Reuse & Salvage for Valvetrain Components {1102, 1108, 1109, 1121, 1123} Caterpillar

Caterpillar Products

All Cat Engines

Introduction

Table 1

Revision	Summary of Changes in SEBF8002
31	Added housing rework procedure / Channel1 video and part numbers 1U-9570, 357-4820, 551-1529, FT-3571, 358-1229, 525-4063, and 358-1230.
30	Added 550-9152 Gage Ring Assembly.
29	Consolidated guidelines M0074821, SEBF8034, SEBF8066, SEBF8067, SEBF8105, SEBF8174, SEBF8191, SEBF8256, SEBF8264, SEBF8266, SEBF8267, SEBF8745, SEBF8822, SEBF9092, SEBF9186, SEBF9253, SEBF9372, added 31 part numbers and repaired 87 pixelated illustrations

© 2019 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 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 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 technical questions when using this document, work with your Dealer Technical Communicator (TC). To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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

Illustration 1	g02139237

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 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 recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. 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.

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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.

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. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine 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 contains the correct tooling and procedures to measure, clean, reuse, and salvage valve train components. This guideline references the procedures in Reuse and Salvage Guideline, SEBF8162, "Reuse and Salvage for Cylinder Head Assemblies".

By following this guideline, reused components can be expected to give normal performance until the next overhaul if the components are used in the same application. Do not install the component if the component is not reusable. During salvage operations, correct any conditions that might have caused the original failure.

Service Letters and Technical Information Bulletins

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NOTICE
The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired.

References

Table 2

References
Media Number	Title
Channel1	"Why Reuse and Salvage Parts"
	https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
Channel1	"C175 Lifter Housing Rework"
	https://channel1.mediaspace.kaltura.com/media/C175+Lifter+Housing+Rework/1_rebjozbz
KENR6052	Disassembly and Assembly, "C175-16 and C175-20 Engines for Caterpillar Built Machines"
M0088789	Tool Operating Manual, " 550-9152 Gage Ring Assembly"
SEBD6847	Truck Engine News, "A New Valve Bridge Is Available for Certain Truck Engines"
SEBF8146	Reuse and Salvage Guideline, "Reuse and Salvage for Camshafts"
SEBF8148	Reuse and Salvage Guideline, "General Salvage and Reconditioning Techniques"
SEBF8162	Reuse and Salvage Guideline, "Reuse and Salvage for Cylinder Head Assemblies"
SEBF8187	Reuse and Salvage Guideline, "Standardized Parts Marking Procedures"
SEHS9031	Special Instructions , "Storage Procedure for Caterpillar Products"
SMHS6998	Special Instruction, "Instructions for the Use of 5P-6518 Dial Indicator Fixture-Parts Reusability"

Tooling and Equipment

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NOTICE
Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools.

Table 3

Part Number	Description
1P-0510	Driver
1P-1855	Retaining Ring Pliers
1S-0258	Hammer (soft tip)
1U-9570	Dowel Puller Group
3P-1568	Dial Indicator
3P-1585	Collet
4C-4804	Penetrant Oil
4C-9442	Flashlight
5P-4160	Tip
5P-4456	Base
5P-6518	Dial indicator Fixture
5S-1330	Valve Spring Compressor
6V-0087	Valve Stem Gauge Group
6V-2010	Polishing Stone
6V-2032	Adapter
6V-2033	Brush
6V-2034	Micrometer Adapter
6V-7030	Depth Micrometer
6V-7059	Micrometer
7B-0337	Surface Plate
8N-3581	Feeler Gage Set
8S-2257	Eye Loupe
8T-5096	Dial Indicator Group
9U-5374(1)	Valve Face Grinder
163-3951	Blast Media
262-8390	Microscope, Pocket 40x
263-7184	Crack Detection Kit
288-4209	Paper Towel
357-4820	Hollow Dowel
357-9456	Bolt
366-5728	Valve Guide Driver
367-9109	Digital Caliper
369-2607	Digital Indicator
384-3712	Hollow Dowel
415-4055	Ultrasonic Tool Group
423-4373	Digital Caliper 0.0 - 203.2 mm (0.00 - 8.00 inch)
431-4150	Micrometer, External 25 mm (1 inch)
441-0714	Spring Tester
459-0184	UV Lamp Group
473-8690	Micrometer, Outside 0.00 - 4.00 inch
473-8691	Micrometer, Outside 2.00 - 6.00 inch
473-8691	Micrometer, Outside 50.8 - 152.4 mm (2.00 - 6.00 inch)
473-8692	Micrometer, Outside 152.4 - 304.8 mm (6.00 - 12.00 inch)
550-9152	Gage Ring Assembly
551-1529	Friction Shims
FT-1753	Valve Stem Protector
FT-3571	Hollow Dowel Installer
-	Valve Guide Removal Tool

(1)	230 Voltage

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

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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. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Valves

Note: For C175 engines replace all intake and exhaust valves at PCR. DO NOT REUSE / RECONDITION / OR REMANUFACTURE INTAKE OR EXHAUST VALVES.

Note: For 3500 engines replace all exhaust valves at PCR. DO NOT REUSE / RECONDITION / OR REMANUFACTURE EXHAUST VALVES.

Nomenclature of the Valve

Illustration 3	g01334820
Valve with a single keeper (1) Retaining groove for the valve spring (2) Valve stem (3) Area of the fillet (4) Valve head (5) Valve face

Illustration 4	g01334821
Valve with a double keeper (1) Retaining grooves for the valve spring (2) Valve stem (3) Area of the fillet (4) Valve head (5) Valve face

Procedure to Clean Valves

To save time, check the condition of the valves before the valves are cleaned, ground, or measured.

Illustration 5	g01334822
The valve on the left has not been cleaned. The valve on the right has been cleaned with the sodium bicarbonate method.

Solvents

If there is only a small amount of carbon residue on the valves, use a good cleaning solvent to clean the valves. Use one or more of the following methods to clean hard carbon deposits.

Sodium Bicarbonate

Use the sodium bicarbonate method to remove oil, grease, and carbon deposits from the area of the fillet, the valve face, and the valve head. For the sodium bicarbonate cleaning method, use a blasting crystal size of 70 microns (0.0028 inch). For best results, use 163-3951 Blast Media which is specially formulated to remove deeply embedded carbon deposits. Use a number four nozzle with a pressure of 483.0 to 550.0 kPa (70.00 to 80.00 psi). Use a flow rate of 2100.0 L/min (554.76 US gpm) of compressed air. Set the differential pressure at 4.45 N (1.000 lb) to control the flow of the media for blasting in the range of 3.34 N (0.750 lb) per minute.

There are many benefits to using sodium bicarbonate as the media for blasting. Unlike other types of blasting media, grease and oil do not need to be cleaned from the valves before blasting. Sodium bicarbonate is soluble in water which provides options for waste disposal. Used sodium bicarbonate can be used as a neutralizer for treatment of waste. Sodium bicarbonate is an environmentally friendly chemical for workers, parts, and the environment.

Glass Beads

Use glass beads to remove heavy carbon deposits from the area of the fillet, the valve face, and the valve head. Use glass beads that are 88 to 150 microns (0.0035 to 0.0059 inch) with 550.0 to 620.0 kPa (80.00 to 90.00 psi) of air pressure for best results. Glass beads that are 125 to 177 microns (0.0049 to 0.0070 inch) through size 74 to 125 microns (0.0029 to 0.0049 inch) are acceptable.

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NOTICE
Never use glass beads that are larger than 230 microns (0.0091 inch). Protection of valve stems from glass beads and steel shot is necessary at all times. Do not mix aluminum oxide or any other material with glass beads.

Note: Do not use glass beads or steel shot in a cabinet that is configured for sodium bicarbonate cleaning. Glass beads and steel shot will not tolerate the grease or oils on the valves and the valves will require a cycle of wash prior to blasting.

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NOTICE
Do not use the glass bead method to clean the valve stem. The results will be rapid wear of the valve guide. Protection of the stem area from glass beads is important.

Steel Shot

Use steel shot to remove heavy carbon deposits from the area of the fillet, the valve face, and the valve head. Use size S170 steel shot for best results. Larger sizes of shot can damage the valve.

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NOTICE
The steel shot will not give an acceptable finish on the valve stem. Use the FT-1753 Valve Stem Protector or similar type of hose on the valve stem to protect the valve stem.

6V-2033 Brush and 6V-2032 Adapter

Illustration 6	g01335052
6V-2033 Brush and 6V-2032 Adapter

One way to clean valve stems is to use tooling 6V-2033 Brush and 6V-2032 Adapter. Refer to Illustration 6. The flap brush has a diameter of 203 mm (8.0 inch). The width is 51 mm (2.0 inch) and the center hole has a diameter of 76 mm (3.0 inch). Tooling 6V-2032 Adapter fits 6V-2033 Brush and 6V-2032 Adapter has a center hole of 13 mm (0.5 inch). If necessary, the center hole can be made larger.

The best speed for the 6V-2033 Brush is 2100 rpm. Do not use a 3450 rpm motor. A motor that runs at 1725 rpm is acceptable only if the motor does not slow down during cleaning of the valves.

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NOTICE
The 6V-2033 Brushcould come apart if it is run faster than 2100 rpm and could result in injury to the operator.

If 6V-2033 Brush is not available, use a Scotch-Brite Type 5A brush. This brush is a fine grade that is used for finishing. Other grades or other brushes from another supplier may result in an incorrect surface texture.

Vibratory Cleaning

A vibratory cleaner can also be used to clean the valves if the cleaner gives the correct final surface texture to the valve stem.

Illustration 7	g03151879
Typical vibratory cleaner

The size and the type of pellet that is used in a vibratory cleaner controls the surface texture of the valves being cleaned. If necessary, polish the valve stem with Scotch-Brite material to get the correct surface texture. If you do not use Scotch-Brite material, check the surface texture on the valves frequently.

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NOTICE
Do not use a wire brush or wire wheel to remove carbon deposits from valves. Wire brushes or wheels will make scratches on the valves, which can cause a valve failure.

Note: Inspect the area of the retaining grooves of the valves for discoloration before using a vibratory cleaner. After cleaning, apply a light coat of oil on the valves to prevent rust.

Note: Do not clean the valves with a grinder that has a Scotch-Brite abrasive disc. Grinding with Scotch-Brite discs creates airborne particles that will contaminate areas of the shop.

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NOTICE
Exhaust valves should never be reused. Always replace exhaust valves at overhaul.

Crack Detection Methods

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NOTICE
Regardless of which crack detection method is used, it is important that the instructions furnished with the detection equipment are followed closely when checking any component. Failure to do so may cause inaccurate results or may cause injury to the operator and/or surroundings.

Crack detection methods or Non-Destructive Testing (NDT) are utilized for examining components for cracks without damaging the component. Visual inspection (VT), Liquid Penetrant Testing (PT), Magnetic Particle Inspection (MT), Ultrasonic Testing (UT), Radiographic Testing (RT) and Eddy-Current Testing (ET) are recommended methods. There may be more than one acceptable crack detection method for the inspection of a given part, though the liquid penetrant is the most versatile. For example, the liquid penetrant method can be used when inspecting smooth machined components such as shafts, gear teeth, and splines, but using the Wet Magnetic Particle Inspection is more accurate. Refer to Table 4 for advantages and disadvantages and Table 5 for standards and requirements for these NDT methods.

Table 4

Crack Inspection Method Advantages vs. Disadvantages
Inspection Method	Advantages	Disadvantages
Visual Surface Inspection (VT)	- Least expensive - Detects most damaging defects - Immediate results - Minimum part preparation	- Limited to surface-only defects - Requires inspectors to have broad knowledge of welding and fabrication inch addition to non-destructive testing
Liquid Penetrant (PT)	- Inexpensive - Minimal training - Portable - Works on nonmagnetic material	- Least sensitive - Detects surface cracks only - Rough or porous surfaces interfere with test
Dry Magnetic Particle (MT)	- Portable - Fast/Immediate Results - Detects surface and subsurface discontinuities	- Works on magnetic material only - Less sensitive than Wet Magnetic Particle
Wet Magnetic Particle (MT)	- More sensitive than Liquid Penetrant - Detects subsurface as much as 0.13 mm (0.005 inch)	- Requires Power for Light - Works on magnetic parts only - Liquid composition and agitation must be monitored
Ultrasonic Testing (UT)	- Most sensitive - Detects deep material defects - Immediate results - Wide range of materials and thickness can be inspected	- Most expensive - Requires operator training and certification - Surface must be accessible to probe
Eddy-Current Testing (ET)	- Surface and near surface flaws detectable -Moderate speed/Immediate results -Sensitive too small discontinuities	- Difficult to interpret - Only for metals -Rough surfaces interfere with test - Surface must be accessible to probe
Radiographic Testing (RT)	-Detects surface and internal flaws - Minimum part preparation - Can inspect hidden areas	- Not for porous materials - Radiation protection needed - Defect able to be detected is limited to 2% of thickness

Table 5

Applicable Crack Detection Standards
Inspection Method	Standard	Acceptance Criteria	Required Personnel Qualifications
Visual Surface Inspection (VT)	EN-ISO 5817 AWS D1.1	EN-ISO 5817 - Level B AWS D1.1 - Table 6.1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Liquid Penetrant Testing (PT)	EN-ISO 3452 ASTM E165	EN-ISO 23277 AWS - D1.1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Magnetic Particle Testing (MT)	EN-ISO 17638 ASTM E709	EN-ISO 23278 - Level 1 AWS D1.1 - Table 6.1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Ultrasonic Testing (UT)	EN-ISO 17640 - Level B AWS D1.1	EN-ISO 11666 Technique 2 - Level 2 AWS D1.1 - Class A - Table 6.3	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Eddy-Current Testing (ET)	EN-ISO 15549 ASTM E426	EN-ISO 20807	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Radiographic Testing (RT)	EN-ISO 5579 ASTM E94	EN-ISO 10657-1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2

Visual Surface Inspection (VT)

Illustration 8	g06085008
Example of Visual Inspection Tools (A) Flashlight or adequate light source (B) Magnifying eye loupe (C) Tape measure or other measuring device (D) Inspection mirror (E) Weld size inspection gauges

Components and welds that are to be inspected using PT, MT, or UT shall first be subject to Visual Surface Inspection (VT). Visual Inspection is often the most cost-effective inspection method and requires little equipment as seen in Illustration 8. It is suggested that at a minimum personnel performing Visual Inspection are either trained to a company standard or have sufficient experience and knowledge regarding the components being inspected. It is also suggested that personnel performing visual inspections take some type of eyesight test regularly.

Liquid Penetrant Testing (PT)

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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.

Refer to Tooling and Equipment Table 3 for part numbers.

• Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.

• Penetrant: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.

• Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrant indications.

• Wire Brush: Removes dirt and paint.

• Cloth or Wipes: Use with cleaner and for other miscellaneous uses.

1. Preclean inspection area. Spray on cleaner / remover to loosen any scale, dirt, or any oil. Wipe the area to inspect with a solvent dampened cloth to remove remaining dirt and allow the area to dry.
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   Illustration 9	g01298458
   Applying the penetrant on the valves

2. Apply penetrant by spraying to the entire area to be examined. Allow 10 to 15 minutes for penetrant to soak. After the penetrant has been allowed to soak, remove the excess penetrant with clean, dry wipe.

3. The last traces of penetrant should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.

4. Before using developer, ensure that it is mixed thoroughly by shaking can. Holding can approximately 203.20 - 304.80 mm (8.00 - 12.00 inch) away from part, apply an even, thin layer of developer over the area being inspected. A few thin layers are a better application method than one thick layer.

5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines in white developer background. Clean the area of application of the developer with solvent cleaner.
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   Illustration 10	g01298498
   Use an ultraviolet lamp to check the valves for cracks.

6. Check the surface with a 459-0184 Ultraviolet Lamp. This lamp will highlight the location of any cracks or damage.

Dry Magnetic Particle Testing (MT)

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 11	g06085930
(A) Indications shown by magnetic particle testing. (B) Typical electromagnetic yoke. (C) Dry powder bulb.

1. Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle indications. The powder shall be of a color that will provide adequate contrast with the background of the surface being inspected.

2. Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles such as sand, and excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree of contamination will determine further use of the powder.

3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not performing.

4. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower should also have sufficient force to remove excess particles without disturbing those particles that are evidence of indications.

6. All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.

2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.

3. Simultaneously apply the dry powder using the dry powder blower.

4. Remove excess powder by lightly blowing away the dry particles.

5. Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple directions of the magnetic field are created.

6. Observe particles and note if any clusters of particles appear revealing an indication.

7. Record the size and shape of any discontinuities or indications found.

Wet Magnetic Particle Testing (MT)

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 12	g06085937
(A) Indications shown by magnetic particle testing. (B) Typical electromagnetic yoke. (D) UV Lamp used in wet magnetic particle inspection process.

Illustration 13	g06003178
Pear Shaped Centrifuge Tube

1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by spraying.

2. Concentration:

   1. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.

   2. Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL (0.0017 oz) 1.0 mL (0.034 oz) divisions, refer to Illustration 13. Before sampling, the suspension shall be thoroughly mixed to assure suspension of all particles, which could have settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between 0.1 mL (0.0034 oz) and 0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.

   3. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.

   4. The oil shall have the following characteristics:

      • Low viscosity not to exceed 50 mSt (5.0 cSt) at any temperature at which the vehicle is to be used.

      • Low inherent fluorescence and be non-reactive.

   5. The conditioning agents used in the conditioned water shall have the following characteristics:

      • Impart good wetting characteristics and good dispersion.

      • Minimize foaming and be non-corrosive.

      • Low viscosity shall not exceed a maximum viscosity of 50 mSt (5.0 cSt) at 38° C (100° F).

      • Non-fluorescent, non-reactive, and odorless.

      • Alkalinity shall not exceed a pH of 10.5.

3. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.

2. Apply the magnetic field using the yoke against the surface in the area to be inspected.

3. For case hardened and ground surfaces:

   • Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be used.

4. Visually inspect for indications of discontinuities using the proper illumination.

5. Record the size and shape of any discontinuities found.

Ultrasonic Testing (UT)

Note: Crack depth cannot be accurately determined by UT, only full depth cracking can be consistently determined. For cracks that are not full depth, an indication of a partial depth cracks can be detected by an experienced technician.

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NOTICE
All personnel involved in ultrasonic testing shall be qualified to Level 2 in accordance to standards stated in Table 5.

Refer to Tooling and Equipment Table 3 for part numbers.

1. Ultrasonic Testing (UT) is a method of Non-Destructive Testing (NDT) using short ultrasonic pulse waves (with frequencies from 0.1-15 MHz up to 50 MHz) to detect the thickness of the object. Ultrasonic testing consists of an ultrasound transducer connected to a diagnostic machine and passed over the object being inspected.

2. There are two methods of receiving the ultrasound waveform from the transducer: reflection and attenuation.

   1. Reflection - Ultrasonic pulses exit the transducer and travel throughout the thickness of the material. When the sound waves propagate into an object being tested, the waves return to the transducer when a discontinuity is discovered along the sonic path. These waves continue and reflect form the backsurface of the material to project the thickness of the material.

   2. Attenuation - A transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after traveling through the medium. Any discontinuities or other conditions within the medium will reduce the amount of sound transmitted, revealing the presence of the imperfections.

Eddy-Current Testing (ET)

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NOTICE
All personnel involved in Eddy-Current Testing shall be qualified to Level 2 in accordance to standards stated in Table 5.

Illustration 14	g06090873
Eddy-Current Testing

Eddy-Current Testing (ET) is a Non-Destructive Testing (NDT) method in which eddy-current flow is induced in the test object. Changes in the flow caused by variations in the specimen are reflected in to a nearby coil or coils for subsequent analysis by suitable instrumentation and techniques. Major applications of eddy-current testing are surface inspection and tubing inspections.

Radiographic Testing (RT)

Note: CAUTION: This process is dangerous. Only qualified personnel and test equipment should be appointed to perform this type of testing.

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NOTICE
All personnel involved in radiographic testing shall be qualified to Level 2 in accordance to standards stated in Table 5.

Illustration 15	g06090892
Radiographic Testing

Radiographic Testing (RT) is a Non-Destructive Testing (NDT) method in which short wavelength of electromagnetic radiation is used to penetrate materials to find hidden discontinuities such as cracks. In radiographic testing, the test object is placed between the radiation source and the film, or x-ray detector. The electromagnetic radiation will penetrate the thickness of the test object and, when all the way through, will project onto the film any indications that have been in the path of the radiation waves.

