SEBF8049 - Visual Inspection of The Piston (1214, 1214) PDF

19/10/2016
BsquedadelmedioSEBF8049VisualInspectionofthePiston{1214,1214}
Pantallaanterior
Bienvenido:r080am5
Producto:NOSEHAESCOGIDONINGUNEQUIPO
Modelo:NOSEHAESCOGIDONINGUNEQUIPO
Configuracin:NOSEHAESCOGIDONINGUNEQUIPO
Pautasdereutilizacinyrecuperacin
VisualInspectionofthePiston{1214,1214}
NmerodemedioSEBF804935
Caterpillar:ConfidentialYellow
Fechadepublicacin10/09/2015
Fechadeactualizacin25/04/2016
i06681780
VisualInspectionofthePiston{1214,1214}
SMCS12140401214
CaterpillarProducts
All
Introduction
Table1
Revision
SummaryofChangesinSEBF8049
35
Addednewserialnumberprefixes
34
AddedBorescopepartnumbers
33
Addednewserialnumberprefixes.
32
RevisedcaptionfromIllustration122.ChangedReusestatementtoDONOTUSEAGAIN.
31
Addednewserialnumberprefixes.
30
Updatedseveralphotographsforclarity
Correctedreferenceforbuffingskirtsinthe"ReconditioningProcedure"
29
UpdatedEffectivity
28
Majorchanges&updatestoentiredocument.Updatedwithnewerphotographsandreorganized
content
27
UpdatedEffectivity
26
UpdatedEffectivity
Added"ImportantSafetyInformation"section.
25
UpdatedEffectivity
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2016CaterpillarAllRightsReserved.ThisguidelineisfortheuseofCatdealersonly.Unauthorizeduseof
thisdocumentortheproprietaryprocessesthereinwithoutpermissionmaybeviolationofintellectualproperty
law.
InformationcontainedinthisdocumentisconsideredCaterpillar:ConfidentialYellow.
ThisReuseandSalvageGuidelinecontainsthenecessaryinformationinordertoallowadealertoestablisha
partsreusabilityprogram.ReuseandsalvageinformationenablesCaterpillardealersandcustomerstobenefit
fromcostreductions.Everyefforthasbeenmadeinordertoprovidethemostcurrentinformationthatisknown
toCaterpillar.Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour
productwhicharenotincludedinthispublication.ThisReuseandSalvageGuidelinemustbeusedwiththe
latesttechnicalinformationthatisavailablefromCaterpillar.
Forquestionsoradditionalinformationconcerningthisguideline,submitaformforfeedbackintheService
InformationSystem.Inordertoaddressanurgentissue,usethefollowingresourcesinordertocommunicate
yourrequesttoCaterpillarRepairProcessEngineering:
CaterpillarDealerTechnicalCommunicator
DealerSolutionNetwork
CaterpillarTechnicalRepresentative
KnowledgeNetwork
CanceledPartNumbersandReplacedPartNumbers
Thisdocumentmaynotincludecanceledpartnumbersandreplacedpartnumbers.UseNPRonSISfor
informationaboutcanceledpartnumbersandreplacedpartnumbers.NPRwillprovidethecurrentpartnumbers
forreplacedparts.
ImportantSafetyInformation
Illustration1
g02139237
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Worksafely.Mostaccidentsthatinvolveproductoperation,maintenance,andrepairarecausedbyfailureto
observebasicsafetyrulesorprecautions.Anaccidentcanoftenbeavoidedbyrecognizingpotentiallyhazardous
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situationsbeforeanaccidentoccurs.Apersonmustbealerttopotentialhazards.Thispersonshouldalsohave
thenecessarytraining,skills,andtoolsinordertoperformthesefunctionsproperly.Safetyprecautionsand
warningsareprovidedinthisinstructionandontheproduct.Ifthesehazardwarningsarenotheeded,bodily
injuryordeathcouldoccurtoyouortootherpersons.Caterpillarcannotanticipateeverypossiblecircumstance
thatmightinvolveapotentialhazard.Therefore,thewarningsinthispublicationandthewarningsthatareon
theproductarenotallinclusive.Ifatool,aprocedure,aworkmethodoroperatingtechniquethatis
notspecificallyrecommendedbyCaterpillarisused,youmustensurethatitissafeforyouandforotherpeople
touse.Youshouldensurethattheproductwillnotbedamagedortheproductwillnotbemadeunsafebythe
operation,lubrication,maintenanceortherepairproceduresthatareused.
Improperoperation,lubrication,maintenanceorrepairofthisproduct
canbedangerousandcouldresultininjuryordeath.
Donotoperateorperformanylubrication,maintenanceorrepairon
thisproduct,untilyouhavereadandunderstoodtheoperation,
lubrication,maintenanceandrepairinformation.
