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Engine - Generator Set  Generator Set  C32  SXC

   


Service Information
 Applied Failure Analysis

 Bench Test Procedures

 Contamination Control Guidelines

 Disassembly And Assembly

 Engine News

 General Service Information

 Information Release Memo

 Operation And Maintenance Manual

 Reuse And Salvage Guidelines

Caterpillar Certified Procedure To Inspect And Clean Air


Filters {1051, 1054}

Caterpillar Service Welding Guide {0374, 0599, 0677,


0678, 0679}

Cleaning Components With Carbon Dioxide (CO2) {0680,


1000, 7000}

Cylinder Block Cleaning And Audit Procedure {0644,


0680, 0701}

Cylinder Block Salvage Procedure Using Belzona® 1311


(Ceramic R Metal) {0679, 0700, 0701, 1000, 1201}

Dynamometer Testing Of Caterpillar Engines {0781,


1000, 1052, 1087}

Electronic Control Module (ECM) Reuse At Rebuild Or

 Overhaul {1901, 3168, 4800, 5700, 7490, 7600, 7610,
7620, 7754, 7967}

Engine Oil Cooler, Hydraulic Oil Cooler, And Fuel System

 Cooler Cleaning, Inspection, Testing, And Repair {1374,
1378, 1712}

Fundamentals Of Arc Spray For Reconditioning


Components {0679, 1000, 7000}

Fundamentals Of Flame Spray For Reconditioning


Components {0100, 0599, 0679}

Fundamentals Of Hvof Spray For Reconditioning


Components {0599, 0679, 1000, 7000}

Fundamentals Of Plasma Transferred Wire Arc (Ptwa)

