Measuring Procedures and Salvage Procedures For Cylinder Head Assemblies and Related Components

Service Information System
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Reuse And Salvage Guidelines

Measuring Procedures and Salvage Procedures for Cylinder Head Assemblies and
Related Components{1100, 1101, 1103, 1104, 1105, 1106, 1108, 1109, 1115, 1117,
1121, 1124, 1125}
Media Number -SEBF8162-30
Publication Date -27/06/2014
Date Updated -27/06/2014
Caterpillar: Confidential Yellow
i05832593
Measuring Procedures and Salvage Procedures for Cylinder

Head Assemblies and Related Components{1100, 1101, 1103,
1104, 1105, 1106, 1108, 1109, 1115, 1117, 1121, 1124, 1125}
SMCS - 1100; 1101; 1103; 1104; 1105; 1106; 1108; 1109; 1115; 1117; 1121; 1124; 1125
Engine: 3400 All, 3300 All, 3200 All, 3100 All, 3000 All, and D-series All All 3500 Engines All
3600 Engines All C280 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 C16 and C-16 All C175 Engines C18 and C-18 All C27 All C32
All C7 All
Introduction
Table 1
Revision
30
29
28
27
26
Summary of Changes in SEBF8162

Added Table 8 to include all Valve Guide Measurement tooling
Updated the Spring Tester in the ""Required Tools" " and ""Test Procedure" "
sections.
Added new serial number prefixes.
Changed section ""Valve Rotators" " to recommend not reusing Valve Rotators/
Rotocoils
Corrected title of SEBF8002
25
Added ""Canceled Part Numbers and Replaced Part Numbers" " section.
Added ""Important Safety Information" " section.
24, 23
22
Added reference to
Reuse and Salvage Guideline, SEBF9234, "Using the Adjustable Idler Positioning
https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/med... 31/10/2014
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Tool for Setting the Cam Gear Backlash on 3406E, 3456, C15, C16, and C18
Engines"
2014 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only.
Unauthorized use of this document or the proprietary processes therein without permission may be
violation of intellectual property law. Information contained in this document is considered
Caterpillar: Confidential Yellow.
This Reuse and Salvage Guideline contains the necessary information 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, use the following resources in
order to communicate your request to Caterpillar Repair Process Engineering:
Caterpillar Dealer Technical Communicator
Dealer Solution Network
Caterpillar Technical Representative
Knowledge Network
Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on
SIS for information about canceled part numbers and replaced part numbers. NPR will provide the
current part numbers for replaced parts.
Important Safety Information

View Image
Illustration 1
g02139237
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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 to
potential 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. If these hazard warnings are not heeded, bodily injury or death could occur to
you or to other persons. Caterpillar cannot anticipate every possible circumstance that might
involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on
the product are not all inclusive. If a tool, a procedure, a work method or operating technique that
is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and
for other people to use. You 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 product

can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on
this product, until you have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the safety alert symbol which is followed by a signal word such as
danger, warning, or caution. The "WARNING" safety alert symbol is shown below.
View Image
Illustration 2
g00008666
This safety alert symbol means:

Pay attention!
Become alert!
Your safety is involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and
in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential
hazard. The safety information in this document and the safety information on the machine
are not all inclusive. You must determine that the tools, procedures, work methods, and
operating techniques are safe. You must determine that the operation, lubrication,
maintenance, and repair procedures will not damage the machine. Also, you must determine
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that the operation, lubrication, maintenance, and repair procedures will not make the
machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on
information which was available at the time of publication. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes
can affect the service that is given to the product. Obtain the complete, most current information
before you start any job. Caterpillar dealers can supply the most current information.
Summary
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.
Before reusing a cylinder head, check for leaks, cracks, and flatness. All 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
Reference section.
When 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.
References
Use the references that are listed below to help complete the rebuild of your cylinder head.
Reference Reuse and Salvage Guideline, SEBF2000, "Metal Spray Guide"
Reference Reuse and Salvage Guideline, SEBF9006, "Specifications for Cylinder Head
Assemblies on C-Series Engines"
Reference Reuse and Salvage Guideline, SEBF8002, "Visual Inspection of Valves, Valve
Springs, and Valve Bridges"
Reference Reuse and Salvage Guideline, SEBF8034, "Valve and Valve Spring Specifications"
Reference Reuse and Salvage Guideline, SEBF8061, "Engine Precombustion Chamber and 3400
Series Engine Direct Injection Nozzle Adapters"
Reference Reuse and Salvage Guideline, SEBF8076, "Specifications to Salvage Cylinder Block
Contact Surfaces"
Assemblies 3600 Engines"
Reference Reuse and Salvage Guideline, SEBF8129, "Procedure to Salvage Cylinder Head
Assemblies for 3600 and G3600 Engines"
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Assemblies for 3500 Series Engines"
Reference Reuse and Salvage Guideline, SEBF8882, "Using Lock-N-Stitch Procedures for
Casting Repair"
Reference Reuse and Salvage Guideline, SEBF8167, "Reconditioning Procedures 3114 and 3116
Engines"
Assemblies 3114, 3116, 3126, and C7 Engines"
Reference Reuse and Salvage Guideline, SEBF8229, "Specifications for Cylinder Head Assembly
3176, 3176B, 3196, C10 and C12 Engines"
3400, 3406E, C15, and C18 Engines"
Reference Reuse and Salvage Guideline, SEBF8302, "Reuse Specifications for 3600 Combustion
Gaskets"
3400 / C16 Engines"
Assemblies 1404 and D Model Engines"
Reference Reuse and Salvage Guideline, SEBF8382, "Cylinder Head Rebuild Process "
Reference Reuse and Salvage Guideline, SEBF8737, "Reuse of Cylinder Heads On C9 Engines
with Injector Tip Damage"
Assemblies 3054 and 3056 Engines"
Reference Reuse and Salvage Guidelines, SEBF9193, "Specifications for Cylinder Head
Assemblies on C175 Engines"
Reference Reuse and Salvage Guideline, SEBF9234, "Using the Adjustable Idler Positioning
Tool for Setting the Cam Gear Backlash on 3406E, 3456, C15, C16, and C18 Engines"
Equipment and Tooling