Safetyprecautionsandwarningsareprovidedinthismanualandontheproduct.Ifthesehazardwarningsare
notheeded,bodilyinjuryordeathcouldoccurtoyouortootherpersons.
Thehazardsareidentifiedbythesafetyalertsymbolwhichisfollowedbyasignalwordsuchasdanger,
warning,orcaution.The"WARNING"safetyalertsymbolisshownbelow.
Illustration2
g00008666
Thissafetyalertsymbolmeans:
Payattention!
Becomealert!
Yoursafetyisinvolved.
Themessagethatappearsunderthesafetyalertsymbolexplainsthehazard.
Operationsthatmaycauseproductdamageareidentifiedby"NOTICE"labelsontheproductandinthis
publication.
Caterpillarcannotanticipateeverypossiblecircumstancethatmightinvolveapotentialhazard.The
safetyinformationinthisdocumentandthesafetyinformationonthemachinearenotallinclusive.You
mustdeterminethatthetools,procedures,workmethods,andoperatingtechniquesaresafe.Youmust
determinethattheoperation,lubrication,maintenance,andrepairprocedureswillnotdamagethe
machine.Also,youmustdeterminethattheoperation,lubrication,maintenance,andrepairprocedures
willnotmakethemachineunsafe.
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Theinformation,thespecifications,andtheillustrationsthatexistinthisguidelinearebasedoninformation
whichwasavailableatthetimeofpublication.Thespecifications,torques,pressures,measurements,
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adjustments,illustrations,andotheritemscanchangeatanytime.Thesechangescanaffecttheservicethatis
giventotheproduct.Obtainthecomplete,mostcurrentinformationbeforeyoustartanyjob.Caterpillardealers
cansupplythemostcurrentinformation.
Summary
Thisdocumentwillaidthetechnicianinthevisualinspectionofmultipletypesofpistons.Italsocoversmultiple
locationsofpistonswithmanydifferentwearandfailurepatterns.
References
ReuseandSalvageGuidelines,SEBF8059,"ProcedureandSpecificationstoCleanandMeasurePistons"
ReuseandSalvageGuidelines,SEBF8051,"InspectionandMeasuringProceduresforPistonPins"
ContaminationControlGuidelines,PEBJ0002,"CaterpillarDealerContaminationControlComplianceGuide"
SpecialInstructions,SEHS8696,"PistonCleaningProcedure"
ToolingandEquipment
Table2
ToolingandEquipment
PartNumber
Description
6V7894
Microlite
6V2196
Microscope
4480722
Probe(17mmSideviewCameraBorescope)
4480723
Probe(5.5mmHDCameraBorescope)
4480724
ToolGp(VideoBorescopeWired)
4480725
ToolGp(VideoBorescopeWireless)
Nomenclature
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Illustration3
g01984853
Aluminumonepiecedirectinjectionpistonwithasinglecompressionring.
(1)Crown
(2)Crater
(3)RingBand
(4)RingGrooves
(5)RingLands
(6)Skirt
(7)PinBore
(8)SnapRingGroove
(9)TopLand
(10)SkirtRelief
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Illustration4
g01984976
Aluminumonepiecedirectinjectionpistonwithadoubleringland.
(1)Crown
(2)Crater
(3)RingBand
(4)RingGrooves
(5)RingLands
(6)Skirt
(7)PinBore
(8)SnapRingGroove
(9)TopLand
(10)CoolingJetRelief
(11)SkirtRelief
Illustration5
g01985115
Aluminumonepiecedirectinjectionpistonwithasingleringland.
(1)Crown
(2)Crater
(3)RingBand
(4)RingGrooves
(5)RingLands
(6)Skirt
(7)PinBore
(8)SnapRingGroove
(9)TopLand
(11)SkirtRelief
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Illustration6
g01985274
Aluminumonepiecepistonfroma3500seriesengine.
(1)Crown
(2)Crater
(3)RingBand
(4)RingGrooves
(5)RingLands
(6)Skirt
(7)PinBore
(8)SnapRingGroove
(9)TopLand
Illustration7
g01985293
Thepistonfromatypicalprecombustionchamberengine
(1)Crown
(2)Crater
(3)RingBand
(4)RingGrooves
(5)RingLands
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(6)Skirt
(7)PinBore
(8)SnapRingGroove
(9)TopLand
(11)SkirtRelief
(12)ReliefforValve
(13)HeatPlug
Illustration8
Atwopiecepistonutilizingasteelcrownandaluminumskirt.