 Spray For Reconditioning Components {0374, 0599,
0679, 1000}

 General Cleaning Methods {1000, 7000}

General Salvage And Reconditioning Techniques {0374,


1000}

Guideline For Proper Gasket Handling And Installation


{0599, 0648, 0681, 1000, 7555}

Index Of Repair Process Engineering Publications {0374,


1000, 7000}

Index Of Wall Charts For Drivetrain, Engine, Hydraulics,


And UNDERCARRIAGE{1000, 4000, 4150, 5050}

Inspection And Reconditioning Procedures Of Main

 Bearing Bores In Cylinder Blocks {1201, 1202, 1224,
1224}

Inspection And Reuse Guideline Of Cylinder Liners In Cat


Engines {0761, 1201, 1213, 1216, 1216}

Inspection And Reuse Of Critical Fasteners Used In All


Engines {1000, 7553, 7553}

Inspection Of Diesel Particulate Filters (Dpf), Diesel


Oxidation Catalysts (Doc) And Crs Bodies {108F, 1091}

Inspection Procedures And Specifications For Pistons


And Piston Pins {1214, 1214}

Reuse & Salvage For Valvetrain Components {1102, 1108,


1109, 1121, 1123}

Reuse & Salvage for Valvetrain Components {1102, 11…

Reuse And Salvage For 3176, 3300, 3400 & C7 Through

 C32 Engine Cylinder Blocks {0670, 0672, 0761, 1201,
7225}

 Reuse And Salvage For Camshafts {1210, 1210}

Reuse And Salvage For Cast Iron & Steel Pulleys And

Stub Shafts {0679, 1205, 1207, 1384, 1389, 1425}

Reuse And Salvage For Cast Iron Cylinder Blocks {0679,


1201, 1201}

 Reuse And Salvage For Connecting Rods {1218}

 Reuse And Salvage For Crankshafts {0674, 0679, 1202}

Reuse And Salvage For Cylinder Head Assemblies {1100,

 1101, 1103, 1104, 1105, 1106, 1108, 1109, 1115, 1117,
1121, 1124, 1125}

Reuse And Salvage For Engine Dampers {0679, 1202,


1205}

 Reuse And Salvage For Flywheel Assemblies {0679, 1156}

Reuse And Salvage For Gear Train And Gear Shafts On


3500 Series And C175 Engines {0679, 1151, 1162, 1206}

Reuse And Salvage For Turbochargers {0679, 0760, 0767,


1052}

Reuse And Salvage Of Linkage Pins And Plain Bearings

For Caterpillar Products {0679, 3020, 3260, 4150, 4267,
4300, 4315, 5102, 5105, 5106, 5107, 5211, 5219, 5229,
5265, 5301, 5303, 5305, 5307, 5309, 5317, 5352, 5354,
 5356, 5456, 5457, 5458, 6001, 6060, 6061, 6063, 6107,
6108, 6116, 6117, 6119, 6128, 6154, 6205, 6310, 6501,
6502, 6506, 6513, 7050, 7054, 7057, 7067, 7069, 7071,
7072, 7113, 7155, 7201, 7206, 7222, 7250, 7253, 7258,
7301, 7325, 7522, 7538, 7543, 7545, 7548}

 Reuse And Salvage Of Water Pumps {1361}

Reuse And Testing Of Fuel Injection Pump Housing


{0374, 1000, 1250, 1300}

Scrap Barrel Analysis {0374, 0599, 0700, 0701, 0738,


1000, 7000}

Standardized Parts Marking Procedures {1000, 6393,


7000}

Thermal Spray Coating Bond Strength Test Procedure


{0374, 0599, 0679, 1000, 7000}

Thermal Spray Procedures For Engine Front Cover {0679,


1150, 1151, 1162}

Thermal Spray Procedures For Hydraulic Cylinder Rods


{0679, 7562, 7562}

Thermal Spray Procedures For Linkage Pins {0679, 5457,


6052, 6108, 6129, 6501, 6502}

Using Lock-N-Stitch Procedures For Casting Repair {0676,


0679, 0685}

Using The 6V-7840 Deck Checking Tool Assembly {0701,


1201, 7225}

Valve Cover Base Threaded Insert Repair For C27 And


C32 Engines {0599, 0676, 0700, 0701, 1107}

Visual Inspection And Repair Of The Protective Foam

 Coating On Rigid Foam Engine Wiring Harness {0649,
1408, 1408, 1408, 1408}

Visual Inspection Of Main Bearings And Connecting Rod


Bearings {1202, 1203, 1225, 1230}

 Schematic

 Service Letter - EAME

 Service Magazine

 Special Instruction

 Specifications

 Systems Operation

 Technical Analysis

 Technical Information Bulletin

 Testing And Adjusting

 Tool Operating Manual

 Torque Specifications

 Troubleshooting

 Truck Engine News

Reuse & Salvage for Valvetrain

2023/03/28 Components {1102, 1108, 1109, 
1121, 1123} (SEBF8002-45)

English (English)

SMCS - 1102, 1108, 1109, 1121, 1123 

Caterpillar Products i09736115
All Cat Engines

Revision History:
Table 1

Summary of Changes in
Revision
SEBF8002

Added 9 new part numbers.

Corrected the repetition of part
number 262-2957.
45
Amended the note on allowable
clearance for 3500B, 3500C, and
3500E engines before Table 46.

44 Updated effectivity

Added Images to the "Inspection of

43 Slipper Followers, Roller Followers,
and Roller Lifters" Section.

42 Added 563-1256 to Table 6.

Added a note stating not to reuse

C175 pushrods.
Added a note stating that C175
rocker arm adjustment screws must
be replaced during every rebuild.
Updated verbiage regarding reuse
of mated pushrods and adjustment
screws in the "Rocker Arm
41
Adjustment Screw" Section.
Corrected Feeler Gauge Set part
number to 8H-8581.
Corrected Button part number to
260-9575.
Removed information on the
canceled never used 107-7745
Rocker Arm (Group).

Revision 31 of this document is the result of the

combination of guidelines M0074821,
SEBF8034, SEBF8066, SEBF8067, SEBF8105,
SEBF8174, SEBF8191, SEBF8256, SEBF8264,
SEBF8266, SEBF8267, SEBF8745, SEBF8822,
SEBF9092, SEBF9186, SEBF9253, and
SEBF9372.

Introduction
© 2022 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).