Table 2
Required Tools
Part Number
Part Description
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Straight Edge
4C-4804
Penetrant
4C-4805
Developer
4C-4736
Kit
8H-8581
Feeler Gauge
5P-7324
Plug
5P-7333
Tool Group
4C-4086
Repair Kit
1U-5566
Ultraviolet Lamp Gp
222-3071
Grinder Angle
6V-0186
Holder 127 mm (5.0 inch)
6V-0185
Abrasive Disc
127 mm (5.0 inch)
or
5P-9718
Holder
178 mm (7.0 inch)
5P-9709
Abrasive Disc
178 mm (7.0 inch)
Table 3
Valve Guides
6V-2012
Measuring and checking devices (1)

Micrometer Depth Gauge Group
or
Dial Caliper
150 mm (6.0 inch)
5P-3536
Valve Guide Gauge Group
6V-7058
Plug Gauge
6V-7068
Valve Guide Gauge
(1)
Measuring devices that are required 0 to 25 mm (0 to 1.0 inch) micrometer, 25 to 50 mm (1.0 to 2.0 inch)
micrometer, 50 to 75 mm (2.0 to 3.0 inch) micrometer, 0 to 150 mm (0 to 6.0 inch) dial caliper, 150 mm (6.0
inch) straight edge and 8H-8581 Feeler Gauge
Table 4
Valves
-
Measuring and checking devices (1)
6V-7926
Indicator Group
5P-6518
Dial Indicator Fixture Gp
1S-0258
Hammer (soft tip)
9U-5383
Vacuum Tester
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or
FT-1741
Vacuum Tester
6V-0087
Valve Stem Gauge
6V-2012
Depth Micrometer
6V-7059
Micrometer
6V-2034
Micrometer Adapter
(1)
Measuring devices that are required 0 to 25 mm (0 to 1.0 inch) micrometer, 25 to 50 mm (1.0 to 2.0 inch)
micrometer, 50 to 75 mm (2.0 to 3.0 inch) micrometer, 0 to 150 mm (0 to 6.0 inch) dial caliper, 150 mm (6.0
inch) straight edge and 8H-8581 Feeler Gauge
Table 5
Valve Springs
-
Measuring and checking devices
7B-0337
Surface Plate
441-0714
Spring Tester
(1)
General Procedures
Use the following guidelines when you are inspecting and reconditioning a cylinder head.
Clean the cylinder head. Remove the gasket material.
Measure the cylinder head thickness.
Measure the flatness of the combustion area.
Inspect the combustion area for cracks or leaks.
Check the combustion area for damage and/or erosion.
Inspect the valves, valve seats, valve springs, valve guides, and valve rotators for damage.
Recondition the components that are requiring salvage and replace the parts that do not meet
the guidelines.
Measure the projection and the recession of the valves.
After you have assembled the cylinder head you will need to run a vacuum test of the valves
for the correct sealing.
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Protect the head against storage or shipping damage.
Nomenclature
View Image
Illustration 3
Nomenclature for the 3200 Engine
g01955530
(1) Intake port

(2) Surface of the valve cover gasket
(3) Seat of the valve spring
(4) Post for the valve guide
(5) Face of the exhaust port
(6) Exhaust port
(7) Valve seat insert
(8) Combustion area
(9) Face of the intake port
View Image
Illustration 4
g01955731
Nomenclature for the 3400 Engine except 3406E
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(1) Intake port

(3) Seat of the valve spring
(4) Post for the valve guide
(5) Face of the exhaust port
(6) Exhaust port
(7) Valve seat insert
(8) Combustion area
(9) Face of the intake port
(10) Bridge dowel
View Image
Illustration 5
g01936936
Nomenclature for the 3500 Engine
(1) Intake port (front or right side)
(4) Valve guide
(6) Exhaust port (rear or left side)
(8) Combustion area
(10) Bridge dowel
(11) Bore of the roller lifter
View Image
Illustration 6
Nomenclature for the C175 Cylinder Head
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g02362776
(1) Intake port

(2) Surface for the valve cover gasket
(4) Valve guide
(6) Exhaust port
Reconditioning Suggestions
Use the information that is below for suggestions on common problems that can occur when you
are reconditioning the cylinder head.
The information in this Reuse and Salvage Guideline is only for current engines with a high
volume. Information for current engines with low volume can be obtained from Service
Manuals that are issued for each engine model.
For minor erosion of 0.28 mm (0.011 inch) that is on the surface of the cylinder head, shave
the area or resurface the area. In all of the following reconditioning procedures, remove the
minimum material that is necessary to make the repair. Refer to the appropriate Reuse and
Salvage Guideline for minimum specifications of the thickness of the cylinder head.
To find the amount of wear, a comparison can be made between the measurement of a worn
part and the specifications of a new part. A part that is worn may be safe to use if an
estimate of the remainder of service life of the part can be made. If this estimate shows that
a short service life is expected, replace that part.
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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, projections of the valves, flatness and surface finish. Measure 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: Dimensions 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. You must adjust
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, extreme
caution must be exercised when using them. If unsure about a
particular cleaning fluid, refer to the manufacturer's instructions and
directions.
Always wear protective clothing and eye protection when working with
cleaning solvents.
Use one of these methods to clean the cylinder head. Remove all oil, dirt, and carbon from the
cylinder head casting. If the initial cleaning of the engine has been performed, the time for
cleaning of the cylinder head will be reduced considerably.
NOTICE
Shot blasting is not a Caterpillar recommended cleaning procedure.
Shot blasting can cause shot to become lodged in internal passages. If
all of the shot material is not removed after cleaning with this method,
the shot can become dislodged after reconditioning and move into the
lubrication and injection systems. The result can be serious damage to
the engine.
Dip Tank
Use a hot caustic solution to clean the cylinder head in a dip tank with a platform that oscillates.
Hot Spray Wash Cabinet

Put the cylinder head into position so the exhaust ports and the combustion area are in line with
the high-pressure stream from the nozzles. 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 5% solution of
Hydrosolv 4106 in water would be a recommended solution. Hydrosolv
4106 is available in a 4 liters (1 gal) container under 4C-8486 Cleaner .
Removing the Gasket