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(1)Crown,(2)Crater,(3)RingGrooves,(4)TopLand,(5)RingLands,(6)PistonPinBushing,(7)Skirt,(8)PinBoreinSkirtand(9)
PistonSideRelief
Illustration9
g03397256
Onepiecepistonwithacoatingofgraphite
(1)Crown,(2)Crater,(3)RingGrooves,(4)TopLand,(5)RingLands,(6)PistonPinBushing,(7)Skirt,(8)PinBoreinSkirtand(9)
PistonSideRelief
Referto"GraphiteCoatedPistons"lateroninthisdocumentformoreinformation.
Note:Thepistonandpistonpinmustbeidentifiedandmarkedwiththecylindernumberandorientationin
referencetothefrontoftheengine.
Note:Donotmixandmatchpistonsandpistonpinsfromdifferentcylinders.Ensurethatthepistonsandpiston
pinsareorientedproperlytothefrontoftheengineuponreassembly.
NOTICE
Pistonandpistonpinsweartogether,mixingthepartsmayleadinpin
seizures.
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Illustration10
g03391885
Thiscolorcodedpistonshowstherisk/stressareasofthepiston.Illustration10isaonepiecegraphitecoatedpistonbutappliesto
allpistons.
(1)RedHighrisk/stressareaofthepiston.
(2)YellowMediumrisk/stressareaofthepiston.
(3)GreenLowrisk/stressareaofthepiston.
GeneralProcedures
Followtheinstructionsinthisguidelineinordertodetermineifapistonisreusable.
1.Makeavisualcheckoftheoverallconditionofthepiston.
2.Cleanthepistonthoroughly.
3.Reinspectthepistonaftercleaningforthefollowing.
Cracks
Scuffing
Holes
Additionalvisibledamagefrompoorhandling
Imbeddedmaterial
Excessivewearofthegraphitecoating
4.Thefollowingareasofthepistonshouldbeinspectedbeforereusing.
Crater
Crown
PinBore
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RingGroove
RingLands
Skirt
SnapRingGroove
Structure
5.MeasurethepistonaccordingtothespecificationsintheReuseandSalvageGuidelines,SEBF8059,
"ProcedureandSpecificationstoCleanandMeasurePistons".
Initialinspection
Makeaquickvisualinspectionofthepistonbeforecleaning.Ifnoobviousfaultsarefound,cleanthepiston
accordingtotheinstructionsintheReuseandSalvageGuidelines,SEBF8059,"ProcedurestoCleanandInspect
Pistons".
FuelErosionandPittingintheCrater
Illustration11
g02776917
Signsofcarbonbuildupfromfueldepositsbutnopittingispresent.Thispistonmaybeusedagainafterpropercleaning.USE
AGAIN
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Illustration12
g02776921
Signsofcarbonbuildupfromfueldepositsbutnopittingispresent.Thispistonmaybeusedagainafterpropercleaning.USE
AGAIN
Illustration13
g02776920
Heavycarbondeposits,butnopittinginthemetalisvisible.Cleanthepistonandinspectagain.USEAGAIN
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Illustration14
g02776859
Signsofcarbonbuildupfromfueldepositsbutnopittingispresent.Nodamagetothecrownisvisibleandnocracksarevisible.This
pistonmaybeusedagainafterpropercleaning.USEAGAIN
Illustration15
g02776858
Minimalfuelerosionisvisibleafterthepistonhasbeencleaned.USEAGAIN
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Illustration16
g02776839
Fuelerosionisslightlydeeperandcanbefeltwithfingernailaftercleaning.Thisisacceptableiftheerosiondoesnotspreadacross
25%ofthepiston.USEAGAIN
Illustration17
g03386299
Thecraterofthepistonshowsdeeperosionthatiscausedbyfuel.DONOTUSEAGAIN
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Illustration18
g01198989
Deepunevenerosioncausedbyfuel.DONOTUSEAGAIN
Illustration19
g01198990
Thecraterofthepistonisshowingmultiplepointsofdeeperosionthatiscausedbyfuel.DONOTUSEAGAIN
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Illustration20
g02776841
Lightpittinginalowstressareaofthepiston.USEAGAIN
Illustration21
g02776856
Minimalpittingthatisconsistentacrossthepiston.USEAGAIN
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Illustration22
g02776848
Fuelerosionhascausedvisiblepittinginthecraterbutthepittingisminimal.USEAGAIN
Illustration23
g02776844
Smallconcentrationoflightpittinginalowstressareaofthepiston.USEAGAIN
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Illustration24
g02776845
Heavydeeppits.DONOTUSEAGAIN
Illustration25
g03386431
Thispistonshowsexcessivepittingthatexhibitsincreasedintensityfromlefttoright.DONOTUSEAGAIN
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Illustration26
g02776849
Deepaggressivepitsinthespraypattern.DONOTUSEAGAIN