Utilize the Dealer Solution Network (DSN) for

urgent issues or questions concerning additional
repair options or modifications to reuse and
salvage techniques and/or methods.

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 include canceled part
numbers and replaced part numbers. Use the
Numerical Part Record (NPR) on the Service
Information System website 2.0 (SIS web 2.0) 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. Ensure that the
product will not be damaged or made unsafe by
the operation, lubrication, maintenance, or the
repair procedures that are used. Ensure that the
product will not be damaged or made unsafe by
any operation, lubrication, maintenance, or the
repair procedures used.

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”. Refer to Illustration 2 for an
example of a “WARNING” Safety Alert Symbol.

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, 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. Life will vary
depending on application, load, lubrication, and
environment. This guideline references the
procedures in Reuse and Salvage Guideline,
SEBF8162 , "Reuse and Salvage for Cylinder
Head Assemblies".

This guideline contains the latest standards of

engineering, which will help minimize owning
and operating costs. Parts are expected to reach
the next Planned Component Rebuild (PCR) if
the parts meet the specifications within this
guideline and are intended for similar
applications. Use this guideline to determine
whether a part should be reused. Do not install
a part that is not reusable. During
reconditioning, correct any condition that might
have caused the original failure.

The dimensions and tolerances provided are to

return a part / component to specification. The
dimensional information alone is not solely used
to condemn a part from reuse.

References
Note: Refer to the appropriate Remove and
Install (R&I), Disassembly and Assembly (D&A),
and Operation and Maintenance Manual (OMM)
for the part or machine of focus before initiating
this inspection or procedure.

Table 2

References

Media
Publication Type & Title
Number

"Why Reuse and Salvage Parts"

Channel1
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z

"C175 Lifter Housing Rework"

Channel1
https://channel1.mediaspace.kaltura.com/media/C175+Lifter+Housing+Rework/1_rebjozbz

Cat
https://catinspectweb.cat.com/
Inspect

KENR6052
Disassembly and Assembly, "C175-16 and C175-20 Engines for Caterpillar Built Machines"


M0088789
Tool Operating Manual, " 550-9152 Gage Ring Assembly"


REHS9247 Special Instruction, "Improved Camshafts, Rocker Arm Assemblies, and High-Pressure Oil
 Pumps Are Now Used on C27 and C32 Machine Engines"

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 Instruction , "Storage Procedure for Caterpillar Products"


SMHS6998 Special Instruction, "Instructions for the Use of 5P-6518 Dial Indicator Fixture-Parts
 Reusability"

Service Advisories, Service

Letters, and Technical Service
Bulletins

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

Tooling and Equipment

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
Description
Number

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
3P-7848

— Loctite® LB 8713 Solvo-Rust (1)

— Loctite® LB 8040 Solvo-Rust (2)

4C-9442 Flashlight

5P-4160 Tip

5P-4456 Air Brake Connector

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

8H-8581 Feeler Gauge Set

8S-2257 Eye Loupe

8T-5096 Dial Indicator Group

9U-5374(3) Valve Face Grinder

163-3951 Blast Media

Microscope, Pocket
262-8390
40x

263-7184 Crack Detection Kit

288-4209
Paper Towel
605-2193

357-4820 Hollow Dowel

357-9456 Bolt

366-5728 Valve Guide Driver

367-9109 Digital Caliper

369-2607
Digital Indicator
592-9032

384-3712 Hollow Dowel

415-4055 Ultrasonic Tool Group

Digital Caliper
423-4373
0.0 - 203.2 mm (0.00 - 8.00 inch)

Micrometer, External
431-4150
25 mm (1 inch)

441-0714 Spring Tester

459-0184 UV Lamp Group

Micrometer, Outside
473-8690
0.00 - 4.00 inch

Micrometer, Outside
473-8691 50.8 - 152.4 mm
(2.00 - 6.00 inch)

Micrometer, Outside
473-8692 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) Available in North America and Australia.
(2) Available in Europe, Africa, and the Middle East.
(3) 230 Voltage

Preparation Recommendations

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and

warnings on the cleaner solvent container before using.

