measuring procedures and salvage procedures for cylinder head assemblies and related components

8/10/2019 Measuring Procedures and Salvage Procedures for Cylinder Head Assemblies and Related Components

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Reuse And Salvage GuidelinesMeasuring Procedures and Salvage Procedures for Cylinder Head Assemblies andRelated Components{1100 1101 110! 110" 110# 110$ 110% 110& 111# 111'11(1 11(" 11(#)Media *umber +S,-.%1$(+!0 Publication /ate +('0$(01" /ate pdated +('0$(01"

Caterpillar2 Confidential 3ello4

i05832593

Measuring Procedures and Salvage Procedures for Cylinder

Head Assemblies and Related Components{1100, 1101, 110,

110!, 110", 110#, 110$, 110%, 111", 111&, 11'1, 11'!, 11'"(

SMCS )1100; 1101; 1103; 1104; 1105; 1106; 1108; 1109; 1115; 1117; 1121; 1124; 1125

*ngine+ !00 All, 00 All, '00 All, 100 All, 000 All, and )series All All "00 *ngines All#00 *ngines All C'$0 *ngines C)10 All C)% and C% All C11 All C1' and C)1' All C1 and

C)1 All C1" and C)1" All C1# and C)1# All C1&" *ngines C1$ and C)1$ All C'& All C'

All C& All

-ntroduction

Table 1

RevisionSummary of C.anges in S*/$1#'

30 Added Table 8 to include all Valve Guide Measureent toolin!

29"#dated t$e %#rin! Tester in t$e &&'e(uired Tools& & and &&Test )rocedure& &

sections*

28 Added ne+ serial nuber #re,i-es*

27.$an!ed section &&Valve 'otators& & to recoend not reusin! Valve 'otators/

'otocoils

26 Added ne+ serial nuber #re,i-es*

25

Added ne+ serial nuber #re,i-es*

.orrected title o, %8002

Added &&.anceled )art ubers and 'e#laced )art ubers& & section*

Added &ortant %a,et n,oration& & section*

24 23Added ne+ serial nuber #re,i-es*

22 Added re,erence to

'euse and %alva!e Guideline %9234 &"sin! t$e Adustable dler )ositionin!

)!ina 1 de 53%ervice n,oration %ste

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Tool for Setting the Cam Gear Backlash on 3406E, 3456, C15, C16, and C18

Engines

! "014 Cater#illar $ll %ights %eser&ed' This g(ideline is for the (se of Cat dealers onl)'

*na(thori+ed (se of this doc(ment or the #ro#rietar) #rocesses therein itho(t #ermission ma) -e

&iolation of intellect(al #ro#ert) la' Information contained in this document is considered

Caterpillar: Confidential Yellow.

This %e(se and Sal&age G(ideline contains the necessar) information in order to allo a dealer to

esta-lish a #arts re(sa-ilit) #rogram' %e(se and sal&age information ena-les Cater#illar dealers

and c(stomers to -enefit from cost red(ctions' E&er) effort has -een made in order to #ro&ide the

most c(rrent information that is knon to Cater#illar' Contin(ing im#ro&ement and ad&ancement

of #rod(ct design might ha&e ca(sed changes to )o(r #rod(ct hich are not incl(ded in this

#(-lication' This %e(se and Sal&age G(ideline m(st -e (sed ith the latest technical information

that is a&aila-le from Cater#illar'

.or /(estions or additional information concerning this g(ideline, s(-mit a form for feed-ack in

the Ser&ice nformation S)stem' n order to address an (rgent iss(e, (se the folloing reso(rces inorder to comm(nicate )o(r re/(est to Cater#illar %e#air rocess Engineering2

Cater#illar ealer Technical Comm(nicator

ealer Sol(tion etork

Cater#illar Technical %e#resentati&e

noledge etork

Canceled Part Numbers and Replaced Part Numbers

This doc(ment ma) not incl(de canceled #art n(m-ers and re#laced #art n(m-ers' *se % on

SS for information a-o(t canceled #art n(m-ers and re#laced #art n(m-ers' % ill #ro&ide the

c(rrent #art n(m-ers for re#laced #arts'

Important Safety Information

View Image

ll(stration 1 g0"137"3

9gina " de 53Ser&ice nformation S)stem

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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 topotential hazards. This person should also have the necessary training, skills, and tools in order to

perform these functions properly. Safety precautions and warnings are provided in this instruction

and on the product. f these hazard warnings are not heeded, bodily in!ury or death could occur to

you or to other persons. "aterpillar cannot anticipate every possible circumstance that mightinvolve a potential hazard. Therefore, the warnings in this publication and the warnings that are on

the product are not all inclusive. f a tool, a procedure, a work method or operating techni#ue that

is not specifically recommended by "aterpillar is used, you must ensure that it is safe for you and

for other people to use. $ou should 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.

------ WARNING!------

Improper operation, lubrication, maintenance or repair of this productcan 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. f these hazard

warnings are not heeded, bodily in!ury 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 %WA&''(% safety alert symbol is shown below.

View Image

llustration ) g****+

This safety alert symbol means-

ay attention/

0ecome alert/

$our safety is involved.

The message that appears under the safety alert symbol e1plains the hazard.

2perations that may cause product damage are identified by %'2T"3% 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 machineare not all inclusive. You must determine that the tools, procedures, wor methods, and

operating techni!ues are safe. You must determine that the operation, lubrication,

maintenance, and repair procedures will not damage the machine. "lso, you must determine

4gina 5 de 65Service nformation System

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4/53

that the operation, lubrication, maintenance, and repair procedures will not mae 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.

#ummary

This guideline gives the measurements and salvage specifications for the inspection of a used or

reconditioned cylinder head that can be used again.

If a cylinder head meets the specifications in this guideline and other applicable guidelines the

head assembly can be expected to give normal performance in the same application until the next

overhaul.

efore reusing a cylinder head, chec! for lea!s, crac!s, and flatness. "ll cylinder head

components must meet the recommended specifications in the guideline before being reused.

This guideline should be used in conjunction with the specific guidelines that are listed in the

#eference section.

$hen the cylinder head will not be inspected for one hour or less the cylinder head should be

coated with a rust or corrosion inhibitor or coated with clean engine oil.

$eferences%se the references that are listed below to help complete the rebuild of your cylinder head.

$eference#euse and &alvage 'uideline, &()*+++, -etal &pray 'uide

$eference#euse and &alvage 'uideline, &()++/, &pecifications for Cylinder 0ead

"ssemblies on C1&eries (ngines

$eference#euse and &alvage 'uideline, &()2++*, 3isual Inspection of 3alves, 3alve

&prings, and 3alve ridges

$eference#euse and &alvage 'uideline, &()2+45, 3alve and 3alve &pring &pecifications

$eference#euse and &alvage 'uideline, &()2+/6, (ngine 7recombustion Chamber and 45++

&eries (ngine 8irect Injection 9o::le "dapters

$eference#euse and &alvage 'uideline, &()2+;/, &pecifications to &alvage Cylinder loc!