Illustration27
g02776847
Multiplepointsoferosioninahighstressareaofthepiston.DONOTUSEAGAIN
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Illustration28
g02776851
Concentrateddeeppitsanderosion.DONOTUSEAGAIN
Illustration29
g02776853
Deeperosionandpittinginonecentralizedlocation.DONOTUSEAGAIN
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Illustration30
g02776855
Deeperosionandpittinginonecentralizedlocation.ThisisacloseupviewofIllustration29DONOTUSEAGAIN
Illustration31
g02776931
Multipledeeppitsacrosstheentirepiston.DONOTUSEAGAIN
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Illustration32
g02776850
Erosionandpittingacrosstheentirepiston.DONOTUSEAGAIN
Illustration33
g01198791
Multiplepitsanderosionacrosstheentirepiston.DONOTUSEAGAIN
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Illustration34
g01198792
Thepistonhasheavyerosiononthecrown.Anypistonthatisdisplayingthisseverityoferosionanywhereonthecrownshouldnot
bereused.DONOTUSEAGAIN
Crown
Illustration35
g02776928
Lightpitting.USEAGAIN
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Illustration36
g02776929
Lightconcentrationofpittingononelocationofthepiston.USEAGAIN
Illustration37
g02776922
Lightpittinginoneareaofthepiston.USEAGAIN
Illustration38
g01198965
Thepistoncrownisshowingnumerousdeeppitsanddistinctpits.
DONOTUSEAGAIN
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Illustration39
g02776930
Thispistonshowsmultipledeepandshallowpitsthatextendnearthebowlrim.Pitsontheedgeofthecombustionbowlarenot
allowed.DONOTUSEAGAIN
Illustration40
g02776923
Alargeconcentrationofsmallandlargerpitsinoneareaofthepiston.Thesepitsaretooclosetothebowl.DONOTUSEAGAIN
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Illustration41
g02776924
Concentrationofshallowpittingtransferringintodeeppitting.DONOTUSEAGAIN
Illustration42
g02776927
Deeppittingonthecrown.DONOTUSEAGAIN
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Illustration43
g02776926
Deeppittingoveralargeareaofcrownandintothecrater.DONOTUSEAGAIN
Illustration44
g02817942
Mildimpactdamagewithnoimbeddedmaterial.Nocracksarepresentandnodamageisoncornersofcrown.Thispistoncanbe
reusedaftersalvageandinspection.USEAGAIN
Illustration45
g02817944
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Mildimpactdamagewithnoimbeddedmaterial.Nocracksarepresent.Thispistoncanbereusedaftersalvageandinspection.USE
AGAIN
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Illustration46
g02776933
Mildimpactfromvalvewithnoimbeddedmaterialandnocracksarepresent.USEAGAIN
Illustration47
g02821348
Mildimpactfromvalvewithnoimbeddedmaterialandnocracksarepresent.USEAGAIN
Illustration48
Mildimpactfromvalve.USEAGAIN
g02817960
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Illustration49
g02817950
Impactdamagefromvalvewithlightraisedmaterial.Theimpactdoesnotshowtheimpressionoftheentirevalve.Thispistoncanbe
reusedaftersalvageandinspection.USEAGAIN
Illustration50
g02817959
Impactdamagefromvalve.Donotreuseanypistonshowingtheentirevalveimpressionwithraisedmaterial.DONOTUSEAGAIN
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Illustration51
g02817947
Heavierimpactdamagefromvalvethatrunsouttothebowl.DONOTUSEAGAIN
Illustration52
g02817945
Heavyimpactdamagefrommultiplevalves.DONOTUSEAGAIN
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Illustration53
g02817961
Heavyimpactdamagewithraisedmaterial.DONOTUSEAGAIN
Illustration54
g02820178
Heavyimpactdamagewithraisedmaterial.DONOTUSEAGAIN
Illustration55
g02820181
Heavyimpactdamagewithdeeppitsandimbeddedmaterial.DONOTUSEAGAIN
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Illustration56
g02820182
Heavyimpactdamagewithdeeppits.DONOTUSEAGAIN
Illustration57
g02820183
Heavyimpactdamagewithdeeppits.DONOTUSEAGAIN
PinBore
Duringthevisualinspectionofthepistonpinbore,carefullyinspectthesnapringgrooveofthepistonfor
damageorwear.Donotusethepistonagainifthegrooveisexcessivelywornordamaged.Pistonsshouldbe
checkedinthesnapringgrooveforundetectedwearbycomparingthefitofthesnapringintheoldpistonand
inanewpiston.Thepistonshouldnotbereusediftheefforttoturnthesnapringintheusedpiston
issignificantlylessthanthenewpiston.
