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Visual Inspection Main & Connecting Rod

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Visual Inspection Main & Connecting Rod

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Reuse And Salvage Guidelines

Visual Inspection of Main Bearings and Connecting Rod Bearings{1202, 1203, 1225,
1230}
Media Number -SEBF8009-11 Publication Date -03/01/2011 Date Updated -03/01/2011

i04174649

Visual Inspection of Main Bearings and Connecting Rod

Bearings{1202, 1203, 1225, 1230}
SMCS - 1202-040; 1203-040; 1225-040; 1230-040

Engine: 3400 All, 3300 All, 3200 All, 3100 All, 3000 All, and D-series All All 3500 Engines C-
10 All C-9 and C9 All C11 All C12 and C-12 All C13 and C-13 All C15 and C-15 All C175
Engines C18 and C-18 All C27 All C32 All C7 All

Introduction
Table 1
Revision Summary of Changes in SEBF8009
11 Updated Effectivity

© 2010 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar Dealers only.
Unauthorized use of this document or the proprietary processes therein without permission may be
violation of intellectual property law.

This Reuse and Salvage Guideline contains the necessary information in order 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 in order 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 questions or additional information concerning this guideline, submit a form for feedback in
the Service Information System. In order to address an urgent issue, please use the following
resources in order to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

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• Caterpillar Technical Representative

• Knowledge Network

Summary
This guideline will provide visual criteria and recommendations in order to show the difference
between a reusable bearing and one that is not reusable. This guideline must be used to determine
whether a bearing is reusable. Bearings that show unacceptable wear must be replaced. If a
bearing meets the specifications in this guideline and other applicable guidelines, the bearing can
be expected to give normal performance until the next overhaul.

This guideline may not be used for failure analysis. To make the illustrations more clear,
descriptions of possible failures have been included. More information on failure analysis can be
found in Applied Failure Analysis, SEBV0544, "Engine Bearings".

References
Applied Failure Analysis, SEBF0544, "Engine Bearings"

General Information
Carefully inspect all bearings. It is also necessary to inspect crankshaft journals and bores. While
it is acceptable to replace only one bearing, replace both halves of the bearing. Clean all parts and
passages. Debris from bearings can damage piston skirts. New bearings are necessary when a
crankshaft has been straightened, ground, or polished. A new bearing is also necessary when a
bore has been machined.

Nomenclature

Illustration 1 g01693334

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Main bearing

(1) Lower bearing half

(2) Upper bearing half

(3) Bearing surface

(4) Oil groove

(5) Oil hole

(6) Locking tab

(7) Mating face

(8) Tab slot

(9) Edge

Illustration 2 g01694173

Thrust bearing

Machining all bearing journals is recommended if you must machine a bore or a crankshaft in
order to remove damage. Always follow the instructions for reconditioning. Instructions for
reconditioning can be found in applicable service manuals.

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Illustration 3 g01694238

(3) Bearing surface

(6) Locking tab

(7) Mating surface

(8) Tab slot

(9) Edge

Illustration 4 g01694261

(10) Thrust surface

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Characteristics of Construction
There are a wide variety of materials and layers that make up bearings. This overview is a basic
description of the layers and materials that make up bearings, starting with the steel backing and
working up to the surface.

• The steel backing is relatively thick. The steel backing also provides strength to the bearing
surface.

• The bonding agent is a thin metallic layer of material, which allows the lining of the bearing
to be bonded to the steel backing. Directly bonding the lining to the steel may not always be
possible. A bonding agent that is made from aluminum is used on aluminum-based material.

• Bearing material is a nonferrous material. Successful operation of the bearing requires

bearing material to give a phase of softness and a phase of hardness. The lining of the
bearing can consist of copper, aluminum, tin, or lead.

• A bonding agent may be a very thin layer of nickel or copper.

• Overlays are typically very soft lead based alloys. Overlays provide a soft layer between
harder materials in the bearing. Lead overlays are also resistant to corrosion.

• Flash coatings typically consist of tin. Flash coatings coat the whole bearing for long-term
storage. Flash coating is about two microns thick. Flash coating can aid the process of break
-in by wearing materials more gently.