Contact &urfaces

$eference#euse and &alvage 'uideline, &()26+/, &pecifications for Cylinder 0ead

"ssemblies 4/++ (ngines

$eference#euse and &alvage 'uideline, &()26*, 7rocedure to &alvage Cylinder 0ead"ssemblies for 4/++ and '4/++ (ngines

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$eferenceReuse and Salvage Guideline, SEBF8155, "Specifications for Cylinder Head

sse!lies for #5$$ Series Engines"

$eferenceReuse and Salvage Guideline, SEBF888%, "&sing 'oc()*)Stitc+ rocedures for

Casting Repair"

$eferenceReuse and Salvage Guideline, SEBF81-., "Reconditioning rocedures #11/ and #11-

Engines"

$eferenceReuse and Salvage Guideline, SEBF8%18, "Specifications for Cylinder Head

sse!lies #11/, #11-, #1%-, and C. Engines"

$eferenceReuse and Salvage Guideline, SEBF8%%0, "Specifications for Cylinder Head sse!ly

#1.-, #1.-B, #10-, C1$ and C1% Engines"

$eferenceReuse and Salvage Guideline, SEBF8%.$, "Specifications for Cylinder Head sse!ly

#/$$, #/$-E, C15, and C18 Engines"

$eferenceReuse and Salvage Guideline, SEBF8#$%, "Reuse Specifications for #-$$ Co!ustionGas(ets"

$eferenceReuse and Salvage Guideline, SEBF8#.#, "Specifications for Cylinder Head sse!ly

#/$$ C1- Engines"

$eferenceReuse and Salvage Guideline, SEBF8#./, "Specifications for Cylinder Head

sse!lies #%$$ Engines"

$eferenceReuse and Salvage Guideline, SEBF8#.5, "Specifications for Cylinder Head

sse!lies ##$$ Engines"

$eferenceReuse and Salvage Guideline, SEBF8#.-, "Specifications for Cylinder Head

sse!lies 1/$/ and 2 3odel Engines"

$eferenceReuse and Salvage Guideline, SEBF8#8%, "Cylinder Head Reuild rocess "

$eferenceReuse and Salvage Guideline, SEBF8.#., "Reuse of Cylinder Heads 4n C0 Engines

it+ 6n7ector ip 2a!age"

$eferenceReuse and Salvage Guideline, SEBF8810, "Specifications for Cylinder Head

sse!lies #$5/ and #$5- Engines"

$eferenceReuse and Salvage Guidelines, SEBF010#, "Specifications for Cylinder Head

sse!lies on C1.5 Engines"

$eferenceReuse and Salvage Guideline, SEBF0%#/, "&sing t+e d7ustale 6dler ositioning

ool for Setting t+e Ca! Gear Bac(las+ on #/$-E, #/5-, C15, C1-, and C18 Engines"

%!uipment and Tooling

ale %

$e!uired Tools

&art 'umber &art Description

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- Straight Edge

4C-4804 Penetrant

4C-4805 Developer

4C-4736 Kit

8H-8581 Feeler a!ge

5P-73"4 Pl!g

5P-7333 #ool ro!p

4C-4086 $epair Kit

1%-5566 %ltraviolet &a'p p

"""-3071 rinder (ngle

6)-0186 Holder 1"7 '' *5+0 in,h

6)-0185(.ra/ive Di/,

1"7 '' *5+0 in,h

or

5P-718Holder

178 '' *7+0 in,h

5P-70(.ra/ive Di/,

178 '' *7+0 in,h

#a.le 3

Valve Guides

- ea/!ring and ,he,2ing devi,e/ *1

6)-"01" i,ro'eter Depth a!ge ro!p

or

-Dial Caliper

150 '' *6+0 in,h

5P-3536 )alve !ide a!ge ro!p

6)-7058 Pl!g a!ge

6)-7068 )alve !ide a!ge

* 1 ea/!ring devi,e/ that are re!ired 0 to "5 '' *0 to 1+0 in,h 'i,ro'eter "5 to 50 '' *1+0 to "+0 in,h

'i,ro'eter 50 to 75 '' *"+0 to 3+0 in,h 'i,ro'eter 0 to 150 '' *0 to 6+0 in,h dial ,aliper 150 '' *6+0

in,h /traight edge and 8H-8581 Feeler a!ge

#a.le 4Valves

- ea/!ring and ,he,2ing devi,e/ *1

Pgina 6 de 53Servi,e nor'ation S/te'

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6V-7926 Indicator Group

5P-6518 Dial Indicator Fixture Gp

1S-0258 Haer !"o#t tip$

9%-5&8& Vacuu 'e"ter

or

F'-17(1 Vacuu 'e"ter

6V-0087 Val)e Ste Gau*e

6V-2012 Dept+ ,icroeter

6V-7059 ,icroeter

6V-20&( ,icroeter dapter

! 1 $ ,ea"urin* de)ice" t+at are re.uired 0 to 25 !0 to 1/0 inc+$ icroeter 25 to 50 !1/0 to 2/0 inc+$

icroeter 50 to 75 !2/0 to &/0 inc+$ icroeter 0 to 150 !0 to 6/0 inc+$ dial caliper 150 !6/0

inc+$ "trai*+t ed*e and 8H-8581 Feeler Gau*e

'ale 5

Valve Springs

- ,ea"urin* and c+ecin* de)ice" !1$

73-0&&7 Sur#ace Plate

((1-071( Sprin* 'e"ter

General Procedures

%"e t+e #ollo4in* *uideline" 4+en ou are in"pectin* and reconditionin* a clinder +ead/

lean t+e clinder +ead/ eo)e t+e *a"et aterial/

,ea"ure t+e clinder +ead t+icne""/

,ea"ure t+e #latne"" o# t+e cou"tion area/

In"pect t+e cou"tion area #or crac" or lea"/

+ec t+e cou"tion area #or daa*e andor ero"ion/

In"pect t+e )al)e" )al)e "eat" )al)e "prin*" )al)e *uide" and )al)e rotator" #or daa*e/

econdition t+e coponent" t+at are re.uirin* "al)a*e and replace t+e part" t+at do not eet

t+e *uideline"/

,ea"ure t+e pro:ection and t+e rece""ion o# t+e )al)e"/

#ter ou +a)e a""eled t+e clinder +ead ou 4ill need to run a )acuu te"t o# t+e )al)e"

#or t+e correct "ealin*/

P;*ina 7 de 5&Ser)ice In#oration S"te

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Protect the head against storage or shipping damage.

Nomenclature

View Image

Illustration 3 g01955530

Nomenclature for the 3200 Engine

(1 Inta!e port

(2 "urface of the #al#e co#er gas!et

(3 "eat of the #al#e spring

($ Post for the #al#e guide

(5 %ace of the e&haust port

(' E&haust port

( )al#e seat insert

(* +om,ustion area

(9 %ace of the inta!e port

View Image

Illustration $ g0195531

Nomenclature for the 3$00 Engine e&cept 3$0'E

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(1 Inta!e port


(3 "eat of the #al#e spring

($ Post for the #al#e guide

(5 %ace of the e&haust port

(' E&haust port

( )al#e seat insert

(* +om,ustion area

(9 %ace of the inta!e port

(10 ridge doel

View Image

Illustration 5 g0193'93'

Nomenclature for the 3500 Engine

(1 Inta!e port (front or right side


($ )al#e guide

(' E&haust port (rear or left side

(* +om,ustion area

(10 ridge doel

(11 ore of the roller lifter

View Image

P-gina 9 de 53"er#ice Information "stem



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Illustration ' g023'2'

Nomenclature for the +15 +linder 6ead

(1 Inta!e port

(2 "urface for the #al#e co#er gas!et

($ )al#e guide

(' E&haust port

Reconditioning Suggestions

7se the information that is ,elo for suggestions on common pro,lems that can occur hen ou

are reconditioning the clinder head.

8he information in this euse and "al#age :uideline is onl for current engines ith a high

#olume. Information for current engines ith lo #olume can ,e o,tained from "er#ice

;anuals that are issued for each engine model.

%or minor erosion of 0.2* mm (0.011 inch that is on the surface of the clinder head< sha#e

the area or resurface the area. In all of the folloing reconditioning procedures< remo#e the

minimum material that is necessar to ma!e the repair. efer to the appropriate euse and

"al#age :uideline for minimum specifications of the thic!ness of the clinder head.