Personal injury can result from air pressure.

Personal injury can result without following proper procedure.

When using pressure air, wear a protective face shield and
protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa
(30 psi) for cleaning purposes.

Note: Clean exterior of the engine prior to

disassembly to minimize cross-contamination.

Before you inspect a part, clean the part

thoroughly to ensure that all components
are free from rust, oil, burrs, and debris prior
to inspection. A surface irregularity can hide
the indication of an unacceptable defect.

Use a proper lifting device to provide safety

to the operator. Also, use a proper lifting
device to prevent damage to the part when
you lift the part.

During cleaning, do not damage machined

surfaces.

Do not use pressurized air to dry internal

components. Compressed air has moisture
and contaminants that can cause premature
failure of internal components.

Put hydraulic oil on all machined surfaces to

prevent rust or corrosion if inspection is not
done immediately after cleaning. Carefully
store the parts in a clean container.
 Inspect all flange mating surfaces for
fretting. Ensure that flange mating surfaces
are true and free from raised material
resulting from rust, nicks, and dents.

Use appropriate thread taps to chase all

threaded holes.

Refer to SEBF8148  Reuse and Salvage

Guidelines , "General Salvage and
Reconditioning Techniques" for available Crack
Detection Methods.

Replacement Parts
Consult the applicable Parts Identification
manual for your engine.

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 cleaning, grinding, or measuring.

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.

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.

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.

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.

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.

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.

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

Inspection of the Valves

Area of the Retaining Grooves

Illustration 8 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 9 g03151237
Severely damaged valve that cannot be reused.

Do not use the valve again.

Illustration 10 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 11 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 12 g01335640
The valve in Illustration 11 after the valve has been cleaned.

Use the valve again.

Illustration 13 g01335641
Erosion on the valve stem

Do not use the valve again.

Illustration 14 g01335642
Rust can be removed by cleaning.

Use the valve again.

Illustration 15 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 16 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.

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 17 g03151418
Grooves cannot be felt with a fingernail.
Use the valve again.

Illustration 18 g03151437
Deep grooves that can be felt with a fingernail.

Do not use the valve again.

Illustration 19 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 20 g03151459
The valve stem shows severe scuffing and/or seizure.

Do not use the valve again.

Illustration 21 g03151578
The valve stem shows moved metal as a result of scuffing
damage.

Do not use the valve again.

Illustration 22 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 23 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 24 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 25 g03151818
Valve stem with a severe change in diameter.

Do not use the valve again.

Illustration 26 g03151856
Valve stem with severe changes in diameter.

Do not use the valve again.

Illustration 27 g03151962
The valve stem is enlarged from engine operation.

Do not use the valve again.

Measurement Requirements

NOTICE
Precise measurements shall be made when the component and
measurement equipment are at 20 °C (68 °F). Measurements
shall be made after both the component and measurement
equipment have had sufficient time to soak at 20 °C (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 28 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.

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 29 g01336038
The micrometer slides over the valve stem.
Do not use the valve again.

Illustration 30 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 31 g03152457
The fillet area has significant cracks.
Do not use the valve again.

Illustration 32 g03153017
Normal bonding between the valve head and the material
of the valve face.

Use the valve again.

Illustration 33 g03153023
Do not use any valve that has been damaged in the fillet
area.

Do not use the valve again.

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 34 g01336048
The area of the fillet contains erosion.
Do not use the valve again.

Illustration 35 g01336051
The area of the fillet contains foreign material.

Do not use the valve again.

Illustration 36 g03153036
The area of the fillet contains pits of rust, scale, and erosion.

Do not use the valve again.

Illustration 37 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 38 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 39 g03153157
All the marks are light and are not near the edge of the
valve head.

Use the valve again.

Illustration 40 g01337701
The valve head is severely damaged.

Do not use the valve again.

Illustration 41 g03154536
The valve head is damaged and cannot be reused.

Do not use the valve again.

Illustration 42 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 43 g03154637
The valve head contains too much erosion and cannot be
reused.

