NUMBER

ENGINEERING
APPARATUS INSTRUCTIONS 2400
ISSUED BY FIRST ISSUED

B. A. Ristig September 7, 1983

APPROVED BY SUPERSEDES

J.H. Gedutis LA GRANGE, ILLINOIS A.I.2400-H

GENERAL TOLERANCES FOR MACHINED, FABRICATED, CAST, AND FORGED PARTS
SUBJECT
AND ASSEMBLIES
AFFECTS MODELS ALL
PART NOS AFFECTED

REF DRAWINGS

Table of Contents
Section No. Name
1. PURPOSE AND SCOPE
2. GENERAL INFORMATION
3. SHEARED, BURNED, OR FORMED PARTS AND FABRICATED ASSEMBLIES
4. CAST PARTS GENERAL
5. CAST PARTS SPECIFIC
6. FORGED PARTS
7. MACHINED PARTS
8. COMMERCIAL TOLERANCES
9. PIPE, TUBE, CONDUIT DETAILS & ASSEMBLIES
10. GEOMETRIC DIMENSIONING AND TOLERANCE
11. REVISION INDICATOR

1. PURPOSE AND SCOPE:

1.1 This Apparatus Instruction ( A.I.) establishes general tolerance applicable to all dimensions not
individually toleranced.

1.2 General tolerances larger or smaller than here stated will be observed only when tolerances are
specifically stated on the drawing.

1.3 This Apparatus Instruction becomes a part of all Progress Rail locomotive (PRL/EMD) Product
Engineering Drawings (engineering drawing(s), drawing(s) for short) unless otherwise stated by the
drawing. This A.I. replaces and supersedes AI 2100 on all legacy drawings.

1.4 The term fabricated assemblies, is any assembly were individual piece parts or smaller fabricated
assemblies are welded, riveted, bonded or bolted together.

1.5 The terms fabricator, supplier or manufacturer is the entity that preforms the manufacturing of parts
and/or assemblies.

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2012 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 1 of 13
 AI 2400
General Tolerances For Machined, Fabricated, Cast, And Forged Parts And Assemblies

1.6 PHILOSOPHY OF ENGINEERING DRAWING INTENT

Product Engineering drawings are dimensioned line to line and arranged to suit the function and mating
relationship of parts to design requirements.

1.7 Explanation of the general PRL/EMD engineering drawing layout.

Additional supporting documents, instructions or requirements if applicable are listed above the “FOR
MANUFACTURING BLOCK” on the engineering drawing. The following is a list of these documents.
• A.I. (Engineer Apparatus Instructions)
• E.D.P.S (Engineering Design Performance Specification)
• E.S.F.R (Engineering Specification for Factory Rebuild)
• E.T.I. (Engineering Test Instructions)
• V.T.S (Vehicle Technical Spec)

Information on the face of the engineering drawing takes precedence over this A.I. or other A.I’s
specified in the “FOR MANUFACTURING BLOCK”.

Special Characteristics (SP) when specified are shown as a list in the upper right corner of the
engineering drawing.

When Geometric dimensioning and tolerancing (GD&T) is applicable to the part or assembly, additional
Datum callouts are shown on the top border of the drawing indicating the location of the datum or
datum feature. Feature control frames when required shall be specified next to the required dimension.
See Section 10 for more information.

Additional drawing note(s) specified on an engineering drawing may contain blanket tolerances that
apply to the noted features on that engineering drawing, the drawing note(s) supersedes this A.I.’s
tolerances for those specified features.

Blanket Material substitutions are shown in IND 2000, IND 2025, IND 2030 & IND 2070. A DA
(deviation approval) is not required for the material substitutions listed in the above material
specifications.

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2021 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 2 of 13
 AI 2400
General Tolerances For Machined, Fabricated, Cast, And Forged Parts And Assemblies

2. GENERAL INFORMATION:

All dimensions are in inches unless otherwise specified in the drawing title block.

2.1 Dimensions describing features may be either nominal or specific. Nominal dimensions convey size
information as a result of common usage and relation to published standards, but do not in themselves
represent specific size. Commonly used nominal dimensions are pipe sizes, mill rolled sections,
structural shapes, sheet metal gages and letter or number sizes of drills and screw threads. The
specific dimensions for the nominal sizes are obtained from standard references.