8o find the amount of ear< a comparison can ,e made ,eteen the measurement of a orn

part and the specifications of a ne part. = part that is orn ma ,e safe to use if anestimate of the remainder of ser#ice life of the part can ,e made. If this estimate shos that

a short ser#ice life is e&pected< replace that part.

P-gina 10 de 53"er#ice Information "stem



11/53

Valve stems with diameters below the minimum or valve guides with diameters above the

maximum can be used if the clearance specification is determined by subtracting the "use

again minimum stem diameter" from the "use again valve guide diameter".

Several factors affect the amount of material that can be removed from the surface of a

component. The factors for removing material are the backlash for the gear drive of the

cam, proections of the valves, flatness and surface finish. !easure these areas as well as the

dimension for minimum thickness of the cylinder head whenever you recondition the block

and the mating surface of the head.

Note: imensions for the thickness of the head assume that no material has been removed from

the rail of the valve cover and the centerline of the crankshaft has not been raised. #ou must adust

the specifications accordingly if machining has already occurred.

Cleaning the Cylinder Head and Removing the Gasket

------ WARNING!------

Personal injury can result from working with cleaning solvent.

Because of the volatile nature of many cleaning solvents e!treme

caution must "e e!ercised when using them. #f unsure a"out a

$articular cleaning fluid refer to the manufacturer%s instructions and

directions.

&lways wear $rotective clothing and eye $rotection when working with

cleaning solvents.

$se one of these methods to clean the cylinder head. %emove all oil, dirt, and carbon from the

cylinder head casting. &f the initial cleaning of the engine has been performed, the time for

cleaning of the cylinder head will be reduced considerably.

N'(#C)

*hot "lasting is not a Cater$illar recommended cleaning $rocedure.

*hot "lasting can cause shot to "ecome lodged in internal $assages. #f

all of the shot material is not removed after cleaning with this method

the shot can "ecome dislodged after reconditioning and move into thelu"rication and injection systems. (he result can "e serious damage to

the engine.

+i$ (ank

$se a hot caustic solution to clean the cylinder head in a dip tank with a platform that oscillates.

Hot *$ray ,ash Ca"inet

'ut the cylinder head into position so the exhaust ports and the combustion area are in line withthe high(pressure stream from the no))les. The spray must go directly into the ports and the face

of the cylinder in order to remove all the carbon.

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NOTICE

If a caustic cleaning solution is used, brass injector sleeves and seals

can be damaged. If these parts are not going to be replaced in a

cylinder head, a soft cleaning solution should be used. A ! solution of

"ydrosolv #$%& in 'ater 'ould be a recommended solution. "ydrosolv

#$%& is available in a # liters ($ gal) container under #C*+#+& Cleaner .

emoving the -aset

------ WARNING!------

/se caution in order to avoid breathing dust that may be generated

from handling any friction material, regardless of 'hether or not the

material contains asbestos. If the dust is inhaled, the dust can be

ha0ardous to you health.

1ear a proper protective breathing device 'hen handling friction

material.

Moisten the gasket material for a cleaner and easier removal. In order to make the removal of

gaskets easier and safer, put the cylinder head into a hot tank or a hot spray wash cabinet. A hot

cleaning solution will make the gasket material soft so that large pieces can be pulled off by hand

and the gasket material is easily removed with a scraper or a grinder. However, if the wet gasket

material is permitted to dry, the gasket material can harden to the part.

2craping

Use a putty knife in order to scrape off a majority of the gasket. craping is preferred over sanding

discs. !his preference is due to the amount of airborne contaminants that are created by the discs.

"isks for metal reconditioning that are mounted on an air tool can be used to remove gasket

material that cannot be removed by hand.

-rinding

NOTICE

If the metal reconditioning disc is used to remove gaset material,

caution should be used to not remove any metal. If used too long in a

small area, the disc may remove so much metal that sealing surfaces

could be affected.

A disk for metal reconditioning that is mounted on an air tool can be used to remove gasket

material that cannot be removed by hand.

View Image

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Removing the gasket by grinding

When you are using this method, the speed o the dis! is important" #he best results $ill be

obtained i the dis! is lat to the sura!e and using only the $eight o the air tool as do$n$ard

pressure" %o not use too mu!h do$n$ard pressure or operate the dis! on the edge, be!ause the pad

may separate rom the holder" #he speed o the dis! should be set bet$een &500 and 4500 rpm or5P-9709 'brasive %is! and 10,000 rpm or 6V-0185 'brasive %is! " I the disk or metal

re!onditioning is used in order to remove gasket material, be !areul not to remove any metal rom

the !ylinder head"

View Image

Illustration ( g01277&&1

%is!s and holder

)12* 6+01(6 -older )127 mm )5"0 in!h* *

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(13) 5P-9718 Holder (178 mm (7.0 inch))

(14) 6V-0185 Discs (127 mm (5.0 inch))

(15) 5P-9709 Discs (178 mm (7.0 inch))

Protection After Cleaning

I !he c"s!in# is $ein# s!ored $eore m"%in# " re&"ir' !hen !he clinder he"d ms! $e &ro!ec!ed rom

corrosion "nd e*!ern"l d"m"#e "!er cle"nin#.

Visual Inspection of Cylinder Head

Cylinder Head Casting

Ins&ec! !he clinder he"d or +isi$le d"m"#e. ,he olloin# e*"m&les o d"m"#e ere !"%en rom

3200 "nd 3400 n#ines "nd !he e*"m&les "lso "&&l !o "ll en#ines.

View Image

Ills!r"!ion 9 #01277373

,he d"m"#e !o !he clinder he"d is loc"!ed "! !he se"l $e!een !he +"l+e co+er "nd !he he"d.

!" #H" PA$# A%AI&'

,he clinder he"d c"n $e sed "#"in "!er !he $rr h"s $een remo+ed.

View Image

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Illustration 10 g01277404Cylinder head is badly damaged in the seat area of the bolt. This area must have a flat surface and complete contact

with a bolt.

!" #H" PA$# A%AI&'

The cylinder head can be used again after damage is repaired.

View Image


Cylinder head is badly damaged in the seat area of the bolt. This area must have a flat surface and

complete contact with a bolt or a mating surface.

!" #H" PA$# A%AI&'

The cylinder head can be used again after damage is repaired.

The part can be used again after the hole has been repaired using oc!"#"$titch. %or complete

information on oc!"#"$titch& refer to 'euse and $alvage (uideline& $)*%+++2& ,-sing oc!"#"

$titch rocedures for Casting 'epair,.

Inspecting t(e Co)*ustion Area for +a)age fro) "rosion

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Make a visual inspection of the combustion area to check for damage and erosion. Erosion in

these areas will have a negative effect on engine operation:

View Image

Illustration 12 g01323!1

Inspect the indicated areas for damage and erosion.

"1# $ire ring

"1%# &eat area

"1'# (he area between the hole of the in)ector no**le and the valve seat. Erosion in other areas should not affectengine operation.

View Image

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Illustration 13 g012!'%Minor pitting or erosion

USE THE PART AGAIN.

View Image

Illustration 1 g012!!31

$oreign material caused this damage. (he valve seats must be replaced.

USE THE PART AGAIN.

View Image

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Illustration 15 g01296968Erosion across the fire ring

The cylinder head can be used again after the surface has been machined and all erosion is removed. The art muststill be !ithin the reusable secifications.

USE THE PART AGAIN.

View Image


"amage across the fire ring

The cylinder head can be used again after the surface has been machined in order to remove all damage.

USE THIS PART AGAIN.

View Image

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Illustration 17 g01297021Concentrated area of erosion

The cylinder head can be used again if a channel is ground out in order to remove erosion. Refer to Reuse andSalvage uideline! S"#$%&7'! (S)ecifications for Cylinder *ead +ssemblies &200 "ngines(.