Inspection of the Valves

Area of the Retaining Grooves

Illustration 16	g03151216
Remove any raised edges with the Scotch-Brite method or use a stone for polishing of a fine grade such as the 6V-2010 Polishing Stone.

Use the valve again.

Illustration 17	g03151237
Severely damaged valve that cannot be reused.

Do not use the valve again.

Illustration 18	g03151297
The valve has surface wear, but no damage to the sides or the bottom of the grooves. Use Scotch-Brite to polish the area.

Use the valve again.

Valve Stem

Illustration 19	g01335635
This valve has discoloration on the valve stem and build-up on the fillet area and the valve face. This valve can be reused after cleaning. Never reuse valves that have discoloration in the area of the retaining grooves.

Clean and then reuse the valve

Illustration 20	g01335640
The valve in Illustration 19 after the valve has been cleaned.

Use the valve again.

Illustration 21	g01335641
Erosion on the valve stem

Do not use the valve again.

Illustration 22	g01335642
Rust can be removed by cleaning.

Use the valve again.

Illustration 23	g03151356
The valve stem contains a small mark or a scratch but the stem does not have any raised or sharp edges. The valve is not reusable if the mark is deeper than the stamp of the part number.

Use the valve again.

Illustration 24	g03151378
The valve stem has a mark or a scratch with a raised or sharp edge after cleaning with the Scotch-Brite or the vibratory method.

Do not use the valve again.

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NOTICE
Do not use a valve if normal cleaning methods will not remove a raised edge on the part of the valve stem that moves inside the valve guide.

Illustration 25	g03151418
Grooves cannot be felt with a fingernail.

Use the valve again.

Illustration 26	g03151437
Deep grooves that can be felt with a fingernail.

Do not use the valve again.

Illustration 27	g03151440
The arrow shows the location of the weld on the valve stem. The weld line cannot be felt with a fingernail.

Use the valve again.

Illustration 28	g03151459
The valve stem shows severe scuffing and/or seizure.

Do not use the valve again.

Illustration 29	g03151578
The valve stem shows moved metal as a result of scuffing damage.

Do not use the valve again.

Illustration 30	g01335679
The chromium coating on the valve is heavily worn. Only a few Caterpillar valves have a chromium coating on the stems.

Do not use the valve again.

Illustration 31	g03151716
Some of the valves have a change in diameter above the area of the fillet. The valves that are used in engines with a 158.8 mm (6.25 inch) bore have a change in diameter above the area of the fillet. This change in diameter is acceptable only if the other valves from the same engine have the same change in diameter.

Use the valve again.

Illustration 32	g03151776
Some of the valves are smaller at the indicated points so the area of the fillet makes a smooth transition with the surface of the stem.

Use the valve again.

Illustration 33	g03151818
Valve stem with a severe change in diameter.

Do not use the valve again.

Illustration 34	g03151856
Valve stem with severe changes in diameter.

Do not use the valve again.

Illustration 35	g03151962
The valve stem is enlarged from engine operation.

Do not use the valve again.

Measurement Requirements

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NOTICE
Precise measurements shall be made when the component and measurement equipment are at 20° (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° (68° F). This will ensure that both the surface and core of the material is at the same temperature.

Measurements of the Valve Stem

Illustration 36	g03152438
Always measure wear on valve stems.

Use a 6V-0087 Valve Stem Gauge or a 6V-7059 Micrometer to measure the diameter of the valve stem. Measure the top and the bottom area that moves inside the valve guide.

If a 6V-7059 Micrometer is used to check the diameter of the valve stem, adjust the 6V-7059 Micrometer to the correct dimension for reusability and locked at the minimum diameter. The valve is worn and the valve must be replaced if the micrometer or the correct gauge slides easily over the stem at any position on the stem.

Note: Some valves have a tapered valve stem.

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NOTICE
Do not use force or roll the valve stem into the gauge or micrometer. Forcing the valve stem can cause early wear on the gauge and incorrect valve stem measurements.

Illustration 37	g01336038
The micrometer slides over the valve stem.

Do not use the valve again.

Illustration 38	g01336039
Use a 6V-0087 Valve Stem Gauge to check the diameter of the valve stem. A 6V-0087 Valve Stem Gauge will not slide easily over the valve stem.

Use the valve again.

Area of the Fillet

Illustration 39	g03152457
The fillet area has significant cracks.

Do not use the valve again.

Illustration 40	g03153017
Normal bonding between the valve head and the material of the valve face.

Use the valve again.

Illustration 41	g03153023
Do not use any valve that has been damaged in the fillet area.

Do not use the valve again.

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NOTICE
Be careful to prevent damage to the fillet area when the valve is installed, ground, or handled. Valves with damaged fillet areas can cause engine damage.

Illustration 42	g01336048
The area of the fillet contains erosion.

Do not use the valve again.

Illustration 43	g01336051
The area of the fillet contains foreign material.

Do not use the valve again.

Illustration 44	g03153036
The area of the fillet contains pits of rust, scale, and erosion.

Do not use the valve again.

Illustration 45	g01336067
Rust is removed when the valve is cleaned and there are no pits, deposits, scale, or erosion under the rust.

Use the valve again.

Valve Head

Illustration 46	g03153076
Large or deep marks exist on the valve head. Some of the marks are near the edge of the valve head.

Do not use the valve again.

Illustration 47	g03153157
All the marks are light and are not near the edge of the valve head.

Use the valve again.

Illustration 48	g01337701
The valve head is severely damaged.

Do not use the valve again.

Illustration 49	g03154536
The valve head is damaged and cannot be reused.

Do not use the valve again.

Illustration 50	g03154599
The valve head contains a small amount of erosion. Do not use a valve if the valve has more erosion than the valve in this illustration.

Use the valve again.

Illustration 51	g03154637
The valve head contains too much erosion and cannot be reused.

Do not use the valve again.

Illustration 52	g03154660
The valve head has a cup more than 0.25 mm (0.001 inch) deep.

Do not use the valve again.

Illustration 53	g03154663
A small cup is normal even on new valves. Use a straight edge and a feeler gauge to check the valve head for a cup.

Use the valve again.

Valve Face

Illustration 54	g01337710
Normal wear on the fillet area of the valve.

Use the valve again.

Illustration 55	g01337713
Too much wear on the valve face.

Do not use the valve again.

Procedure to Grind Valves

Note: C175 valves are NOT to be ground. The valves are precision machined and the valves do not have enough material to grind successfully. Any attempt to do so will cause the valve to lose durability.

Note: After a valve has been ground, inspect the face and measure the thickness of the lip. Refer to the "Procedure to Measure Valve Lip Thickness" section of this guideline.

The intake and exhaust valves for 3600 engines are the largest valves from Caterpillar. Special heavy-duty equipment for grinding may be necessary. It may also be necessary to modify the existing equipment for grinding. The machine for grinding valves must be capable of grinding a valve with the typical dimensions given in Table 6.

Table 6

General Valve Dimensions
Measurement	Dimension
Length	393.7 mm (15.50 inch)
Stem Diameter	15.97 mm (0.629 inch)
Head Diameter	90.00 mm (3.543 inch)

The machine for grinding valves must be capable of grinding the valve face, so the result of the face to runout of stem diameter is 0.10 mm (0.004 inch). Check the accuracy of the grinder to duplicate machining operations by removing the ground valve. Clamp in the collet again and recheck the total indicated runout.

Standard machines for grinding valves normally will not accept the larger stem diameter of these valves. A different head collet or head may be required to grind these valves. Also, the length of the valve stem will require some modification to the table to accept the longer length of the stem. The valve should always be installed in the collet with the chuck on the chrome finish.

Valve Face

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Illustration 56	g03154737

1. Adjust the carriage on the grinder to the correct valve face angle. The valve must have line contact near the outside diameter of the valve seat face when the valve is seated against the face of the insert seat.
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   Illustration 57	g03154916

2. Follow the manufacturer's instructions for installation of the valve into the chuck.
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   Illustration 58	g03154956

3. Adjust the stop on the carriage for maximum movement to the left.
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   Illustration 59	g03154997

4. Always dress the grinding wheel so the grinding wheel does not have any nicks, grooves, or foreign material.
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   Illustration 60	g03155021
   Valve face that has been unevenly ground

5. Examine the rotating valve in the grinder to determine if the valve is warped or bent. Valves that are warped or bent can cause uneven grinding. Bad maintenance of the grinder will also cause uneven grinding. Valves that are warped must be replaced unless the thickness of the lip is correct after grinding.

   Do not use the valve again.

6. Adjust the flow of cooling liquid so the flow is directly on the point of contact between the grinding wheel and the valve face. Always wet-grind valves.
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   Illustration 61	g01945500

7. Check the runout of the valve face to the stem.

   If the maintenance on the valve grinding machine is not correct, valve failure is possible. To check the valve grinder chuck, install a new valve in the chuck and use a dial indicator to check the runout on the face of the valve. The runout must not be more than 0.025 mm (0.0010 inch). If the dial indicator reads too much runout, the chuck is damaged and needs to be repaired or the bearings are bad or loose.

8. Follow the manufacturer's instructions to properly grind the valve.
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   Illustration 62	g01337941

9. After the valve is ground, inspect the valve face. There must be no grooves, pits, marks, or burns on the face.

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NOTICE
Check the channels that the valve grinding machine slides in. If any movement can be felt, then the channels must be adjusted or a repair must be made. When the valve grinding equipment is in good condition, lapping of the valves is not necessary.

Procedure to Measure Valve Lip Thickness

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.

Illustration 63	g01337997
This illustration shows the thickness of the lip on the valve. Use either of the following two methods to check thickness of the lip.

Illustration 64	g01338011
Use a 5P-6518 Dial Indicator Fixture to measure the thickness of the lip on the valve.

Illustration 65	g01338013
Use a 6V-7059 Micrometer with a 6V-2034 Micrometer Adapter to measure the thickness of the lip on the valve.

Measure the thickness of the lip with either a 5P-6518 Dial Indicator Fixture or a 6V-7059 Micrometer with a 6V-2034 Micrometer Adapter. Refer to Special Instruction, SMHS6998, "Instructions for the Use of 5P-6518 Dial Indicator Fixture-Parts Reusability" for more information.

Note: Remove any burrs from the vee blocks on the fixture with a small 6V-2010 Polishing Stone. Burrs can damage the valve stem.

Note: Some difference in thickness of the lip is permissible. If the thickness of the lip is less than the minimum specification at any point, do not use that valve again.

The existing micrometer adapter 6V-2034 Micrometer Adapter enables measurement of valve lip thickness for 45 degree and 60 degree valves. Many 3400, 3500, 3600 and C175 engine valves are 70 degree.

Note: For C175 engines replace all intake and exhaust valves at PCR. DO NOT REUSE / RECONDITION / OR REMANUFACTURE INTAKE OR EXHAUST VALVES.

Note: For 3500 engines replace all exhaust valves at PCR. DO NOT REUSE / RECONDITION / OR REMANUFACTURE EXHAUST VALVES.

550-9152 Ring Gage Assembly is used to accurately measure valve lip thickness on 70 degree angle valves. The gage can be used with a 369-2607 Digital Indicator with the 5P-4160 Tip on a 5P-4456 Base and a 3P-1585 Collet. A 6V-7030 Depth Micrometer, 8H-3581 Feeler Gage Set, or precision gage blocks can also be used to determine reusability.

The gage eliminates possible measuring errors by locating the measuring surface on the factory established gage point. Comes with removeable centering bushings to measure valves with 9.4 mm or 11.0 mm stems.

Refer to M0088789Tool Operating Manual, "550-9152 Gage Ring Assembly" for more information.

Repair of the Valve Stem End

Illustration 66	g01953486
Examples of reusable tip wear. (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.

Illustration 67	g01337963
The end of the valve stem has not been ground.

Illustration 68	g01337993
The end of the valve stem has been ground.

Use the valve again.

The end of the valve stem must be smooth and level. The end of the valve stem should have a maximum surface texture of 0.81 µm (32.000 µinch). Remove only 0.025 mm (0.0010 inch) with each grind. Then inspect the end of the valve stem.

Note: All the valves do not need to be the same length.

Illustration 69	g03155038
Grind the end of the valve stem to create a smooth surface.

Use the valve again if any of the original chamfer can be seen. Remove sharp edges with Scotch-Brite or with an Arkansas stone.

Specifications of the Valves

Illustration 70	g01400727
(A) Stem diameter (B) Thickness of the lip (C) Diameter of the head (D) Angle of the face

Illustration 71	g06266339
C175 and 3500 Valves (A) Upper Stem diameter (B) Thickness of the lip (C) Diameter of the head (D) Angle of the face (E) Lower Stem diameter

Table 7

Specifications for Intake Valves
Part Number of the Valve	Minimum Stem Diameter (1) (A) & (E)	Minimum Thickness of the Lip (B)	Diameter of the Head (C)	Angle of the Face (Degrees) (D)
1N-4885 1N-4886	9.408 mm (0.3704 inch)	2.04 mm (0.080 inch)	44.98 mm (1.771 inch)	45.50
1W-1761	15.939 mm (0.6275 inch)	4.79 mm (0.189 inch)	92.00 mm (3.622 inch)	60.45
1W-8606	9.408 mm (0.3704 inch)	3.84 mm (0.151 inch)	63.63 mm (2.505 inch)	60.50
1W-1818 8H-1993	12.55 mm (0.494 inch)	4.00 mm (0.158 inch)	59.51 mm (2.343 inch)	45.50
2S-8143 7S-2514	7.833 mm (0.3084 inch)	1.99 mm (0.078 inch)	36.32 mm (1.430 inch)	45.50
2W-2620 100-7860	9.408 mm (0.3704 inch)	2.02 mm (0.08 inch)	51.31 mm (2.020 inch)	60.75
2W-2621 4W-1670 5S-6452 7W-7490 247-6892	9.408 mm (0.3704 inch)	2.67 mm (0.105 inch)	51.31 mm (2.020 inch)	60.75
3N-0514 9L-3160	9.408 mm (0.3704 inch)	2.66 mm (0.105 inch)	48.13 mm (1.895 inch)	60.45
4W-5374	9.408 mm (0.3704 inch)	2.56 mm (0.101 inch)	44.98 mm (1.771 inch)	60.75
4P-2854 180-9044	15.939 mm (0.6275 inch)	5.21 mm (0.205 inch)	90.00 mm (3.543 inch)	69.75
4P-3079	15.939 mm (0.6275 inch)	4.79 mm (0.189 inch)	90.00 mm (3.543 inch)	59.75
6H-3026	11.05 mm (0.435 inch)	1.19 mm (0.047 inch)	51.51 mm (2.028 inch)	45.50
6I-1589 163-2431	7.963 mm (0.3135 inch)	1.87 mm (0.074 inch)	47.00 mm (1.850 inch)	60.25
7C-0362	9.423 mm (0.3710 inch)	2.00 mm (0.079 inch)	53.19 mm (2.094 inch)	60.00
7C-2422 7E-1403 9Y-6232	15.939 mm (0.6275 inch)	4.79 mm (0.189 inch)	90.00 mm (3.543 inch)	59.75
7C-5188	9.408 mm (0.3704 inch)	3.23 mm (0.127 inch)	56.00 mm (2.205 inch)	59.50
7C-5215 7E-9578 124-2692 136-4336 157-0672 192-9213	9.408 mm (0.3704 inch)	2.35 mm (0.093 inch)	45.00 mm (1.772 inch)	60.75
7H-6891	12.55 mm (0.494 inch)	2.27 mm (0.089 inch)	53.98 mm (2.125 inch)	60.50
7M-7358	9.408 mm (0.3704 inch)	2.38 mm (0.094 inch)	48.13 mm (1.895 inch)	60.50
7M-7817	12.55 mm (0.494 inch)	3.82 mm (0.150 inch)	63.63 mm (2.505 inch)	60.50
7W-8064 161-4280	7.963 mm (0.3135 inch)	1.96 mm (0.077 inch)	47.00 mm (1.850 inch)	60.25
8M-2553	9.408 mm (0.3704 inch)	1.31 mm (0.0515 inch)	42.16 mm (1.660 inch)	45.15
8N-5645	9.408 mm (0.3704 inch)	1.84 mm (0.072 inch)	53.19 mm (2.094 inch)	60.00
9H-4811	9.408 mm (0.3704 inch)	2.03 mm (0.080 inch)	43.08 mm (1.696 inch)	60.50
9L-7682	9.425 mm (0.3711 inch)	1.84 mm (0.072 inch)	53.19 mm (2.094 inch)	60.00
9N-0180	9.425 mm (0.3711 inch)	1.63 mm (0.064 inch)	48.13 mm (1.895 inch)	60.00
9Y-9804 122-7353 212-0932 358-1229 525-4063	9.408 mm (0.3704 inch)	2.81 mm (0.111 inch)	44.98 mm (1.771 inch)	70.75
115-2368 122-0322	9.408 mm (0.3704 inch)	2.49 mm (0.098 inch)	44.98 mm (1.771 inch)	60.75
141-4317 145-7390 252-7801	7.963 mm (0.3135 inch)	2.04 mm (0.080 inch)	40.00 mm (1.575 inch)	60.25
144-9992	15.939 mm (0.6275 inch)	4.78 mm (0.188 inch)	90.00 mm (3.543 inch)	45.00
152-8380	9.408 mm (0.3704 inch)	3.02 mm (0.119 inch)	47.00 mm (1.850 inch)	60.75
153-7023 236-5605 391-1106 490-7198 490-7199	9.408 mm (0.3704 inch)	2.75 mm (0.108 inch)	47.00 mm (1.850 inch)	60.75
157-7129 252-7801	7.963 mm (0.3135 inch)	1.87 mm (0.074 inch)	40.00 mm (1.575 inch)	60.25
163-2442 490-1719	9.408 mm (0.3704 inch)	2.03 mm (0.080 inch)	36.00 mm (1.417 inch)	65.75
164-2543	9.408 mm (0.3704 inch)	2.33 mm (0.092 inch)	44.98 mm (1.771 inch)	60.75
187-4123	9.408 mm (0.3704 inch)	1.86 mm (0.073 inch)	36.00 mm (1.417 inch)	65.75
206-7953	15.939 mm (0.6275 inch)	4.61 mm (0.182 inch)	90.00 mm (3.543 inch)	69.75
210-2542 468-8824	9.408 mm (0.3704 inch)	3.46 mm (0.136 inch)	56.00 mm (2.205 inch)	70.60
241-8382 242-1542 262-2957 490-1726	7.962 mm (0.3135 inch)	1.81 mm (0.0713 inch)	39.00 mm (1.535 inch)	60.50
252-7802 224-3028	9.408 mm (0.3704 inch)	2.46 mm (0.097 inch)	44.50 mm (1.752 inch)	60.75
252-7803	7.962 mm (0.3135 inch)	1.79 mm (0.0705 inch)	39.00 mm (1.535 inch)	60.25
255-8675 490-1729	7.962 mm (0.3135 inch)	1.79 mm (0.0705 inch)	41.50 mm (1.634 inch)	60.50
262-2957	8.00 mm (0.3150 inch)	2.03 mm (0.080 inch)	36.00 mm (1.417 inch)	65.75
309-6678	N/A	N/A	N/A	N/A
452-5415 498-1592	10.986 mm (0.43252 inch)	3.46 mm (0.136 inch)	56.00 mm (2.205 inch)	70.60

(1)	Measure the top and the bottom areas of wear.

