Refer to Tooling and Equipment Table 3 for part numbers.

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.

   1. 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 backsurface of the material to project the thickness of the material.

   2. 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)

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NOTICE
All personnel involved in Eddy-Current Testing shall be qualified to Level 2 in accordance to standards stated in Table 6.

Illustration 51	g06090873
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.

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NOTICE
All personnel involved in radiographic testing shall be qualified to Level 2 in accordance to standards stated in Table 6.

Illustration 52	g06090892
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

Illustration 53	g06290427
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

Illustration 54	g06290433
Example of a bore cooled liner. (A) Thickness of Liner Flange (B) Height of Fire Dam (E) Diameter of Liner Bore (F) Width of the top Seal Ring Groove

Use the following reference table for measuring the cylinder liners.

Table 7

Critical Dimensions for Top Supported Liners
Liner Part Number	A	B	C	D	E	F
1W-7900 7E-8268	33.00 ± 0.03 mm (1.299 ± 0.001 inch)	3.5 ± 0.03 mm (0.138 ± 0.001 inch)	N/A	N/A	280.025 ± 0.025 mm (11.02458 ± 0.0010 inch)	N/A
7C-4981 7E-8298 111-1656 385-3468	33.00 ± 0.03 mm (1.299 ± 0.001 inch)	3.5 ± 0.03 mm (0.138 ± 0.001 inch)	N/A	N/A	280.025 ± 0.025 mm (11.02458 ± 0.0010 inch)	7.000 ± 0.130 mm (0.2756 ± 0.0051 inch)
7C-5044 343-4443	33.00 ± 0.03 mm (1.299 ± 0.001 inch)	3.5 ± 0.03 mm (0.138 ± 0.001 inch)	N/A	N/A	300.035 mm (11.8124 inch)	N/A
110-5800 371-5941	10.282 ± 0.020 mm (0.405 ± 0.001 inch)	1.02 ± 0.13 mm (0.040 ± 0.005 inch)	N/A	N/A	120.638 mm (4.7495 inch) - 120.879 mm (4.7590 inch)	N/A
123-8206 211-7826	12.65 ± 0.02 mm (0.498 ± 0.001 inch)	1.06 ± 0.08 mm (0.04173 ± 0.00315 inch)	N/A	N/A	170.000 mm (6.6929 inch) - 170.229 mm (6.7019 inch)	N/A
132-6881 197-9348 420-2631 473-9034	8.89 ± 0.02 mm (0.35000 ± 0.001 inch)	1.12 ± 0.05 mm (0.044 ± 0.002 inch)	N/A	N/A	139.660 mm (5.4984 inch) - 139.889 mm (5.5074 inch)	N/A
179-3167 179-3168 195-3507 343-4444 343-4445 377-6887 385-3470	33.00 ± 0.03 mm (1.299 ± 0.001 inch)	3.5 ± 0.03 mm (0.138 ± 0.001 inch)	290.025 ± 0.025 mm (11.418 ± 0.001 inch)	57.5 ± 0.1 mm (2.264 ± 0.004 inch)	280.025 ± 0.025 mm (11.02458 ± 0.0010 inch)	N/A
197-9322	8.89 ± 0.02 mm (0.350 ± 0.001 inch)	1.04 ± 0.13 mm (0.041 ± 0.005 inch)	N/A	N/A	137.160 mm (5.4000 inch) - 137.389 mm (5.4090 inch)	N/A
259-1046 385-3469	33.00 ± 0.03 mm (1.299 ± 0.001 inch)	3.5 ± 0.03 mm (0.138 ± 0.001 inch)	290.025 ± 0.025 mm (11.418 ± 0.001 inch)	53.5 ± 0.1 mm (2.106 ± 0.004 inch)	279.995 ± 0.025 mm (11.023 ± 0.001 inch)	N/A
211-7826 350-0074 374-3576 447-3915	12.65 ± 0.02 mm (0.498 ± 0.001 inch)	1.06 ± 0.08 mm (0.04173 ± 0.00315 inch)	N/A	N/A	170.000 mm (6.6929 inch) - 170.229 mm (6.7019 inch)	N/A
322-1126 516-9693	8.89 ± 0.02 mm (0.35000 ± 0.001 inch)	1.04 ± 0.13 mm (0.041 ± 0.005 inch)	N/A	N/A	144.975 mm (5.7077 inch) - 145.204 mm (5.7167 inch)	N/A

Critical Dimensions for Mid Mounted Liners

Illustration 55	g06290437
Typical dimensions for mid mounted liners. Some liners will not have all of 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

Table 8

Critical Reuse Dimensions for Mid Supported Liners
Liner Part Number	A	B	C	D	E
6I-3550	100.120 ± 0.025 mm (3.942 ± 0.001 inch)	1.10 ± 0.08 mm (0.043 ± 0.003 inch)	N/A	N/A	125.000 mm (4.9213 inch) - 125.241 mm (4.9307 inch)
148-2125 469-5314	100.120 ± 0.025 mm (3.942 ± 0.001 inch)	1.13 ± 0.05 mm (0.045 ± 0.002 inch)	N/A	N/A	125.000 mm (4.9213 inch) - 125.241 mm (4.9307 inch)
148-2130 197-9330 469-5314	100.120 ± 0.025 mm (3.94172 ± 0.00098 inch)	1.13 ± 0.05 mm (0.045 ± 0.002 inch)	N/A	N/A	130.000 mm (5.1181 inch) - 130.229 mm (5.1271 inch)
190-3562 385-7276 469-5312	130.000 ± 0.025 mm (5.120 ± 0.001 inch)	1.13 ± 0.05 mm (0.045 ± 0.002 inch)	N/A	N/A	112.000 mm (4.409 inch) - 112.229 mm (4.419 inch)
267-6686 469-5313	130.000 ± 0.025 mm (5.120 ± 0.001 inch)	1.13 ± 0.05 mm (0.045 ± 0.002 inch)	N/A	N/A	115.00 mm (4.528 inch) - 115.229 mm (4.5366 inch)
313-7141 377-8485	114.7 ± 0.1 mm (4.516 ± 0.004 inch)	N/A	185.545 ± 0.020 mm (7.304 ± 0.001 inch)	23.85 ± 0.03 mm (0.939 ± 0.001 inch)	175.000 mm (6.8898 inch) - 175.229 mm (6.8988 inch)

Measuring Flange Thickness

Flange Thickness for Top Supported Liners

Measure the thickness of the flange with a micrometer. Thickness of the flange must meet the dimensions in Table 7 for reuse.

Illustration 56	g02020697

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.

Illustration 57	g06290442
(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

Illustration 58	g06290448
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

Illustration 59	g06290453
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.

Illustration 60	g01838754
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.