View Image

Illustration 1% g012970%,+ small amount of erosion


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#ad erosion around the area of the valve seat.

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DO NOT USE THE PART AGAIN.

View Image


Engine failure caused this damage.

DO NOT USE THE PART AGAIN.

Erosion

The flow of coolant through the engine is known for causing erosion. This is shown in Illustration19. The erosion will not damage the engine if the coolant does not go from the coolant passage to

any of the following

! "ire ring in the com#ustion cham#er

! $il passages

! %olt holes

! $utside of the engine

View Image

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Illustration 21 g01297592Erosion that is caused from the flow of coolant

(16) Fire ring

(19) Outer surface

(20) oolant !assage

(21) Oil !assage

(22) Erosion must not e"tend #e$ond this area%

(2&) 'olt hole

For traditional head gasets if the distance #etween the erosion and an$ feature that is s!ecified in

Illustration 21 is less than *%0 mm (0%16 inch) do not use the c$linder head again% +se the !art

again onl$ if the erosion has #een remo,ed in order to lea,e a minimum of *%0 mm (0%16 inch)

sealing area%

View Image

Illustration 22 g01&--997

.ulti!le la$ered steel /./ gaset

he arrows indicate a raised la$er of the gaset% Erosion cannot come in contact with this area.

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Note the sealing area of the "MLS" gasket. The seal is created by the raised area of the gasket.

Any erosion or an uneven surface could create a bad seal.

Illustration 23 and Illustration 2 sho! the location of #rings or seals around the holes of the

coolant $assages. %rosion !ill not har& the engine bet!een these areas.

%rosion is not acce$table at the $oint of contact bet!een the #ring or seal and the cylinder head.

If any erosion occurs the co&bustion area &ust be ground do!n.

View Image

Illustration 23 g'(2)*+,3

%rosion is acce$table in areas -2 and -2/. %rosion is not acce$table in area -2,. This $hoto sho!s acce$tableerosion0 and the head can be used again.

-2 1oolant $assage and the inside dia&eter of the #ring

-2/ Seal and the outside dia&eter of the #ring

-2, Seal and the gasket


View Image

Illustration 2 g'(2)*++2

%rosion is not acce$table in area -2* .

nly reuse the cylinder head if the erosion has been &achined fro& area -2*. That area is at the $oint of contact

bet!een the #ring or seal and the cylinder head.

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USE THIS PART AGAIN..

Thread Inspection

Make a visual inspection of all threaded holes for damaged threads and broken bolts or studs.

View Image


amaged threads

!he part can be used again after the hole has been repaired using "ock#$#%titch. &or complete information on "ock#

$#%titch' refer to (euse and %alvage )uideline' %*+&8882' ,-sing "ock#$#%titch rocedures for /asting (epair,.


Inspection Methods

/aterpillar recommends several methods of inspecting clinder head and related components for

indications of cracks. !he folloing three methods and procedures ill be described liuid

fluorescent inspection' liuid non#fluorescent inspection and dr magnetic particle.

!he inspection b the fluorescent penetrant ith the use of a black light is the most preferable

procedure for inspecting components for indications of cracks. !he black light ith high intensit

and fluorescent chemicals ill identif cracks that are not normall found ith other methods.

Liquid Fluorescent Inspection

------ WARNING!------

Personal inur! can result "ro# i#proper handlin$ o" che#icals.

Ma%e sure !ou use all the necessar! protecti&e equip#ent required to

do the o'.

Ma%e sure that !ou read and understand all directions and ha(ards

descri'ed on the la'els and #aterial sa"et! data sheet o" an! che#ical

that is used.

)'ser&e all sa"et! precautions reco##ended '! the che#ical

#anu"acturer "or handlin$* stora$e* and disposal o" che#icals.

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NOTICE

Use safety glasses in order to reduce fatigue of the eyes and increase

the contrast between the fluorescent area and the background. Safety

glasses will also reduce the chance of having chemicals srayed into an

eye.

Tooling for this method consists of a !C"!#$! Penetrant and a !C"!#$% Developer . A &U"%%''

Ultraviolet Lamp Gp will also be used.

The head must be clean and dry in order to use this method. Follow the steps below in order to use

the liuid fluorescent inspection to chec! for crac!s.

". #lean the surface that will be inspected with mineral spirits. Then wipe the surface with

clean$ dry paper towels.

%. &pray the cleaner fluid on the cylinder head in order to remove any residual oil orcontaminants from the surface. 'ipe the head dry with clean paper towels.

(. &pray the penetrant on the surface under inspection. Allow the penetrant to remain on the

surface for five to thirty minutes. This will allow the penetrant to penetrate the smallest

crac!s.

View Image

)llustration %* g+"%,-/-Applying the penetrant on the valves

View Image

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)llustration %6 g+"%,-*

. 7nce the penetrant is allowed to settle into the crac!s$ the e8cess penetrant must be removed

from the surface.

Note: #lean the head with moist paper towels in order to remove the penetrant. 'ashing the

head with water will also remove the penetrant. Ta!e care not to wash the surface

e8cessively. Dry the surface with paper towels. Use a blac! light in order to ma!e sure that

the chemical has been removed from the surface.

/. &pray and coat the developer onto the entire dry surface. Use compressed air to reduce

drying time. 7nce the developer has been applied and the developer has dried$ a minimumtime for developing of ten minutes is reuired. During this time$ the developer will draw the

penetrant from the crac!s to the surface.

*. #hec! the surface with a 1U-5566 Ultraviolet Lamp Gp . This will highlight the location of

any crac!s or damage.

View Image

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Illustration 28 g01298498Use a black light to check the valves for cracks.

View Image


Use a black light to check the inserts of the valve seat.

Liquid Non-Fluorescent Inspection

------ WARNING!------

Personal injury can result from improper handling of chemicals.

Make sure you use all the necessary protective equipment required todo the jo.

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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.

NOTIC

!se safety glasses in order to reduce fatigue of the eyes and increase

the contrast bet"een the fluorescent area and the background. #afety

glasses "ill also reduce the chance of having chemicals sprayed into an

eye.

Tooling for this method consists of a $C%$&'$ Penetrant and a $C%$&'( Developer .

Note) This method will not always find cracks of 0.05 mm (0.002 inch) or less.

The head must e clean and dry in order to use this method. !ollow steps elow in order to use the

li"uid non#fluorescent inspection method in order to check for cracks.

$. %lean the surface that will e inspected with mineral spirits. Then wipe the surface with

clean& dry paper towels.

2. 'pray the cleaner on the cylinder head in order to remove any residual oil for checking.

'pray the cleaner on the cylinder head in order to remove any contamination for checking.

. 'pray the penetrant on the surface in order to e inspected. llow the penetrant to remain on

the surface for five to thirty minutes. This will allow the penetrant to enter the smallestcracks.

View Image

*llustration 0 g0$2+,-0

Dye will penetrate into cracks.

. /nce the penetrant is allowed to settle into the cracks& the ecess penetrant must e removed

from the surface.

5. 1ipe the penetrant from the surface y using a clean paper towel.

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6. Spray a light coat of the developer on the surface in order to be inspected. A crack will

appear as a colored line in the developer.

View Image

Illustration 31 g012!"#"

$racks begin at the preco%bustion cha%ber or the hole of the direct in&ection adapter. 'he length of the crack on the

co%bustion area %ust not be %ore than 6.3# %% (0.2#0 inch). 'he crack %ust not be %ore than three threads deep.

*se the %ethod of dye penetrant to find the depth of the cracks.


'he following illustrations show e+a%ples of cracks that would constitute replacing the cylinder

head.