Although bearings are constructed similarly, there are differences between standard bearings and
thrust bearings.

• Thrust bearings do not have an overlay of lead tin on flanges of the thrust bearing or thrust
plates.

• The bonding agent is different on some bearings. Older bearings have a second layer of
bonding agent between the steel back and aluminum.

• The lead, or lead tin preventive coating gives bearings a dull gray or white color. Bearing
operation may cause a color change of the bearing.

• Bearing color is also determined by the flash type. Lead tin coated bearings will typically be
darker in color, while tin coated bearings will be lighter in color. Operation of moving parts
in an engine will also change the color of the bearing.

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Illustration 5 g016943

Layers of material

(11) Tin or lead tin flash

(12) Lead tin overlay

(13) Steel back

(14) Bonding agent

(15) Aluminum bearing material

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Illustration 6 g01695153

(12) Lead tin overlay

(14) Bonding agent

(15) Aluminum bearing material

Do not reuse bearings that show a large area of either the bonding agent or aluminum surface.

Identifying, Preparing and Storing Bearings

Bearing identification is a very important part of visual inspection. To ensure that proper
identification of the bearing can be maintained, mark each half of the bearing with a "U" for
upper, or an "L" for lower. It will also be necessary to note the location of each bearing with a
number. Make sure that you record the location and the position of a bearing half. It is acceptable
to write next to the tab of a bearing. Note the position and the location of a bearing on the back
side of a bearing if it is not possible to note next to a tab. For main bearing caps, use the number of
the bearing cap. For rod bearings, use the number of the cylinder. Limit identification marks to the
area next to the mating face.

Illustration 7 g01696015

Identification marks

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Illustration 8 g01696081

Identification marks

Illustration 9 g01905637

After identification of the bearings, preparations must be made for inspection, installation, or
storage of the bearings. Clean Bearings with a solvent such as Stanisol. The bearings can also be
cleaned with a solvent such as Brake Clean. Caterpillar recommends using these solvents. These
solvents are recommended because of quick evaporation. The Use of gasoline is too dangerous.
The use of diesel is restricted by a slow rate of evaporation. Do not use gasoline, sandpaper, emery
polishing paper, crocus cloth, files, brushes, glass beads, soft cloth, or paper cloth to clean
bearings. Bearings must be coated with oil if immediate use is not in order. Oil will prevent the
bearings from corroding. Be sure to clean bearings after storage. Dry off the bearings before
installation. Original marks that have been removed during cleaning must be recorded again.

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Illustration 10 g01696194

Damage on the bearing surface

Do not use a bearing that has damage from improper preparation and storage procedures.

Illustration 11 g01696353

Damage on the bearing surface

Do not use a bearing that has damage from improper preparation and storage procedures.

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Illustration 12 g01696534

Protection during storage

Do not allow bearing surfaces to touch other bearing surfaces. Bearing surfaces can damage other
bearing surfaces. Illustration 12 represents a properly protected bearing.

Normal Wear

Illustration 13 g01696561

(16) Area of load for standard connecting rods

(17) Area of load for serrated connecting rods

Bearings have typical areas of wear. Areas of heavy wear must be inspected, even if heavy wear is
expected. This area is known as the load zone.

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Illustration 14 g01697033

(1) Lower bearing half

(2) Upper bearing half

Minimal wear will appear at the mating faces of the bearing halves. Most wear will occur on the
side of the load. Since a load pushes down on the connecting rod, the upper half of the bearing
will wear more than the lower half.

Illustration 15 g01697594

(1) Lower bearing half

(2) Upper bearing half

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Illustration 16 g0169783

(18) Area of load for main bearings

Illustration 17 g01698033

Upper and lower bearing halves

Lower halves of main bearings will wear more quickly than upper halves.

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Illustration 18 g01698174

(2) Upper bearing half

(1) Lower bearing half

Shiny areas on bearing halves may be a sign of early wear. Illustration 18 accurately represents
bearings that have worn early. Upper halves of main bearings will wear more slowly than lower
halves. On bearings that show early wear, be sure to check the profile of the crankshaft. It is
acceptable to reuse bearings that show early wear if wear is within specifications.