Do not use the valve again.

Illustration 44 g03154660
The valve head has a cup more than 0.25 mm (0.001 inch)
deep.

Do not use the valve again.

Illustration 45 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 46 g01337710
Normal wear on the fillet area of the valve.
Use the valve again.

Illustration 47 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 4.

Table 4

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

Illustration 48 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.

Illustration 49 g03154916
 2. Follow the manufacturer's instructions for
installation of the valve into the chuck.

Illustration 50 g03154956

3. Adjust the stop on the carriage for

maximum movement to the left.

Illustration 51 g03154997

4. Always dress the grinding wheel so the

grinding wheel does not have any nicks,
grooves, or foreign material.

Illustration 52 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.

Illustration 53 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.

Illustration 54 g01337941

9. After the valve is ground, inspect the valve

face. There must be no grooves, pits, marks,
or burns on the face.

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 55 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 56 g01338011
Use a 5P-6518 Dial Indicator Fixture to measure the
thickness of the lip on the valve.

Illustration 57 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 592-9032 Digital Indicator with the 5P-4160
Tip on a 5P-4456 Base and a 3P-7848 Collet. A
6V-7030 Depth Micrometer, 8H-8581 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 M0088789 Tool Operating Manual,

"550-9152 Gage Ring Assembly" for more
information.

Repair of the Valve Stem End

Illustration 58 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 59 g01337963
The end of the valve stem has not been ground.

Illustration 60 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 61 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 62 g01400727
(A) Stem Diameter
(B) Thickness of the Lip
(C) Diameter of the Head
(D) Angle of the Face

Illustration 63 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 5

Specifications for Intake Valves

Part A&E B D
C
Number Minimum Minimum Angle
Diameter of the
of the Stem Thickness of of the
Head
Valve Diameter (1) the Lip Face

1N-4885 9.408 mm 2.04 mm 44.98 mm

45.50°
1N-4886 (0.3704 inch) (0.080 inch) (1.771 inch)

15.939 mm 4.79 mm 92.00 mm

1W-1761 60.45°
(0.6275 inch) (0.189 inch) (3.622 inch)

9.408 mm 3.84 mm 63.63 mm

1W-8606 60.50°
(0.3704 inch) (0.151 inch) (2.505 inch)

1W-1818 12.55 mm 4.00 mm 59.51 mm

45.50°
8H-1993 (0.494 inch) (0.158 inch) (2.343 inch)

2S-8143 7.833 mm 1.99 mm 36.32 mm

45.50°
7S-2514 (0.3084 inch) (0.078 inch) (1.430 inch)

2W-2620 9.408 mm 2.02 mm 51.31 mm

60.75°
100-7860 (0.3704 inch) (0.08 inch) (2.020 inch)

2W-2621
4W-1670
9.408 mm 2.67 mm 51.31 mm
5S-6452 60.75°
(0.3704 inch) (0.105 inch) (2.020 inch)
7W-7490
247-6892

2W-2622 9.408 mm 2.56 mm 44.98 mm

60.75°
108-5902 (0.3704 inch) (0.101 inch) (1.771 inch)

3N-0514 9.408 mm 2.66 mm 48.13 mm

60.45°
9L-3160 (0.3704 inch) (0.105 inch) (1.895 inch)

9.408 mm 2.56 mm 44.98 mm

4W-5374 60.75°
(0.3704 inch) (0.101 inch) (1.771 inch)

4P-2854 15.939 mm 5.21 mm 90.00 mm

69.75°
180-9044 (0.6275 inch) (0.205 inch) (3.543 inch)

15.939 mm 4.79 mm 90.00 mm

4P-3079 59.75°
(0.6275 inch) (0.189 inch) (3.543 inch)

11.05 mm 1.19 mm 51.51 mm

6H-3026 45.50°
(0.435 inch) (0.047 inch) (2.028 inch)

7.963 mm 1.87 mm 47.00 mm

163-2431 60.25°
(0.3135 inch) (0.074 inch) (1.850 inch)