------ WARNING! ------
Use caution in order to avoid breathing dust that may be generated

from handling any friction material, regardless of whether or not the
material contains asbestos. If the dust is inhaled, the dust can be
hazardous to you health.
Wear a proper protective breathing device when 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.
Scraping
Use a putty knife in order to scrape off a majority of the gasket. Scraping is preferred over sanding
discs. This preference is due to the amount of airborne contaminants that are created by the discs.
Disks for metal reconditioning that are mounted on an air tool can be used to remove gasket
material that cannot be removed by hand.
Grinding
NOTICE
If the metal reconditioning disc is used to remove gasket 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
Illustration 7
Removing the gasket by grinding
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g01276547
When you are using this method, the speed of the disc is important. The best results will be
obtained if the disc is flat to the surface and using only the weight of the air tool as downward
pressure. Do not use too much downward pressure or operate the disc on the edge, because the pad
may separate from the holder. The speed of the disc should be set between 3500 and 4500 rpm for
5P-9709 Abrasive Disc and 10,000 rpm for 6V-0185 Abrasive Disc . If the disk for metal
reconditioning is used in order to remove gasket material, be careful not to remove any metal from
the cylinder head.
View Image
Illustration 8
Discs and holder
g01277331
(12) 6V-0186 Holder (127 mm (5.0 inch) )
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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

If the casting is being stored before making a repair, then the cylinder head must be protected from
corrosion and external damage after cleaning.
Visual Inspection of Cylinder Head

Cylinder Head Casting
Inspect the cylinder head for visible damage. The following examples of damage were taken from
3200 and 3400 Engines and the examples also apply to all engines.
View Image
Illustration 9
g01277373
The damage to the cylinder head is located at the seal between the valve cover and the head.
USE THE PART AGAIN.

The cylinder head can be used again after the burr has been removed.
View Image
Pgina 15 de 53
Illustration 10
g01277404
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.
USE THE PART AGAIN.

The cylinder head can be used again after damage is repaired.
View Image
Illustration 11
g01277417
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.
USE THE PART AGAIN.
The cylinder head can be used again after damage is repaired.
The part can be used again after the hole has been repaired using Lock-N-Stitch. For complete
information on Lock-N-Stitch, refer to Reuse and Salvage Guideline, SEBF8882, "Using Lock-NStitch Procedures for Casting Repair".
Inspecting the Combustion Area for Damage from Erosion
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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
Inspect the indicated areas for damage and erosion.
g01326391
(16) Fire ring

(17) Seat area
(18) The area between the hole of the injector nozzle and the valve seat. Erosion in other areas should not affect
engine operation.
View Image
Illustration 13
Minor pitting or erosion
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g01296874
USE THE PART AGAIN.

View Image
Illustration 14
g01296931
Foreign material caused this damage. The valve seats must be replaced.
USE THE PART AGAIN.

View Image
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Illustration 15
Erosion across the fire ring
g01296968
The cylinder head can be used again after the surface has been machined and all erosion is removed. The part must
still be within the reusable specifications.
USE THE PART AGAIN.

View Image
Illustration 16
Damage across the fire ring
g01296991
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
Concentrated area of erosion
g01297021
The cylinder head can be used again if a channel is ground out in order to remove erosion. Refer to Reuse and
Salvage Guideline, SEBF8374, "Specifications for Cylinder Head Assemblies 3200 Engines".

View Image
Illustration 18 g01297085
A small amount of erosion

View Image
Illustration 19
Bad erosion around the area of the valve seat.
g01297091
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DO NOT USE THE PART AGAIN.

View Image
Illustration 20
Engine failure caused this damage.
g01297298
DO NOT USE THE PART AGAIN.
Erosion
The flow of coolant through the engine is known for causing erosion. This is shown in Illustration
19. The erosion will not damage the engine if the coolant does not go from the coolant passage to
any of the following:
Fire ring in the combustion chamber
Oil passages
Bolt holes
Outside of the engine
View Image
Illustration 21
Erosion that is caused from the flow of coolant
Pgina 21 de 53
g01297592
(16) Fire ring

(19) Outer surface
(20) Coolant passage
(21) Oil passage
(22) Erosion must not extend beyond this area.
(23) Bolt hole
For traditional head gaskets, if the distance between the erosion and any feature that is specified in
Illustration 21 is less than 4.0 mm (0.16 inch), do not use the cylinder head again. Use the part
again only if the erosion has been removed in order to leave a minimum of 4.0 mm (0.16 inch)
sealing area.
View Image
Illustration 22
Multiple layered steel "MLS" gasket
g01388997
The arrows indicate a raised layer of the gasket. Erosion cannot come in contact with this area.
Pgina 22 de 53
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 24 show the location of O-rings or seals around the holes of the
coolant passages. Erosion will not harm the engine between these areas.
Erosion is not acceptable at the point of contact between the O-ring or seal and the cylinder head.
If any erosion occurs the combustion area must be ground down.
View Image
Illustration 23
g01297863
Erosion is acceptable in areas (24) and (25). Erosion is not acceptable in area (26). This photo shows acceptable
erosion, and the head can be used again.
(24) Coolant passage and the inside diameter of the O-ring
(25) Seal and the outside diameter of the O-ring
(26) Seal and the gasket

View Image
Illustration 24
Erosion is not acceptable in area (27) .
g01297882
Only reuse the cylinder head if the erosion has been machined from area (27). That area is at the point of contact
between the O-ring or seal and the cylinder head.
Pgina 23 de 53
USE THIS PART AGAIN..
Thread Inspection
Make a visual inspection of all threaded holes for damaged threads and broken bolts or studs.
View Image
Illustration 25
Damaged threads
g01298139
The part can be used again after the hole has been repaired using Lock-N-Stitch. For complete information on LockN-Stitch, refer to Reuse and Salvage Guideline, SEBF8882, "Using Lock-N-Stitch Procedures for Casting Repair".
Inspection Methods
Caterpillar recommends several methods of inspecting cylinder head and related components for
indications of cracks. The following three methods and procedures will be described: liquid
fluorescent inspection, liquid non-fluorescent inspection and dry magnetic particle.
The inspection by the fluorescent penetrant with the use of a black light is the most preferable
procedure for inspecting components for indications of cracks. The black light with high intensity
and fluorescent chemicals will identify cracks that are not normally found with other methods.
Liquid Fluorescent Inspection

------ WARNING! ------
Personal injury can result from improper handling of chemicals.