Note:Orientationofthepistonandpistonpiniscriticalespeciallywithonepiecegraphitecoatedpistons.Keep
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thepinsorientatedexactlyhowthepinswereremovedfromthepistons.Failuretodosomayleadtopinseizure
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andenginefailure.
Illustration58
g02821938
Slightwearinretainingringgroove.USEAGAIN
Illustration59
g02821939
Smalldamagetotheringgroove.USEAGAIN
Illustration60
g02821940
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Veryslightweartopinbore.USEAGAIN
Illustration61
g02821957
Slightwearintheringgroovefrominstallationorremovalofthesnapring.USEAGAIN
Illustration62
g02821956
Themachininggroovesarenolongervisibleintheringgroove.Thispistonpinboreisworn.DONOTUSEAGAIN
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Illustration63
g01199584
Thepistonhaslightwearontheedgeofthebore,butthemeasurementsoftheborearecorrect.USEAGAIN
Illustration64
g01199614
Thepistonhasdiscolorationonthebottomofthepiston.Measurethepistonpinboresinordertomakesurethatthereisno
distortion.USEAGAIN
Usethepistonagain.
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Illustration65
g01199941
Thepistonhasawearpatterninsidethepinbore.USEAGAIN
Illustration66
g01199944
Thepistonshowswearandlightscratchesinthepinborethatcannotbefeltwithafingernail.USEAGAIN
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Illustration67
g02827245
Slightwear/discolorationonbushing.USEAGAIN
Illustration68
g02827241
Slightdiscolorationonbushing.USEAGAIN
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Illustration69
g02831059
Smallscratchtobushingthatcanbefeltwithafingernail.DONOTUSEAGAIN
Illustration70
g02831062
Chainingabrasiveweartobushing.DONOTUSEAGAIN
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Illustration71
g02827239
Temperingtothebushing.DONOTUSEAGAIN
Illustration72
g02827238
Polishingtothebushing.DONOTUSEAGAIN
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Illustration73
g02831057
Slighttemperingandpolishingtothebushing.DONOTUSEAGAIN
Note:Ifpistonpinbushinghaswornthroughthephosphatecoatingitisoutofspecificationandmustbe
replaced.Failuretoreplacethepistononcethecoatingiswornawaycanresultinpistonpinseizureandengine
failure.
Illustration74
g02831064
Phosphatecoatingworn.DONOTUSEAGAIN
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Illustration75
g02831069
Illustration76
g02833158
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Illustration77
g02833159
Illustration78
g02833161
Illustration79
g02833163
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Illustration80
g02827249
Phosphatecoatingwornandpittingstartinginthebushing.DONOTUSEAGAIN
RingGrooves
Note:Allpistonringgroovesthatshowanywearstepsmustbemeasuredandwithinspecifications.Measure
thepistonaccordingtothespecificationsintheReuseandSalvageGuidelines,SEBF8059,"Procedureand
SpecificationstoCleanandMeasurePistons".
Illustration81
g02833886
Smallwearstep.USEAGAIN
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Illustration82
g02833885
Largewearstep.DONOTUSEAGAIN
Illustration83
g02833879
Carbonintheringgroove.Cleanthepistonagainandreinspect.Thispistonisreusableifthecarboncanberemoved.USEAGAIN
Illustration84
g02833877
Corrosiononthetopringgrove.DONOTUSEAGAIN
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Illustration85
g02833882
Pittinginthebottomringgroove.DONOTUSEAGAIN
RingLands
Illustration86
g02833887
Slightscuffing/adhesivewear.Anarrowpatchofscuffingisacceptableforreuse.USEAGAIN
Illustration87
g02833890
Slightscuffing/adhesivewear.ThisisacloseupphotoofIllustration86.USEAGAIN
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Illustration88
g02835377
Slightscuffing/adhesivewearonthesecondland.Thiscontactpatternistoowideforreuseofthepiston.DONOTUSEAGAIN
Illustration89
g02835379
Adhesivewearonringlands.DONOTUSEAGAIN
Illustration90
g02839518
Middleringlandpolishedsmoothbutnoscratches.USEAGAIN
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Illustration91
g02835376
Slightpittinginthetopringland.USEAGAIN
Illustration92
g02835578
Slightpittingonthebottomland.USEAGAIN
Illustration93
g02835576
Smallnickswithoutraisedmaterial.USEAGAIN
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Illustration94
g02835382
Slightweartobottomlandwithnoraisedmetalandthemachiningmarksstillvisible.USEAGAIN
Illustration95
g02835586
Smalldingtomiddleringlandthatdoesnotextendintotheringgroove.Thispistoncanbereusedaftersalvageandinspection.