Illustration 19 g01698334

Upper and lower bearing halves

The bearing halves in illustration 19 accurately represent signs of early wear.

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Illustration 20 g01698537

Lower main bearing halves

Lower main bearing halves may show more wear than upper bearing halves. Generally, there is
very little wear on upper halves. It is acceptable to reuse bearings that show early wear if bearings
are within specifications.

Illustration 21 g01698653

Upper halves of connecting rod bearings

A crankshaft that is out of round may cause bearings to wear early. The upper connecting rod
bearings in illustration 21 show signs of early wear of the connecting rod. Do not reuse bearings
that have been badly worn, early.

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Illustration 22 g0170037

(12) Lead tin overlay

(14) Bonding agent

(15) Aluminum bearing material

Do not reuse upper main bearings that show heavily worn upper bearings. Check the condition of
the crankshaft journal and bore for any possible causes for early wear.

Visual Inspection Procedures

There are certain guidelines to follow during bearing inspection.

• Clean bearings with kerosene or diesel fuel and a soft cloth in order to remove any debris.
Make sure that you do not scratch the bearing surface.

• Inspect the back of the bearings for scratches or color changes, and any other obvious
damage.

• Inspect the surface of the bearing for any damage or heavy wear.

• Inspect the edges and mating faces of the bearings. Thoroughly check the area near the tabs.

• While inspecting bearings use care. Improperly handling bearings may scratch the bearing
surfaces.

Inspecting the back sides of bearings

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Illustration 23 g01701395

(19) Debris

Use kerosene or diesel fuel to remove debris. Use a soft cloth to wipe off bearings. Paint, tape,
rust, and dirt are all examples of debris. If debris and dirt can be removed from the bearing by
cleaning, it is acceptable to reuse the bearing.

Illustration 24 g01701513

Use kerosene or diesel fuel to remove debris. Use a soft cloth to wipe off bearings.

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Illustration 25 g01701593

(20) Shiny area

Shiny surfaces on the bearing can be caused by shifting of a bearing in a bore.

Illustration 26 g01701634

(21) Moved material and fretting

Do not reuse bearings that show signs of moved material or fretting.

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Illustration 27 g01701815

(21) Moved material and fretting

Do not reuse bearings that show signs of moved material or fretting.

Note: Never reuse a bearing that shows signs of fretting on the back. If fretting is found, inspect
the bearing cap and bolts. Make sure that bores are the proper diameter. A small amount of
fretting is common after many hours of operation. Fretting must be removed from the bore in the
connecting rod or connecting rod cap. Remove debris from the bore with a small grinder in the
area of the smeared material only. Do not use emery cloth over a large area of the bore. Machining
a bore may be necessary to remove damage. You must use a bearing that is over size after
machining.

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Illustration 28 g01701914

Normal wear

The bearing in illustration 28 represents a bearing with normal wear on the back side of the
bearing.

Illustration 29 g01701953

Normal wear

The bearing in illustration 29 represents a bearing with normal wear on the back side of the
bearing.

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Illustration 30 g01701973

Normal wear

The bearing in illustration 30 represents a bearing with normal wear on the back side of the
bearing.

Inspecting bearing surfaces

Illustration 31 g01702562

Normal wear

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Reuse bearings that do not show aluminum bearing material or the bonding agent of the bearing.

Illustration 32 g01703153

Normal wear

Reuse bearings that do not show aluminum bearing material or the bonding agent of the bearing.

Illustration 33 g01703253

Normal wear

Reuse bearings that do not show aluminum bearing material or the bonding agent of the bearing.

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Illustration 34 g01703294

Normal wear

The bearing in illustration 34 shows signs of normal wear over a long period of time. Do not reuse
a bearing if large amounts of aluminum bearing material or bonding agent can be seen.

Illustration 35 g01703499

(15) Aluminum bearing material

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Illustration 36 g01704628

Normal bearing wear

You may not reuse bearings if the lead tin overlay is worn enough to see large amounts of
aluminum bearing material.