Make sure you use all the necessary protective equipment required to
do the job.
Make sure that you read and understand all directions and hazards
described on the labels and material safety data sheet of any chemical
that is used.
Observe all safety precautions recommended by the chemical
manufacturer for handling, storage, and disposal of chemicals.
Pgina 24 de 53
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 sprayed into an
eye.
Tooling for this method consists of a 4C-4804 Penetrant and a 4C-4805 Developer . A 1U-5566
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 liquid fluorescent inspection to check for cracks.
1. Clean the surface that will be inspected with mineral spirits. Then wipe the surface with
clean, dry paper towels.
2. Spray the cleaner fluid on the cylinder head in order to remove any residual oil or
contaminants from the surface. Wipe the head dry with clean paper towels.
3. Spray 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
cracks.
View Image
Illustration 26
Applying the penetrant on the valves
g01298458
View Image
Illustration 27
Pgina 25 de 53
g01298464
4. Once the penetrant is allowed to settle into the cracks, the excess penetrant must be removed
from the surface.
Note: Clean the head with moist paper towels in order to remove the penetrant. Washing the
head with water will also remove the penetrant. Take care not to wash the surface
excessively. Dry the surface with paper towels. Use a black light in order to make sure that
the chemical has been removed from the surface.
5. Spray and coat the developer onto the entire dry surface. Use compressed air to reduce
drying time. Once the developer has been applied and the developer has dried, a minimum
time for developing of ten minutes is required. During this time, the developer will draw the
penetrant from the cracks to the surface.
6. Check the surface with a 1U-5566 Ultraviolet Lamp Gp . This will highlight the location of
any cracks or damage.
View Image
Pgina 26 de 53
Illustration 28
g01298498
Use a black light to check the valves for cracks.
View Image
Illustration 29
g01298518
Use a black light to check the inserts of the valve seat.
Liquid Non-Fluorescent Inspection

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

do the job.
Pgina 27 de 53
that is used.
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 sprayed into an
eye.
Tooling for this method consists of a 4C-4804 Penetrant and a 4C-4805 Developer .
Note: This method will not always find cracks of 0.05 mm (0.002 inch) or less.
The head must be clean and dry in order to use this method. Follow steps below in order to use the
liquid non-fluorescent inspection method in order to check for cracks.
2. Spray the cleaner on the cylinder head in order to remove any residual oil for checking.
Spray the cleaner on the cylinder head in order to remove any contamination for checking.
3. Spray the penetrant on the surface in order to be inspected. Allow the penetrant to remain on
the surface for five to thirty minutes. This will allow the penetrant to enter the smallest
cracks.
View Image
Illustration 30
Dye will penetrate into cracks.
g01298740
4. Once the penetrant is allowed to settle into the cracks, the excess penetrant must be removed
from the surface.
5. Wipe the penetrant from the surface by using a clean paper towel.
Pgina 28 de 53
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
g01298757
Cracks begin at the precombustion chamber or the hole of the direct injection adapter. The length of the crack on the
combustion area must not be more than 6.35 mm (0.250 inch). The crack must not be more than three threads deep.
Use the method of dye penetrant to find the depth of the cracks.

The following illustrations show examples of cracks that would constitute replacing the cylinder
head.
View Image
Illustration 32
Crack in the nozzle hole (3200 Engine)
g01298781
Pgina 29 de 53
DO NOT USE THIS PART AGAIN.

View Image
Illustration 33
g01299782
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 Salvage Guideline, SEBF8374, "Specifications for Cylinder Head Assemblies
3200 Engines".

View Image
Illustration 34
g01298740
Cracks between the valve seats (3200 and 3400 Engines)

View Image
Pgina 30 de 53
Illustration 35
g01299804
Cracks between the precombustion chamber or the hole for the direct injection adapter and valve seats (3400
Engine) .

View Image
Illustration 36
g01299842
Cracks between the hole of the core plug and the bore of the valve guide on the top deck (3400 Engine)
Method for Dry Magnetic Particle

------ WARNING! ------
Pgina 31 de 53
do the job.
that is used.
NOTICE
Use safety glasses in order to reduce the risk of having chemicals
sprayed into an eye.
Use the 263-7184 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.
2. Spray the fluid for cleaning and the fluid for removal on the cylinder head in order to
remove any residual oil for checking. The fluids can also be used to remove contamination.
View Image
Illustration 37
g01299867
An electromagnet in the shape of a yoke that is checking for cracks
3. Place the magnetic yoke on the surface at a right angle (90) to the area in order to be
checked.
Pgina 32 de 53
4. Magnetic powder should be applied to the surface when the yoke is energized.
View Image
Illustration 38
g01300124
5. Inspect the area for cracks. If there is a crack between the arms of the yoke, the magnetic
powder will go into the crack. The crack will then appear as a line of magnetic particles.
Lock-N-Stitch Full Torque Threaded Inserts
View Image
Illustration 39
g01042620
If a bolt hole contains cracked threads or stripped threads, Lock-N-Stitch Full Torque Threaded
Inserts should be used. The cracks must be no deeper than 6.4 mm (0.25 inch) down the
Pgina 33 de 53
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 Salvage
Guideline, SEBF8882, "Using Lock-N-Stitch Procedures for Casting Repair". Full Torque Thread
Insert Kits 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 FFB5SP010K Full Torque
Thread Insert Kit from LOCK-N-STITCH. These parts can be ordered through LOCK-NSTITCH. This kit is not stocked by Caterpillar. Refer to Reuse and Salvage Guideline, SEBF8882,
"Using Lock-N-Stitch Procedures for Casting Repair" for other LOCK-N-STITCH parts that are
stocked by Caterpillar.
Installing a Threaded Insert can be done in a short amount of time. Installing a Threaded Insert
will increase the strength of the threads.
For more information or questions concerning LOCK-N-STITCH, contact LOCK-N-STITCH. For
a complete catalog of products, contact LOCK-N-STITCH. See www.locknstitch.com for more
repair procedures, training, and catalogs.
LOCK-N-STITCH Inc.
1015 S. Soderquist Rd.
Turlock, CA 95380
www.locknstitch.com
(209) 632-2345(800) 736-8261
Measurement Procedures
View Image
Illustration 40
g01953237
Measurement location for the thickness of typical heads
(2) Valve cover gasket
(8) Combustion area
(A) Thickness of the head
Cylinder Head Thickness
Pgina 34 de 53
Before the cylinder head can be reused, the cylinder head thickness must be measured.
The cylinder head can be machined in order to remove any damage. At the time of this
publication, some cylinder heads must remain within factory specifications. Refer to the
appropriate Reuse and Salvage Guideline of specifications for the minimum thickness of the
cylinder head. The cylinder head must be within the minimum thickness specifications in order to
comply with the regulations on emissions. If the thickness of the head is beyond the minimum
thickness, the head can be reconditioned by utilizing thermal spray.
Note: An alternative solution will be provided in the future for the engines that must remain
within factory specifications.
Measure the thickness of the cylinder head. Refer to the appropriate Reuse and Salvage Guideline
for specifications. For C-Series engines, refer to Reuse and Salvage Guideline, SEBF9006,
"Specifications for Cylinder Head Assemblies on C-Series Engines".
If the head surface requires reconditioning, the surface must be built up utilizing metal spray so
the cylinder head thickness will be maintained at the original specifications. Refer to Thermal
Spray Guide, SERF8473, "Caterpillar Arc Spray Guide CD", and Thermal Spray Guide,
SERF8704, "Caterpillar Flame Spray Guide CD".
Flatness of the Surface