2.1.2 Fractional tolerances apply to fractional dimensions.

2.2 No manufacturing or measurement process can produce absolutely exact sizes, and acceptable
variances from desired size are applied to descriptive dimensions to insure that part function,
interchangeability and appearance are controlled. Acceptable variations of size may be stated either
through the use of limit dimensions or nominal dimensions to which a tolerance is applied.

2.2.1 Tolerances and dimensions which are affected by subsequent welding, machining and
fabricating processes are not covered by AI 2400. These tolerances shall be indicated on the
next level engineering drawing if deemed important for interchangeability. Special
Characteristics (SC) may be used for these types of dimensions.

2.2.2 In order to achieve assembly sizes as indicated on the engineering print, weld shrinkage must
be considered by the manufacturer of the assembly. Piece parts of an assembly may need to
be lengthened or reduced to achieve the overall assembly size after welding.

2.2.3 When dealing with stack up tolerances or when inch to metric thickness substitutions are
allowed, piece parts of an assembly may need to be lengthened or reduced to achieve the
overall assembly size.

2.3 Limit dimensions are the applicable maximum and minimum size differential.

2.3.1 Bilateral Tolerance:

Defined as a tolerance in which variation is permitted in both directions from the specified
dimension.

2.3.2 Examples of dimensions:

4.754
+ .004
4.750 - .002
4.748

LIMIT NOMINAL DIMENSION

DIMENSIONS BILATERAL TOLERANCE

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2021 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 3 of 13
 AI 2400
General Tolerances For Machined, Fabricated, Cast, And Forged Parts And Assemblies

2.4 Reference Dimension

A dimension, usually without tolerance, used only for information purposes and does not govern
production or inspection operations. A reference dimension may be derived from other values shown
on the drawing or on a related drawing. Reference dimensions are show inside parentheses (xx.x) or
the word “REF” may be shown after the dimension on older legacy engineering drawings.

2.5 Basic Dimension (GD & T)

A numerical value used to describe the theoretically exact size, shape or location of a feature or datum
target. It is the basis from which permissible variations are established by tolerances on other
dimensions, in notes or within feature control symbols. Gage dimensions (untoleranced dimensions
used to establish gaging points, line or planes) may be specified as "basic" dimensions.

2.6 Where interpretation of drawings or dimensioning is required, refer to PRL/EMD Product Design
Website/Drafting Standards, (also refer to ASME Y14.5).

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2021 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 4 of 13
 AI 2400
General Tolerances For Machined, Fabricated, Cast, And Forged Parts And Assemblies

3. SHEARED, BURNED, OR FORMED PARTS AND FABRICATED ASSEMBLIES:

3.1 For qualification by Quality Control, all fabricated sheet steel assemblies shall be manufactured to a
flatness not exceeding 0.19” (3/16”) (5mm) deviation in 24.00” (600mm). The deviation limit shall be
proportionately lower when surfaces under 24.00” (600mm) are measured. For example, the allowable
flatness deviation will be 0.12” (1/8”) (3mm) in 16.00” (400mm) or 0.06” (1/16”) (1.5mm) in 8.00”
(200mm). Accumulated maximum sheet flatness tolerance must not exceed 0.25" (1/4”) (6mm) in
96"(2500mm).

3.2 Unless otherwise specified on the engineering drawing, the maximum surface roughness (Ra) of all
thermal cut edges shall not exceed 1000 microinch (25 microns). Interpretations of surface roughness
values are defined by the American National Standards Institute ASME B46.1. All thermal cut surfaces
must be free of slag. If a surface roughness exceeds the above values, additional manufacturing
processes such as machining or grinding shall be performed to comply with the above values.

3.3 The dimensions as shown on the engineering drawing (unless otherwise stated on the drawing) are line
to line allowing for welding root gap where required, but making no allowance for weld shrinkage,
fixture, or assembly fit up clearance.

3.4 For all weld size, length, profile, etc. tolerances see A.I. 1046 and A.I. 1651.

3.5 The fabricator of parts and/or assemblies is responsible for meeting the actual sizes of parts fabricated
within the tabulated tolerance listed in sections 3.6 and 3.7, unless otherwise specified on the
engineering drawing.