Table 8

Specifications for the Exhaust Valves
Part Number of the Valve	Minimum Stem Diameter (1) (A) & (E)	Minimum Thickness of the Lip (B)	Diameter of the Head (C)	Angle of the Face (Degrees) (D)
1M-0982 2M-7727	9.408 mm (0.3704 inch)	2.24 mm (0.088 inch)	39.99 mm (1.574 inch)	60.50
1S-2903	7.833 mm (0.3084 inch)	2.12 mm (0.084 inch)	34.80 mm (1.370 inch)	45.50
1W-1819(2)	9.408 mm (0.3704 inch) 9.373 mm (0.3690 inch)	2.68 mm (0.106 inch)	57.96 mm (2.282 inch)	45.50
1W-1822(2) 2W-3211(2)	9.408 mm (0.3704 inch) 9.373 mm (0.3690 inch)	3.71 mm (0.146 inch)	59.69 mm (2.350 inch)	60.50
2W-2443	9.408 mm (0.3704 inch)	2.56 mm (0.101 inch)	41.81 mm (1.646 inch)	60.75
2W-2877 7W-7491 498-1691	9.408 mm (0.3704 inch)	2.67 mm (0.105 inch)	48.16 mm (1.896 inch)	60.50
3N-0516	9.408 mm (0.3704 inch)	3.95 mm (0.156 inch)	44.98 mm (1.771 inch)	70.50
4F-0212	11.05 mm (0.435 inch)	1.22 mm (0.048 inch)	46.73 mm (1.840 inch)	45.50
4F-2719	10.998 mm (0.4330 inch)	0.68 mm (0.027 inch)	42.55 mm (1.675 inch)	45.75
4P-3079	15.939 mm (0.6275 inch)	4.79 mm (0.189 inch)	90.00 mm (3.543 inch)	30.25
5S-5323	12.55 mm (0.494 inch)	3.71 mm (0.146 inch)	59.69 mm (2.350 inch)	60.50
5S-6449 6N-9916 8N-0875	9.408 mm (0.3704 inch)	2.67 mm (0.105 inch)	48.16 mm (1.896 inch)	60.50
6I-1590 7W-2699 105-1779 136-0819 163-2432	7.963 mm (0.3135 inch)	1.48 mm (0.058 inch)	40.00 mm (1.575 inch)	45.00
7C-1586 109-5334 124-2693 133-3550 133-7029 157-0671	9.408 mm (0.3704 inch)	1.94 mm (0.076 inch)	42.00 mm (1.654 inch)	45.75
7E-7830	9.408 mm (0.3704 inch)	2.04 mm (0.080 inch)	41.81 mm (1.646 inch)	45.50
7M-9595	6.642 mm (0.2615 inch)	1.26 mm (0.0500 inch)	23.81 mm (0.937 inch)	45.83
7N-0573	9.408 mm (0.3704 inch)	2.37 mm (0.0933 inch)	48.16 mm (1.896 inch)	60.45
7N-5693	9.408 mm (0.3704 inch)	2.55 mm (0.100 inch)	41.81 mm (1.646 inch)	60.50
7W-9778 201-8114	15.939 mm (0.6275 inch)	4.80 mm (0.189 inch)	90.00 mm (3.543 inch)	60.13
8H-1994	12.55 mm (0.494 inch)	2.68 mm (0.106 inch)	57.96 mm (2.282 inch)	45.50
8M-2552	9.408 mm (0.3704 inch)	1.31 mm (0.0515 inch)	37.08 mm (1.460 inch)	44.15
8N-3723	12.55 mm (0.494 inch)	3.68 mm (0.145 inch)	59.69 mm (2.350 inch)	60.50
8N-3724 9M-4163	9.408 mm (0.3704 inch)	2.68 mm (0.106 inch)	44.98 mm (1.771 inch)	60.50
8N-3737	12.522 mm (0.4930 inch)	2.28 mm (0.0900 inch)	49.23 mm (1.938 inch)	60.50
9L-7683(2) 9N-0185 9N-5125 119-6772(2)	9.408 mm (0.3704 inch) 9.373 mm (0.3690 inch)	1.28 mm (0.050 inch)	45.82 mm (1.804 inch)	45.00
9Y-6232	15.939 mm (0.6275 inch)	4.79 mm (0.189 inch)	90.00 mm (3.543 inch)	59.75
100-4639 311-7555	9.408 mm (0.3704 inch)	3.37 mm (0.133 inch)	41.81 mm (1.646 inch)	70.75
100-7861 148-7455	9.408 mm (0.3704 inch)	2.11 mm (0.083 inch)	48.16 mm (1.896 inch)	60.75
101-8314 212-0933 358-1230	9.408 mm (0.3704 inch)	2.81 mm (0.111 inch)	41.81 mm (1.646 inch)	70.75
104-7184 307-4641 308-9177 498-1692 500-8527 500-8528	9.408 mm (0.3704 inch)	3.46 mm (0.13622 inch)	56.00 mm (2.205 inch)	70.75
115-2367 164-2542	9.408 mm (0.3704 inch)	1.99 mm (0.078 inch)	41.81 mm (1.646 inch)	45.75
122-0321	9.408 mm (0.3704 inch)	1.99 mm (0.0783 inch)	41.81 mm (1.646 inch)	45.75
144-9992	15.939 mm (0.6275 inch)	4.78 mm (0.188 inch)	90.00 mm (3.543 inch)	45.00
147-8211	9.408 mm (0.3704 inch)	1.63 mm (0.064 inch)	43.00 mm (1.693 inch)	45.00
148-7455	9.408 mm (0.3704 inch)	2.11 mm (0.083 inch)	48.16 mm (1.896 inch)	60.75
152-7585 153-7024 289-9231 391-1107 464-4668 490-7200	9.408 mm (0.3704 inch)	2.05 mm (0.081 inch)	41.81 mm (1.646 inch)	45.75
154-2417 319-9074	15.939 mm (0.6275 inch)	6.12 mm (0.241 inch)	90.00 mm (3.543 inch)	69.75
157-7130(2)	9.408 mm (0.3704 inch) 9.373 mm (0.3690 inch)	1.60 mm (0.063 inch)	43.00 mm (1.693 inch)	45.00
185-1103	15.939 mm (0.6275 inch)	5.61 mm (0.221 inch)	90.00 mm (3.543 inch)	69.75
188-3122 241-8383 246-9855 490-1721 490-1723 490-1725	9.408 mm (0.3704 inch)	1.62 mm (0.064 inch)	37.50 mm (1.476 inch)	45.75
194-4897(2) 443-2712(2) 450-4379(2) 468-8825 498-1593 502-5058	12.421 mm (0.48901 inch)(3) 12.529 mm (0.49327 inch)(3)	2.86 mm (0.11260 inch)	56.00 mm (2.205 inch)	45.60
224-3030	9.408 mm (0.3704 inch)	2.14 mm (0.084 inch)	41.50 mm (1.634 inch)	45.75
248-1467	9.408 mm (0.3704 inch)	1.94 mm (0.076 inch)	41.50 mm (1.634 inch)	45.75
255-8676 490-1728	7.962 mm (0.3135 inch)	1.62 mm (0.064 inch)	36.00 mm (1.417 inch)	45.75
328-7496	15.939 mm (0.6275 inch)	5.21 mm (0.2051 inch)	90.00 mm (3.543 inch)	69.75
339-9637	N/A	N/A	N/A	N/A

(1)	Measure the top and the bottom areas of wear.
(2)	The diameter of the valve stem must be measured approximately 12.7 mm (0.50000 inch) from the bottom of travel and 12.7 mm (0.50000 inch) from the top of travel of the part. Do not use a combination of a valve and a guide that has a difference that is larger than 10.0 mm (0.39370 inch)
(3)	Tapered valves have two dimensions for the minimum valve stem diameter. Refer to Illustration 71 for measuring at point (A) and (E).

Gas Admission Valve for G3600

This section outlines the procedure to rebuild the Gas 3600 Gas Admission Valve. If the procedures are followed in this section, then the pre-chamber insert can be expected to give normal performance until the next overhaul when used in the same application.

Required Tooling

• 5S-1330 Valve Spring Compressor

• 366-5728 Driver - Valve Guide

• Custom Valve Guide Removal Tool. Refer to Illustration 72.

Illustration 72	g06267092
Fabricated Tool for Valve Guide Removal (A) 25.0 mm (1.0 inch) (B) 60.0 mm (2.36 inch) (C) 10.5 mm (0.40 inch) (D) 57.0 mm (2.25 inch) (E) 9.3 mm (0.37 inch) (F) 20.0 mm (0.79 inch)

Gas Admission Valve Overview

Illustration 73	g03774501
Typical Gas Admission Valve Parts identified in red are included in the 453-3534 Valve Kit for rebuild. (1) 2A-4429 Retainer Locks (2) 197-6999 Rotocoil As (3) 7N-1904 Spring-Outer (4) 7N-1903 Spring-Inner (5) 6I-2313 Seal (6) 209-0962 Washer (7) 100-4996 Valve Guide (8) Support (9) 9X-3978 O-Ring Seal (10) 061-9455 O-Ring Seal (11) 8J-4351 O-Ring Seal (12) 7W-5718 Seal (13) 7E-7074 Retainer (14) 115-2367 Exhaust Valve

Gas Admission Valve - Disassemble

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 74	g03774568
Removing Lockers

1. Use 5S-1330 Valve Spring Compressor tooling, compress the valve springs.
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   Do not remove or install the spring locks with your fingers. If the spring should move, personal injury may result.

2. Use a magnet and remove Lockers (1). Release the pressure of the valve spring compressor.

3. Remove Valve (14)
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   Illustration 75	g03776099

4. Secure Support Assembly (8) in a vice. Use a breaker bar or ratchet, remove Retainer (13).
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   Illustration 76	g03776143

5. Use adequate tooling, remove, and discard Retainer Seal (13) from the retainer.
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   Illustration 77	g03776164

6. Clean the retainer and inspect the top surface for damage.
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   Illustration 78	g03776293

7. Using the tool made from Illustration 72, a hydraulic press, and a hollow tube of steel press out the valve guide from the support assembly.

8. Remove and discard all seals.

9. Clean the support assembly and inspect for damage.

10. Mark the support assembly according to Reuse And Salvage Guidelines, SEBF8187, "Standardized Parts Marking Procedures"

Gas Admission Valve - Assemble

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Illustration 79	g03776302

1. Use a hydraulic press and 366-5728 Valve Guide Driver press in new guide.

   The guide must be pressed in and not driven in using impact forces. Watch for a pressure spike in hydraulic pressure. The pressure spike indicates that the guide has bottomed in the support.

2. Install new guide seal.

3. Install new seal in retainer.

4. Secure Support Assembly (8) in a vice. Install Retainer (13) and torque to 100 N·m (75 lb ft).

5. Install the exhaust valve, washer, seal, springs, and rotocoil.

6. Use a 5S-1330 Valve Spring Compressor compress the valve springs and install Lockers (1).

7. Release the pressure of the valve spring compressor.

Valve Springs

Inspection and Reuse

This section contains graphics of springs that can and cannot be reused. Do not reuse valve springs that this guide recommends not to use again.

Note: Do not reuse the following valve springs. 194-4901, 281-6157, 316-5976, 450-0908 Outer Spring and 194-4902, 316-5977 and 450-0909 Inner Spring.

Note: C175 valve springs must be replaced at full life overhaul. C175 valve springs may be reused at mid-life overhaul if they pass visual inspection.

Illustration 80	g01338022
Nicks and deep scratching on the valve spring.

Do not use the spring again.

Illustration 81	g03155598
Light wear in the first 180 degrees of turn is acceptable.

Use the spring again.

Illustration 82	g01338028
Rust deposits on the spring.

Do not use the spring again.

Illustration 83	g03155618
Notches at the end of the spring are not acceptable.

Do not use the spring again.

Illustration 84	g01338033
Wear on the valve spring between the coils and on the end of the spring.

Do not use the spring again.

Illustration 85	g03155696
Spring has wear on the sides and cannot be reused.

Do not use the spring again.

Illustration 86	g01338038
Use a square or use a straight edge and a feeler gauge to check each valve spring for distortion.

A 7B-0337 Surface Plate and a 150 mm (6.0 inch) square will be used to measure the straightness of the spring.

Use the spring again if it passes distortion checks.

Note: Do not use a spring again if the spring has more distortion than the dimensions given in Table 9.

Test Procedure for Valve Springs

All current valve springs can be measured by using the 441-0714 Valve Spring Tester to test for reusability of load and rebound. 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 dial caliper.

Illustration 87	g03680564
Use 441-0714 Spring Tester to test the springs.

1. Adjust the stop at the top of the valve spring tester to compress the spring only to the Minimum Operating Length.

2. Put the spring under compression until the spring is at the Assembled Length. Make a record of the force that is needed to hold the spring at this length.

3. Continue to compress the spring until the spring is at the Minimum Operating Length. Make a record of the force that is needed to hold the spring at this length.

4. Make a comparison of the results to the specifications given in Table 9.

Valve Spring Specifications

Illustration 88	g01420828
(E) Spring within tolerance (F) Outside Diameter (G) Minimum operating length (H) Assembled length (J) Approximate free length (K) 90 degree angle

Table 9

Specifications for the Valve Springs
Part Number	Dimensions
	Approximate Free Length (J)	Outside Diameter (F)	Assembled Length (H)	Minimum Load (H)	Minimum Operating Length (G)	Minimum Load (G)	Spring Within Tolerance (E)
1B-9704 Spring	88.90 mm (3.500 inch)	26.87 mm (1.058 inch)	61.12 mm (2.406 inch)	39.0 N (8.77 lb)	46.83 mm (1.844 inch)	N/A	3.10 mm (0.122 inch)
1C-6765 Spring (Outer)	48.40 mm (1.90551 inch)	39.96 mm (1.57323 inch)	39.70 mm (1.56299 inch)	187 N (42.03947 lb)	29.0 mm (1.14173 inch)	N/A	2.30 mm (0.09055 inch)
1C-6766 Spring (Outer) 9M-5350 Spring (Outer)	65.38 mm (2.574 inch)	43.51 mm (1.713 inch)	56.36 mm (2.219 inch)	253.5 N (56.99 lb)	41.00 mm (1.614 inch)	736.5 N (165.57 lb)	2.28 mm (0.090 inch)
1W-1748 Spring (Outer)	114.00 mm (4.490 inch)	68.0 mm (2.68 inch)	84.87 mm (3.341 inch)	667.5 N (150.06 lb)	58.37 mm (2.298 inch)	1376.0 N (309.34 lb)	3.98 mm (0.157 inch)
1W-1749 Spring (Inner)	107.00 mm (4.210 inch)	47.92 mm (1.887 inch)	79.25 mm (3.120 inch)	318.0 N (71.49 lb)	52.75 mm (2.077 inch)	664.0 N (149.27 lb)	3.74 mm (0.147 inch)
1W-4259 Spring	50.70 mm (1.996 inch)	39.62 mm (1.560 inch)	45.77 mm (1.802 inch)	186.6 N (41.95 lb)	29.63 mm (1.167 inch)	735.0 N (165.24 lb)	1.77 mm (0.070 inch)
2S-4213 Spring(1)	58.67 mm (2.310 inch)	37.74 mm (1.486 inch)	49.53 mm (1.950 inch)	206.5 N (46.42 lb)	37.34 mm (1.470 inch)	595.5 N (133.87 lb)	2.05 mm (0.081 inch)
2S-5627 Spring 9H-9164 Spring	67.31 mm (2.650 inch)	32.57 mm (1.282 inch)	59.44 mm (2.340 inch)	229.6 N (51.61 lb)	46.84 mm (1.844 inch)	N/A	2.35 mm (0.093 inch)
2S-7339 Spring	53.85 mm (2.120 inch)	25.99 mm (1.023 inch)	48.11 mm (1.894 inch)	186.9 N (42.02 lb)	37.44 mm (1.474 inch)	589.4 N (132.50 lb)	1.88 mm (0.074 inch)
3S-3018 Spring 159-7303 Spring	49.78 mm (1.960 inch)	30.86 mm (1.215 inch)	44.15 mm (1.738 inch)	180.0 N (40.47 lb)	31.95 mm (1.258 inch)	596.0 N (133.99 lb)	1.74 mm (0.069 inch)
4F-5408 Spring	61.52 mm (2.422 inch)	41.66 mm (1.640 inch)	49.61 mm (1.953 inch)	220.3 N (49.53 lb)	34.26 mm (1.349 inch)	N/A	2.15 mm (0.085 inch)
4F-5409 Spring	59.92 mm (2.359 inch)	29.09 mm (1.145 inch)	48.82 mm (1.922 inch)	117.1 N (26.33 lb)	33.48 mm (1.318 inch)	N/A	2.09 mm (0.082 inch)
4N-5906 Spring	62.74 mm (2.470 inch)	31.75 mm (1.250 inch)	54.99 mm (2.165 inch)	291.5 N (65.53 lb)	42.93 mm (1.690 inch)	836.0 N (187.94 lb)	2.19 mm (0.086 inch)
4W-2471 Spring (Outer)	59.46 mm (2.341 inch)	37.31 mm (1.469 inch)	53.24 mm (2.096 inch)	211.1 N (47.46 lb)	38.96 mm (1.534 inch)	765.0 N (171.98 lb)	2.08 mm (0.082 inch)
4W-2472 Spring (Inner)	65.70 mm (2.587 inch)	25.13 mm (0.989 inch)	50.24 mm (1.978 inch)	155.1 N (34.87 lb)	35.97 mm (1.416 inch)	326.0 N (73.29 lb)	2.29 mm (0.090 inch)
5B-6030 Spring (Outer)	91.95 mm (3.620 inch)	34.29 mm (1.350 inch)	73.15 mm (2.880 inch)	N/A	62.99 mm (2.480 inch)	N/A	N/A
5F-3111 Spring (Inner)	46.04 mm (1.813 inch)	28.35 mm (1.116 inch)	38.89 mm (1.531 inch)	66.1 N (14.87 lb)	28.18 mm (1.109 inch)	N/A	1.61 mm (0.063 inch)
5F-3112 Spring (Outer)	48.42 mm (1.906 inch)	37.05 mm (1.459 inch)	39.69 mm (1.563 inch)	184.3 N (41.44 lb)	28.97 mm (1.141 inch)	N/A	1.69 mm (0.067 inch)
6I-2307 Spring	81.00 mm (3.189 inch)	28.66 mm (1.128 inch)	70.80 mm (2.787 inch)	568.5 N (127.81 lb)	59.00 mm (2.323 inch)	1259.0 N (283.04 lb)	2.83 mm (0.111 inch)
7C-4273 Spring	71.00 mm (2.795 inch)	28.81 mm (1.134 inch)	65.86 mm (2.593 inch)	185.5 N (41.70 lb)	50.70 mm (1.996 inch)	815.0 N (183.22 lb)	2.48 mm (0.098 inch)
7N-1903 Spring (Inner)	51.54 mm (2.029 inch)	29.24 mm (1.151 inch)	45.49 mm (1.791 inch)	104.0 N (23.38 lb)	31.27 mm (1.231 inch)	388.0 N (87.23 lb)	1.80 mm (0.071 inch)
7N-1904 Spring (Outer)	62.50 mm (2.460 inch)	43.96 mm (1.731 inch)	56.36 mm (2.219 inch)	212.5 N (47.77 lb)	42.13 mm (1.659 inch)	800.0 N (179.85 lb)	2.18 mm (0.086 inch)
7N-7713 Spring	53.3 mm (2.09842 inch)	35.60 mm (1.40157 inch)	47.20 mm (1.85826 inch)	195 N (43.83795 lb)	36.8 mm (1.44882 inch)	568 N (127.69208 lb)	1.90 mm (0.07480 inch)
7S-7144 Spring 394-8211 Spring	52.07 mm (2.050 inch)	35.21 mm (1.386 inch)	44.86 mm (1.766 inch)	217.0 N (48.78 lb)	32.28 mm (1.271 inch)	658.0 N (147.93 lb)	1.82 mm (0.072 inch)
7S-6323 Spring	66.37 mm (2.613 inch)	43.98 mm (1.732 inch)	56.36 mm (2.219 inch)	351.3 N (78.98 lb)	41.00 mm (1.614 inch)	N/A	2.32 mm (0.091 inch)
7W-7082 Spring (Outer) 214-0586 Spring (Outer) 332-2152 Spring (Outer)	62.70 mm (2.469 inch)	34.00 mm (1.339 inch)	52.95 mm (2.085 inch)	274.0 N (61.60 lb)	37.40 mm (1.472 inch)	811.0 N (182.32 lb)	2.19 mm (0.086 inch)
7W-7083 Spring (Inner) 224-4441 Spring (Inner)	64.10 mm (2.524 inch)	23.24 mm (0.915 inch)	50.47 mm (1.987 inch)	128.5 N (28.89 lb)	34.92 mm (1.375 inch)	367.0 N (82.51 lb)	2.24 mm (0.088 inch)
8H-9488 Spring	59.92 mm (2.359 inch)	31.63 mm (1.245 inch)	53.19 mm (2.094 inch)	181.3 N (40.75 lb)	42.06 mm (1.656 inch)	N/A	2.09 mm (0.082 inch)
9L-9172 Spring (Inner)	47.12 mm (1.855 inch)	25.35 mm (0.998 inch)	43.56 mm (1.715 inch)	50.3 N (11.32 lb)	30.86 mm (1.215 inch)	315.6 N (70.95 lb)	1.65 mm (0.065 inch)
9L-9190 9N-3387 9N-3617 Spring (Outer)(2)	47.09 mm (1.854 inch)	36.58 mm (1.440 inch)	42.04 mm (1.655 inch)	191.1 N (42.96 lb)	26.63 mm (1.048 inch)	730.0 N (164.11 lb)	1.64 mm (0.065 inch)
9M-5349 Spring (Inner)	55.35 mm (2.179 inch)	28.57 mm (1.125 inch)	45.49 mm (1.791 inch)	78.0 N (17.54 lb)	30.15 mm (1.187 inch)	214.0 N (48.11 lb)	1.93 mm (0.076 inch)
9N-5495 Spring (Inner)	48.77 mm (1.920 inch)	26.67 mm (1.050 inch)	45.77 mm (1.802 inch)	76.4 N (17.18 lb)	27.23 mm (1.072 inch)	289.5 N (65.08 lb)	1.70 mm (0.067 inch)
9N-5496 Spring (Outer)	51.77 mm (2.038 inch)	39.62 mm (1.560 inch)	45.77 mm (1.802 inch)	155.0 N (34.85 lb)	30.23 mm (1.190 inch)	589.0 N (132.41 lb)	1.81 mm (0.071 inch)
9Y-3326 Spring (Outer)	69.04 mm (2.718 inch)	42.61 mm (1.678 inch)	53.24 mm (2.096 inch)	469.0 N (105.44 lb)	38.96 mm (1.534 inch)	942.0 N (211.77 lb)	2.41 mm (0.095 inch)
9Y-3327 Spring (Inner)	70.90 mm (2.790 inch)	29.83 mm (1.174 inch)	50.42 mm (1.985 inch)	238.0 N (53.50 lb)	36.14 mm (1.423 inch)	423.0 N (95.09 lb)	2.48 mm (0.098 inch)
103-2454 Spring	54.37 mm (2.141 inch)	35.56 mm (1.400 inch)	44.93 mm (1.769 inch)	350.6 N (78.81 lb)	31.43 mm (1.237 inch)	864.6 N (194.36 lb)	1.90 mm (0.075 inch)
119-3045 Spring	76.00 mm (2.992 inch)	28.91 mm (1.138 inch)	65.86 mm (2.593 inch)	426.5 N (95.89 lb)	50.70 mm (1.996 inch)	1083.0 N (243.47 lb)	2.65 mm (0.104 inch)
137-6718 Spring 391-9854 Spring	92.08 mm (3.625 inch)	28.82 mm (1.135 inch)	80.27 mm (3.160 inch)	610.5 N (137.25 lb)	66.27 mm (2.609 inch)	1387.0 N (311.81 lb)	3.24 mm (0.128 inch)
140-6188 Spring 391-9855 Spring	67.50 mm (2.658 inch)	28.59 mm (1.126 inch)	60.40 mm (2.378 inch)	266.0 N (59.80 lb)	46.40 mm (1.827 inch)	862.5 N (193.90 lb)	2.36 mm (0.093 inch)
165-7585 Spring (Inner)	107.40 mm (4.230 inch)	49.51 mm (1.949 inch)	81.70 mm (3.220 inch)	343.0 N (77.11 lb)	55.20 mm (2.170 inch)	706.0 N (158.72 lb)	3.75 mm (0.148 inch)
165-7586 Spring (Outer)	115.90 mm (4.560 inch)	69.0 mm (2.72 inch)	84.90 mm (3.340 inch)	723.0 N (162.54 lb)	58.40 mm (2.300 inch)	1351.0 N (303.72 lb)	4.05 mm (0.159 inch)
190-6115 Spring (Inner)	57.80 mm (2.276 inch)	23.18 mm (0.913 inch)	36.50 mm (1.437 inch)	197.0 N (44.29 lb)	24.50 mm (0.965 inch)	301.0 N (67.67 lb)	2.02 mm (0.080 inch)
190-6117 Spring (Outer)	57.80 mm (2.276 inch)	31.79 mm (1.252 inch)	37.70 mm (1.484 inch)	333.0 N (74.87 lb)	25.70 mm (1.012 inch)	574.0 N (129.04 lb)	2.02 mm (0.080 inch)
194-4902 Spring (Inner)	60.70 mm (2.390 inch)	30.70 mm (1.210 inch)	50.34 mm (1.982 inch)	135.2 N (30.40 lb)	31.54 mm (1.242 inch)	418.0 N (93.97 lb)	2.12 mm (0.084 inch)
211-3122 Spring (Inner) 390-0989 Spring (Inner)	71.70 mm (2.823 inch)	25.17 mm (0.991 inch)	60.14 mm (2.368 inch)	119.5 N (26.87 lb)	44.02 mm (1.733 inch)	382.0 N (85.88 lb)	2.50 mm (0.098 inch)
211-3123 Spring (Outer) 247-9908 Spring (Outer) 392-4530 Spring (Outer)	76.70 mm (3.020 inch)	36.30 mm (1.429 inch)	67.12 mm (2.643 inch)	288.0 N (64.75 lb)	51.00 mm (2.008 inch)	848.0 N (190.64 lb)	2.68 mm (0.106 inch)
224-4441 Spring (Inner)	64.10 mm (2.524 inch)	23.24 mm (0.915 inch)	50.47 mm (1.987 inch)	128.5 N (28.89 lb)	34.92 mm (1.375 inch)	367.0 N (82.51 lb)	2.24 mm (0.088 inch)
241-8385 Spring (Outer)	67.69 mm (2.665 inch)	28.56 mm (1.124 inch)	44.00 mm (1.732 inch)	300.0 N (67.44 lb)	32.00 mm (1.260 inch)	441.0 N (99.14 lb)	2.36 mm (0.093 inch)
241-8386 Spring (Inner)	56.68 mm (2.232 inch)	21.34 mm (0.840 inch)	42.80 mm (1.685 inch)	146.0 N (32.82 lb)	30.80 mm (1.213 inch)	275.5 N (61.94 lb)	1.98 mm (0.078 inch)
255-8677 Spring (Inner) 349-5303 Spring (Inner)	74.60 mm (2.937 inch)	21 mm (0.824 inch)	46.15 mm (1.817 inch)	221.0 N (49.68 lb)	34.15 mm (1.345 inch)	333.5 N (74.97 lb)	2.61 mm (0.103 inch)
276-8132 Spring 436-0521 Spring	N/A	N/A	N/A	N/A	N/A	N/A	N/A
255-8678 Spring (Outer) 349-5307 Spring (Outer)	77.90 mm (3.067 inch)	29.4 mm (1.157 inch)	47.35 mm (1.864 inch)	442.0 N (99.37 lb)	35.35 mm (1.392 inch)	640.2 N (143.92 lb)	2.72 mm (0.107 inch)
281-6157 Spring (Outer)	75.80 mm (2.980 inch)	43.47 mm (1.711 inch)	59.29 mm (2.334 inch)	534.0 N (120.05 lb)	40.49 mm (1.594 inch)	1188.0 N (267.07 lb)	2.65 mm (0.104 inch)
316-5976 Spring (Outer)	74.8 mm (2.94488 inch)	43.47 mm (1.71141 inch)	60.29 mm (2.37362 inch)	437 N (98.24197 lb)	41.49 mm (1.63346 inch)	1043 N (234.47683 lb)	2.61 mm (0.10276 inch)
316-5977 Spring (Inner)	71.4 mm (2.81102 inch)	30.7 mm (1.20866 inch)	57.5 mm (2.26378 inch)	235.6 N (52.96524 lb)	38.7 mm (1.52362 inch)	561.4 N (126.20833 lb)	2.49 mm (0.09803 inch)