Maintain the original specifications for all cylinder head assemblies during reconditioning. Refer
to the appropriate Reuse and Salvage Guideline of Specifications for the recommended flatness.
Table 6
Tooling
8H-8581
-
Feeler Gauge
600 mm (24.0 inch) straight edge
150 mm (6.0 inch) straight edge
View Image
Illustration 41
g01300274
Measurement of total surface for flatness (3200 Engine)
Pgina 35 de 53
View Image
Illustration 42
g01300282
Measurement of total surface for flatness (3400 Engine)
Flatness of the cylinder head can be measured by using a straight edge and a feeler gauge. This is
shown in Illustration 41 and Illustration 42. A 600 mm (24.0 inch) straight edge for measuring the
total flatness of surface is required. A 150 mm (6.0 inch) straight edge should be used for
measuring a small area.
Sleeves for the Injectors of Cylinder Heads

A stainless steel sleeve is used between each unit injector and the cylinder head casting. The
injector sleeve is used to seat the injector. The injector sleeve is also used to seal the injector into
the casting. The injector sleeves are reusable unless the sleeves become damaged.
Refer to the Disassembly and Assembly for your machine in order to find the tooling that is used
to remove a unit injector sleeve. Refer to the Disassembly and Assembly for your machine for
Disassembly and Assembly information.
Inspect the inside surface of the sleeves for cracks, pitting, erosion, and other visual damage.
Sleeves should be replaced during the general overhaul of the cylinder head with high hours.
NOTICE
When reaming the injector seat area, be very careful not to damage the
surface. Do not drop the reamer onto the seat, or apply too much
downward pressure with the tool because it may create radial lines on
the sealing surface of the sleeve. Radial lines will cause poor sealing
between the sleeve cone and the injector tip, which may result in fuel
leakage into the cylinder, or combustion pressure leakage into the fuel.
Check the area at the bottom of the valve seat for normal wear. If the valve seat appears worn or
distorted slightly, the sleeve must be replaced. Check the guide for Disassembly and Assembly for
the procedures and the lists for tooling.
Valve Guides
Table 7
Pgina 36 de 53
Tooling
6V-2012
Micrometer Depth Gauge Group
8H-8581
Feeler Gauge
Table 8
Valve Guide Measurement Tools
Part
Number
Dimensions Which Gauge

(Green End) is Used to
Check New or Knurled
Value Guides
Dimensions and Engines In Which Gauge (Red

End) Is Used to Check Worn Valve
12.672 mm (0.498 in) (3508, 3512, 3516)
12.594 mm (0.4958 in)
12.7 mm (0.5 in) (3500 Engines - exhaust valves

only)
8.08 mm (0.318 in) (3114, 3116)
8.035 mm (0.316 in)
9.55 mm (0.376 in) [1673, 1693, 1100, Series,

3100 Series, 3204 3208, 3304, 3306, D330C,
D333C, D342, D343, D346, D348, D349, D353,
D379, D398, D399, 137.2 (5.4 in) Bore 90 degree
V-8]
9.5 mm (0.374 in), 1100

Series, 3100 Series, 3204 and
3208
9.54 mm (0.3755 in) (3406, 3408, 3412, 3508,

3512, 3516, 9.65 mm (0.38 in) intake and exhaust
valve)
9.460 mm (0.3725 in)
261-3687
4C-9734
6V-7058
6V-7068
6V-7895
12.775 mm (0.503 in) (D379, D398, D399)
9U-6399
16.003 x 175 mm (0.630 x 6.9 in) (Go)
16.059 x 50.8 mm (0.6322 x

2.0 in) (No-Go)
16.106 x 50.8 mm (0.634 x 2.0 in) (Go)
16.209 x 50.8 mm (0.6381 x