View Image

Illustration 32 g012!"!1

$rack in the no,,le hole (3200 -ngine)

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DO NOT USE THIS PART AGAIN.

View Image


The crack goes into the valve seat. If the crack does not go into the counterbore of the area of the valve seat, the head

can be salvaged. Refer to Reuse and alvage !uideline, "#$837%, &'ecifications for ()linder *ead +sseblies

3200 "ngines&.


View Image

Illustration 3% g012987%0

(racks bet-een the valve seats 3200 and 3%00 "ngines/


View Image

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Illustration 3 g0129980%(racks bet-een the 'recobustion chaber or the hole for the direct in5ection ada'ter and valve seats 3%00

"ngine/ .


View Image

Illustration 3 g012998%2

(racks bet-een the hole of the core 'lug and the bore of the valve guide on the to' deck 3%00 "ngine/


Method for Dry Magnetic Particle

------ WARNING!------

Personal in!ry can res!lt fro" i"#ro#er handling of che"icals.

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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.

NOT!"

#se safety glasses in order to reduce the risk of having chemicals

sprayed into an eye.

Use the $%&'()*+ Crack Detection Kit in order to perform the dry magnetic particle inspection for

cracks.

The head must be clean and dry in order to use this method. Follow the steps below in order to use

the method for dry magnetic particle in order to check for cracks.

1. Clean the surface that will be inspected with mineral spirits. Then wipe the surface with

clean, dry paper towels.

. !pray the fluid for cleaning and the fluid for remo"al on the cylinder head in order to

remo"e any residual oil for checking. The fluids can also be used to remo"e contamination.

View Image

#llustration $% g&1''()%

*n electromagnet in the shape of a yoke that is checking for cracks

$. +lace the magnetic yoke on the surface at a right angle '&- to the area in order to be

checked.

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4. Magnetic powder should be applied to the surface when the yoke is energized.

View Image


. Inspect the area for cracks. If there is a crack between the ar!s of the yoke" the !agnetic

powder will go into the crack. #he crack will then appear as a line of !agnetic particles.

Lock-N-Stitch Full Torque Threaded Inserts

View Image

Illustration 3$ g01042%20

If a bolt hole contains cracked threads or stripped threads" &ock'(')titch *ull #or+ue #hreaded

Inserts should be used. #he cracks !ust be no deeper than %.4 !! ,0.2 inch- down the

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counterbore of the bolt hole. The cracks cannot run into the cylinders. The cracks must only run

into water jackets. The number of cracks per hole does not matter. Mark all bad holes with a paint

pen.

The procedure utilizes Lock-N-Stitch products that were introduced in Reuse and Sala!e

"uideline# S$%&'''(# )*sin! Lock-N-Stitch +rocedures for ,astin! Repair). &ull Torue Thread

nsert /its are used to repair the cracked bolt holes and stripped bolt holes. The threaded inserts

and the parts that accompany the threaded inserts are included in &&%0S+121/ &ull Torue

Thread nsert /it from L3,/-N-STT,4. These parts can be ordered throu!h L3,/-N-

STT,4. This kit is not stocked by ,aterpillar. Refer to Reuse and Sala!e "uideline# S$%&'''(#

)*sin! Lock-N-Stitch +rocedures for ,astin! Repair) for other L3,/-N-STT,4 parts that are

stocked by ,aterpillar.

nstallin! a Threaded nsert can be done in a short amount of time. nstallin! a Threaded nsert

will increase the stren!th of the threads.

&or more information or uestions concernin! L3,/-N-STT,4# contact L3,/-N-STT,4. &or

a complete catalo! of products# contact L3,/-N-STT,4. See www.locknstitch.com for more

repair procedures# trainin!# and catalo!s.

LOCK-N-STITCH Inc.

1015 S. Soderquist Rd.

Turlock, CA 5!"0

###.locknstitc$.co%

&'0( )!'-'!*5&"00( +!)-"')1

Measurement Procedures

View Image

llustration 51 !12607(78

Measurement location for the thickness of typical heads

9(: ;ale coer !asket

9': ,ombustion area

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%efore the cylinder head can be reused# the cylinder head thickness must be measured.

The cylinder head can be machined in order to remoe any dama!e.


35/53

View Image

llustration 5( !12711('(

Measurement of total surface for flatness 97511 $n!ine:

&latness of the cylinder head can be measured by usin! a strai!ht ed!e and a feeler !au!e. This is

shown in llustration 52 and llustration 5(. < B11 mm 9(5.1 inch: strai!ht ed!e for measurin! the

total flatness of surface is reuired. < 201 mm 9B.1 inch: strai!ht ed!e should be used for

measurin! a small area.

Sleeves for the Injectors of Cylinder Heads

< stainless steel sleee is used between each unit injector and the cylinder head castin!. The

injector sleee is used to seat the injector. The injector sleee is also used to seal the injector into

the castin!. The injector sleees are reusable unless the sleees become dama!ed.

Refer to the Cisassembly and


36/53

Tooling

6V-2012 Micrometer Depth Gauge Group

8H-8581 Feeler Gauge

Table 8

Valve Guide Measurement Tools

Part

NumberDimensions and Engines In Which Gauge (Red

End) Is sed to !hec" Worn Valve

Dimensions Which Gauge

(Green End) is sed to

!hec" Ne# or $nurled

Value Guides

261-368712672 mm !0"#8 i$% !3508& 3512& 3516% 125#" mm !0"#58 i$%

127 mm !05 i$% !3500 '$gi$e( - e)hau(t *al*e(o$l+%

-

",-#73"

808 mm !0318 i$% !311"& 3116% 8035 mm !0316 i$%

6V-7058

#55 mm !0376 i$% 1673& 16#3& 1100& .erie(&

3100 .erie(& 320" 3208& 330"& 3306& D330,&

D333,& D3"2& D3"3& D3"6& D3"8& D3"#& D353&

D37#& D3#8& D3##& 1372 !5" i$% /ore #0 egree

V-8

#5 mm !037" i$%& 1100

.erie(& 3100 .erie(& 320" a$

3208

6V-7068 #5" mm !03755 i$% !3"06& 3"08& 3"12& 3508&

3512& 3516& #65 mm !038 i$% i$tae a$ e)hau(t

*al*e%

#"60 mm !03725 i$%

6V-78#5

12775 mm !0503 i$% !D37#& D3#8& D3##%-

#-63##

16003 ) 175 mm !0630 ) 6# i$% !Go%

1605# ) 508 mm !06322 )

20 i$% !4o-Go%

#-6"01

16106 ) 508 mm !063" ) 20 i$% !Go%1620# ) 508 mm !06381 )

20 i$% !4o-Go%

5-3536 7#2 mm !0312 i$%&

#52 mm !0375%& a$

127 mm !0500 i$% !D37#& D3#8& D3##& G37#& G3#8& a$ G3##%

Thi( (ectio$ (ho( the tool( or i$(pecti$g *al*e guie( i$ ,aterpillar e$gi$e( Val*e guie( mu(tbe mea(ure or i$(talle height rom the top ec a$ the i$(ie bore iameter eer to the

appropriate eu(e a$ .al*age Guieli$e o .peciicatio$( or (peciicatio$( o *al*e guie(

9gi$a 36 e 53.er*ice :$ormatio$ .+(tem

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Refer to the appropriate Disassembly and Assembly Manual for removal and installation

instructions for the valve guides.

Note: Do not reuse any valve guide with obvious damage. Do not use a valve guide if the wear

exceeds the permitted allowance according to available specifications. Loose valve guides or

damaged valve guides must be removed and new valve guides must be installed. Correct any

condition that could have caused the original damage or wear. The valve guide will not reuire

any machining after installation.