3..6 Tolerances for individual parts, less than 0.25” (1/4”) (6.4mm) thick unless otherwise specified. Note:
start with smallest width dimension first.

Parts 0.25” (1/4”) (6.4mm) or less in thickness Length and width Length or width greater
36.00"(900mm) or less than 36.00" (900mm)

DIMENSION DECIMAL OR TOLERANCE

FRACTIONAL
To 15.00” (380mm) Include ±.06”(1/16”) (1.5mm) ±.08” (5/64”) (2mm)
Over 15.00” (380mm) to 25.00” (635mm) Incl. ±.06”(1/16”) (1.5mm) ±.08” (5/64”) (2mm)
Over 25.00” (380mm) to 36.00” (914mm) Incl. ±.06”(1/16”) (1.5mm) ±.09” (3/32”) (2.3mm)
Over 36.00” (914mm) to 46.00” (1168mm) Incl. ±.11” (7/64”) (2.8mm)
Over 46.00” (1168mm) to 57.00” (1448mm) Incl. ±.11” (7/64) (2.8mm)
Over 57.00” (1448mm) to 67.00” ( 1700mm) Incl. ±.12” (1/8”) (3mm)
Over 67.00” (1700mm) to 77.00” (1955mm) Incl. ±.12” (1/8”) (3mm)
Over 77.00” (1955mm) to 200.00” (5080mm) Incl. ±.20” (13/64”) (5mm)
Over 200” (5080mm) ±.30” (19/64”) (7.6mm)

3.6.1 Example: The tolerance on a part .25” (1/4”) x 30.00” x 77.00” would be ± .09” (3/32”) on the
30.00” dimension and ± .12” (1/8”) on the 77.00” dimension.

3.6.2 The above tolerances will also apply to a machined surface located from a sheared, burned,
formed, or rough surface of a piece part, unless otherwise specified.

3.6.3 On all formed parts the radius specified is to the inside, unless otherwise indicated.

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2021 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 5 of 13
 AI 2400
General Tolerances For Machined, Fabricated, Cast, And Forged Parts And Assemblies

3.7 Tolerance for parts over 0.25” (1/4”) (6.4mm) thick and assemblies unless otherwise specified.

Parts over 0.25” (1/4") (6.4mm) thick and assemblies

DECIMAL
DIMENSION OR FRACTIONAL
TOLERANCE
To 15.00” (380mm) Include ±.08” (5/64) (2mm)
Over 15.00” (380mm) to 25.00 (635mm) Incl. ±.09” (3/32) (2.3mm)
Over 25.00” (635mm) to 36.00” (915mm) Incl. ±.11” (7/64) (2.8mm)
Over 36.00” (914mm) to 46.00” (1168 mm) Incl. ±.12” (1/8”) (3mm)
Over 46.00” (1168mm) to 57.00 (1148mm) Incl. ±.14” (9/64”) (3.5mm)
Over 57.00” (1148mm) to 67.00” (1700mm) Incl. ±.16” (5/32”) (4.0mm)
Over 67.00” (1700mm) to 77.00” (1955mm) Incl. ±.17” (11/64”) (4.3mm)
Over 77.00” (1955mm) to 200.00” (5080mm) Incl. ±.20” (13/64”) (5mm)
Over 200” (5080mm) ±.30”(19/64”) (7.6mm)

3.8 Tolerances for underframe assembly and hood lengths are to be ± .31” (5/16”) (8mm) unless otherwise
specified.

3.9 Underframe fabrication and hole quality are to be per AI 2134 unless otherwise specified.

3.10 All punched and pierced holes to be free of burrs and sharp edges.

3.10.1 Tolerance on punched and pierce holes ± .010” (0.25mm).

3.11 Squareness tolerance for individual parts or fabricated assemblies.

Parts 0.25” (1/4”) Parts over 0.25” (1/4”)

Overall length
(6.4mm) or less (6.4mm)
or width
thick & assemblies thick
To 12.00” (304mm) .03” (1/32”) (0.8mm) .05” (3/64”) (1.3mm)
Over 12.00” (304mm) to 24.00” (610mm) Incl. .06” (1/16”) (1.5mm) .09” (3/32”) (2.3mm)
Over 24.00 (610mm) to 36.00” (914mm) Incl. .09” (3/32”) (2.3mm) .14” (9/64”) (3.5mm)
Over 36.00” (914mm) .12” (1/8”) (3mm) .16” (5/32”) (4mm)

3.12 Squareness of cut edge for a weld connection (non-machined) unless otherwise specified. When a
finish symbol is indicated on an edge, machined tolerances apply. Thickness over 1.0” (25mm) must
be defined on the engineering drawing.