2.0 in) (No-Go)
9U-6401
5P-3536
7.92 mm (0.312 in),

9.52 mm (0.375), and
12.7 mm (0.500 in) (D379, D398, D399, G379, G398, and G399)
This section shows the tools for inspecting valve guides in Caterpillar engines. Valve guides must
be measured for installed height from the top deck and the inside bore diameter. Refer to the
appropriate Reuse and Salvage Guideline of Specifications for specifications of valve guides.
Pgina 37 de 53
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 require
any machining after installation.
View Image
Illustration 43
5P-3536 Valve Guide Gauge Group
g01300432
View Image
Illustration 44
Typical plug gauge
g01300451
The specifications of installed height for valve guides in all current Caterpillar cylinder heads can
be measured with a 6V-2012 Micrometer Depth Gauge Group . The 150 mm (6.0 inch) dial
caliper, and the 8H-8581 Feeler Gauge are also needed.
The inside diameter of the valve guide can be measured with tools such as a 5P-3536 Valve Guide
Gauge Group , 6V-7058 Plug Gauge , and 6V-7068 Valve Guide Gauge . The rest of the tooling
available is in Table 8, along with their corresponding engines. There are different tools for the
different sizes of valve guides.
Refer to the Special Instruction, GMG02562, "Using the 5P-3536 Dial Bore Gauge Group to
Check Valve Guides" for complete instructions on the use of the 5P-3536 Dial Bore Gauge
Group .
Pgina 38 de 53
Measurements
View Image
Illustration 45
Measure the diameter of the bore.
g01300601
View Image
Illustration 46
g01300692
The end of the plug gauge must not go into the bore of the valve guide more than 19.0 mm (0.75 inch).
Measure both ends of each valve guide. The measurement should be taken 19.0 mm (0.75 inch)
from each end of the bore. If the valve guide is counterbored, measurements must be taken in this
area. If plug gauges are used, the end of the gauge should not extend into the valve guide more
than 19.0 mm (0.75 inch). If the measurement of the valve guide exceeds the dimension, then the
valve guide is worn beyond the allowable dimension for reusability.
Pgina 39 de 53
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 guideline for C15, C16, C18, C27, and C32 Engines.
This section contains specifications of reusability for valves and valve seats which are used in
Caterpillar engines. This section also includes a list of the tools needed in order to measure the
valve dimensions. Valves must be measured for stem diameter, thickness of the lip on the valve
head, and the diameter of the valve guide bore.
Note: Contact between the face of the valve and the seat of the valve is expected in the area at the
outer edge of the valve seat. The minimum thickness of the lip must be maintained.
If the thickness of the head is machined beyond factory specifications, the valve seats must also be
machined. Machine the surface of the insert so the same amount of material is removed from the
head and the insert in order to maintain the proper projection of the valve. After the head has been
machined, the sealing angle must be within like-new specifications.
View Image
Illustration 47
g01378077
Machining the valve seat to like-new specifications after machining the head
View Image
Illustration 48
Examples of reusable tip wear.
Pgina 40 de 53
g01953486
(27) Reusable valve stems after regrinding

(28) The valve stems are reusable with optional polishing. The tip of the stem can be polished with a 6V-2033
Brush . This polishing is not necessary.
Never use any kind of hammer to push the valve seat into the head. Installation of the valve seat
insert requires a careful technique. The valve seat inserts are installed in a counterbore in the
cylinder head under a press fit. Care must be taken with valve seat inserts. The inserts must be
properly seated in the counterbore. The insert must be in full contact with the bottom of the
counterbore. The inserts are usually chilled on dry ice before installation. Frost may build up on
the bottom of the insert. This may not allow the insert to seat properly. Installation frequently
involves hammering of the insert, which does not allow the valve seat insert to seat properly. The
best results have been obtained by installing the valve seat insert at room temperature with steady
hydraulic pressure.
The initial firing of the engine will seat an improperly seated precision insert. The only impact
from an improperly placed precision insert is a reduction in lash for the valve.
An insert that is machined after installation that does not seat properly will cause problems. The
insert will be machined when the insert is not fully seated. When the valve seat insert seats
properly, there will be an improper seating face. Elevated wear rates will occur and the valve may
fail.
Reconditioning Tips
Determining the projection of the valve and the recession of the valve through a measurement is
no guarantee that the valves and valve seats have been correctly reconditioned. The following
criteria will help to further determine the reusability of both valves and valve seats.
1. The wide valve seats do not cause problems with valves. The outer diameter of the finished
seat insert can be larger than the diameter of the valve head. This should not cause any
problems.
Pgina 41 de 53
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 upper limit
on the width of the seat.
3. Grind the finished surface of the valve seat after the valve seat inserts have been installed
into the head. Grinding the seat insert correctly is essential to valve life. This process is not
necessary on recent 3500 Heads with premachined inserts.
4. Contacting the valve seat insert to the sealing face of the valve head at the middle of the
sealing face of the valve was an acceptable practice for rebuilding cylinder heads. With the
introduction of the 3500 Engine, the traditional sealing area moved closer to the edge of the
valve head. Premachined seat inserts and precision valve guides moved the sealing area to
0.51 to 1.02 (0.020 to 0.040) from the outer dimension of the valve head. Do not grind the
sealing faces of the inserts if new premachined valve seat inserts are installed during the
rebuild of a head. The components do not need to be machined after installation due to the
precise manufacturing process.
5. If the seat face cannot be ground without grinding into the head, replace the insert. Do not
grind the head under any circumstance.
6. Never use a valve with less than the specified minimum thickness of lip.
7. Heads that have been resurfaced may require the bores of the inserts to be machined to a
deeper dimension. This will ensure the correct location of the insert in relation to the head.
8. Valve seat inserts should not extend above the surface of the head. Recessing the inserts
0.25 mm (0.010 inch) below the surface is a good habit.
9. Lapping valves and lapping seat inserts is not recommended or necessary if the correct
angles of the valve seat are maintained during the process of resurfacing the valves and
valve seats.
Required Tools
The valve stem diameter for all current valves can be measured by using the 6V-0087 Valve Stem
Gauge or a 0 to 25 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 25 mm (0 to
1.0 inch) micrometer, 25 to 50 mm (1.0 to 2.0 inch) micrometer, or a 50 to 75 mm (2.0 to 3.0 inch)
micrometer. The diameter of the valve head can also be measured by using a 0 to 150 mm (0 to
6.0 inch) dial caliper.
The valve lip thickness for all current valves can be measured by using a 6V-7059 Multiple Anvil
Micrometer plus a 6V-2034 Adapter , a 5P-6518 Dial Indicator Fixture Gp , or a 0 to 150 mm (0
to 6.0 inch) dial caliper.
View Image
Pgina 42 de 53
Illustration 49
g01302418
6V-7059 Multiple Anvil Micrometer with the 6V-2034 Adapter
View Image
Illustration 50
5P-6518 Dial Indicator Fixture Gp
g01302423
Measurements
View Image
Illustration 51
Always measure wear on valve stems.
Pgina 43 de 53
g01302640
Use either a 6V-0087 Valve Stem Gauge or a micrometer to measure the diameter of the valve
stem. Measure the top and bottom areas that move in the valve guide. Refer to the appropriate
Reuse and Salvage Guideline of Specifications of valves.
View Image
Illustration 52
g01302680
Use a 6V-0087 Valve Stem Gauge to check the diameter of the valve stem. The gauge will not slide easily over the
stem.
USE THE PART AGAIN.