(1)	Install the spring with the painted end upward.
(2)	Replace these springs with 1W-4259 Spring on 3200 Series of engines. Use this spring on the 3100 and 1100 Series of engines.

Valve Rotocoils and Locks

Illustration 89	g06229852

Do not reuse valve rotocoils or locks.

Caterpillar recommends against the reuse of rotocoils or locks. The disassembling, cleaning, inspecting, and reassembling of rotocoils requires specialized tooling and processes.

Floating Valve Bridges

Illustration 90	g00008666

DO NOT REUSE a bridge with a new valve. The components create a wear system which they become a matched pair, and the reuse of a worn bridge (even slightly) with a new valve can lead to accelerated valve wear.

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NOTICE
Do not attempt to reuse the 6I-1458 Valve Bridge. The 6I-1458 Valve Bridge can cause valve lash adjustment problems on cylinder heads that have been salvaged. Therefore, the 6I-1458 Valve Bridge has been canceled and replaced with the 348-7743 Valve Bridge. If there is trouble setting valve lash after the 348-7743 Valve Bridges are installed, then the 363-3731 Valve Bridges must be used. The 363-3731 Valve Bridges are thinner than the 348-7743 Valve Bridges. Refer to Truck Engine News, SEBD6847 for more information on the application of the 363-3731 Valve Bridges.

3406E and C15 Bridges

Illustration 91	g01338184
No pitting, raised material, waving, or wear steps on top of the bridge or in the holes on the valve stem.

Use the bridge again.

Illustration 92	g01338297
Pitting, raised material, waving, or a wear step on top of the bridge or in the holes on the valve stem.

Do not use the bridge again.

Illustration 93	g01338288
The depth of the pocket on the valve stem is less than 6.7 mm (0.26 in). No pitting, raised material, waving, or wear steps.

Use the bridge again.

Illustration 94	g01338291
The depth of the pocket on the valve stem is greater than 6.7 mm (0.26 in) or the pocket of the valve is worn and damaged.

Do not use the bridge again.

3126B Bridges

Illustration 95	g01352432
No pitting, raised material, waving, or wear steps on top of the bridge.

Use the bridge again.

Illustration 96	g01352475
Pitting, raised material, waving, or a wear step on top of the bridge.

Do not use the bridge again.

Illustration 97	g01352479
No pitting, raised material, waving, or wear steps in the pocket for the valve stem.

Use the bridge again.

Illustration 98	g01352485
Pitting, raised material, waving, or a wear step in the pocket for the valve stem.

Do not use the bridge again.

C10, C12, 3176, 3196 Bridges

Illustration 99	g01352489
No pitting, raised material, waving, or wear steps on top of the bridge.

Note: If corresponding rocker arm is used again, then the same bridge must also be used again.

Use the bridge again.

Illustration 100	g01352491
Pitting, raised material, waving, or a wear step on top of the bridge.

Do not use the bridge again.

Illustration 101	g01352492
No pitting, raised material, waving, or wear steps in the pocket of the valve stem.

Use the bridge again.

Illustration 102	g01352493
Pitting, raised material, waving, or a wear step in the pocket for the valve stem.

Do not use the bridge again.

Illustration 103	g02157060
Bridge button (or elephant's foot) cannot be replaced.

Note: If button does not meet reuse specifications, the bridge assembly cannot be reused.

3406, 3408, and 3412 Bridges

Illustration 104	g01352505
No pitting, raised material, waving, or wear steps on top of the bridge.

Use the bridge again.

3500 Bridges

Type 1

Illustration 105	g06209425
(19) Shaft assembly, (20) Adjustment screw, (21) Rocker arm, (22) Rocker arm, (23) Bridge assembly, (24) Retainer ring, (25) Button, (26) Nut, (27) Base assembly, (28) Screw and (29) Bridge assembly

Illustration 106	g02142927
109-3824 Valve Mechanism Group (30) Adjustment Screw and Jam Nut (31) Rocker Arm (32) Bridge Assembly (33) Screw and Nut

Illustration 107	g06266695
Valve mechanism group from the Gas 3500 engine and the Gas 3520B engine (34) Adjustment screw and jam nut (35) Rocker arm (36) Bridge assembly (37) Screw and nut

Illustration 108	g01210346

Inspect surface (38) for wear from the valve stem.

Do not reuse the component if any of the following characteristics are found on surface:

• Wear steps

• Scuffing

• Marks from seizure

Illustration 109	g01210351
(39) Valve bridge (40) Wear seat (41) Surface for wear (42) Oil supply hole (43) Seat for the valve stem (44) Bridge bore (45) Bore

Inspection of the bridge assembly for wear must include the following items:

• Bridge contact surface with the valve stems

• The surface for wear from the button (41)

• Bridge Bore (44)

• Bore (45)

• Rocker arm bore for wear from the valve stem

Do not use the bridge assembly again if any of the following characteristics are on the inside diameter of bore:

• Scuffing

• Marks from seizure

• Diameter is greater than 11.15 mm (0.4390 inch).

Do not use the bridge assembly again if the seat (43) or bore (44) shows any significant wear.

Do not use the bridge assembly again if the seat shows any of the following characteristics:

• Scuffing

• Marks from seizure

• Excessive wear step

Illustration 110	g06209444
(1) Bolts, (2) Rocker Arm, (3) Adjustment Screw, (4) Rocker Arm, (5) Shaft Assembly, (6) Socket, (7) Button, (8) Retaining Ring, (9) Bridge, and (10) Head

Illustration 111	g06209447
(12) Surface for Wear, (13) and (14) Oil Supply Holes and (15) and (16) Seats for the Valve Stems

The measurement for the depth of the bore for 265-7537 Bridge, 265-7538 Bridge, and 450-5413 Bridge are 8.0 ± 0.3 mm (0.315 ± 0.012 inch).

Inspection of the bridge assembly for wear must include the following items:

• The surface for wear (12)

• The pockets for the seat for the valve stem

Do not use the bridge assembly again if the seats (15) or (16) show any significant wear.

Do not use the bridge assembly again if the seat shows any of the following characteristics:

• Scuffing

• Marks from seizure

• Excessive wear step

If the bridge has any damage from being out of position due to a valve failure, the bridge should not be used again.

Illustration 112	g01352495
No pitting, raised material, waving, or wear steps on top of the bridge.

Use the bridge again.

Illustration 113	g01352497
Pitting, raised material, waving, or a wear step on top of the bridge.

Do not use the bridge again.

Illustration 114	g01352498
No pitting, raised material, waving, or wear steps in the pocket for the valve stem.

Use the bridge again.

Illustration 115	g01352501
Pitting, raised material, waving, or a wear step exist in the pocket for the valve stem.

3600 Bridges

Visually inspect the bridge for wear. Check the outside diameter and the height of the bridges. The diameter of the bridge must be within 19.055 ± 0.003 mm (0.7502 ± 0.0001 inch). The height of the bridge dowel must not exceed 105.0 ± 2.00 mm (4.1339 ± 0.0787 inch). If the bridge does not meet these specifications, the bridges will need to be replaced.

C175 Bridges

Illustration 116	g06209505

Illustration 117	g06209509
(A) Valve step pockets for the valve stem (B) Surface for wear (C) Oil supply hole

Illustration 118	g02920157

The top of the bridge is polished with no signs of wear. The bridge can be used again.

Illustration 119	g06209513

Illustration 120	g02920918

The valve stem pockets of the bridge do not show any significant wear. This bridge can be used again.

The depth of both bores in the bridge is 7.5 ± 0.25 mm (0.30 ± 0.010 inch)

Be sure to inspect the surface for wear and the seat for the valve stem during the inspection of the bridge assembly.

Do not use the bridge assembly again if the valve stem pockets show any significant wear.

Do not use the bridge assembly again if the valve stem pockets show any of the following characteristics:

• Scuffing

• Marks from seizure

• Excessive wear step

If the bridge has any damage from being out of position due to a valve failure, the bridge should not be used again.

Lifter Guide Springs for 3500 Engines

3400 and 3500 Lifter Guide Springs mustneverbe reused. Always replace the Lifter Guide Springs in 3500 Engines. Due to high rates of wear and the minimal cost advantage to reuse these parts, Caterpillar recommends against the reuse of Lifter Guide Springs in 3500 engines.

7N-4782 Lifter Guide Spring

The following illustrations show common types of wear for the 7N-4782 Lifter Guide Spring.

Illustration 121	g06267073
Location of the Lifter Guide Spring

Illustration 122	g06267075
Do Not Use Again

Illustration 123	g06267077
Do Not Use Again

Illustration 124	g06267078
Do Not Use Again

Illustration 125	g06267079
Do Not Use Again

Illustration 126	g03688601
Do Not Use Again

This spring shows signs of metal that has moved, possibly because of smearing, fretting, or scuffing.

Illustrations 122123,124125, 126 show examples of wear. Do not reuse any 3400 or 3500 Lifter Guide Springs

Inspection of Slipper Followers, Roller Followers, and Roller Lifters

Slipper Followers, roller followers, and roller lifters are used in Caterpillar engines. This guideline contains information about the reusability of followers and lifters. Followers and lifters wear a specific fit with the camshaft lobes.

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NOTICE
It is recommended that used followers and lifters be installed in their original bores during reassembly. If the followers and lifters are not, the difference in wear patterns can result in a faster rate of wear or a failure.

Caterpillar recommends marking each follower and each lifter during disassembly. This will provide positive identification of the correct sequence during assembly. Never permit followers or lifters to become mixed. Do not install followers or lifters against a different lobe. Never install a used follower or a used lifter of any type with a new camshaft.

Slipper Followers, roller followers, and roller lifters that are used again in accordance with the information in this guideline will provide normal performance until the next overhaul of the engine.

Apply oil to all followers and lifters during assembly.

General Guidelines Slipper Followers, Roller Followers, and Roller Lifters

• When a new camshaft is installed, always replace the used followers and/or used lifters as well. Using a used roller lifter or slipper follower with a new camshaft can cause aggressive wear to both the camshaft and the lifter or follower.

• A new roller lifter can be installed on a used camshaft if the camshaft does not have wear on the lobe that can be easily seen or felt. The original roller lifter must have a smooth wear pattern. If either the roller lifter or the camshaft lobe has heavy wear, the camshaft should be replaced. Refer to Reuse and Salvage Guideline, SEBF8146, "Camshaft Inspection Process" for further guidance.

• Check the roller for excessive movement. Do not reuse any rollers that are excessively loose. Do not reuse rollers that do not turn smoothly. Excessive wear on the pin or the roller in direction (C) is not acceptable. Refer to Table 12 for wear limits.

• Check for damage on the surface. There must be no pits, corrosion, or smeared material on the contact surfaces. Inspect each follower carefully with an 8S-2257 Eye Loupe. Surfaces that look and feel acceptable can have small pitting or defects which cannot be seen without an eye loupe. Circumferential wear patterns are acceptable if the surface has no defects. Circumferential wear patterns are unacceptable if the patterns can be felt with a fingernail.

Handling and Storage

Poor handling and storage procedures can cause a great deal of damage and may prevent the parts from being used again. Typical handling and storage damage includes: rust, dents, nicks, and scratches. To avoid damage, parts should be handled carefully and never dropped or thrown. Place parts in racks designed to prevent the parts from contacting each other. Putting the parts in racks should prevent damage to any parts during transportation and cleaning.

If the scratches are shallow, the roller can be lightly polished and used again. The polishing procedure should not use abrasive materials. The polishing procedure should not cause a change in the diameter of the roller. If the scratches are not shallow, the roller should not be used again. Shallow scratches cannot be felt with a fingernail.

Roller lifters can receive a great deal of damage from poor handling and storage practices. Such damage can prevent the parts from being used again. Typical handling and storage damage includes rust, dents, nicks, and scratches. To avoid damage, parts should be handled carefully, not dropped or thrown. Place the parts in racks designed to prevent the lifters from contacting each other. This practice should prevent damage during transportation and cleaning.

To avoid storage damage, parts must be coated with a rust preventative and stored in a clean, dry place where the parts will not be subjected to moisture. Engine oil is an adequate rust preventative if the parts will be used within a few days. If longer storage of parts is required, it may be necessary to wrap individual parts in sealed containers, such as plastic bags.

Cleaning Procedure

The roller lifters can be cleaned using any good quality cleaning solution with a petroleum base. Diesel fuel works well, because diesel fuel also provides some lubrication. Some cleaners will not protect the parts after cleaning because the cleaners dry oil free. Kerosene is not as good as diesel fuel, because kerosene provides less lubrication.

Make sure that the cleaning solution is clean since the clearances in roller lifters are very close. If the cleaning solution is not kept clean, foreign material or debris can get between the pin and roller, thus causing damage or premature failure.

Visual Inspection

The following general information should be used when working with roller followers and lifters:

1. Used followers and lifters cannot be used on a new camshaft. A new camshaft requires the use of new followers and lifters. Used followers and lifters can only be used with the original camshaft. Always install used followers and roller lifters in the original bores with the original orientation.

2. New followers and rollers can be installed on a used camshaft if the camshaft does not have wear on the lobe that can be easily seen or felt. The original lifter must have had a typical pattern or a normal pattern of smooth wear. If either the lifter or the camshaft has experienced heavy wear, Caterpillar recommends installing a replacement camshaft.