Overall thickness Tolerance Dimension Angle

Less than or equal 0.12” (3mm) Incl. ± .03” (1/32”) (0.8mm) ±15°
Over .12” (3mm) to 1.0” (25mm) Incl. ± .06” (1/16”) (1.5mm) ±7°

3.13 Cracks are not allowed in formed or bent parts.

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2021 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 6 of 13
 AI 2400
General Tolerances For Machined, Fabricated, Cast, And Forged Parts And Assemblies

4. CAST PARTS GENERAL:

4.1 Dimensional tolerance for all castings unless otherwise specified:

Wall Thickness +.09” (3/32”) (2mm)

-.03” (1/32”) (0.8mm)

Outside Diameter +.09” (3/32”) (2mm)

-.03” (1/32”) (0.8mm)

Length and Width +.09” (3/32”) (2mm)

-.03” (1/32”) (0.8mm)

Corner and Fillet Radii +.06” (1/16”) (1.5mm)

-.00

Draft (from specified angle) +.03” per inch (1/32”) (0.8mm per 25mm)
-.01” per inch (1/64”) (0.25mm per 25mm)

Flash Extension .12”(1/8”) (3mm)

Actual Mismatch .00 to .06”(1/16”) (1.5mm)

(at parting line)

Total Mismatch .00 to .12”(1/8”) (3mm)

(at parting line)

4.2 Unless otherwise specified on the engineering drawing, the minimum steel casting visual surface
acceptance criteria shall be per ASTM A802, Level III latest revision.

5. CAST PARTS SPECIFIC:

5.1 Dimensional tolerance for sand castings unless otherwise specified.

Not exceeding 14.00” (355mm) . . + .05” (1.3mm)

.. - .02” (.50mm) + .003” per inch, (0.07mm per 25mm)
of nominal lineal dimension
Over 14.00” (355mm) . . . . . . . . . . + .09” (2mm)
... -.03” (0.8mm) + .001” per inch (0.025mm per 25mm)
of nominal lineal dimension

5.1.1 Tolerances to a machined surface located from a rough cast surface + .05”/-.02” (+1.3mm/ -.50
mm)

5.1.2 Draft angles to be 2° and added to the lineal dimension unless otherwise specified on drawing.

5.1.3 Tolerance on draft angles to be (±1/2°) .008” per inch (2mm per 25mm), not to exceed a
maximum deviation of .12” (1/8)” (12mm).

5.1.4 Angular relationships between any two features ± 1° unless otherwise specified on drawing.

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2021 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 7 of 13
 AI 2400
General Tolerances For Machined, Fabricated, Cast, And Forged Parts And Assemblies

5.2 Tolerances for large or critical castings will be completely specified on Design Engineering drawings.

5.3 Tolerances for truck frames and bolsters are to be per AI 2401.

5.4 Dimensional tolerance for investment castings per the Investment Casting Institute (I.C.I.) handbook,
unless otherwise specified.

5.5 Dimensional tolerance for die castings per the American Die Casting Institute (A.D.C.I.) handbook,
unless otherwise specified.

5.6 Dimensional tolerance for permanent mold castings per the Aluminum Association Inc. (A.A.I.)
handbook, unless otherwise specified.

6. FORGED PARTS:

6.1 Dimensional tolerance for forged parts, unless otherwise specified.

Thickness +.09” (3/32”) (2mm)

-.03” (1/32”) (0.8mm)

Outside Diameter +.09” (3/32”) (2mm)

-.03” (1/32”) (0.8mm)

Length and Width +(.09”)(3/32) (2mm)

-(.03)(1/32) (0.8mm)

Corner and Fillet Radii ±.06” (1/16”) (1.5mm)

Draft (from specified angle) +.03” per inch (1/32”) (0.08mm per 25mm)
-.01” per inch (1/64”) (0.25mm per 25mm)

Flash Extension .12” (1/8”) (3mm)

Actual Mismatch .06” (1/16”) (1.5mm)

(at parting line)

Total Mismatch .12” (1/8”) (3mm)

( at parting line)

NOTE: Total mismatch is measured parallel to the main parting lines of the dies.