View Image
Illustration 53
The micrometer slides over the stem.
g01302696

The minimum specifications for stem diameter can be found in the appropriate Reuse and Salvage
Guideline of Specifications. The specifications for minimum allowable stem diameter are given in
the appropriate Reuse and Salvage Guideline of Specifications.
Pgina 44 de 53
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 Engines

ONLY
For specifications of C-Series engines, refer to Reuse and Salvage Guideline, SEBF9006,
"Specifications for Cylinder Head Assemblies on C-Series Engines".
After machining the head, the exhaust valve seats must be machined in place in order to achieve
the proper projection of the valve. Use a standard replacement valve seat only if the bore for the
exhaust valve is undamaged. If the bore for the exhaust valve is damaged, the bore must be
rebored and an oversized valve seat must be used.
NOTICE
Some valve seats cannot be machined. Specialized manufacturing
processes were used on these parts. Machining these parts will
significantly decrease the life of the engine.
Some inlet seats cannot be machined under any circumstance. Caterpillar uses specialized
manufacturing techniques on inlet valve seats of some engine models. Refer to Reuse and Salvage
Guideline, SEBF9006, "Specifications for Cylinder Head Assemblies on C-Series Engines" 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 must
be replaced with seats that can be machined.
View Image
Illustration 54
g01377282
Finding the pin location by using a probe
In order to keep the valve guide and the valve seat concentric, use a dial indicator and a tapered
pilot pin to find the center line of the valve guide.
Oversized seats are available if the head has been damaged. If an oversized insert has already been
installed, second oversized inserts are available for certain models. If an oversized seat will be
Pgina 45 de 53
used, use either a probe or a dial indicator in order to keep the valve guide and the valve seat
concentric.
1. If an oversize valve seat will be used, locate the center of the valve guide with a gauge pin.
2. Find the center of the tapered pilot pin as close as possible to the valve guide.
3. Use a dial indicator in order to find the center of the tapered pilot pin.
4. Machine the bore for the valve seat in the location that is concentric with the valve guide.
The tapered pins are supplied with the grinder for the valve seat. If the tapered pilot pins need to
be purchased, contact the supplier for your valve seat grinder. Woodward Equipment is a supplier
for the tapered pilot pins.
Woodward Equipment
15790 SE Piazza Ave, Suite 104
Clackamas, OR 97015
Toll Free: 1-800-433-1870, or 503-657-6680
Valve Recession and Projection

After 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 when the valve is closed.
View Image
Illustration 55
(B) Valve Recession
g01953705
View Image
Illustration 56
(C) Projection of the Valve
Pgina 46 de 53
g01954044
Tools
View Image
Illustration 57
6V-7926 Indicator Group
g01954142
(29) 8S-3158 Indicator

(30) 3P-1565 Collet Clamp
(31) 5P-4156 Indicator Base
The valve recession can be measured by using any of the following tools.
1. 6V-7926 Indicator Group
a. 8S-3158 Gauge
b. 3P-1565 Collet Clamp
c. 5P-4165 Base
2. 6V-2012 Micrometer Depth Gauge Group
3. 8H-8581 Feeler Gauge and a 150 mm (6.0 inch) straight edge
Pgina 47 de 53
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. Record the measurement.
b. For a projected valve, set the gauge on top of the valve. The tip of the indicator
should be on the surface of the head. Record the measurement.
3. If the measurements do not meet the required specifications, refer to the section
""Correcting the Excessive Projection of the Valves" ".
The excessive projection of valves can cause the head of the valve to contact the piston during
normal engine operation.
Correcting the Excessive Projection of the Valves

There are two ways to correct a valve that exceeds the maximum dimension of projection.
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 example, if 0.25 mm (.010 inch) has been removed from the bottom of the head, the
counterbore can be recessed 0.25 mm (.010 inch).
Note: If a valve exceeds the maximum recessed dimension, the valve position is too deep. To
correct this condition, either a new valve must be installed. Replacing the valve seat may also be
necessary.
Valve Springs
This section contains procedures for checking the reusability of valve springs. Refer to Reuse And
Salvage Guidelines, SEBF8034, "Valve and Valve Spring Specifications".
Required Tools
All current valve springs can be measured by using the 441-0714 Valve Spring Tester to test for
reusability of load and rebound. A 7B-0337 Surface Plate and a 150 mm (6.0 inch) square will be
used to measure the straightness of the spring. To measure the diameter and free length of a
spring, use either a 25 to 50 mm (1.0 to 2.0 inch) micrometer or a 0 to 150 mm (0 to 6.0 inch) dial
caliper.
Pgina 48 de 53
View Image
Illustration 58
g01303268
Use a square or a straight edge to check each valve spring for distortion. A feeler gauge must also be used.
Test Procedure
View Image
Illustration 59
Use the 441-0714 Spring Tester to test springs
g03680564
Pgina 49 de 53
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 60
Spring with a polished end that is acceptable
g01303321
Valve Rotators
Caterpillar Recommends against the reuse of rotocoils. The disassembling, cleaning, inspecting,
and reassembling of rotocoils requires specialized tooling and processes.
Vacuum Test for Valves