3. If a camshaft was replaced, replace all followers and lifters.

4. Do not use any followers and lifters that operated against damaged lobes.

5. Check the followers and roller for excessive movement. Do not reuse any followers and rollers that are loose. Do not reuse any followers and rollers that do not turn smoothly. Measure and evaluate according to specifications in Table
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   Illustration 127	g01742913
   8S-2257 Eye Loupe used for visual inspection

6. Check for surface damage. There must be no pits, corrosion, or smeared material on contact surfaces. Inspect each lifter carefully with the 8S-2257 Eye Loupe. Surfaces that look and feel acceptable can have small pitting or defects that cannot be seen without magnification. As long as the surface is free of defects, circumferential wear patterns are acceptable unless the wear can be felt with a fingernail.

7. Inspect the shaft bore in the assembly for unusual signs of wear. The bore should be smooth with no signs of galling or seizure to the shaft. If damage has occurred, the assembly must be replaced.
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   Illustration 128	g06266663
   (4) Pin Hole

8. Check the press fit of the pin securing the roller to the body by tapping the pin with a brass or plastic mallet. If the pin moves, replace the assembly, If two or more assemblies have loose pins, replace all assemblies.
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   Illustration 129	g03192138
   The stamped arrow on the pin must be pointing up for the pin to be correctly aligned. The arrow indicates the stamped arrow on the pin.

9. During assembly on roller followers, make sure the stamped arrow on the end of the pin is pointing up, Illustration 129. If the stamped arrow is not pointing straight up, the pin is not aligned correctly.
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   Illustration 130	g02717564
   (A) The hole in the pin is aligned with the hole in the fork. (B) The hole in the pin is more than 2 degrees from a vertical centerline.

10. There have been reports of damage to roller lifters after an engine has exceeded the maximum rpm limit. This condition is called overspeeding. Overspeeding has been shown to cause the roller pin to move sideways. Overspeeding can also cause the pin to rotate in the forks of the lifter. The pin uses an interference fit in the forks of the lifter and the pin is installed recessed 0.50 ± 0.25 mm (0.020 ± 0.010 in) from the side. During rebuilding process of the engine, inspect the pin to determine whether the pin has rotated from the initial position as shown in Illustration 130. The small hole in the end of the pin must still be aligned within 2 degrees of the vertical lifter. If the hole in the pin is more than 2 degrees from the vertical centerline, the lifter cannot be used again.
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    Illustration 131	g01743613
    (14) Lifter (15) Insert

11. Inspect the end that is opposite of the roller. Make sure that the insert is in the bore of the roller lifter. Make sure that there is no damage to the lifter body or the insert.
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    Illustration 132	g06266668
    Roller Lifter (5) Roller (6) Pin

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    Illustration 133	g03353393
    Push rod insert.

12. The push rod insert is peened in 3 locations to retain position during assembly and handling. It is not important if the insert rotates.

Injector Roller Follower

Illustration 134	g03199936
Wear on injector roller followers. (1) Heavy pitting. Do Not Use Again (2) Light circumferential wear. Use again if wear cannot be felt with a fingernail. (3) Normal wear on roller. Use Again.

Valve Roller Follower

Illustration 135	g03200039
Wear on valve roller followers (4) Normal wear. Use Again. (5) Slight wear on the roller that cannot be felt with a fingernail. Use again. (6) Wear on roller that covers a small area, but is deep enough to be felt with a fingernail. Do Not Use Again. (7) Heavy pitting or galling. Do Not Use Again.

Corrosion

Illustrations 136 and 137 show corrosion from poor storage procedures.

Illustration 136	g01745733
Rust on the body near the roller Reuse the lifter.

Illustration 137	g01745893
Damage from rust on the opposite end of the body from the roller Reuse the lifter after polishing.

Illustration 138	g01746656
This lifter has damage from corrosion to the roller. This roller was allowed to get wet and the moisture caused rust. The roller cannot be used again because the rust is in a highly loaded area. The roller will crush from fatigue at the rust locations. Do not reuse the lifter.

Handling and Storage Damage

Illustration 139	g01746736
Scratches on the roller from improper handling Reuse the lifter.

Note: Polishing can cause flat spots on the roller. Dents or nicks can also be found due to poor storage and poor handling. If there is raised material around the damage, the material must be removed by polishing. The roller lifter may be reused if the diameter of the body is within the diameter limits listed in Table 13. Reuse the lifter only if scratches or dents are shallow.

Illustration 140	g01746855
Dents and nicks from improper handling Reuse the lifter after polishing.

Wear of the Roller

Illustration 141	g01996694
The lifter has normal, circumferential wear.

Reuse the lifter.

Note: Certain models are designed so that the roller cannot be removed from the lifter.

This example shows frosting, which is a result of micro-spalling. Notice there are circumferential lines and horizontal lines of frosting.

Illustration 142	g01746896
Frosting of the roller Do not reuse the lifter.

The next four examples show typical wear. The bright appearance and the polished appearance are typical. The circumferential scratches are usually the result of dirt or debris.

Illustration 143	g01746973
Normal wear on the roller Reuse the lifter.

Illustration 144	g01748013
Normal wear on the roller Reuse the lifter.

Illustration 145	g01748074
Typical example of light circumferential wear Reuse the lifter.

Illustration 146	g01748258
Typical example of light circumferential wear that cannot be felt with a fingernail Reuse the lifter.

Illustration 147	g01748700
Typical example of heavy pitting or galling Do not reuse the lifter.

Illustration 148	g01748997
Typical example of pitting. The pitting is not heavy, but is still unacceptable. Do not reuse the lifter.

Illustration 149	g01749234
Typical example of non-circumferential wear. Scuffing of the roller can be seen between the arrows. Scuffing is an indication that the roller has not been properly rotating. Do not reuse the lifter.

Illustration 150	g01750253
Typical example of damage caused by pin wear or roller wear. Do not reuse the lifter.

Wear on the Body

The following examples all show typical wear. The wear areas on the body of the roller lifter may take several forms from dull and scratched to bright and polished. The areas of wear should be polished to remove any raised material from the scratches.

The diameter of the body should be measured after the lifter has been polished.

Illustration 151	g01750813
Typical wear to the body Reuse the lifter.

The wear pattern stops in a straight line in these examples. These roller lifters can be used again unless a wear step can be felt with a fingernail. The areas of wear should be polished to remove any raised material from the scratches. After the polishing procedure, the diameter of the body should be measured. This measurement will make sure that the diameter is within the specified limits.

Illustration 152	g01750994
Typical wear of the body Reuse the lifter.

Illustration 153	g01751698
Typical wear of the body Reuse the lifter.

Slipper Followers

Visual Inspection

Illustration 154 shows the condition of the contact surface in a new slipper follower. Illustration 155, Illustration 156, Illustration 159, and Illustration 160 show some of the more common types of wear to slipper followers.

For good service life, each slipper follower must be installed in the original location so that the follower runs against the same camshaft lobe.

You can install a new slipper follower on a used camshaft if the camshaft does not have wear on the lobe that can be easily seen or felt and if the original slipper follower also had a wear pattern that was normal and smooth. If either the slipper follower or the camshaft lobe has heavy wear, the camshaft should be replaced.

With new camshafts, new or reconditioned followers must be used.

A slipper follower is wearing normally if the surface has a mirror finish. If the surface of the lifter that contacts the camshaft is dull, the lifter is experiencing rapid wear. The lifter should be replaced.

Illustration 154	g06266631
The contact surface is convex on a new slipper follower.

Illustration 155	g06266632
The contact surface of this used slipper follower is concave. The wear goes to the outside diameter and the wear has caused a rough edge.

Do not reuse the follower.

Illustration 156	g01995593
The contact surface of this slipper follower is concave.

Reuse the follower if the follower meets the specifications in Illustration 157.

Illustration 157	g01995954
(A) Length of follower (B) Depth of concave surface

The follower can be reused if the depth of the concave surface is less than 0.25 mm (0.010 inch). This type of wear is only acceptable if the follower is installed on the same camshaft lobe. The camshaft must meet the criteria in Reuse and Salvage Guideline, SEBF8146, "Camshaft Inspection Process".

Illustration 158	g01996053
Measurement for maximum allowable concave wear (B) Depth of concave surface (1) 3P-1568 Dial Indicator (2) Slipper Follower (3) Surface Plate

Illustration 159	g01996134
The follower has a normal amount of circumferential wear.

Reuse the follower.

Illustration 160	g01996138
Some of the wear is not circumferential. The rotation of the slipper in the bore has not been constant.

Do not reuse the follower.

Salvage of Slipper Followers

Illustration 161	g01996974
(F) Minimum reusable length (6) Ball for measuring (7) Radius on face

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NOTICE
Followers that are too short can result in early wear of the camshaft and follower because the follower does not have the necessary hardness.

Illustration 161 shows the location of measurement for slipper followers that have been ground. The specifications for minimum reuse apply to the follower after 0.25 mm (0.010 inch) have been ground off.

To measure the minimum length for reuse, put the correct ball on the end of the slipper follower. Use a micrometer to measure the distance over the end of the follower and the outside diameter of the ball as shown in Illustration 161.

The surface finish of the follower must be 0.20 µm (8.0 µinch) or smoother.

Note: Some followers may have a layer of protection over the surface which will make the surface finish rougher.

The slipper face must be crowned. The radius must be the same as the radius on a new lifter. Approximate radii are shown in Table 10.

Use a dressing stone to shape the follower to the correct radius. To check the radius, lightly grind the face of a new lifter and check for correct profile.

The crown on the slipper follower must be exactly symmetrical to the sides of the follower. There are two quality control checks for checking the grinding machine.

Illustration 162	g01997274
(B) Height of convex surface (1) 3P-1568 Dial Indicator (8) Location to start the measurement for runout of the crown. (9) Highest point of the crown (10) Location to end measurement for runout of the crown

1. Check the runout of the crown.

   1. Put the tip of the indicator at point (8) while the follower is on the grinder.

   2. Turn the follower from (8) to (10). The dial indicator must not move more than the specification for total indicated runout shown in Table 10.

2. Check the correct amount of radius or “crown”.

   1. Put the follower on a surface plate.

   2. Install a 3P-1568 Dial Indicator on a magnetic base and measure the height between location (9) and locations (8) and (10).

   3. The difference must be acceptable according to the specifications in Table 10.

Table 10

Reference Dimensions
Part Number	Minimum Reusable Length	Diameter of the ball	Approximate Radius on Face	T.I.R.	Checking Diameter	Height of Crown
102-1561	123.22 mm (4.851 inch)	11.910 mm (0.469 inch)	11940.00 mm (470.078 inch)	0.038 mm (0.0015 inch)	38.10 mm (1.500 inch)	0.005 mm - 0.025 mm (0.0002 inch - 0.0010 inch)
5S-1220	133.53 mm (5.257 inch)	11.910 mm (0.469 inch)	11940.00 mm (470.078 inch)	0.038 mm (0.0015 inch)	38.10 mm (1.500 inch)	0.005 mm - 0.025 mm (0.0002 inch - 0.0010 inch)
5M-2277	59.44 mm (2.340 inch)	N/A	2032.00 mm (78.000 inch)	0.025 mm (0.0010 inch)	25.40 mm (1.000 inch)	0.030 mm - 0.051 (0.0012 inch - 0.0020)
2H-3069	165.28 mm (6.507 inch)	11.910 mm (0.469 inch)	11940.00 mm (470.078 inch)	0.038 mm (0.0015 inch)	38.10 mm (1.500 inch)	0.005 mm - 0.025 mm (0.0002 inch - 0.0010 inch)
9N-5786	54.69 mm (2.153 inch)	11.113 mm (0.438 inch)	3962.00 mm (155.984 inch)	0.0191 mm (0.00075 inch)	19.05 mm (0.750 inch)	0.0076 mm - 0.0152 mm (0.00030 inch - 0.00060 inch)
7S-3161	66.55 mm (2.620 inch)	11.113 mm (0.438 inch)	2032.00 mm (78.000 inch)	0.020 mm (0.0008 inch)	25.40 mm (1.000 inch)	0.031 mm - 0.051 mm (0.0012 inch - 0.0020 inch)

Roller Followers

Nomenclature

Illustration 163	g03191717
Camshaft Roller Follower Nomenclature (1) Roller (2) Roller Pin (3) Body (4) Lifter shaft assembly

Wear Limits

Maximum wear limits have been established to aid in determining the reusability of camshaft roller followers. Use the following information to determine if a roller follower can be used again.

Check the movement of the roller on the lifter arm. If movement of the roller is greater that the value in Table 11, replace the lifter assembly.

Illustration 164	g03191856
Allowable vertical and horizontal movement of the roller in the lifter assembly. The allowable movement applies to both the injector roller follower and the valve roller follower. Refer to Table 11 for the correct specifications. (1) Valve roller follower (2) Injector roller follower

Table 11

Maximum Allowable Movement of Roller Follower and Minimum Diameter of Lifter Shaft Assembly
Maximum Movement in Direction A	Maximum Movement in Direction B	Minimum Outside Diameter of Shaft
0.165 mm (0.0065 inch)	0.165 mm (0.0065 inch)	15.60 mm (0.6142 inch)

Roller Lifters

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NOTICE
Never permit lifters to become mixed or install lifters against a different lobe. Mixing the lifters and camshaft lobes will result in a faster wear rate or failure. Never install a used lifter with a new camshaft.

Nomenclature

Illustration 165	g06266661
Camshaft Roller lifter Nomenclature. (1) Body (2) Roller pin (3) Roller

Lubricating Ports

Illustration 166	g01736853
(1) Pressure lubricating ports (2) The location of oil flow if lube passages are not plugged. (3) 3500B and 3500C Roller Lifters (4) 3500A Roller Lifter (5) 3500A Non-Pressure Lubricated Engine Lifter

Prior to the installation of the lifter, use an oil can with clean oil to lubricate the roller pin. Use the lube port to pump the oil into the roller. If the lube passage in the lifter body is not plugged, clean oil will flow from the clearance between the pin and the roller and from the forks of the lifter body at location (1) in Illustration 166.

The roller lifters from 3500A engines may not be pressure lubricated. Lifters that are not pressure lubricated will not have the lube port on the side of the filter. In that case, the roller lifters should be submerged in an oil bath for at least 1 hour. The best method is to hang the roller lifters in a vertical manner. This is the orientation the lifters would have in an engine. This method ensures that oil fills the space between the roller pin and the roller. This method can be carried out by making a tank and a rack that holds the roller lifters for one complete engine.

Wear Limits

Maximum wear limits have been established to aid in determining the reusability of roller lifters. Use the following information along with Illustration 167 through 169 to determine reusability.

Illustration 167	g06266675
Movement in the direction of callout (D) is normal. Movement in the direction of callout (C) should not exceed the amount of movement in direction (D). If movement in direction (C) is greater, heavy pin wear is likely.

Table 12

Maximum Allowable Total Movement for Reusability
Engine	Direction of movement (C)	Direction of movement (D)	Direction of movement (E)
C7 3114 3116 3126	0.40 mm (0.016 inch)	0.40 mm (0.016 inch)	0.80 mm (0.032 inch)
C9	0.116 mm (0.00457 inch)	0.116 mm (0.00457 inch)	4.99 mm (0.19646 inch)
C15 C18 C27 C32	0.116 mm (0.0046 inch)	0.116 mm (0.0046 inch)	0.375 mm (0.0148 inch)
3208	0.178 mm (0.0070 inch)	0.178 mm (0.0070 inch)	0.508 mm (0.0200 inch)
3306B	0.115 mm (0.0045 inch)	0.115 mm (0.0045 inch)	0.375 mm (0.0148 inch)
3400	0.178 mm (0.0070 inch)	0.178 mm (0.0070 inch)	0.508 mm (0.0200 inch)

Illustration 168	g06267067
Refer to Table 13 for specifications on maximum allowable movement.

Note: For directions (A) and (B), measure along the centerline of the roller.

Table 13

Maximum Allowable Movement and Minimum Diameter
Engine	3500A(1)	Valve Lifter from 3500B and C Series Engines	Injector Lifter from 3500B and C Series Engines
Direction (A)	0.38 mm (0.015 inch)	0.71 mm (0.028 inch)	0.38 mm (0.015 inch)
Direction (B)	0.38 mm (0.015 inch)	0.71 mm (0.028 inch)	0.38 mm (0.015 inch)
Direction (C)	0.71 mm (0.028 inch)	0.71 mm (0.028 inch)	0.71 mm (0.028 inch)
Minimum OD of body (D)	29.882 mm (1.1765 inch)	29.890 mm (1.1768 inch)	34.932 mm (1.3752 inch)
Minimum OD of body at length (E)	29.890 mm (1.1768 inch)	29.890 mm (1.1768 inch)	34.940 mm (1.3756 inch)(2)

(1)	Pressure Lubricated
(2)	Some early injector lifters from the 3500B series of engines were ground to 34.915 mm (1.3746 inch) minimum diameter. These injector lifters can be reused if wear has not reduced the diameter below 34.915 mm (1.3746 inch).

Illustration 169	g06267068

Table 14

Dimension	3500A	Valve from 3500B and C Series Engines	Injector from 3500B and C Series Engines
(F)	150.00 ± 1.00 mm (5.906 ± 0.039 inch)	146.50 ± 1.00 mm (5.768 ± 0.039 inch)	146.50 ± 1.00 mm (5.768 ± 0.039 inch)
(G)	87.30 ± 0.30 mm (3.437 ± 0.012 inch)	87.30 ± 0.30 mm (3.437 ± 0.012 inch)	78.00 ± 0.50 mm (3.070 ± 0.017 inch)
(H)	63.00 ± 0.50 mm (2.480 ± 0.020 inch)	59.80 ± 0.30 mm (2.354 ± 0.012 inch)	58.00 ± 0.50 mm (2.283 ± 0.197 inch)
(I)	17.00 ± 0.50 mm (0.669 ± 0.020 inch)	17.00 ± 0.50 mm (0.669 ± 0.020 inch)	17.00 ± 0.50 mm (0.669 ± 0.020 inch)

The roller lifter should not have nicks, dents, or scratches. Check for any damage that causes any form of raised material on outside diameter (J) of the body of the roller lifter. Minor wear and damage can be removed by polishing. The outside diameter must be greater than the specification for the minimum diameter. The minimum diameter is shown in Table 13.

C175 Lifter Assembly Mechanism

Illustration 170	g06209516
(A) Housing (B) Lifter assembly (C) Lifter shaft

Lifter Housing

Illustration 171	g06319943
Bottom view and inspection surface of 384-5330 Housing Assembly

Illustration 172	g06319949
Example of crack found along thin cross-sections beside the two hollow dowels.

Illustration 173	g06218924
(1) Hollow dowel (2) Machining marks

384-5330 Housing Assembly:

• Inspect abutment surface of housing for fretting or damage. Any housings with a wear step or damage to a depth of 0.26 mm (0.01024 inch) or beyond (relative to the original surface) should not be reused / reworked with a new lifter shaft. Inspect housings for cracks in the thin cross-sections beside the two hollow dowels which locate the shaft.

• If the original machining marks are visible through the wear, refer to Illustration 173 (machine marks in wear). The lifter shaft cover can be reused as long as the same shaft is installed on the same lifter shaft cover in the same orientation.

Illustration 174	g06219123
Cover orientation

• Mark the lifter shaft cover similar to Illustration 174 (cover orientation) to establish orientation. Mark the lifter shaft in the same manner and number the shaft and cover.

• The lifter shaft cover and lifter shaft must be installed together, and in this orientation for the parts to be reused.

Illustration 175	g06219125

• The cover can be reused if the hollow dowel is damaged as shown in Illustration 175.

The 357-9456 Bolts that attach the lifter shaft to the lifter shaft housing should only be used one time. If the bolts are removed for any reason, new bolts should be installed.

Lifter Housing Rework

To provide addition clarification and details, a Caterpillar Channel 1 video has been created outlining the critical steps in removing and installing dowels. Reviewing the video is recommended prior to starting the process.

Note: A CWS login is required to access Caterpillar Channel 1 Videos.

Table 15

Caterpillar Channel 1
Title:	"C175 Lifter Housing Rework"
Caterpillar Channel 1 URL:	https://channel1.mediaspace.kaltura.com/media/C175+Lifter+Housing+Rework/1_rebjozbz

Show/hide table

Illustration 176	g06353192
1U-9570 Dowel Puller Group

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Illustration 177	g06353200
Hollow dowels from the housing.