6.1.1 These tolerances will also apply to a machined surface located from a rough forged surface.

6.1.1.1 Tolerance on draft angles to be +1/2 degree (.008” per inch) (2mm per 25mm), not
to exceed a maximum deviation of .12” (1/8”) (3mm) from nominal.

6.2 Large or critical forgings will be completely dimensioned on Design Engineering Drawings.

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2021 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 8 of 13
 AI 2400
General Tolerances For Machined, Fabricated, Cast, And Forged Parts And Assemblies

7. MACHINED PARTS:

7.1 The following tolerances will apply to all un-toleranced dimensions between machined surfaces:

7.1.1 Machine tolerance on inch dimensions, unless otherwise specified on the drawing:

± .02 allowed on two place decimals.

± .010 allowed on three place decimals and all fractional dimensions.
± .0050 allowed on four place decimals.
± 0 degrees 30' allowed on angles.

7.1.2 Machining tolerances on metric dimensions, unless otherwise specified on the drawing:

± 0.5 mm allowed on one place decimals

± 0.25 mm allowed on two place decimals
± 0.127 mm allowed on three place decimals
± 0 degrees 30' allowed on angles.

7.1.3 For dimensions between a machined and an unfinished surface the applicable casting,
forging, or fabricated tolerance will apply.

7.1.4 Machined surfaces are to be true such that deviations from flatness, parallelism, circularity,
or angularity (profile of a surface) are less than .002” per inch (.05mm per 25mm) of lineal
dimension to a maximum of the applicable general tolerance. Any measurement of a
dimension is to fall within the tolerance band as stated in Paragraphs 7.1.1, 7.1.2 or
otherwise specified on the drawing.

7.2 Runout of machined diameters not covered by specific drawing notes is to be within .020” (0.5mm)
total indicator reading (TIR) or full indicator reading (FIM) between any two diameters.

7.3 Locations of holes in flanges, mounting pads, etc., are to be within .028” (.70mm) diameter of the
true position determined by the untoleranced basic dimensions whether located by coordinates or by
bolt circle and angular relationship.

7.4 Diametrical tolerances for drilled holes not otherwise restricted are:

Under .250” (6mm) Dia. Plus .006” (.15mm) Minus .002” (0.05mm)
.250” (6mm) to .750” (19mm) Dia. Plus .009” (.23mm) Minus .003” (0.07mm)
Over .750” (19mm) to 1.500” (38mm) Dia. Plus .010” (.25mm) Minus .005” (0.13mm)
Over 1.500” (38mm) Dia. Plus .015” (.38mm) Minus .005” (0.13mm)

7.4.1 Drilled holes are to be within .010” per inch (0.25mm per 25mm) of nominal perpendicular or
other specified angle unless otherwise specified.

7.5 Surface texture roughness specifications are in accordance with American National Standards Institute
ASME Y14.36 - Latest revision, Surface Texture Symbols & American National Standards Institute
ASME B46.1 - Latest revision, Surface Texture. Surface roughness average (Ra) of machined surfaces
not having specific designations are to be no greater than Ra 200 microinches (5 microns) when
measured in accordance with the above standards.

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2021 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 9 of 13
 AI 2400
General Tolerances For Machined, Fabricated, Cast, And Forged Parts And Assemblies

7.6 All blind tapped holes must have a countersink of 90° to 118° x one thread deep. All through tapped
holes must have a countersink of 90° to 118° x one thread deep on the tap entry side only.

All tapping pads must be applied with the 90° to 118° x one thread deep countersink facing the fastener
entry.

7.7 Break all sharp corners +.010” +.25mm

.015” x 45° .38mm x 45°
-.000” -.00mm

8. COMMERCIAL TOLERANCES:

8.1 Commercial tolerance apply to sheet metal gauges, plates, structural, bar stock, tubing, pipe, roller,
drawn or extruded sections and standard parts. For permitted material thickness variations
(tolerances), see PRL/EMD IND0000 material specifications and/or the related ASTM or other material
standards as indicated on the engineering drawing.