View Image

!llustration "# g$%#$$"#&

'()#'#* +alve ,uide ,auge ,roup

View Image

!llustration "" g$%#$$"'%

Typical plug gauge

The specifications of installed height for valve guides in all current Caterpillar cylinder heads can

be measured with a 6V-2012 Micrometer Depth ,auge ,roup . The %'$ mm -*.$ inch dial

caliper/ and the 8H-8581 0eeler ,auge are also needed.

The inside diameter of the valve guide can be measured with tools such as a 5P-3536 +alve ,uide

,auge ,roup / 6V-7058 (lug ,auge / and 6V-7068 +alve ,uide ,auge . The rest of the tooling

available is in Table 1/ along with their corresponding engines. There are different tools for the

different si2es of valve guides.

Refer to the 3pecial !nstruction/ ,M,$&'*&/ 45sing the '()#'#* Dial 6ore ,auge ,roup to

Chec7 +alve ,uides4 for complete instructions on the use of the 5P-3536 Dial 6ore ,auge

,roup .

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Measurements

View Image

!llustration "' g$%#$$*$%

Measure the diameter of the bore.

View Image

!llustration "* g$%#$$*?&

The end of the plug gauge must not go into the bore of the valve guide more than %?.$ mm -$.9' inch.

Measure both ends of each valve guide. The measurement should be ta7en %?.$ mm -$.9' inch

from each end of the bore. !f the valve guide is counterbored/ measurements must be ta7en in this

area. !f plug gauges are used/ the end of the gauge should not extend into the valve guide morethan %?.$ mm -$.9' inch. !f the measurement of the valve guide exceeds the dimension/ then the

valve guide is worn beyond the allowable dimension for reusability.

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Note: Do not force the plug gauge or turn the plug gauge into the guide of the bore. Doing so

will damage the gauge.

Valves and Valve Seats

Note: Refer to ""Reconditioning for C15, C16, C18, C27, and C32 Engines ONLY" " section of

this guideine for C15, C16, C18, C27, and C32 Engines!

his section contains s#ecifications of reusa$iit% for &a&es and &a&e seats 'hich are used in

Cater#iar engines! his section aso incudes a ist of the toos needed in order to (easure the

&a&e di(ensions! )a&es (ust $e (easured for ste( dia(eter, thic*ness of the i# on the &a&e

head, and the dia(eter of the &a&e guide $ore!

Note: Contact $et'een the face of the &a&e and the seat of the &a&e is e+#ected in the area at the

outer edge of the &a&e seat! he (ini(u( thic*ness of the i# (ust $e (aintained!

f the thic*ness of the head is (achined $e%ond factor% s#ecifications, the &a&e seats (ust aso $e

(achined! -achine the surface of the insert so the sa(e a(ount of (ateria is re(o&ed fro( thehead and the insert in order to (aintain the #ro#er #ro.ection of the &a&e! /fter the head has $een

(achined, the seaing ange (ust $e 'ithin i*e0ne' s#ecifications!

View Image

ustration 7 g137877

-achining the &a&e seat to i*e0ne' s#ecifications after (achining the head

View Image

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Illustration 48 g01953486Examples of reusable tip wear.

(2! "eusable #al#e stems after regrin$ing

(28! %&e #al#e stems are reusable wit& optional polis&ing. %&e tip of t&e stem 'an be polis&e$ wit& a 6)2033*rus& . %&is polis&ing is not ne'essar+.

,e#er use an+ -in$ of &ammer to pus& t&e #al#e seat into t&e &ea$. Installation of t&e #al#e seat

insert reuires a 'areful te'&niue. %&e #al#e seat inserts are installe$ in a 'ounterbore in t&e

'+lin$er &ea$ un$er a press fit. /are must be ta-en wit& #al#e seat inserts. %&e inserts must be

properl+ seate$ in t&e 'ounterbore. %&e insert must be in full 'onta't wit& t&e bottom of t&e

'ounterbore. %&e inserts are usuall+ '&ille$ on $r+ i'e before installation. rost ma+ buil$ up ont&e bottom of t&e insert. %&is ma+ not allow t&e insert to seat properl+. Installation freuentl+

in#ol#es &ammering of t&e insert w&i'& $oes not allow t&e #al#e seat insert to seat properl+. %&e

best results &a#e been obtaine$ b+ installing t&e #al#e seat insert at room temperature wit& stea$+&+$rauli' pressure.

%&e initial firing of t&e engine will seat an improperl+ seate$ pre'ision insert. %&e onl+ impa't

from an improperl+ pla'e$ pre'ision insert is a re$u'tion in las& for t&e #al#e.

n insert t&at is ma'&ine$ after installation t&at $oes not seat properl+ will 'ause problems. %&e

insert will be ma'&ine$ w&en t&e insert is not full+ seate$. &en t&e #al#e seat insert seats

properl+ t&ere will be an improper seating fa'e. Ele#ate$ wear rates will o''ur an$ t&e #al#e ma+fail.

Reconditioning Tips

etermining t&e proe'tion of t&e #al#e an$ t&e re'ession of t&e #al#e t&roug& a measurement is

no guarantee t&at t&e #al#es an$ #al#e seats &a#e been 'orre'tl+ re'on$itione$. %&e following

'riteria will &elp to furt&er $etermine t&e reusabilit+ of bot& #al#es an$ #al#e seats.

1. %&e wi$e #al#e seats $o not 'ause problems wit& #al#es. %&e outer $iameter of t&e finis&e$

seat insert 'an be larger t&an t&e $iameter of t&e #al#e &ea$. %&is s&oul$ not 'ause an+

problems.

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2. While the width of the seat will vary with the engine model, the width of the finished insert

must be at least 1.0 mm (0.04 inch) for good valve life. There is no need for an uer limit

on the width of the seat.

!. "rind the finished surface of the valve seat after the valve seat inserts have been installed

into the head. "rinding the seat insert correctly is essential to valve life. This rocess is not

necessary on recent !#00 $eads with remachined inserts.

4. %ontacting the valve seat insert to the sealing face of the valve head at the middle of the

sealing face of the valve was an accetable ractice for rebuilding cylinder heads. With the

introduction of the !#00 &ngine, the traditional sealing area moved closer to the edge of the

valve head. 'remachined seat inserts and recision valve guides moved the sealing area to

0.#1 to 1.02 (0.020 to 0.040) from the outer dimension of the valve head. o not grind the

sealing faces of the inserts if new remachined valve seat inserts are installed during the

rebuild of a head. The comonents do not need to be machined after installation due to the

recise manufacturing rocess.

#. f the seat face cannot be ground without grinding into the head, relace the insert. o not

grind the head under any circumstance.

*. +ever use a valve with less than the secified minimum thicness of li.

-. $eads that have been resurfaced may reuire the bores of the inserts to be machined to a

deeer dimension. This will ensure the correct location of the insert in relation to the head.

/. alve seat inserts should not etend above the surface of the head. ecessing the inserts

0.2# mm (0.010 inch) below the surface is a good habit.

3. aing valves and laing seat inserts is not recommended or necessary if the correct

angles of the valve seat are maintained during the rocess of resurfacing the valves andvalve seats.

Required Tools

The valve stem diameter for all current valves can be measured by using the 6V-0087 alve 5tem

"auge or a 0 to 2# mm (0 to 1.0 inch) micrometer.

The diameter of the valve head for all current valves can be measured by using a 0 to 2# mm (0 to

1.0 inch) micrometer, 2# to #0 mm (1.0 to 2.0 inch) micrometer, or a #0 to -# mm (2.0 to !.0 inch)

micrometer. The diameter of the valve head can also be measured by using a 0 to 1#0 mm (0 to

*.0 inch) dial calier.