1. Remove the two hollow dowels from the housing using 1U-9570 Dowel Puller Group.
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   Illustration 178	g06353210

2. Mill 0.26 mm (0.01024 inch) (A) from both lifter shaft abutment pads on the housing.
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   Illustration 179	g06353223

3. Remachine 1.0 mm (0.03937 inch) (B) chamfer on the 4 long edges (perpendicular to the lifter shaft) of the abutment pads. This will ensure that the edges of the pads do not contact the internal fillet on the shaft prior to full surface contact between the housing and shaft mounting faces.
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   Illustration 180	g06353232

4. Thoroughly flush internal threads and oil passage within the housing to ensure that there are no machining chips remaining
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   Illustration 181	g06353238

5. Reinstall two new 357-4820 Hollow Dowels within the housing using FT-3571 to control the depth of insertion into the housing.

   Note: Installing the dowels to the point of bottoming out within the housing bore can lead to a reduction in oil supply to the lifter / roller assembly.

   Show/hide table

   Illustration 182	g06353240

6. Slide two 551-1529 Friction Shims over the two hollow dowels until they contact the mounting surfaces on the housing. Take care to orient the shims such that the edges of the shims are parallel with the sides of the two mounting pads in the housing.

7. Install the lifter shaft (with lifters and spacers assembled) onto the two dowels until the shaft contacts the surface of the friction shim. Refer to KENR6052 Disassembly and Assembly procedure for lifters & shaft.

   Note: If the shims and shaft are installed correctly, the two rectangular tabs at each end of the shim should be visible beyond the diameter of the shaft.

8. Install two new 357-9456 Bolts and torque to specified torque value.

Lifter Lever Assembly

Illustration 183	g06209518
(F) Roller

Illustration 184	g02921337

This bushing shows no signs of significant wear and meets the specifications that are listed. This bushing can be used again.

Illustration 185	g02921338

The roller on this lifter shows no signs of significant wear. No pitting is visible and no wear can be felt with a fingernail. This roller lifter can be used again.

Table 16

Lift Lever Assembly
Callout	Description	Value
D	Inner Diameter of Bushing	38.1 ± 0.013 mm (1.50 ± 0.0005 inch)
	Surface Texture of Bushing	0.8 µm (31.50 µinch)
	Installation Depth of Bushing	0.5 ± 0.25 mm (0.020 ± 0.010 inch)
E	Indicator Mark	Do not reuse the lift lever assembly if the mark (E) on the roller has rotated more than 5 degrees past the vertical plane.

Shaft

Visual check for any nicks and dings.

Illustration 186	g06219130
357-4823 Shaft Assembly: (3) Check for fretting on bottom of hole pads (4) Check for fretting on top of hole pads

• Fretting or wear is not desirable on the lifter shaft housing mounting face of the lifter shaft. If you can feel a wear step or any raised material on the lifter shaft housing mounting face, the shaft should not be reused with a new lifter shaft cover.

• As described above, the lifter shaft can be reused with the matching lifter shaft cover as long as the shaft and cover are marked and documented as a matching set.

• Fretting or wear is not allowable on the 357-4823 Shaft Assembly bolt mounting face of the lifter shaft. If you can feel a wear step or any raised material on the 357-4823 Shaft Assembly bolt mounting face, the shaft should not be reused.

Illustration 187	g06271518

Ensure that the plug is not loose and can withstand 800 kPa (116 psi) without loosening in the shaft.

Illustration 188	g06271556

Ensure that oil gallery and oil holes are clean and free from debris. Check for ball inside the oil gallery.

Illustration 189	g06271537

Table 17

Lift Lever Shaft
(B) Shaft Diameter (Four Places)	38.04 ± 0.013 mm (1.498 ± 0.0005 inch)Surface Texture 0.125 µm (4.92126 µinch)
Surface Texture	0.125 µm (4.92126 µinch)

3600 Injector and Valve Lifter Group

During the operation of any engine, each roller follower wears to a specific fit with the cam lobe it runs against. At the point of contact, each follower and lobe will develop a similar wear pattern.

Note: Used followers need to be installed in the original bores during reassembly. If not, the differences in wear patterns can result in a faster rate of wear and/or failure.

Illustration 190	g06267082
Part numbers facing out, as shown

When installing the lifter, in the lifter guide, the part number must face "out" as shown.

Mark each follower during disassembly to provide positive identification and to make sure that the follower is installed in the original location. Never permit followers to become mixed or installed against a different lobe on the camshaft. Never install a used follower of any type with a new camshaft unless the follower is in "like new" condition.

Roller followers that are used again according to the information given in this guideline and other applicable guidelines can be expected to give normal performance until the next overhaul when used again in the same application.

Components of Lifter Group

Illustration 191	g06267086

Illustration 192	g06267087

Table 18

Chart A 1W-2470 Valve Lifter Group
Item	Qty	Part Number	Description
1	4	8D-7941	Bolt
2	1	1W-0020	Lifter Guide
3	2	194-0629	Valve Lifter As
4	1	194-0630	Unit Injector Lifter Assembly
5	2	1W-2473	Guide Spring(1)
6	3	5P-7701	O-Ring Seal
7	3	1W-1756	Lifter Insert
8	3	8T-6759	Pipe Plug

(1)	Lifter guide springs may be assembled on lifter assemblies only ONCE. Refer to the "Note" that follows.

Note: If a lifter spring is removed from a lifter assembly, the guide spring must be replaced with a new guide spring before reassembly. Lifter assemblies may be removed from guide bores and reassembled without replacing guide springs if the guide spring was not removed from the lifter assembly and the lifter assembly is assembled in the same guide bore.

Component Reusability Specifications

Valve Lifter Body

Illustration 193	g06267088

Table 19

Chart D Valve Lifter Body
Item	Description	Min. Reuse	Max. Reuse
A	Lifter body diameter	41.870 mm (1.6484 inch)	N/A
B	Roller diameter	N/A	60.00 mm (2.362 inch)

Injector Lifter Body

Illustration 194	g06267089

Table 20

Chart E Injector Lifter Body
Item	Description	Min. Reuse	Max. Reuse
A	Lifter body diameter	55.860 mm (2.1992 inch)	N/A
B	Roller diameter	N/A	80.00 mm (3.148 inch)

Lifter Guide Housing

Illustration 195	g06267090

Table 21

Chart F Lifter Guide Housing
Dimension	Max. Reuse
Injector lifter bore (A)	56.050 mm (2.2067 inch)
Valve lifter bore (B)	42.050 mm (1.6555 inch)

Visual Inspection of Rocker Arms

During the operation of the engine, each rocker arm and rocker arm shaft develops a specific wear pattern. This wear pattern is unique to each particular bearing and rocker arm socket. Therefore, to assure maximum component life, each rocker arm, and rocker arm shaft must be reinstalled in its original position. If the rocker arm and rocker arm shaft are not installed in the same location, the difference in the wear patterns will result in a faster rate of wear, or possible failure.

These matching wear patterns are also formed on rocker arms and valve bridges, push rods and injector rocker arms, and adjusting screws and buttons. If one of the two parts in these pairs is replaced, so must the other. If one is used again, its corresponding part must also be used again.

Valve train components that meet these salvage guidelines and specifications can be expected to perform normally in the same application until the next engine overhaul. Never install a part that this Guideline indicates cannot be used again. Before installing a used or reconditioned part, correct any conditions that may have caused the original wear.

A new rocker can be installed on a used camshaft if the camshaft meets reusability criteria. A new camshaft requires the use of a new roller. Never install a used roller rocker onto a new camshaft or premature wear can result.

Excessive wear patterns can be detected with simple inspection methods. This type of wear is typically visible to the eye. Excessive wear patterns indicate that the part should not be reused. Check for wear at the contact surfaces between the rocker arm assembly and the bridge. Typically excessive wear is not present in this area.

Check all parts for surface damage. There must not be any pitting, corrosion, or smeared material on the contact surfaces. If all the parts show normal wear patterns and are free from defects, they can be used again.

Check the rocker arm shaft for excessive wear. An obvious indication of excessive wear is when the rocker arm feels loose on the rocker arm shaft. If the wear is excessive and can be felt with the fingernail, do not use the shaft again.

Rocker Arms for 3176, 3196, C-10, and C-12

Rocker Arms

Inspect the pad of the valve rocker arm for wear. The pad should be smooth and shiny. Roughness, pitting, or wear over more than half the surface makes the rocker arm unusable. An exhaust valve rocker arm is shown in illustrations 196 through 198, however the same use again criteria applies to the intake valve rocker arms.

Illustrations 196 through 198 show progressive stages of wear to the rocker arm pad.

Illustration 196	g06267424
Minimal wear. The wear area is shown in white.

Use again if all other reusability requirements are met.

Illustration 196 shows a rocker arm pad with minimal wear. The shiny area, shown in white, is small. This shiny area grows progressively larger as the pad wears.

Illustration 197	g06267427
Center-to-center distance of worn pad area (A) cannot exceed 60 percent of the pad area or 8 mm (0.3 inch) on either the intake or exhaust rocker arms. The wear area is shown in white.

Use again if wear area does not exceed specifications.

The wear area shown in Illustration 197 covers approximately 60 percent or 8 mm (0.3 inch) of the pad, which is the maximum allowable amount of wear.

Illustration 198	g06267430
Excessive wear. Greater than 60 percent or 8 mm (0.3 inch) of pad area. (B) Raised material. (C) Worn away material.

Do not use again

Illustration 198 shows a rocker arm pad with excessive wear. Raised edges will appear on the pad because an excessive amount of material has worn away from the center of the pad. Do not reuse a rocker arm that has raised material in the pad area.

Illustration 199	g06267432
Maximum allowable wear on exhaust valve rocker arm.

Use again if all other reusability requirements are met.

Illustration 199 shows the maximum allowable wear on an exhaust valve rocker arm pad. The worn area appears as a shiny spot on the pad area and covers approximately 60 percent or 8 mm (0.3 inch) of the pad. Make sure that the worn area is free from raised material, pitting, or rippling. Exhaust valve rocker arms with this amount of wear, or less, can be reused.

Illustration 200	g06267435
Maximum allowable wear is 60 percent or 8 mm (0.3 inch) of pad area on intake valve rocker arm.

Use again if all other reusability requirements are met.

Illustration 200 shows the maximum allowable wear on an intake valve rocker arm pad. The worn area appears as a shiny spot on the pad area and covers approximately 60 percent or 8 mm (0.3 inch) of the pad. Make sure that the worn area is free from raised material, pitting, or rippling. Intake valve rocker arms with this amount of wear, or less, can be reused.

Illustration 201	g06267441
Rocker arm pad with raised material.

Do not use again

The rocker arm pad in Illustration 201 has excessive wear resulting in raised material. This raised material appears as small dark slivers around the edge of the worn area. These raised areas may only be on one side of the worn area. Regardless of the location, do not use rocker arms with raised material on the pads.

Illustration 202	g06267442
Raised material on the pad of an intake valve rocker arm.

Do not use again

Illustration 202 shows an intake rocker with raised material on one side of the worn area. Regardless of the location, do not use rocker arms with raised material on the pads.

Illustration 203	g06267444
Raised material on tip of rocker arm pad.

Do not use again

Illustration 204	g06267447
This rocker arm pad is rough. Even though the wear area is less than 60 percent or 8 mm (0.3 inch), roughness on the pad is not allowed.

Do not use again

Illustration 205	g06267448
This rocker arm pad shows signs of pitting. Any type of pitting is unacceptable. Even though the damaged area is less than 60 percent or 8 mm (0.3 inch), pitting on the pad is not allowed.

Do not use again

Illustration 206	g06267451
This rocker arm has pitting and waviness in the pad area.

Do not use again

Injector Rocker Arm Adjusting Screw and Button

Illustration 207	g06267454
Adjusting screw.

Use again if it is unblemished, with no sharp edges, and measures greater than 12.6 mm (0.50 inch) in diameter. See Illustration 209.

Illustration 208	g06267456
Adjusting screw.

Do not use again

The adjusting screw head is out of round, scarred, and is less than 12.6 mm (0.50 inch) in diameter.

Illustration 209	g06267460
Use a micrometer to measure outside diameter (D) of adjusting screw head.

Illustration 210	g06267462
Button. Do not reuse buttons with a new adjusting screw. The button O-ring can be reused if there is no visible damage.

Do not use again if button shows pitting, scarring, grooves, or excessive wear.

Push Rod and Injector Rocker Arm Insert

Illustration 211	g06267465
Top view of injector push rod. If the injector push rod is replaced, the injector rocker arm must also be replaced.

Do not use again if there is raised material, smearing in cup or shows signs of wear, grooves, or stepping.

Nomenclature for C9, and C-9 Engines

Illustration 212	g02159597
Nomenclature for the valve mechanism group. (1) Nut (M10 x 1.5 Thread) (2) Valve adjusting screw (3) Bolt (M12 x 1.75 Thread) (4) Washer (5) Insert (6) Button (7) Shaft support (end) (8) Plug (9) Intake valve rocker arm (10) Spring (11) Exhaust valve rocker arm (12) Rocker arm shaft assembly (13) Shaft support (middle) (14) Shaft support (oil)

Table 22

Specifications for 155-7927 Valve Mechanism
Item	Part Number	Description	Maximum Diameter	Minimum Diameter
(2)	183-4365 260-7524	Adjusting Screw	8.40 mm (0.331 inch)	8.00 mm (0.315 inch)
(5)	161-3394	Insert	7.089 mm (0.279 inch)	7.063 mm (0.278 inch)
(6)	164-5671	Button	8.06 mm (0.317 inch)	8.02 mm (0.316 inch)
(7)	164-5669	Shaft Support (End)	28.063 mm (1.105 inch)	28.037 mm (1.104 inch)
(8)	8F-6575	Plug	19.38 mm (0.763 inch) Average
(9)	161-3392	Rocker Arm (Intake valve)	28.063 mm (1.105 inch)	28.037 mm (1.104 inch)
(10)	163-2459	Spring I.D. Spring O.D.	29.98 mm (1.180 inch) 34.80 mm (1.370 inch)
(11)	161-3391	Rocker Arm (Exhaust valve)	28.063 mm (1.105 inch)	28.037 mm (1.104 inch)
(12)	161-3389	Rocker Arm Shaft (O.D.)	28.013 mm (1.1029 inch)	27.987 mm (1.1019 inch)
		Rocker Arm Shaft (I.D. for plug)	19.12 mm (0.753 inch)	19.18 mm (0.755 inch)
(13)	176-5913	Shaft Support (Middle)	28.063 mm (1.105 inch)	28.037 mm (1.104 inch)
(14)	176-5914	Shaft Support (Oil)	28.063 mm (1.105 inch)	28.037 mm (1.104 inch)
N/A	133-6379 264-6156	Push Rod (Int/Exh)	11.201 mm (0.4409 inch)	11.049 mm (0.4350 inch)

Table 23

Specifications for 348-9896 Valve Mechanism
Item	Part Number	Description	Maximum Diameter	Minimum Diameter
(2)	260-7524	Adjusting Screw	8.40 mm (0.331 inch)	8.00 mm (0.315 inch)
(5)	260-9576	Insert	7.089 mm (0.279 inch)	7.063 mm (0.278 inch)
(6)	260-9576	Button	8.05 mm (0.31693 inch)	8.01 mm (0.31535 inch)
(8)	0L-1026	Plug	13.0 mm (0.51181 inch) Average
(9)	255-8670	Rocker Arm (Intake valve)	21.561 mm (0.84886 inch)	21.535 mm (0.84783 inch)
(11)	347-8749	Rocker Arm (Exhaust valve)	21.561 mm (0.84886 inch)	21.535 mm (0.84783 inch)
(12)	274-5874	Rocker Arm Shaft (O.D.)	21.487 mm (0.84594 inch)	21.513 mm (0.84697 inch)
		Rocker Arm Shaft (I.D. for plug)	12.777 mm (0.50303 inch)	12.827 mm (0.50500 inch)
N/A	261-0205	Push Rod (Int/Exh)	11.201 mm (0.4409 inch)	11.049 mm (0.4350 inch)

Table 24

Surface Texture
Description	Specification
Rocker Arm Shaft	0.50µm (19.690 µinch)
Rocker Arm	0.80 µm (31.4960 µinch)

Nomenclature for 3044 Engines

Illustration 213	g06270802
Nomenclature for the 3044 valve mechanism group (1) Adjusting screw and locknut (2) Spring (3) Rocker shaft bracket (4) Rocker arm assembly (5) Snap ring (one at each end)

Nomenclature for 3046 Engines

Illustration 214	g06270804
Nomenclature for the 3046 valve mechanism group (6) Snap ring (one at each end) (7) Rocker arm assembly (8) Rocker shaft bracket (9) Spring (10) Shaft assembly (11) Plug (one at each end)

Nomenclature for 3054, and 3056 Engines

Illustration 215	g06270822
(1) Rocker Arm Shaft (2) Rocker Arm Bushing (3) Rocker Arm

Table 25

Valve Mechanism Group for 3054, and 3056 Engines
Item	Description	Maximum Diameter	Minimum Diameter
(1)	Arm Shaft	19.04 mm (0.74960 inch)	19.01 mm (0.74842 inch)
(2)	Rocker Arm Bushing Outside Diameter	22.31 mm (0.87834 inch)	22.28 mm (0.87716 inch)
	Rocker Arm Bushing Inside Diameter	19.01 mm (0.74842 inch)	19.06 mm (0.75039 inch)
	Clearance Between the Rocker Arm Bushing and Rocker Shaft	0.09 mm (0.00354 inch)	0.03 mm (0.00118 inch)
	Maximum Permissible Clearance Between the Rocker Arm Bushing and Rocker Shaft	0.13 mm (0.00512 inch)	N/A
(3)	Rocker Arm	22.26 mm (0.87638 inch)	22.23 mm (0.87520 inch)

Table 26

Surface Texture
Description	Specification
Rocker Arm Shaft	0.80 µm (31.4960 µinch)
Rocker Arm

Nomenclature for 3064, and 3066 Engines

Illustration 216	g06270805
Nomenclature for the 3066 and 3064 valve mechanism group (12) Clip (13) Spacer (14) Shaft assembly (15) Rocker arm (16) Rocker arm bushing (17) Rocker shaft bracket (18) Spring (19) Oil supply tube (20) Bolt

Note: The 3066 Engine has two cylinder heads, while the 3064 Engine has one cylinder head.

Illustration 217	g01239077

Measure the inside diameter of the rocker arm bushing (21) and measure the diameter of the shaft assembly (22). See Illustration 217. Determine the clearance of the oil between the rocker arm bushing and the shaft assembly by subtracting the dimension of the shaft assembly from the dimension of the rocker arm bushing. Compare the dimension with the specifications in Table 27 and 28. If the dimension is not between the maximum and the minimum, replace the bushing. If the dimension is more than the repair limit replace both the rocker arm bushing and the shaft assembly.

The following chart provides the specifications for the valve mechanism group. Use these specifications to inspect the rocker arms and use these specifications to assemble the rocker arms.

Table 27

Specifications for 3044 and 3046 Valve Mechanism Group
Part Description	Nominal	Maximum	Minimum	Repair Limit
Rocker arm bushing The bore dimension of the rocker arm bushing	19 mm (0.7480 inch)	19.030 mm (0.7492 inch)	19.010 mm (0.7484 inch)	N/A
Rocker arm shaft Diameter of the rocker arm shaft	19 mm (0.7480 inch)	19.000 mm (0.7480 inch)	18.980 mm (0.7472 inch)	N/A
Clearance of the rocker arm bushing and the shaft	N/A	0.050 mm (0.0020 inch)	0.010 mm (0.0004 inch)	0.070 mm (0.0028 inch)

Table 28

Specifications for 3064 and 3066 Valve Mechanism Group
Part Description	Nominal	Maximum	Minimum	Repair Limit
Rocker arm bushing The bore dimension of the rocker arm bushing	20 mm (0.7874 inch)	20.094 mm (0.7911 inch)	20.011 mm (0.7878 inch)	N/A
Rocker arm shaft Diameter of the rocker arm shaft	20 mm (0.7874 inch)	19.984 mm (0.7868 inch)	19.966 mm (0.7861 inch)	N/A
Clearance of the rocker arm bushing and the shaft	N/A	0.128 mm (0.0050 inch)	0.27 mm (0.0106 inch)	0.15 mm (0.0059 inch)

Illustration 218	g06270807

Inspect the bushing (24) for wear or damage. Use the driver to remove the old rocker bushing from the rocker arm (23). Use the driver to install the new rocker arm bushing in the rocker arm.

Illustration 219	g01239096

When there is a need to replace the bushing in the rocker arm align the oil hole in the rocker arm bushing with the oil hole in the rocker arm. See Illustration 219.