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2021 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 10 of 13
 AI 2400
General Tolerances For Machined, Fabricated, Cast, And Forged Parts And Assemblies

9. PIPE, TUBE, CONDUIT DETAILS & ASSEMBLIES:

9.1 The cutting length tolerance for all pipe, tube and conduit details unless otherwise specified; ± .06"
(1.5mm).

9.2 The following tolerance will apply to all pipe and brazed tube assemblies unless otherwise specified:

Threaded pipe per joint ±.06" (1.5mm)

Welded or brazed per joint ±.03" (0.8mm)

9.2.1 The maximum accumulated allowable tolerance per assembly must not exceed ±.25" (6mm).

9.2.1.1 Example: The tolerance for an assembly with one pipe and two welded fitting, one at
each end of the pipe would be 0.06" (1.5mm) for the pipe and 0.03" (0.76mm) for each
welded fitting. The accumulated tolerance for the assembly would be ± .12" (3mm).

9.2.2 Symmetrical welded flange flatness .03" (0.8mm) must not be concave. Non-symmetrical
welded flange flatness .06" (1.5mm) must not be concave.

9.2.3 Angularity tolerance of threaded fittings ± 2° brazed or welded fittings ± 1/2°.

9.2.4 End to end after bending one or two bends ±.12" (3mm) three or more bends ±.25" (6mm).

9.2.5 Break sharp corners on piping means deburr and ream.

9.2.6 Angularity tolerance for bend offsets is ± 1/2°.

9.3 Unless otherwise specified on the engineering drawing the following tolerance will applies to all flexible
tubes, hoses and conduit assemblies. Engineering must specify the tolerance on the engineering
drawing if the tolerance below is not acceptable for the assembly.

9.3.1 As a general rule, the flexible assembly length shall be no less than the nominal dimension
shown on the engineering print. Maximum length should not be greater than approximately
10% or 2” (50mm), whichever the lesser value.

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2021 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 11 of 13
 AI 2400
General Tolerances For Machined, Fabricated, Cast, And Forged Parts And Assemblies

10. GEOMETRIC DIMENSIONING AND TOLERANCE:

10.1 Geometric dimensioning and tolerancing is in accordance with American National Standards Institute
ASME Y14.5 – Latest revision, Dimensioning and Tolerancing.

10.2 Tolerances as specified in the geometric control block are absolute.

10.2.1 Unless otherwise specified on the drawing, perfect form at maximum material condition is
required.

10.2.2 Unless otherwise specified on the drawing, for diametric features, roundness must be within the
maximum material condition (MMC) and the least material condition (LMC). Separate true
position callouts may be gaged separately, regardless+ of datum reference.

10.3 See Figure 10.1 for examples of Geometric Characteristic Symbols.

CHARACTERISTIC SYMBOL

STRAIGHTNESS

FLATNESS

CIRCULARITY

CYLINDRICITY

PROFILE OF A LINE

PROFILE OF A SURFACE

ANGULARITY

PERPENDICULARITY

PARALLELISM

POSITION

CIRCULAR RUNOUT *

TOTAL RUNOUT *
*Arrowheads may be filled or not filled

Figure 10.1

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2021 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 12 of 13
 AI 2400
General Tolerances For Machined, Fabricated, Cast, And Forged Parts And Assemblies

10.4 Datum feature plane verse Datum feature center plane.

10.4.1 When the Datum feature is shown in line with a dimension, the datum is a center plane, see
Figure 10.2. The Datum is the true center of that geometric feature.

Figure 10.2

10.4.2 When a Datum feature is shown on a surface or dimension extension line, not in line with a
dimension, the Datum is the edge or surface plane of that feature, see Figure 10.3.

Figure 10.3

11. REVISION INDICATOR:

Marginal Indicia:
A change bar ( | ) located in the left margin is for the convenience of the user in locating areas of technical
revisions made from the previous issue of this document. The word “ALL” specified in the pages affected footer
indicates a complete revision of this document; no change bars will be shown. Change bars are not used in
original publications.

REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

J 12-12-2021 CR211551 See change bars M. E. Oddie J. L. Buchman
UPDATED 03/25/2019 REV. E
© 2023 Caterpillar. All Rights Reserved. The information hereon is the property of Progress Rail Locomotive Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
Page 13 of 13