Professional Documents
Culture Documents
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i05832593
Introduction
Table 1
Revision
30
29
28
27
26
25
Added ""Canceled Part Numbers and Replaced Part Numbers" " section.
Added ""Important Safety Information" " section.
24, 23
Added new serial number prefixes.
22
Added reference to
Reuse and Salvage Guideline, SEBF9234, "Using the Adjustable Idler Positioning
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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
Illustration 1
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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! ------
Illustration 2
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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"
Reference Reuse and Salvage Guideline, SEBF8106, "Specifications for Cylinder Head
Assemblies 3600 Engines"
Reference Reuse and Salvage Guideline, SEBF8129, "Procedure to Salvage Cylinder Head
Assemblies for 3600 and G3600 Engines"
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Reference Reuse and Salvage Guideline, SEBF8155, "Specifications for Cylinder Head
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"
Reference Reuse and Salvage Guideline, SEBF8218, "Specifications for Cylinder Head
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"
Reference Reuse and Salvage Guideline, SEBF8270, "Specifications for Cylinder Head Assembly
3400, 3406E, C15, and C18 Engines"
Reference Reuse and Salvage Guideline, SEBF8302, "Reuse Specifications for 3600 Combustion
Gaskets"
Reference Reuse and Salvage Guideline, SEBF8373, "Specifications for Cylinder Head Assembly
3400 / C16 Engines"
Reference Reuse and Salvage Guideline, SEBF8374, "Specifications for Cylinder Head
Assemblies 3200 Engines"
Reference Reuse and Salvage Guideline, SEBF8375, "Specifications for Cylinder Head
Assemblies 3300 Engines"
Reference Reuse and Salvage Guideline, SEBF8376, "Specifications for Cylinder Head
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"
Reference Reuse and Salvage Guideline, SEBF8819, "Specifications for Cylinder Head
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"
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
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
Dial Caliper
150 mm (6.0 inch)
5P-3536
6V-7058
Plug Gauge
6V-7068
(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
-
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6V-7926
Indicator Group
5P-6518
1S-0258
9U-5383
Vacuum Tester
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or
FT-1741
Vacuum Tester
6V-0087
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
-
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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Nomenclature
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Illustration 3
Nomenclature for the 3200 Engine
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Illustration 4
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Nomenclature for the 3400 Engine except 3406E
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Illustration 5
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Nomenclature for the 3500 Engine
(1) Intake port (front or right side)
(2) Surface of the valve cover gasket
(4) Valve guide
(6) Exhaust port (rear or left side)
(8) Combustion area
(10) Bridge dowel
(11) Bore of the roller lifter
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Illustration 6
Nomenclature for the C175 Cylinder Head
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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.
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.
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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 .
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.
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Illustration 7
Removing the gasket by grinding
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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.
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Illustration 8
Discs and holder
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Illustration 9
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The damage to the cylinder head is located at the seal between the valve cover and the head.
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Illustration 10
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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.
Illustration 11
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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".
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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:
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Illustration 12
Inspect the indicated areas for damage and erosion.
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Illustration 13
Minor pitting or erosion
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Illustration 14
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Foreign material caused this damage. The valve seats must be replaced.
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Illustration 15
Erosion across the fire ring
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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.
Illustration 16
Damage across the fire ring
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The cylinder head can be used again after the surface has been machined in order to remove all damage.
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Illustration 17
Concentrated area of erosion
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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".
Illustration 18 g01297085
A small amount of erosion
Illustration 19
Bad erosion around the area of the valve seat.
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Illustration 20
Engine failure caused this damage.
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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
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Illustration 21
Erosion that is caused from the flow of coolant
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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.
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Illustration 22
Multiple layered steel "MLS" gasket
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The arrows indicate a raised layer of the gasket. 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 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.
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Illustration 23
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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
Illustration 24
Erosion is not acceptable in area (27) .
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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.
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Thread Inspection
Make a visual inspection of all threaded holes for damaged threads and broken bolts or studs.
View Image
Illustration 25
Damaged threads
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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.
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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 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.
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Illustration 26
Applying the penetrant on the valves
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Illustration 27
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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.
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Illustration 28
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Use a black light to check the valves for cracks.
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Illustration 29
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Use a black light to check the inserts of the valve seat.
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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.
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.
1. Clean the surface that will be inspected with mineral spirits. Then wipe the surface with
clean, dry paper towels.
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.
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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.
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Illustration 31
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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.
Illustration 32
Crack in the nozzle hole (3200 Engine)
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Illustration 33
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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".
Illustration 34
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Cracks between the valve seats (3200 and 3400 Engines)
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Illustration 35
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Cracks between the precombustion chamber or the hole for the direct injection adapter and valve seats (3400
Engine) .
Illustration 36
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Cracks between the hole of the core plug and the bore of the valve guide on the top deck (3400 Engine)
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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.
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.
1. Clean the surface that will be inspected with mineral spirits. Then wipe the surface with
clean, dry paper towels.
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
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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.
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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.
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
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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 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
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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".
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)
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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.
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
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Tooling
6V-2012
8H-8581
Feeler Gauge
Table 8
Valve Guide Measurement Tools
Part
Number
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)
9U-6401
5P-3536
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.
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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 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 .
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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.
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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.
Illustration 47
g01378077
Machining the valve seat to like-new specifications after machining the head
View Image
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Illustration 48
Examples of reusable tip wear.
Pgina 40 de 53
g01953486
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.
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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 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
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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
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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.
Illustration 53
The micrometer slides over the stem.
g01302696
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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.
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
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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
Illustration 55
(B) Valve Recession
g01953705
View Image
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Illustration 56
(C) Projection of the Valve
Pgina 46 de 53
g01954044
Tools
View Image
Illustration 57
6V-7926 Indicator Group
g01954142
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
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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. 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.
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.
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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
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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 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.
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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.
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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 (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)
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(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)
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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) .
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