Illustration 220	g01239103

Measure each pushrod (27) runout using V-blocks and a dial indicator. If the measurement is more than the standard replace the pushrod.

Table 29

Pushrod for 3046 and 3046 Engines	Standard
Runout of pushrod	0.3 mm (0.012 inch) or less

Table 30

Pushrod for 3064 and 3066 Engines	Standard
Runout of the pushrod	0.4 mm (0.0157 inch) maximum

Illustration 221	g06270810
Number 28 in the illustration shows a normal contact pattern. Numbers 29 and 30 in the illustration show abnormal contact patterns.

Check the camshaft contact surface of each tappet. Replace the tappet if the surface is abnormally worn. See Illustration 221.

Note: Investigate the causes of abnormal wear and correct the conditions that caused the abnormal wear.

Illustration 222	g01239109

Measure the outside diameter of each tappet (31) and measure the corresponding tappet bore (32) in the cylinder block. See Illustration 222. Determine the clearance between the tappet and the corresponding tappet bore in the cylinder block by subtracting the dimension of the tappet from the dimension of the corresponding tappet bore in the cylinder block. Compare the dimension with the specifications in Table 31 and 32. If the dimension is more than the repair limit replace the tappet.

Table 31

3044 and 3046 Engines	Standard	Repair Limit	Service Limit
Inside diameter of the tappet bore in the cylinder block	14.000 to 14.018 mm (0.5512 to 0.5519 inch)	N/A	14.100 mm (0.5551 inch)
Clearance between the tappet and the tappet bore in the cylinder block	0.016 to 0.052 mm (0.0006 to 0.0021 inch)	0.08 mm (0.0031 inch)	N/A

Table 32

3064 and 3066 Engines	Standard	Repair Limit	Service Limit
Inside diameter of tappet bore in the cylinder block	22.000 to 22.021 mm (0.86614 to 0.86697 inch)	N/A	22.100 mm (0.87008 inch)
Clearance between the tappet and the tappet bore in the cylinder block	0.035 to 0.086 mm (0.0014 to 0.00339 inch)	0.120 mm (0.0047 inch)	N/A

Nomenclature for 3114, and 3116 Engines

Illustration 223	g06270823
Nomenclature for 107-7745, 107-7722, 115-4186, and 119-2910 Valve Rocker Arm Groups

Illustration 224	g06270825
Nomenclature for 115-4180 Valve Rocker Arm Groups

Table 33

Specifications for 107-7722 Rocker Arm Group
Part Number	Description	Maximum Diameter	Minimum Diameter
6I-0586	Rocker Arm (Exhaust Valve)	24.828 mm (0.97748 inch)	24.788 mm (0.97590 inch)
6I-0586	Rocker Arm (Intake Valve)	24.828 mm (0.97748 inch)	24.788 mm (0.97590 inch)
105-1775	Rocker Arm (Injector)	27.937 mm (1.09988 inch)	27.897 mm (1.09830 inch)
7W-4138	Arm Shaft	24.765 mm (0.97500 inch)	24.745 mm (0.97421 inch)
7W-3980	Bearing inside diameter after machining	24.822 mm (0.97724 inch)	24.782 mm (0.97567 inch)

Table 34

Specifications for 107-7745 Rocker Arm Group
Part Number	Description	Maximum Diameter	Minimum Diameter
6I-0586	Rocker Arm (Exhaust Valve)	24.828 mm (0.97748 inch)	24.788 mm (0.97590 inch)
6I-0586	Rocker Arm (Intake Valve)	24.828 mm (0.97748 inch)	24.788 mm (0.97590 inch)
107-7739	Rocker Arm (Injector)	27.937 mm (1.09988 inch)	27.897 mm (1.09830 inch)
7W-4138	Arm Shaft	24.765 mm (0.97500 inch)	24.745 mm (0.97421 inch)
7W-3980	Bearing inside diameter after machining	24.822 mm (0.97724 inch)	24.782 mm (0.97567 inch)

Table 35

Specifications for 115-4186 Rocker Arm Group
Part Number	Description	Maximum Diameter	Minimum Diameter
115-4191	Rocker Arm (Exhaust Valve)	24.828 mm (0.97748 inch)	24.788 mm (0.97590 inch)
115-4191	Rocker Arm (Intake Valve)	24.828 mm (0.97748 inch)	24.788 mm (0.97590 inch)
105-1775	Rocker Arm (Injector)	27.937 mm (1.09988 inch)	27.897 mm (1.09830 inch)
7W-4138	Arm Shaft	24.765 mm (0.97500 inch)	24.745 mm (0.97421 inch)
7W-3980	Bearing inside diameter after machining	24.822 mm (0.97724 inch)	24.782 mm (0.97567 inch)

Table 36

Specifications for 119-2910 Rocker Arm Group
Part Number	Description	Maximum Diameter	Minimum Diameter
115-4191	Rocker Arm (Exhaust Valve)	24.828 mm (0.97748 inch)	24.788 mm (0.97590 inch)
115-4191	Rocker Arm (Intake Valve)	24.828 mm (0.97748 inch)	24.788 mm (0.97590 inch)
105-1775	Rocker Arm (Injector)	27.937 mm (1.09988 inch)	27.897 mm (1.09830 inch)
7W-4138	Arm Shaft	24.765 mm (0.97500 inch)	24.745 mm (0.97421 inch)
7W-3980	Bearing inside diameter after machining	24.822 mm (0.97724 inch)	24.782 mm (0.97567 inch)

Table 37

Specifications for 115-4180 Rocker Arm Group
Part Number	Description	Maximum Diameter	Minimum Diameter
115-4191	Rocker Arm (Exhaust Valve)	24.828 mm (0.97748 inch)	24.788 mm (0.97590 inch)
115-4191	Rocker Arm (Intake Valve)	24.828 mm (0.97748 inch)	24.788 mm (0.97590 inch)
7W-4138	Arm Shaft	24.765 mm (0.97500 inch)	24.745 mm (0.97421 inch)

Table 38

Surface Texture
Description	Specification
Rocker Arm Shaft	0.125 µm (4.92126 µinch)
Bearing	0.80 µm (31.4960 µinch)

Nomenclature for 3176, 3196, C-10, and C-12 Engines

Illustration 225	g06267468
Nomenclature for valve rocker arm group. Refer to Table 39 for item identification.

Table 39

Valve Rocker Arm Group Nomenclature for 3176, 3196, C-10, and C-12 Engines
Item	Description
(1)	Exhaust valve rocker arm
(2)	Nut (M10 x 1.5 Thread)
(3)	Valve adjusting screw
(4)	Nut (M12 x 1.5 Thread)
(5)	Injector Arm Adjusting Screw
(6)	Intake valve rocker arm
(7)	Unit injector rocker arm assembly
(8)	O-ring seal
(9)	Button
(10)	Arm shaft assembly
(11)	Shaft support assembly
(12)	Valve Bridge
(13)	Button
(14)	Injector push rod
(15)	Valve push rod

Illustration 226	g06267472
Nomenclature for unit injector rocker arm assembly. Refer to Table 40 for item identification.

Table 40

Unit Injector Rocker Arm Group Nomenclature
Item	Description
(7)	Unit injector rocker arm assembly
(16)	Bearing
(17)	Bearing joint
(18)	Injector rocker arm insert
(E)	5 degree angle
(F)	Finished bore diameter

Illustration 227	g06267474
Bearing nomenclature. Refer to Table 41 for item identification.

Table 41

Bearing Nomenclature
Item	Description
(16)	Bearing
(17)	Bearing joint
(19)	Oil holes
(20)	Oil groove

Specifications for 3176, 3196, C-10, and C-12 Engines

Tables 42,43, and 44 provide the specifications for specific valve rocker arm groups. Use these specifications and those found in the "Oil Hole Location Specifications" section to inspect and assemble the rocker arms.

Table 42

Specifications for 7W-7818 Rocker Arm
Item	Part Number	Description	Maximum Diameter	Minimum Diameter
(1)	7E-7588	Rocker Arm (Exhaust valve)	30.090 mm (1.1846 inch)	30.060 mm (1.1835 inch)
(3)	7C-1798	Arm Adjustment Screw	13.2 mm (0.52 inch)	12.6 mm (0.50 inch)
(6)	7W-6448	Rocker Arm (Intake valve)	30.090 mm (1.1846 inch)	30.060 mm (1.1835 inch)
(7)	7E-8872	Rocker Arm As (Injector)	30.065 mm (1.1837 inch)	30.035 mm (1.1825 inch)
(7)	7E-8531	Rocker Arm (Injector)	33.02 mm (1.300 inch)	32.98 mm (1.298 inch)
(10)	7E-3982	Arm Shaft	30.01 mm (1.182 inch)	29.99 mm (1.181 inch)
(12)	7E-6887 144-2916	Bridge As	13 mm (0.5 inch)	13 mm (0.5 inch)
(13)	7W-7235 258-8721	Button	18.15 mm (0.715 inch)	17.85 mm (0.703 inch)
(14)	7W-5401	Push Rod (Injector)	20.25 mm (0.797 inch)	19.75 mm (0.778 inch)
(15)	7W-5402	Valve Pushrod Int/Exh	16.25 mm (0.640 inch)	15.75 mm (0.620 inch)
(16)	7W-6452	Bearing Joint (A) Inside diameter (B) after machining	5 Degrees 30.065 mm (1.1837 inch)	5 Degrees 30.035 mm (1.1825 inch)

Table 43

Specifications for 6I-1616 Rocker Arm
Item	Part Number	Description	Maximum Diameter	Minimum Diameter
(1)	6I-1618	Rocker Arm (Exhaust valve)	32.090 mm (1.2634 inch)	32.060 mm (1.2622 inch)
(3)	7C-1798	Arm Adjustment Screw	13.2 mm (0.52 inch)	12.6 mm (0.50 inch)
(6)	6I-1617	Rocker Arm (Intake valve)	32.090 mm (1.2634 inch)	32.060 mm (1.2622 inch)
(7)	6I-1623	Rocker Arm As (Injector)	32.065 mm (1.2624 inch)	32.035 mm (1.2612 inch)
(7)	6I-1624	Rocker Arm Injector	35.02 mm (1.379 inch)	34.98 mm (1.377 inch)
(10)	6I-1622	Rocker Arm Shaft	32.01 mm (1.260 inch)	31.99 mm (1.259 inch)
(12)	6I-1659 115-9407 138-2554 144-2913 176-4168	Valve Bridge As	13 mm (0.5 inch)	13 mm (0.5 inch)
(13)	7W-7235 258-8721	Button	18.15 mm (0.715 inch)	17.85 mm (0.703 inch)
(14)	7W-5401	Push Rod (Injector)	20.25 mm (0.797 inch)	19.75 mm (0.778 inch)
(15)	7W-5402	Valve Pushrod Int/Exh	16.25 mm (0.640 inch)	15.75 mm (0.620 inch)
(16)	6I-1625	Bearing Joint (A) Inside diameter (B) after machining	5 Degrees 32.065 mm (1.2624 inch)	5 Degrees 32.035 mm (1.2612 inch)

Table 44

Specifications for 115-9397 Rocker Arm
Item	Part Number	Description	Maximum Diameter	Minimum Diameter
(1)	115-9398	Rocker Arm (Exhaust valve)	34.090 mm (1.3421 inch)	34.060 mm (1.3409 inch)
(3)	7C-1798	Arm Adjustment Screw	13.2 mm (0.52 inch)	12.6 mm (0.50 inch)
(6)	115-9399	Rocker Arm (Intake valve)	34.090 mm (1.3421 inch)	34.060 mm (1.3409 inch)
(7)	115-9400	Rocker Arm As (Injector)	34.065 mm (1.3411 inch)	34.035 mm (1.3400 inch)
(7)	115-9401	Rocker Arm Injector	37.02 mm (1.4575 inch)	36.98 mm (1.4559 inch)
(10)	115-9404	Rocker Arm Shaft	34.01 mm (1.339 inch)	33.99 mm (1.338 inch)
(12)	138-2554 144-2913 176-4168	Valve Bridge As	13 mm (0.5 inch)	13 mm (0.5 inch)
(13)	7W-7235 258-8721	Button	18.15 mm (0.715 inch)	17.85 mm (0.703 inch)
(14)	104-3568 341-8889	Push Rod (Injector)	20.25 mm (0.797 inch)	19.75 mm (0.778 inch)
(15)	104-3567 341-8888	Valve Pushrod Int/Exh	14.5 mm (0.571 inch)	13.5 mm (0.531 inch)
(16)	115-9402	Bearing Joint (A) Inside diameter (B) after machining	5 Degrees 34.065 mm (1.3411 inch)	5 Degrees 34.035 mm (1.3400 inch)

Surface Texture

Table 45

Surface Texture
Description	Specification
Rocker Arm Shaft	0.125 µm (4.92126 µinch)
Bearing	0.80 µm (31.4960 µinch)

Oil Hole Location Specifications

The following illustrations and specifications provide the information required to install a new bearing into the unit injector rocker arm.

Illustration 228	g06267532
Section view of 6I-1625 Bushing and oil hole location specifications.

(G) 35 degrees.

(H) 50 degrees.

Note: The oil groove connects with the oil holes on the 7W-6452 Bushing.

Illustration 229	g06267535
Section view of 115-9402 Bearing and oil hole location specifications. Refer to Illustration 230 for alternate design of 115-9402 Bearing.

(G) 50 degrees.

(H) 50 degrees.

Note: The oil holes in the 115-9402 Bearing are slotted.

Illustration 230	g06267536
Section view of 115-9402 Bearing (alternate design) and oil hole location specifications.

(G) 50 degrees.

(H) 50 degrees.

(J) 35 degrees.

(21) Locating hole.

Bearing Installation Procedure

Proper orientation of the bearing in the rocker arm is essential for adequate lubrication of the rocker arm. In addition to the oil hole alignment, the bearing joint must be at the top of the rocker arm within 5 degrees.

Illustration 231	g06267537
Make sure the angle of the oil holes in the rocker arm are aligned with the bearing oil holes.

1. Lay the rocker arm on a flat surface as shown in Illustration 231. Each type of rocker arm has the oil holes drilled at different angles.

2. Lay the bearing next to the rocker arm and make sure that the oil holes will align and the bearing joint will be at the top of the rocker arm.
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   NOTICE
   It is critical that the bearing is installed correctly. If the bearing is misaligned or installed upside down, the oil groove will not lubricate the arm shaft assembly properly, resulting in faster wear of the bearing and the shaft.

3. Use a 1P-0510 Driver, and press the bearing into the rocker arm.

4. Machine the inside diameter of the bearing to the dimensions shown in Tables 2543, and 44. The inside diameter of the bearing must have 100 percent clean-up. The surface texture must be 0.80 µm (31.4960 µinch) or smoother.

5. Thoroughly clean the rocker arm and oil hole passages to remove any metal shavings.

Nomenclature for 3300 Gas Engines

Illustration 232	g03684911
(1) Rocker arm shaft assembly (2) Intake rocker arm (3) Exhaust rocker arm (4) Nut (5) Adjusting screw (6) Seat

Illustration 233	g03684953
(2) Intake rocker arm (3) Exhaust rocker arm (6) Seat (7) Bearing

Note: The allowable clearance between the shaft and the bearing is 0.046 ± 0.013 mm (0.0018 ± 0.0005 inch).

Table 46

Surface Texture
Description	Specification
Rocker Arm Shaft	0.125 µm (4.92126 µinch)
Bearing	0.80 µm (31.4960 µinch)

Illustration 234	g03684961
(1) Rocker arm shaft assembly (2) Intake rocker arm (3) Exhaust rocker arm (8) Spring (9) Washer (10) Bracket (11) Washer (12) Ring (13) Washer

Illustration 235	g03690778
Exploded view of the rocker arm assembly (4) Nut (5) Adjusting screw (6) Seat (7) Bearing

Illustration 236	g03690779
Oil passages within the rocker arm (A) Rocker arm oil passage (B) Bearing oil passage

Illustration 237	g03690780
Driver tooling pressing out the bearing 1P-0510 Driver pressing out bearing (7).

Note: Make sure that the bores of the rocker arm and the sleeve bearing are thoroughly clean.

1. The sleeve bearing and the rocker arm have oil supply holes. The holes must be aligned when the bearing is installed in the rocker arm. Align the joint of the bearing toward the top of the rocker arm. Align the oil hole in the bearing with the oil hole in the rocker arm. Use 1P-0510 Driver to install the bearing (7) into the rocker arm.

2. It is important to machine the bearing (7) to the proper ID once it is pressed in. Machine the rocker bearing (7) to a final bore size of 18.48 ± 0.013 mm (0.727 ± 0.0005 inch).

Rollers of the Rocker Arms

Oil Hole Alignment

Illustration 238	g06267360

On the rollers of the rocker arms, make sure that pin hole on the roller (7) and oil hole on the rocker arm (8) are aligned.

Illustration 239	g06267365

Align oil hole (9) in the rocker arm bearing and the rocker arm.

Heavy Pitting

Pitting in the roller is unacceptable. Do not reuse any roller of the rocker arm that is pitted on the roller.

Illustration 240	g06267370

The roller has a concentrated area of pitting or galling.

Illustration 241	g06267375

The roller has heavy pitting or galling across the entire width.

Circumferential Scratches

Circumferential scratches on the roller are acceptable. The roller of the rocker arm can be reused.

Illustration 242	g06267381

The roller of the rocker arm has light circumferential scratches. These scratches are known as tracking.

Illustration 243	g06267387

The roller of the rocker arm has heavier scratches on the roller.

Rocker Side Arm Wear

If the difference in the surface flatness cannot be felt with a finger tip, then the rocker is acceptable.

Illustration 244	g03175776
Reuse Surface roughness cannot be felt with a finger tip.

Illustration 245	g03176096
Do Not Reuse Surface roughness can be felt with a finger tip.

Rocker Arm Adjustment Screw

Illustration 246	g01950447
(11) Wear surface for the adjustment screw

Engine Brake Rockers

Brake Socket Wear

Illustration 247	g03177349
Shiny and black spots (light discoloration) in the socket are acceptable for reuse.

Illustration 248	g03177777
Do not reuse Damage area in the socket

Illustration 249	g03177790
Do not reuse Wear on cone area near socket.

Illustration 250	g03177816
Do not reuse Excessive gauges and wear in the cone area.

Illustration 251	g03177080
Reuse A small amount of wear on any side is acceptable.

Illustration 252	g03177255
Reuse Broken edge wear. Deburr the socket edge and reuse.

Illustration 253	g03177271
Reuse Material damage wear. Deburr the socket and reuse.

Illustration 254	g03177299
Do NOT Reuse Adhesive wear within socket.

Flat Brake Rockers

If the brake flat area is smooth and free of pitting, then it acceptable for reuse. If the brake flat has pitting, then do not reuse the rocker.

Illustration 255	g03177964
Reuse Light polishing with smooth wear.

Illustration 256	g03177982
Do not reuse Excessive pitting damage.

Nomenclature for 3500

Illustration 257	g01208242
(1) Pin hole, (2) Shaft for the Rocker Arm Shaft Assembly, (3) Adjustment Screw, (4) Rocker Arm Cover Base, (5) Jam Nut, (6) Valve Rocker Arm Assembly, (7) Injector Rocker Arm Assembly, (8) Socket of the Injector Arm, (9) Retainer Ring, (10) Button, (11) Sleeve Bearing, (12) Gasket and (13) Socket of the Valve Rocker Arm

Specifications

Illustration 258	g01208290
(A) Outside diameter of the sleeve bearing, (B) Inside diameter of the valve and fuel injector rocker arm, (C) Inside diameter of the sleeve bearing, (D) Radius of the socket for the arm, (E) Diameter of the rocker arm shaft, (F1) Outside diameter of the dowel pin and (F2) Inside diameter of the rocker arm shaft

Illustration 259	g06267545
1W-8465 Valve Mechanism Gp (H) Spacer

Refer to Table 47 for the specifications for the rocker arm and the rocker arm shaft.

Note: The outside diameter of the sleeve bearing (A) is specified in the free state. This state is present when the bearing is not installed.

Note: The inside diameter of the valve and fuel injector rocker arm (B) is the correct dimension before the sleeve bearing is installed.

Note: Make sure that you refer to the correct part number (C). Three sleeve bearings are referenced in table 47. These values refer to the dimensions after installation in the rocker arm.

Note: The allowable clearance between the shaft and the bearing is 0.056 ± 0.028 mm (0.0022 ± 0.0011 inch).