The valve li thicness for all current valves can be measured by using a 6V-7059 6ultile 7nvil

6icrometer lus a 6V-2034 7dater , a 5P-6518 ial ndicator 8iture " , or a 0 to 1#0 mm (0

to *.0 inch) dial calier.

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6V-7059 Multiple Anvil Micrometer it! t!e 6V-2034 A"apter

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5#-6518 $ial In"icator %i&ture 'p

Measurements

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Always measure wear on valve stems.

Use either a 6V-0087 Valve Stem Gauge or a mirometer to measure the !iameter o" the valve

stem. #easure the to$ an! %ottom areas that move in the valve gui!e. &e"er to the a$$ro$riate

&euse an! Salvage Gui!eline o" S$ei"iations o" valves.

View Image

Illustration 52 g013026'0

Use a 6V(00') Valve Stem Gauge to he* the !iameter o" the valve stem. +he gauge will not sli!e easily over the

stem.

USE THE PART AGAIN.

View Image

Illustration 53 g013026,6

+he mirometer sli!es over the stem.


+he minimum s$ei"iations "or stem !iameter an %e "oun! in the a$$ro$riate &euse an! Salvage

Gui!eline o" S$ei"iations. +he s$ei"iations "or minimum allowa%le stem !iameter are given inthe a$$ro$riate &euse an! Salvage Gui!eline o" S$ei"iations.

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If a micrometer is used to check the diameter of the valve stem, adjust the micrometer to the

reusable diameter. The valve may not be reused if the micrometer slides over the valve stem at any

point. Make sure that the micrometer is set and locked at the minimum diameter.

Note: Some valve stems have a taper. The measurements at the top and the bottom are different.

Reconditioning for C15, C16, C18, C27, and C32 EnginesONLY

For specifications of C-Series enines, refer to !euse and Salvae "uideline, S#$F%&&',

(Specifications for Cylinder )ead *ssemblies on C-Series #nines(.

*fter machinin the head, the e+haust valve seats must be machined in place in order to achieve

the proper projection of the valve. se a standard replacement valve seat only if the bore for the

e+haust valve is undamaed. If the bore for the e+haust valve is damaed, the bore must be

rebored and an oversied valve seat must be used.

NOTICE

o!e "a#"e seats cannot $e !ac%ined& 'ecia#i(ed !an)fact)ring

'rocesses *ere )sed on t%ese 'arts& +ac%ining t%ese 'arts *i##

significant# decrease t%e #ife of t%e engine&

Some inlet seats cannot be machined under any circumstance. Caterpillar uses specialied

manufacturin techniues on inlet valve seats of some enine models. !efer to !euse and Salvae

"uideline, S#$F%&&', (Specifications for Cylinder )ead *ssemblies on C-Series #nines( in

order to determine if your valve seats can be machined. If the thickness of the head has been

machined beyond factory specifications, do not machine these inlet seats. These inlet seats mustbe replaced /ith seats that can be machined.

View Image

Illustration 01 &2344565

Findin the pin location by usin a probe

In order to keep the valve uide and the valve seat concentric, use a dial indicator and a tapered

pilot pin to find the center line of the valve uide.

7versied seats are available if the head has been damaed. If an oversied insert has already been

installed, second oversied inserts are available for certain models. If an oversied seat /ill be

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used, use either a probe or a dial indicator in order to keep the valve uide and the valve seat

concentric.

2. If an oversie valve seat /ill be used, locate the center of the valve uide /ith a aue pin.

5. Find the center of the tapered pilot pin as close as possible to the valve uide.

3. se a dial indicator in order to find the center of the tapered pilot pin.

1. Machine the bore for the valve seat in the location that is concentric /ith the valve uide.

The tapered pins are supplied /ith the rinder for the valve seat. If the tapered pilot pins need to

be purchased, contact the supplier for your valve seat rinder. >ood/ard #uipment is a supplier

for the tapered pilot pins.

Woodward Equipment

15790 SE Piazza Ave, Suite 104

Clacama!, "# 97015

$oll %ree& 1'(00'4))'1(70, or 50)'*57'**(0

Valve Recession and Projection

*fter the cylinder head has been reconditioned, the projection of the valve must be measured. The

projection of the valve is measured from the combustion area of the cylinder head to the valve

head /hen the valve is closed.

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Illustration 00 &2%034&0?$@ Aalve !ecession

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(C) Projection of the Valve

Tools

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6V7926 In!icator "rou#

(29) $%&15$ In!icator

(&0) &P1565 Collet Cla'#

(&1) 5P4156 In!icator ase

he valve recession can *e 'easure! *+ using an+ of the follo,ing tools-

1- 6V-7926 In!icator "rou#

a- 8S-3158 "auge

*- 3P-1565 Collet Cla'#

c- 5P-4165 ase

2- 6V-2012 .icro'eter /e#th "auge "rou#

&- 8H-8581 eeler "auge an! a 150 '' (6-0 inch) straight e!ge

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Measurement Procedure

Take these measurements after the valves are installed in the head.

1. Before starting this procedure, set the gauge to zero.

a. Place the indicator on a flat surface.

b. Move the dial face, and align the hand of the gauge to the zero mark.

c. Tighten the lock on the dial face.

2. Take the measurements and record the measurements on all valves.

a. For a recessed valve, set the gauge on surface of the head and over the center of the

valve. ecord the measurement.

b. For a pro!ected valve, set the gauge on top of the valve. The tip of the indicator

should be on the surface of the head. ecord the measurement.

". #f the measurements do not meet the re$uired specifications, refer to the section

%%&orrecting the '(cessive Pro!ection of the )alves% %.

The e(cessive pro!ection of valves can cause the head of the valve to contact the piston duringnormal engine operation.

Correcting the Excessive Projection of the Valves

There are t*o *a+s to correct a valve that e(ceeds the ma(imum dimension of pro!ection.

1. Material can be ground from the sealing angle of the seat insert and the valve face.

2. The seat insert can be recessed farther into the counterbore.

Note: For e(ample, if .2- mm .1 inch/ has been removed from the bottom of the head, the

counterbore can be recessed .2- mm .1 inch/.

Note: #f a valve e(ceeds the ma(imum recessed dimension, the valve position is too deep. To

correct this condition, either a ne* valve must be installed. eplacing the valve seat ma+ also be

necessar+.

Valve Springs

This section contains procedures for checking the reusabilit+ of valve springs. efer to euse 0nd

alvage uidelines, 'BF3"4, %)alve and )alve pring pecifications%.

Required ools

0ll current valve springs can be measured b+ using the !!"#$%"! )alve pring Tester to test for

reusabilit+ of load and rebound. 0 %$''% urface Plate and a 1- mm 5. inch/ s$uare *ill be

used to measure the straightness of the spring. To measure the diameter and free length of aspring, use either a 2- to - mm 1. to 2. inch/ micrometer or a to 1- mm to 5. inch/ dial

caliper.

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View Image


Use a square or a straight edge to check each valve spring for distortion. A feeler gauge ust also !e used.

est Procedure

View Image

Illustration 5" g0368056#Use the ##1$0%1# &pring 'ester to test springs

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1. Make an adjustment to the stop at the top of the valve spring tester so the spring can be

compressed only to the length at the valve open position.

2. Compress the spring until the spring is at the assembled length. Make a record of the force

needed in order to hold the spring at this length.

3. Continue to put the spring under compression until the spring is at length at the valve open

position. Make a record of the force needed in order to hold the spring at this length.

4. Make a comparison of the test results to the specifications in the appropriate guideline.

View Image

Illustration ! g!13!3321

"pring #ith a polished end that is acceptable

Valve Rotators

Caterpillar $ecommends againstthe reuse of rotocoils. %he disassembling& cleaning& inspecting&

and reassembling of rotocoils re'uires speciali(ed tooling and processes.