Testing the valves by vacuum in a cylinder head is used to identify a poor seal between the valve
and the valve seat. This procedure should be performed after a cylinder head has been
reconditioned. The cylinder head must be completely assembled before the vacuum test.
Note: The procedure for the vacuum test should only be used to identify leakage between the
valve and the valve seat. This test procedure should only be used if the leakage is extremely out of
the acceptable specification.
An unavoidable minor amount of leakage between the valve and the valve seat is permissible. It is
impractical to use the vacuum test to identify minor leaks between the valve and the valve seat.
The following specifications and equipment can be used to identify the gross leak. Any
combination of valve and valve seat that does not maintain 40 cm Hg (16.0 inch Mercury) or more
is considered to be a gross leak.
Pgina 50 de 53
Equipment and Tooling
View Image
Illustration 61
9U-5383 Vacuum Tester
g01303479
The 9U-5383 Vacuum Tester consists of a hand-held vacuum pump and connecting parts. Most
Caterpillar engines will work with the set of eight adapters that can be fabricated from the drawing
of the fabricated tool FT-1741 Vacuum Tester . For a complete list of all parts and fabricated
dimensions, request a drawing of the FT-1741 Vacuum Tester .
Dealers in NACD, LACD, EAME, and APD can order fabricated tool drawings from the
following address:
Dealer Service Tools
501 SW Jefferson Ave.
Peoria, IL 61630-2125
USA: 1-800-542-8665Illinois: 1-800-541-8665Canada: 1-800-523-8665World: 1-309-6756277Fax: 1-309-675-9773
Be sure to include your dealer code and your address so that your request will receive immediate
attention.
Test Procedure
The 9U-5383 Vacuum Tester is suitable for use when a vacuum test of 45 cm Hg (18.0 inch
Mercury) or less is required. For complete information on the vacuum tester, refer to Special
Instruction, SEHS9498, "Using the 9U-5383 Vacuum Tester".
The gauge has detected a leak if a drop in vacuum occurs. An adjustment screw is provided on the
top of the tool in order to vary the sensitivity of the gauge. To check valve seats for leaks, the
adjustment screw must be set for maximum sensitivity. When a constant vacuum of 45 cm Hg
(18.0 inch Mercury) is applied for 15 seconds, the vacuum should not drop below 40 cm Hg (16.0
inch Mercury). A gauge reading of less than 40 cm Hg (16.0 inch Mercury) can have enough
magnitude in order to adversely affect valve life.
1. Plug in the inlet for the vacuum, and pull out the trigger for the air supply.
Pgina 51 de 53
2. Back out the adjustment screw until maximum vacuum is attained. The maximum reading
should be less than 38 cm Hg (15.0 inch Mercury).
3. Turn the adjustment screw inward until a drop in vacuum of 2.5 cm Hg (1 inch Mercury)
occurs. The minimum adjusted set point is now 35 cm Hg (14 inch Mercury).
4. Tighten the nylon jam nut in order to prevent any air leaks from giving a false leakage
reading.
5. After adjusting the screw for sensitivity has been adjusted, attach the correct adapter to the
vacuum tester.
6. Place the adapter over the valve in order to be tested.
7. Hold the trigger for the air supply in the open position for a minimum of 15 seconds.
Note: Make sure that the adapter is in full contact with the combustion area of the cylinder
head.
8. The seal between the valve and the valve seat is not acceptable if the gauge indicates a
reading less than the Test Specification in Table 9. The Maximum Capability of the Gun
determines the Test Specification that should be applied.
9. Apply slight pressure with a press on the top of the valve stem and test again.
10. If the gauge still indicates a low reading, the valve must be removed and the sealing
surfaces must be inspected. Grinding or lapping the valve seat or the valve face again might
also be necessary.
Table 9
Specifications for Testing by Vacuum (1)
Maximum Capability of the Gun
Adjusted
Set Point
Test
Specification
53 (21.0)
51 (20)
44 (17.5)
52 (20.5)
49 (19.5)
43 (17.0)
51 (20.0)
48 (19.0)
43 (17.0)
49 (19.5)
47 (18.5)
42 (16.5)
48 (19.0)
46 (18.0)
41 (16.0)
47 (18.5)
44 (17.5)
39 (15.5)
46 (18.0)
43 (17.0)
38 (15.0)
(1)
Pgina 52 de 53
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)
All of the dimensions are in cm (inch) of Mercury.
Probable Causes of Leaks

Incorrect finish of valve face or contact area of the valve seat
The valve seat is improperly installed or the valve seat is not seated in the head (Incorrect
Total Indicator Readout) .
Damaged valve face
Debris between valve face and valve seat
Damaged contact area of the valve seat
Bent valve
Cracked valve face or valve seat
Backlash of the Drive Gear for the Cam

The backlash which occurs on the drive gear for the cam in engines with overhead cams limits the
amount of material that can be removed from the joint faces of the cylinder head and cylinder
block. A minimum of 0.038 mm (0.0015 inch) relative movement for backlash must be available
after reconditioning. The backlash is accounted for in the specifications in this Guideline.
Three or four locations on the gear need to be checked for backlash of the drive gear of the cam.
Small differences in the gear teeth and the gear runout make these different checks necessary. To
check the backlash, hold one of the gears steady and use a dial indicator to measure the relative
movement of one gear to the other gear. Positioning the dial indicator correctly is important in
order to get an accurate reading.
ReferenceRefer to Reuse and Salvage Guideline, SEBF9234, "Using the Adjustable Idler
Positioning Tool for Setting the Cam Gear Backlash on 3406E, 3456, C15, C16, and C18
Engines"
View Image
Pgina 53 de 53
Illustration 62
g01306281
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 90 degrees to the centerline of the teeth (as close as possible) .
Metal Spray of Gasket Contact Surfaces

The process of metal spraying can be used in order to restore the contact surfaces to the original
dimensions. An acceptable process in metal spraying is the Metco 6P II Thermospray system.
Refer to Thermal Spray Guide, SERF8473, "Caterpillar Arc Spray Guide CD", and Thermal Spray
Guide, SERF8704, "Caterpillar Flame Spray Guide CD" for guidelines of metal spray in order to
salvage cylinder head castings. For additional information about this guideline, consult Repair
Process Engineering of the Marketing & Product Support Division at 1 (309) 675-5434.
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All Rights Reserved.
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Measuring Procedures and Salvage Procedures For Cylinder Head Assemblies and Related Components

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Reuse And Salvage Guidelines

Publication Date -27/06/2014

Date Updated -27/06/2014

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