Table 47

Item	Part Description	3500A	3500B	G3520C and G3520E	G3500 and G3520B
A	Sleeve Bearing (1)	40.382 ± 0.020 mm (1.5898 ± 0.0008 inch)	48.298 ± 0.020 mm (1.9015 ± 0.0008 inch)	40.382 ± 0.020 mm (1.5898 ± 0.0008 inch)	40.382 ± 0.020 mm (1.5898 ± 0.0008 inch)
B	Rocker Arm Inside Dimension (2)	40.317 ± 0.015 mm (1.5873 ± 0.0006 inch)	48.233 ± 0.015 mm (1.8989 ± 0.0006 inch)	40.317 ± 0.015 mm (1.5873 ± 0.0006 inch)	40.317 ± 0.015 mm (1.5873 ± 0.0006 inch)
C	1W-4594 Sleeve Bearing (3)	37.140 ± 0.015 mm (1.4622 ± 0.0006 inch)	N/A	N/A	37.140 ± 0.015 mm (1.4622 ± 0.0006 inch)
	230-2620 Sleeve Bearing (3) Refer to Illustration 258.	N/A	45.077 ± 0.015 mm (1.7747 ± 0.0006 inch)	N/A	N/A
	201-8300 Sleeve Bearing (3)	N/A	N/A	37.140 ± 0.015 mm (1.4622 ± 0.0006 inch)	N/A
D	8N-7197 Arm Socket(4)	Replace With New Part	Replace With New Part	Replace With New Part	Replace With New Part
E	Rocker Arm Shaft	37.084 ± 0.013 mm (1.4600 ± 0.0005 inch)	45.000 ± 0.013 mm (1.7717 ± 0.0005 inch)	37.084 ± 0.013 mm (1.4600 ± 0.0005 inch)	37.084 ± 0.013 mm (1.4600 ± 0.0005 inch)
F1	Dowel Pin	16.380 ± 0.130 mm (0.6449 ± 0.0051 inch)	19.672 ± 0.140 mm (0.7745 ± 0.0055 inch)	16.380 ± 0.130 mm (0.6449 ± 0.0051 inch)	16.380 ± 0.130 mm (0.6449 ± 0.0051 inch)
F2	Dowel Pin Hole in the Rocker Shaft	15.8875 ± 0.06255 mm (0.62549 ± 0.00256 inch)	19.055 ± 0.062 mm (0.7502 ± 0.0024 inch)	15.8875 ± 0.06255 mm (0.62549 ± 0.00256 inch)	15.8875 ± 0.06255 mm (0.62549 ± 0.00256 inch)
G	Installed Dowel Pin	6.000 mm (0.2362 inch)	6.000 mm (0.2362 inch)	6.000 mm (0.2362 inch)	N/A
H	Inside Diameter of the Spacer	N/A	N/A	N/A	37.155 ± 0.030 mm (1.4628 ± 0.0012 inch)
	Width of the Spacer	N/A	N/A	N/A	38.750 ± 0.010 mm (1.5256 ± 0.0004 inch)

(1)	Bearing in free state
(2)	The dimension is without the sleeve bearing.
(3)	Dimensions are given for an installed bearing.
(4)	Refer to Illustration 258. This part should be replaced. This part should not be reused.

Surface Texture

Table 48

Surface Texture
Description	Specification
Rocker Arm Shaft	0.125 µm (4.92126 µinch)
Bearing	0.80 µm (31.4960 µinch)

Disassembly and Assembly of the Rocker Shaft

Table 49

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-0510	Driver	1

Disassembly

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Illustration 260	g06209408
(1) Shaft for the Rocker Arm Shaft Assembly, (6) Valve Rocker Arm Assembly, and (7) Injector Rocker Arm Assembly

1. Slide shaft (1) out of valve rocker arm assemblies (6) and injector rocker arm assembly (7). If necessary, remove the dowel from the shaft.
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   Illustration 261	g06209412
   (5) Jam nut, (6) Valve rocker arm assembly, (10) Button, (11) Sleeve bearing, (14) Adjustment screw, (16) Socket for the rocker arm and (17) Retainer ring

2. Remove adjustment screw (14) and the jam nut (5) from the valve rocker arm assemblies (6).

3. Use a hammer and a punch to remove the socket for the rocker arm (16) from the valve rocker arm assemblies (6).

4. Remove button (10) from the socket for the rocker arm (16). Remove retainer ring (17) from button (10).

5. Use Tooling (A) to remove sleeve bearing (15) from valve rocker arm assembly (6).

Assembly

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Illustration 262	g06209414
Oil holes (6) Valve rocker arm assembly and (16) Socket for the rocker arm

Note: The oil hole extends through the end of the rocker arm (6). A ball may have been placed in the opening for the oil hole during manufacturing. The ball is used to stop an existing leak. If no leaks were detected in the manufacturing process the rocker arm (6) will not contain a ball.

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Illustration 263	g06209416
(6) Valve rocker arm assembly and (A) Driver group

Note: Make sure that the bore of the rocker arm and the sleeve bearing is thoroughly clean.

1. The sleeve bearing and the rocker arm have oil supply holes. The holes must be aligned when the bearing is installed in the rocker arm. Align the joint of the bearing toward the top of the rocker arm. Align the oil hole in the bearing with the oil hole in the rocker arm. Use Tooling (A) to install the sleeve bearing in rocker arm (6).

   After the bearing is installed, measure the bore of the bearing. The bore must be 45.056 ± 0.015 mm (1.7740 ± 0.0006 inch).

2. Align the scribe mark on socket (16) with the scribe mark on rocker arm (6). Press socket (16) fully into rocker arm (6).
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   Illustration 264	g06209419
   (6) Valve rocker arm assembly, (10) Button, (14) Adjustment screw, (16) Socket for the rocker arm and (17) Retainer ring

3. Place retainer ring (17) on button (10). Install button (10) in the socket for the rocker arm (16).

4. Install adjustment screw (14) and the nut on the valve rocker arm assembly (6).
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   Illustration 265	g06209422
   (2) Shaft for the Rocker Arm Shaft Assembly and (6) Valve Rocker Arm Assembly

5. If the dowel was removed from the shaft for the rocker arm assembly (2), install a new dowel. The dowel must project 6.0 mm (0.24 inch) above the surface of the shaft for the rocker arm assembly (2).

6. Coat the bearings of rocker arms (6, 7) and coat the shaft for the rocker arm assembly (2) with clean engine oil. Install rocker arms (6, 7) on the shaft for the rocker arm assembly (2).

Nomenclature for C175

Illustration 266	g06209468
(1) Nut (2) Adjustment screw (3) Pushrod (4) Rocker arm shaft (5) Support (6) Button (7) Bridge (8) Bushing

Specifications

Illustration 267	g06209475
(A) The inside diameter of the rocker arm (B) Inside diameter of the sleeve bearing after installation (C) Diameter of the rocker arm shaft (D) Thickness of the rocker arm shaft between flats (E) Installation depth of rocker arm bushing

Illustration 268	g06209492

Press in socket (F) to the full depth.

The minimum force to pull off the button (H) is 200 N (45 lb).

Each oil hole in the bushing (G) must be aligned with each of the oil holes (I) in the rocker arm when the new bushing is installed.

Table 50

Rocker Arm, Bearing, Shaft, and Support Block
Part Description	Dimension	New
Inner Bore of Rocker Arm	A	53.233 ± 0.02 mm (2.0958 ± 0.001 inch)
Inside Diameter of Bushing AFTER Installation and machining to size	B	50.086 ± 0.015 mm (1.9719 ± 0.0006 inch)
Diameter of the Rocker Arm Shaft	C	50.000 ± 0.013 mm (1.9685 ± 0.0005 inch)
Thickness of the Rocker Arm Shaft Between Flats	D	34.1 mm (1.34 inch)
Installation Depth of Rocker Arm Bearing	E	.5 ± 0.25 mm (0.02 ± 0.010 inch)

Table 51

Maximum Surface Texture
Description	Specification
Rocker Arm Shaft (C)	0.125 µm (4.9212 µinch)
Rocker Arm Bearing (I)	0.8 µm (31.50 µinch)

Rocker Arm Shaft

When engines come in for PCR ensure that the depth of the rocker arm dowel shaft holes (H) are 14.0 ± 0.5 mm (0.55118 ± 0.01969 inch) and not 8.0 mm (0.31496 inch). The rocker arm shafts can be easily drilled to 14.0 ± 0.5 mm (0.55118 ± 0.01969 inch) to be reused.

Illustration 269	g06369734
(H) 14.0 ± 0.5 mm (0.55118 ± 0.01969 inch) in depth.

Illustration 270	g02920016

Discoloration on the rocker arm shaft in the areas shown is from the manufacturing process and is normal. Use the rocker arm shaft again.

Rocker Arm Adjustment Screw

The rocker arm adjustment screw should be replaced at every rebuild.

Reuse and Salvage of Rocker Arms

C13 Injector Rockers

All bearings in C13 Injector Rockers showing an "H" pattern should be replaced to a 303-1299 Bearing.

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Illustration 271	g06110690

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Illustration 272	g06110743

1. Place the rocker arm lightly into a vice. Remove the rocker arm adjustment nut. Remove the rocker arm adjusting screw.
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   Illustration 273	g06110750

2. Place the rocker arm in a press. Use a suitable press tool that is sized correctly to press out the bearing without damaging the bore for the bearing. The bore for the bearing should measure 37.00 ± 0.02 mm (1.4567 ± 0.0008 inch)
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   Illustration 274	g06110750

3. Place the 303-1299 Bearing onto the rocker arm. Align the lubrication ports on the bearing with the lubrication ports on the rocker arm. Press the bearing into the rocker arm. Once the bearing is installed, be sure that the bearing does not extend past either face of the rocker arm.
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   Illustration 275	g06110764

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   Illustration 276	g06110783

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   Illustration 277	g06110786

4. Once the bearing has been installed, ensure that the lubrication ports are fully open. Be sure that both oil holes are open to the lubrication ports in the rocker arm
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   Illustration 278	g06110758

5. Machine the rocker arm bearing to 34.05 ± 0.015 mm (1.3406 ± 0.0006 inch). The surface texture must be a maximum of 0.8 µm (32 µinch).
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   Illustration 279	g06111208

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   Illustration 280	g06111209

6. After the bearing has been machined, the rocker arm must be thoroughly cleaned. Flush the lubrication ports to ensure that the rocker arms is free of debris.
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   Illustration 281	g06110690

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   Illustration 282	g06110688

7. Place the rocker arm lightly in a vice. Install the adjustment screw and the lock nut.

3406E, C15, C16, C18, C27 , and C32 Valve Rockers

Some valve rocker arms were manufactured with rocker shaft bearings and some were not. Rocker arms manufactured without bearings can be salvaged by over sizing the rocker shaft bore and installing 6I-1002 Bearing. If bearings are being retrofitted or replaced the pin and roller must be removed.

Rocker arms without bearings may be reused as long as there is no damage in the rocker shaft bore and to the roller. The bore must measure 40.065 ± 0.015 mm (1.5774 ± 0.0006 inch). If the roller has damage the pin and roller can be replaced without any machine work to the rocker shaft bore.

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Illustration 283	g06111224

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Illustration 284	g06111232

1. Place the rocker arm in a press. Use suitable tooling to press out the pin without damaging the bore. If the roller and pin are just being replaced skip to the installation of the pin and roller.

   Note: Be sure to support the lower rocker arm ear. If the ear is bent during removal of the pin the rocker arm may not be suitable for reuse.

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   Illustration 285	g06111223

2. Machine the rocker shaft bore to 43.00 ± 0.02 mm (1.6929 ± 0.0008 inch). Once the rocker arm shaft bore is machined the 6I-1002 Bearing can be installed.
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   Illustration 286	g06111695

3. Set the 6I-1002 Bearing on the rocker arm. Be sure that the lubrication port is lined up. The groove in the 6I-1002 Bearing should be on the bottom of the rocker arm.
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   Illustration 287	g06111698

4. Press the 6I-1002 Bearing into the rocker arm. The bearing should not extend past either face of the rocker arm. Ensure that the lubrication port is open and free of debris.
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   Illustration 288	g06111223

5. Machine the 6I-1002 Bearing to 40.065 ± 0.015 mm (1.5774 ± 0.0006 inch). The surface texture must be a maximum of 0.8 µm (32 µinch).
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   Illustration 289	g06114986

6. After the bearing has been machined, the rocker arm must be thoroughly cleaned. Flush the lubrication ports to that the rocker arm is free of debris.

7. Once the rocker arm bearing is machined the pin and roller can be installed. The pin should be chilled to at least −62° C (−80° F).

   Note: The following illustrations of the rocker arms are for illustrative purposes. The bearing should be installed and machined before installing the pin and roller if that salvage process is being performed.

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   Illustration 290	g06111670

8. The pin must be aligned properly to allow oil flow to the roller. The rocker arm has a lubrication port drilled in it that must mate up with the lubrication port in the pin. Align the marking on the pin with the holes drilled in the rocker arm.
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   Illustration 291	g06111676
   Using a feeler gauge as a spacer to create a positive stop.

9. Place the roller into the rocker arm ears. Use a 0.203 mm (0.008 inch) to 0.254 mm (0.010 inch) spacer to create a positive stop between the roller and rocker arm ear. The positive stop will prevent the rocker arm ears from bending during pin installation.
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   Illustration 292	g06111679

10. Place the pin in the correct location. Use a press to start the pin. Use a driver smaller than the pin diameter. This will prevent bending of the ears when the pin is fully pressed in place.
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    Illustration 293	g06111704

11. Once the pin is partially installed stop to be sure that the spacer is not blocking the pin bore in the rocker arm ear. If needed pull out the spacer until the pin bore is fully open while leaving the outer edge of the roller supported by the spacer. Press the pin fully into the rocker arm
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    Illustration 294	g06111684

12. The pin should not extend past the ears on either side of the rocker arm. This pin is fully seated on both sides. Remove the rocker arm from the press. The roller should spin freely on the pin and should not contact the rocker arm ears.

13. Once the rocker arm has had the pin and roller installed thoroughly clean the rocker arm. The rocker arm is now ready to be put back in service.

3406E, C15, C16, C18, C27 , and C32 Injector Rockers

Complete disassembly of the rocker arm must be completed to replace the rocker shaft bearing. Removal of the pin and roller, removal and installation of the bearing, machining, and installation of the pin and roller are required.

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Illustration 295	g06111233

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Illustration 296	g06111237

1. Place the rocker arm in a press. Use suitable tooling to press out the pin without damaging the bore for the pin.

   Note: Be sure to support the lower rocker arm ear. If the ear is bent during removal of the pin the rocker arm may not be suitable for reuse.

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   Illustration 297	g06111238

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   Illustration 298	g06111253

2. Mark the locations of the lube holes on the outside of the rocker arm. This will aid in reinstallation of the bearing. Use suitable tooling to press out the bearing without damaging the bore for the bearing. The bore for the bearing measures 43.00 ± 0.02 mm (1.693 ± 0.0008 inch).
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   Illustration 299	g06111238

3. Press a 207-9576 Bearing into the rocker arm. Use the marks made on the rocker arm to help guide the bearing to location. The bearing must not extend past either bore of the rocker arm.
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   Illustration 300	g06111623

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   Illustration 301	g06111624

4. Once the bearing is pressed in place, be sure that the lubrication ports are open and not being blocked by the bearing.
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   Illustration 302	g06111217
   The roller and pin should not be installed during machining. This is for illustrative purposes only.

5. Machine the rocker arm bearing to 40.065 ± 0.015 mm (1.5774 ± 0.0006 inch). The surface texture must be a maximum of 0.8 µm (32 µinch).
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   Illustration 303	g06114960

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   Illustration 304	g06114982

6. After the bearing has been machined, the rocker arm must be thoroughly cleaned. Flush the lubrication ports to ensure that the rocker arm is free of debris.

7. Once the rocker arm bearing is machined the pin and roller can be installed. The pin should be chilled to at least −62° C (−80° F).

   Note: The following illustrations of the rocker arms are for illustrative purposes. The bearing should be installed and machined before installing the pin and roller.

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   Illustration 305	g06111643

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   Illustration 306	g06111649
   The lubrication port is drilled through the ear of the rocker arm into the rocker shaft bore.

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   Illustration 307	g06111670
   Alignment mark on the pin and lubrication port on the rocker arm in alignment. The alignment marks and lubrication ports are similar for both injector and valve rocker arms.

8. The pin must be aligned properly to allow oil flow to the roller. The rocker arm has a lubrication port drilled in it that must mate up with the lubrication port in the pin. Align the marking on the pin with the holes drilled in the rocker arm.
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   Illustration 308	g06111652
   Using a feeler gauge as a spacer to create a positive stop.

9. Place the roller into the rocker arm ears. Use a 0.254 mm (0.010 inch) to 0.305 mm (0.012 inch) spacer to create a positive stop between the roller and rocker arm ear. The positive stop will prevent the rocker arm ears from bending during pin installation.
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   Illustration 309	g06111655

10. Place the pin in the correct location. Use a press to start the pin in the bore. Use a driver smaller than the pin diameter. This driver will prevent bending of the ears when the pin is fully pressed into place.
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    Illustration 310	g06111663

11. Once the pin is partially installed stop to be sure that the spacer is not blocking the pin bore in the rocker arm ear. If needed pull out the spacer until the pin bore is fully open while leaving the outer edge of the roller supported by the spacer. Press the pin fully into the rocker arm.
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    Illustration 311	g06111666

12. The pin should not extend past the ears on either side of the rocker arm. This pin is fully seated on both sides. Remove the rocker arm from the press. The roller should spin freely on the pin and should not contact the rocker arm ears.

13. Once the rocker arm has had the pin and roller installed thoroughly clean the rocker arm. The rocker arm is now ready to be put back in service.

C175 Rocker Arms

The C175 rocker arms can be reconditioned with new bearings, adjuster screws, inserts, and buttons. If the bearings are going to be replaced the entire rocker arm assembly must be disassembled.

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Illustration 312	g06234638

1. Place the rocker arm into a vice with brass jaws. Remove the adjusting screw.
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   Illustration 313	g06234642

2. Remove the button from the insert using plastic jawed pliers. This practice will reduce the risk of damaging the button.
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   Illustration 314	g06234644

3. Drive the insert out of the rocker arm. If the insert is going to be reused, do not allow the insert to strike the work surface.
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   Illustration 315	g06234646

4. Place the rocker arm in a press. Use a suitable press tool that is sized correctly to press out the bearing without damaging the bore for the bearing.
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   Illustration 316	g06234656

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   Illustration 317	g06234657

5. Inspect the bearing bore for damage. The bearing bore should measure 53.233 ± 0.02 mm (2.0958 ± 0.0008 inch).
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   Illustration 318	g06234661

6. Place the rocker arm in a press. Use a suitable press tool that is sized correctly to press in the bearing without damaging the bore for the bearing. Freezing the bearing prior to installation will aid in the installation. The bearing should not protrude past the bearing bore in the rocker arm.
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   Illustration 319	g06236278

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   Illustration 320	g06236280

7. Once the bearing is installed into the rocker arm be sure that the lubrication ports are aligned.
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   Illustration 321	g06111223
   A rocker arm being machined.

8. Machine the rocker arm bearing to 50.086 ± 0.015 mm (1.9719 ± 0.0006 inch). The surface texture must be a maximum of 0.8 µm (32 µinch).
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   Illustration 322	g06111208
   Rocker arm lubrication ports being flushed.

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   Illustration 323	g06111209
   Rocker arm lubrication ports being flushed.

9. After the bearing has been machined, the rocker arm must be thoroughly cleaned. Flush the lubrication ports to ensure that the rocker arm is free of debris.
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   Illustration 324	g06235821

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   Illustration 325	g06235823

10. Install the insert into the rocker arm. Take caution from damaging the flat on the insert. Use a rubber mallet to drive the insert into the rocker arm. Be sure that the insert sits flush onto the rocker arm.
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    Illustration 326	g06235827

11. Install the button onto the insert. Use a rubber mallet to drive the button onto the insert.
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    Illustration 327	g06234638

12. Install the rocker arm adjusting screw and the jamb nut.

13. Once the rocker arm is fully assembled, thoroughly clean the rocker arm. The rocker arm is ready now ready to return to service.

Storage Procedures

Proper protection of the components from corrosion is important. Corrosion will start in as little as one hour after the components have been cleaned.

When the components will not be inspected for one hour or less the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The components should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 328.

When the components will not be inspected in two days or more the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil and should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic to prevent damage and contamination to the components. See Illustration 329.

Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.

Illustration 328	g06278538
Example of protection for a component that is stored for a shorter term

Illustration 329	g06278539
Example of protection for a component that is stored for a longer period