Vacuum est for Valves

%esting the valves by vacuum in a cylinder head is used to identify a poor seal bet#een the valve

and the valve seat. %his procedure should be performed after a cylinder head has been

reconditioned. %he cylinder head must be completely assembled before the vacuum test.

Note: %he procedure for the vacuum test should only be used to identify leakage bet#een the

valve and the valve seat. %his test procedure should only be used if the leakage is e)tremely out of

the acceptable specification.

*n unavoidable minor amount of leakage bet#een the valve and the valve seat is permissible. It is

impractical to use the vacuum test to identify minor leaks bet#een the valve and the valve seat.

%he follo#ing specifications and e'uipment can be used to identify the gross leak. *ny

combination of valve and valve seat that does not maintain 4! cm +g ,1.! inch Mercury- or more

is considered to be a gross leak.

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Equipment and Tooling

View Image

Illustration 61 g013034799U-5383 Vacuum Tester

The 9U-5383 Vacuum Tester consists of a hand-held acuum !um! and connecting !arts" #ost

$ater!illar engines %ill %or& %ith the set of eight ada!ters that can 'e fa'ricated from the dra%ing

of the fa'ricated tool FT-1741 Vacuum Tester " (or a com!lete list of all !arts and fa'ricated

dimensions) re*uest a dra%ing of the FT-1741 Vacuum Tester "

+ealers in ,$+) .$+) /#/) and + can order fa'ricated tool dra%ings from the

follo%ing address

Dealer Service Tools501 SW Jefferson Ave.

Peoria, IL 61630-2125

USA 1-!00-5"2-!665Illinois 1-!00-5"1-!665#ana$a 1-!00-523-!665Worl$ 1-30%-6&5-

62&&'a( 1-30%-6&5-%&&3

2e sure to include our dealer code and our address so that our re*uest %ill receie immediate

attention"

Test Procedure

The 9U-5383 Vacuum Tester is suita'le for use %hen a acuum test of 45 cm g 18"0 inch#ercur or less is re*uired" (or com!lete information on the acuum tester) refer to !ecial

Instruction) /9498) Using the 9U-5383 Vacuum Tester"

The gauge has detected a lea& if a dro! in acuum occurs" n adustment scre% is !roided on the

to! of the tool in order to ar the sensitiit of the gauge" To chec& ale seats for lea&s) the

adustment scre% must 'e set for ma:imum sensitiit" ;hen a constant acuum of 45 cm g

18"0 inch #ercur is a!!lied for 15 seconds) the acuum should not dro! 'elo% 40 cm g 16"0

inch #ercur" gauge reading of less than 40 cm g 16"0 inch #ercur can hae enough

magnitude in order to adersel affect ale life"

1" lug in the inlet for the acuum) and !ull out the trigger for the air su!!l"

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2. Back out the adjustment screw until maximum vacuum is attained. The maximum reading

should be less than 38 cm Hg (1.! inch "ercur#$.

3. Turn the adjustment screw inward until a dro% in vacuum o& 2. cm Hg (1 inch "ercur#$

occurs. The minimum adjusted set %oint is now 3 cm Hg (1' inch "ercur#$.

'. Tighten the n#lon jam nut in order to %revent an# air leaks &rom giving a &alse leakage

reading.

. &ter adjusting the screw &or sensitivit# has been adjusted) attach the correct ada%ter to the

vacuum tester.

*. +lace the ada%ter over the valve in order to be tested.

,. Hold the trigger &or the air su%%l# in the o%en %osition &or a minimum o& 1 seconds.

Note: "ake sure that the ada%ter is in &ull contact with the combustion area o& the c#linder

head.

8. The seal between the valve and the valve seat is not acce%table i& the gauge indicates a

reading less than the Test -%eci&ication in Table . The "aximum /a%abilit# o& the 0un

determines the Test -%eci&ication that should be a%%lied.

. %%l# slight %ressure with a %ress on the to% o& the valve stem and test again.

1!. & the gauge still indicates a low reading) the valve must be removed and the sealing

sur&aces must be ins%ected. 0rinding or la%%ing the valve seat or the valve &ace again might

also be necessar#.

Table Specifications for Testing by Vacuum (1$

Maximum Capability of the GunAdjusted

Set oint

Test

Specification

3 (21.!$ 1 (2!$ '' (1,.$

2 (2!.$ ' (1.$ '3 (1,.!$

1 (2!.!$ '8 (1.!$ '3 (1,.!$

' (1.$ ', (18.$ '2 (1*.$

'8 (1.!$ '* (18.!$ '1 (1*.!$

', (18.$ '' (1,.$ 3 (1.$

'* (18.!$ '3 (1,.!$ 38 (1.!$

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44 (17.5) 42 (16.5) 38 (15.0)

43 (17.0) 42 (16.5) 36 (14.0)

42 (16.5) 39 (15.5) 34 (13.5)

41 (16.0) 38 (15.0) 34 (13.5)

39 (15.5) 37 (14.5) 33 (13.0)

38 (15.0) 36 (14.0) 32 (12.5)

( 1 ) All of the dimensions are in cm (inch) of Mercur.

Probable Causes of Leaks

! "ncorrect finish of #al#e face or contact area of the #al#e seat

! $he #al#e seat is im%ro%erl installed or the #al#e seat is not seated in the head ("ncorrect

$otal "ndicator &eadout) .

! 'amaed #al#e face

! 'eris et*een #al#e face and #al#e seat

! 'amaed contact area of the #al#e seat

! +ent #al#e

! ,rac-ed #al#e face or #al#e seat

Backlash of the Drive Gear for the Cam

$he ac-lash *hich occurs on the dri#e ear for the cam in enines *ith o#erhead cams limits the

amount of material that can e remo#ed from the oint faces of the clinder head and clinderloc-. A minimum of 0.038 mm (0.0015 inch) relati#e mo#ement for ac-lash must e a#ailale

after reconditionin. $he ac-lash is accounted for in the s%ecifications in this /uideline.

$hree or four locations on the ear need to e chec-ed for ac-lash of the dri#e ear of the cam.

mall differences in the ear teeth and the ear runout ma-e these different chec-s necessar. $o

chec- the ac-lash hold one of the ears stead and use a dial indicator to measure the relati#e

mo#ement of one ear to the other ear. ositionin the dial indicator correctl is im%ortant in

order to et an accurate readin.

Reference&efer to &euse and al#ae /uideline +9234 sin the Adustale "dler

ositionin $ool for ettin the ,am /ear +ac-lash on 3406 3456 ,15 ,16 and ,18nines

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The correct position of the dial indicator for measuring the backlash of the drive gear of the cam drive. Keep the tip

of the dial indicator at 0 degrees to the centerline of the teeth !as close as possible" .

Metal Spray of Gasket Contact Surfaces

The process of metal spra#ing can be used in order to restore the contact surfaces to the original

dimensions. $n acceptable process in metal spra#ing is the %etco 6& II Thermospra# s#stem.

'efer to Thermal (pra# )uide* (+',8-3* /aterpillar $rc (pra# )uide /* and Thermal (pra#

)uide* (+',80-* /aterpillar ,lame (pra# )uide / for guidelines of metal spra# in order to

salvage c#linder head castings. ,or additional information about this guideline* consult 'epair

&rocess +ngineering of the %arketing &roduct (upport ivision at 1 !30" 64-3-.

Copyright 1993 - 2014 Caterpillar Inc.All Rights Reserve.!rivate "etwor# $or %I% &icensees.

$ri 'ct 31 2014 0()3*)30 +,-0*00 /ora est. !acico %amrica5

&5gina 3 de 3(ervice Information (#stem

measuring procedures and salvage procedures for cylinder head assemblies and related components

Documents