USEAGAIN
Illustration96
g02836556
Smalldingontopofcrown.USEAGAIN
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Illustration97
g02835579
Handlingdamagewithslightraisedmaterial.Thispistoncanbereusedaftersalvageandinspection.USEAGAIN
Illustration98
g02835582
Lighthandlingdamagewithnoraisedmaterial.USEAGAIN
Illustration99
g02835584
Handlingdamagewithraisedmaterialacrosstheentireland.DONOTUSEAGAIN
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Illustration100
g02835588
Handlingdamagethatrunsacrossthelands.DONOTUSEAGAIN
Illustration101
g02836657
Handlingdamagewithraisedmaterialthatextendsintotheringgroove.DONOTUSEAGAIN
Illustration102
g02836716
Lighthandlingdamage.USEAGAIN
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Illustration103
g03586270
Dingintopringlandthathasnoraisedmaterial.USEAGAIN
Illustration104
g02836719
Dentthatispresentacrossmorethanonelandandalsohasraisedmaterialintotheringgroove.DONOTUSEAGAIN
Illustration105
g03586268
Smalldentinbottomlandwithnoraisedmaterial.USEAGAIN
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Illustration106
g02836721
Smalldentinthetoplandwithlightraisedmaterial.Thispistoncanbereusedaftersalvageandinspection.USEAGAIN
Skirt
Illustration107
g03586266
Thehorizontalmarkingisdiscolorationanddoesnotaffectthereusabilityofthepiston.USEAGAIN
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Illustration108
g03586265
Thehorizontalmarkingsaretheresultofthemanufacturingprocessandarenotadefect.USEAGAIN
Illustration109
g01993079
Discolorationisduetothecleaningsolution.USEAGAIN
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Illustration110
g02840281
Abuffedandpolishedskirtthatisreadyforreuse.USEAGAIN
Illustration111
g02870179
Polishingmarkswiththeoriginalmachiningmarksstillshowingafterpolishing.USEAGAIN
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Illustration112
g02839818
Verysmalldingswithnoraisedmetal.USEAGAIN
Illustration113
g02870421
Slightdingonedgeandsidesurfacewithnoraisedmetal.USEAGAIN
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Illustration114
g02862484
Slightpitting.USEAGAIN
Illustration115
g02839920
Slightpittingwithnoraisedareas.USEAGAIN
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Illustration116
g02839819
Lightscratchesonthebottomoftheskirt.USEAGAIN
Illustration117
g02840168
Minorscratchesinthebottomofskirt.USEAGAIN
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Illustration118
g02839919
Lighthandlingdamagewithnoraisedmaterial.USEAGAIN
Illustration119
g02840167
Verylightscratchesintheskirt.USEAGAIN
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Illustration120
g02840164
Steelpistonwithascratchintheskirtthatshowsnoraisedmaterial.USEAGAIN
Illustration121
g02840257
Thispistonhasbeenbuffedandstillshowsalongdeepscratch.DONOTUSEAGAIN
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Illustration122
g02840159
Deephorizontalscratchwithraisedmaterial.DONOTUSEAGAIN
Illustration123
g02840290
Thescratchesonthisskirtaredeeperthanthemachiningmarksandisquitelarge.DONOTUSEAGAIN
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Illustration124
g02840171
Largescratchesdeeperthanmachiningmarksandalsowithraisedmaterial.DONOTUSEAGAIN
Illustration125
g02840387
Lightscratchontheskirt.USEAGAIN
Illustration126
g02840280
Scratchthatstillshowsafterpolishingtheskirt.DONOTUSEAGAIN
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Illustration127
g02840386
Lightscuffing.USEAGAIN
Illustration128
g02871536
Twodingsintheskirtwithlightraisedmaterial.Thispistoncanbereusedaftersalvageandinspection.USEAGAIN
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Illustration129
g02840170
Deepgougesintheskirt.DONOTUSEAGAIN
Illustration130
g02840237
Largegougeabovethepinbore.DONOTUSEAGAIN
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Illustration131
g03585897
Damageontopsurfaceoftheskirt.Thisdamageislocatedatthejointbetweentheskirtandthecrownontwo
piecepistons.Nodamageisallowedinthisarea.DONOTUSEAGAIN
Illustration132
g02872467
Scuffingontheskirtwithtransferredmaterial.DONOTUSEAGAIN
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Illustration133
g02871660
Illustration134
g02862798
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Illustration135
g02840288
Severescuffingduetoseizure.DONOTUSEAGAIN
Illustration136
g02864699
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Illustration137
g02864704
Note:Noembeddedmaterialisallowed.Embeddedmaterialappearsasdarkhardspecksintheskirtsurfacethat
canscratchthecylinderwall.Donotreuseanypistonskirtthathasembeddedmaterial.