Illustration 37 g01704773

Normal bearing wear

You may not reuse bearings if the lead tin overlay is worn enough to see large amounts of
aluminum bearing material.

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Illustration 38 g01704857

Normal bearing wear

You may not reuse bearings if the lead tin overlay is worn enough to see large amounts of
aluminum bearing material.

Illustration 39 g01704894

Normal bearing wear

You may not reuse bearings if the lead tin overlay is worn enough to see large amounts of
aluminum bearing material.

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Illustration 40 g01705078

Shiny areas on a bearing

You may reuse a bearing that shows signs of early wear if most of the tin flash is still in place. If
there is a scratch in the center of the bearing, you may still reuse the bearing as long as the scratch
is no wider than 1.0 mm (0.040 inch). You must repair a crankshaft if the runout of the crankshaft
exceeds the specification.

Note: Scratches and light polishing of the tin flash are permissible in both the upper and lower
halves of the bearing. Fine scratches around the bearing are permissible on both halves of the
bearing. Reuse a bearing that shows fine scratches that have extended into the aluminum bearing
material if the edges are smooth. To make sure that the bearing surface is free of debris, run your
finger across the surface.

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Illustration 41 g01705333

Fine scratches on bearing surface

Debris may cause fine scratches to appear on the surface of the bearing. You may reuse the
bearing if the surface is smooth and free of debris.

Illustration 42 g01707267

Fine scratches on bearing surface

Debris may cause fine scratches to appear on the surface of the bearing. You may reuse the
bearing if the surface is smooth and free of debris.

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Illustration 43 g01707353

Fine scratches on bearing surface

Debris may cause fine scratches to appear on the surface of the bearing. You may reuse the
bearing if the surface is smooth and free of debris.

Illustration 44 g01707381

Fine scratches on bearing surface

Debris may cause fine scratches to appear on the surface of the bearing. You may reuse the
bearing if the surface is smooth and free of debris.

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Illustration 45 g01707535

Fine scratches on bearing surface

Small particles of aluminum embedded in the surface of a bearing are acceptable. The particles
must be fine, and the surface must be flat. Do not reuse a bearing if any other material is
embedded in the surface of a bearing.

Illustration 46 g01707656

Fine scratches on bearing surface

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Illustration 47 g01707693

Fine scratches on bearing surface

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Illustration 48 g01707753

Embedded debris

Illustration 48 represents a bearing that has embedded debris in the bearing surface. Bearings that
show large amounts of embedded debris should not be reused.

Illustration 49 g01707956

(22) Particles of aluminum

In illustration 49, aluminum flakes and hard debris are present on the bearing surface. Do not use a
bearing if debris is present on the surface. Bearings that show small particles of aluminum are
reusable.

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Illustration 50 g01708074

Particles of aluminum

Illustration 50 represents a bearing with acceptable amounts of aluminum on the bearing surface.

Illustration 51 g01708140

Large scratches

Do not reuse a bearing that has scratches more than 1.0 mm (0.040 inch) wide.

Check the runout of the crankshaft if large scratches appear on the bearings.

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Illustration 52 g01708237

Scratches on the bearing surface

Do not reuse bearings that have scratches wider than 1.0 mm (0.040 inch). Be sure to check the
runout of the crankshaft if large scratches appear on the bearing surface.

Illustration 53 g01708199

Scratches on the bearing surface

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Bearings that have many scratches are not reusable, even if the scratches are less than 1.0 mm
(0.040 inch) wide. Check the runout of the crankshaft if large scratches appear on the bearings.

Illustration 54 g01708593

Scratches on the bearing surface

You may reuse a bearing that has a scratch, if the scratch is less than 1.0 mm (0.040 inch).

Illustration 55 g01709694

(23) Heavy scratches

Do not reuse bearings that show scratches as a result of debris.

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Illustration 56 g01709773

Smearing of the bearing surface

Do not reuse a bearing that shows signs of smearing, even if the surface is smooth.

Illustration 57 g01710053

Unusual wear

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