G3500 Valve Runout Tool{0760, 1100, 1101, 1103, 1104, 1105} Caterpillar

Engine:

G3512C (S/N: GNX1-UP)

G3512E (S/N: PBJ1-UP; SSR1-UP; GTX1-UP)

G3516C (S/N: GSB1-UP; TJB1-UP; GZC1-UP; TJC1-UP; TJD1-UP; GZZ1-UP)

G3516E (S/N: GAS1-UP; SLY1-UP)

G3520 (S/N: HET1-UP)

G3520C (S/N: GZA1-UP; GZB1-UP; MAD1-UP; GZJ1-UP; GZK1-UP; GZL1-UP; GZM1-UP; GZN1-UP; B9P1-UP; RLP1-UP; LGS1-UP; HAT1-UP; CWW1-UP; CWY1-UP)

G3520E (S/N: GZG1-UP; GZH1-UP; HAL1-UP; SXY1-UP)

Introduction

Important Safety Information

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Think Safety

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 to perform these functions properly.

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 and followed by a Signal Word such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of 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 warnings in this publication and on the product are therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. 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 and most current information before you start any job.

When replacement parts are required for this product, Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information, and should be stored with the tool group.

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety Section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information Section describes tooling functions and features. This section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation Section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.

Maintenance Section

The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal

Safety Section

Safety Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

Prohibited Action

Do not drill

Do not weld

Hazard Avoidance

Crushing Hazard

Electrical Hazard

Pinch Point

Safety Alert Symbol

General Information Section

Introduction

The G3500 Valve Runout Tool is used to rebuild and recondition G3500C/E cylinder valve seats. The valve gauge allows the operator to check the concentricity between the valve seat and the valve guide.

The valve seat gauge is graduated in increments of thousandths or ten thousandths to check the accuracy of the total valve seat runout. The gauge will detect if there is a bad valve seat or any valve leakage in order to maintain perfect contact between the valve and valve seat.

Valve Guide to Valve Seat Runout

Nomenclature

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Pilot Wrench

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Pilot

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Dial Indicator

Assembly of Valve Seat Dial Indicator

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1. Insert the pilot into the pilot wrench.

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2. Insert the pilot in the dial gauge.

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Procedure to Measure Valve Guide to Valve Seat Runout

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1. Insert the pilot into the valve guide.

2. Tighten the pilot wrench.

   Note: In order to prevent damage to the tooling or the valve guide, the pilot wrench only needs to be lightly tightened by hand.

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3. Place the tip on the face of the valve seat and zero out the dial indicator.

4. Rotate the tip around the face of the valve seat.

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5. Measure the runout of the valve seat insert. The valve guide to seat runout should be no more than 0.05 mm (0.002 inch).

   If runout is in excess of 0.05 mm (0.002 inch) remove the valve guide and install a new one. After installation, measure the runout again. If the runout is still excessive, replace the seat and measure the runout. If the runout is still excessive, the bores for the valve seat and guide should be checked and the head should be replaced.

   Note: No guide or valve seat insert should ever be reused after being removed from the head.

Additional Contact Information

For additional information, contact the Cat Dealer Service Tools hotline:

USA: 800-542-8665, Option 1

International: 1-309-578-7372

E-mail: dealerservicetool_hotline@cat.com