Illustration138
g01989435
Materialisembeddedintothesurface.
DONOTUSEAGAIN
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Illustration139
g03585901
Materialisembeddedintothesurface.
DONOTUSEAGAIN
Illustration140
g03585902
Smallamountsofembeddedmaterialareunacceptable.
DONOTUSEAGAIN
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Illustration141
g01993234
Thisexampleshowsheavyconcentrationofembeddedparticles.
DONOTUSEAGAIN
Illustration142
g01993235
Asinglelargeembeddedparticleisunacceptable,evenifscratchesarelight.
DONOTUSEAGAIN
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Illustration143
g01993236
Scratchesarenotdeepandnoembeddedmaterialisvisible.
USEAGAIN
Illustration144
g01993237
Scratchesarenotdeepandnoembeddedmaterialisvisible.
USEAGAIN
Structure
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Illustration145
g02872659
Cleanundersideofpiston.Nodiscolorationoranyotherdefectsseen.USEAGAIN
Illustration146
g02872661
Cleanundersideofpiston.Nodiscolorationoranyotherdefectsseen.USEAGAIN
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Illustration147
g02872665
SlightPitting.USEAGAIN
Illustration148
g02872677
SlightPitting.USEAGAIN
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Illustration149
g02872679
HeavyPitting.DONOTUSEAGAIN
GraphiteCoatedPistons
Note:Ifapistonhasseverescoring,materialtransfer,embeddedmaterial,orotherobviousdamagethepiston
shouldnotbeusedagain.
Illustration150
g03398643
Ifthelowercoverplatesofthecoolinggalleryarefoundtobeloosethepistoncannotbeusedagain.Greatcare
shouldbetakentoinspecttheinsideofthecoolinggalleryfordebris.Theuseofaborescopemayaidin
inspectingthegallery.
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Illustration151
g02863420
Verymildwearofgraphitecoatingwithnoscratches.USEAGAIN
Illustration152
g02862678
Verymildweartographitewithscratchnotpenetratingthegraphitecoating.USEAGAIN
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Illustration153
g02863421
Verymildweartographitecoatingwithnoscratches.Slightpolishingtoupperskirtarea.USEAGAIN
Note:Donotusethepistonagainifthelossofcoatingontheskirtexceedshalftheareaoftheskirt.Thepiston
shouldnotbereusedifthewearisfromhardcontact.
Illustration154
g02863439
Nodeepscratchesbutoverhalfofgraphitecoatingiswornaway.DONOTUSEAGAIN
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Illustration155
g02862679
Polishingshouldnotgoouttotheedgeoftheskirt.DONOTUSEAGAIN
Illustration156
g02863418
Minorscratches/coatingwear/handlingdamage.USEAGAIN
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Illustration157
g02862736
Scratcheswithoverhalfofthegraphitecoatingworn.DONOTUSEAGAIN
Illustration158
g02862756
Overhalfofthegraphitecoatingisworn.DONOTUSEAGAIN
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Illustration159
g02862796
Illustration160
g02864698
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Illustration161
g02877646
Debondingofthegraphitecoating.DONOTUSEAGAIN
Illustration162
g02864702
Debondingofthegraphitecoating.DONOTUSEAGAIN
CracksinthePiston
Smallcracksaroundtheheatplugarenormal.Tomeasurethesecracks,usea34gaugewirethathasadiameter
of0.15mm(0.006inch)asagauge.A6V2196Microscopeand6V7894Microlitecanalsobeused.
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Illustration163
g01198526
Ifnecessary,usea6V2196Microscopeand6V7894Microlitetomeasurethesizeofthecracksaroundtheheatplug.
Illustration164
g01198531
Viewthecracksthroughtheeyepieceofthe6V2196Microscope.Thiscrackiswiderthan0.15mm(0.006inch).
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Illustration165
g01198512
Smallcracksthatarelessthan0.15mm(0.006inch)widearoundtheheatplug.USEAGAIN
Illustration166
g01198517
Thearrowsshowcracksthatarewiderthan0.15mm(0.006inch).DONOTUSEAGAIN
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Illustration167
g01198535
Largecracksconnectedtoeachother.DONOTUSEAGAIN
Illustration168
g01198569
Thecrackgoesacrosstheareabetweenthereliefforthevalves.DONOTUSEAGAIN
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Illustration169
g01198570
Cracksinthecraterthatarenotwiderthan0.15mm(0.006inch).USEAGAIN
Note:Directinjectionaluminumpistonshaveasharpedgeattheedgeofthecraterbowlinordertoensuregood
engineperformanceforemissionsandfueleconomy.Finecrackscanbeginatthissharpedgeduetothermal
fatigueandmechanicalfatigue.Althoughsomefinecrackingmaybenormal,largercrackscanbeasignof
severeengineloadfactor.Thepistonswithcratercracksthatarelessthan6.00mm(0.236inch)longmaybe
reused.Thepistoncanbereusedifthecracksareontheedgeofthecraterrimofthepiston.Thecracksinthe
pistonshouldnotbewithin30degreesofthecenterlineofthepistonpinbore.
Illustration170
g02877359
Cracksthatarelessthan6.00mm(0.236inch)longareallowedwithintheshadedarea.
(A)30degrees
(B)6.00mm(0.236inch)
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Illustration171
g01198667
Thecracksareinthecraterareaofanaluminumdirectinjectionpiston.Measurethelengthandangleofthecrackinrelationtothe
pinbore.Usethepistonagainifthecrackislessthan6.00mm(0.236inch)longandthecrackisnotwithin30degreesofthepin
bore.Thiscrackisover6.00mm(0.236inch).DONOTUSEAGAIN
Illustration172
g01198673
Thecrackinthepistonisoutsideoftheallowableareaforcracks.
DONOTUSEAGAIN
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Illustration173
g01199027
Acrackinthetoplandofthepiston.DONOTUSEAGAIN
Illustration174
g01199157
Thecrackisintheringlandofthepiston.DONOTUSEAGAIN
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Illustration175
g01199333
Thepistonisshowingheavydamagetotheskirt.Apistonwithcracksinanyareaoftheskirtmakethepistonunusable.DONOT
USEAGAIN
Note:Illustration176,177and178arethesamepiston.Thereiswearontheoutsideoftheskirtbutcloser
inspectionshowsacrackontheinsideoftheskirt.
Illustration176
g03390700
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Illustration177
g03390704
Illustration178
g03390736
Nocracksarepermitted.DONOTUSEAGAIN
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Illustration179
g01201914
Thepistonhasacrackinthewebarea.Thereisalsodamagenearthepinboreofthepiston.DONOTUSEAGAIN
DamagefromImproperHandling
Illustration180
g02840163
Topskirtdamage.Thispistoncanbereusedaftersalvageoperationandreinspectpiston.USEAGAIN
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Illustration181
g02776937
Smalldingincrown.Thispistoncanbereusedaftersalvageoperationandinspection.USEAGAIN
Illustration182
g02817941
Smalldentinveryedgeofcrown.USEAGAIN
Illustration183
g02776936
Smalldentincrown.Thispistoncanbereusedaftersalvageoperationandinspection.USEAGAIN
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Illustration184
g02783251
Largedentinveryedgeofcrown.DONOTUSEAGAIN
Illustration185
g02783259
Illustration186
g02817940
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Illustration187
g02821959
Nickinthepinbore.DONOTUSEAGAIN
ReconditioningProcedure
Thereareseveralmethodsforreconditioningminordamagetothepistoncrownandthepistonskirt.Usethe
methodforcleaningthatisleastaggressiveduringtheprocessforreconditioningofthepiston.
Adepressionresultswhenapartisscratched,nicked,ordented.Thescratch,thenick,orthedentcanalsoresult
inanareathatisraised.
Illustration188
g02882814
Carefullyremovetheraisedmetalareathatiscausedbynicks,dents,andscratches.Illustration177showsexamplesofthevarious
typesofdamagetothepiston.Inorderforthepistontobereused,thepistonmustbecleanedandtheareaofmetalthatisraisedmust
beremovedfromthesurface.
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Theraisedareasofthepistoncanberemovedbyseveralmethods.Themostcommonmethodsofremoving
raisedmetalareafile,apolishingwheel,oraScotchBriteabrasivedisc.Thefileisthemostaggressivemethod
forremovingraisedmaterial.Thefileisrecommendedforsmallareasonthesurfaceformaterialthathasbeen
raisedmorethan0.20mm(0.008inch).Usecautiontoensurethatonlytheraisedmaterialisremoved.Besure
thatnoindentationsareleftbehindfromthereconditioningprocedure.
ThepolishingwheelandtheScotchBriteabrasivediscareusedtoremovesmallscratchesinlargerareas.The
pistonskirtismadefromaluminum.Inordertoreducetheriskofdamagetothepiston,manualbuffingis
preferredtoapolishingwheeltoremovescratchesandimperfections.Illustration110andIllustration111shows
anexampleofaskirtthatwasbuffedwithaScotchBriteabrasivedisc.
Copyright19932016CaterpillarInc.
Todoslosderechosreservados.
RedprivadaparalicenciadosdelSIS.
WedOct19201618:44:29GMT0500(Horaest.Pacfico,Sudamrica)
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SEBF8049 - Visual Inspection of The Piston (1214, 1214) PDF

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