9.423 mm 2.00 mm 53.19 mm

7C-0362 60.00°
(0.3710 inch) (0.079 inch) (2.094 inch)

7C-2422
15.939 mm 4.79 mm 90.00 mm
7E-1403 59.75°
(0.6275 inch) (0.189 inch) (3.543 inch)
9Y-6232

9.408 mm 3.23 mm 56.00 mm

7C-5188 59.50°
(0.3704 inch) (0.127 inch) (2.205 inch)

7C-5215
7E-9578
124-2692 9.408 mm 2.35 mm 45.00 mm
60.75°
136-4336 (0.3704 inch) (0.093 inch) (1.772 inch)
157-0672
192-9213

12.55 mm 2.27 mm 53.98 mm

7H-6891 60.50°
(0.494 inch) (0.089 inch) (2.125 inch)

9.408 mm 2.38 mm 48.13 mm

7M-7358 60.50°
(0.3704 inch) (0.094 inch) (1.895 inch)

12.55 mm 3.82 mm 63.63 mm

7M-7817 60.50°
(0.494 inch) (0.150 inch) (2.505 inch)

7W-8064 7.963 mm 1.96 mm 47.00 mm

60.25°
161-4280 (0.3135 inch) (0.077 inch) (1.850 inch)

9.408 mm 1.31 mm 42.16 mm

8M-2553 45.15°
(0.3704 inch) (0.0515 inch) (1.660 inch)

9.408 mm 1.84 mm 53.19 mm

8N-5645 60.00°
(0.3704 inch) (0.072 inch) (2.094 inch)

9.408 mm 2.03 mm 43.08 mm

9H-4811 60.50°
(0.3704 inch) (0.080 inch) (1.696 inch)

9.425 mm 1.84 mm 53.19 mm

9L-7682 60.00°
(0.3711 inch) (0.072 inch) (2.094 inch)

9.425 mm 1.63 mm 48.13 mm

9N-0180 60.00°
(0.3711 inch) (0.064 inch) (1.895 inch)

9Y-9804
122-7353
9.408 mm 2.81 mm 44.98 mm
212-0932 70.75°
(0.3704 inch) (0.111 inch) (1.771 inch)
358-1229
525-4063

115-2368 9.408 mm 2.49 mm 44.98 mm

60.75°
122-0322 (0.3704 inch) (0.098 inch) (1.771 inch)

141-4317
7.963 mm 2.04 mm 40.00 mm
145-7390 60.25°
(0.3135 inch) (0.080 inch) (1.575 inch)
252-7801

15.939 mm 4.78 mm 90.00 mm

144-9992 45.00°
(0.6275 inch) (0.188 inch) (3.543 inch)

9.408 mm 3.02 mm 47.00 mm

152-8380 60.75°
(0.3704 inch) (0.119 inch) (1.850 inch)

153-7023
236-5605
9.408 mm 2.75 mm 47.00 mm
391-1106 60.75°
(0.3704 inch) (0.108 inch) (1.850 inch)
490-7198
490-7199

157-7129 7.963 mm 1.87 mm 40.00 mm

60.25°
252-7801 (0.3135 inch) (0.074 inch) (1.575 inch)

163-2442 9.408 mm 2.03 mm 36.00 mm

65.75°
490-1719 (0.3704 inch) (0.080 inch) (1.417 inch)

9.408 mm 2.33 mm 44.98 mm

164-2543 60.75°
(0.3704 inch) (0.092 inch) (1.771 inch)

9.408 mm 1.86 mm 36.00 mm

187-4123 65.75°
(0.3704 inch) (0.073 inch) (1.417 inch)

15.939 mm 4.61 mm 90.00 mm

206-7953 69.75°
(0.6275 inch) (0.182 inch) (3.543 inch)

210-2542 9.408 mm 3.46 mm 56.00 mm

70.60°
468-8824 (0.3704 inch) (0.136 inch) (2.205 inch)

225-5495 N/A N/A N/A N/A

241-8382
7.962 mm 1.81 mm 39.00 mm
242-1542 60.50°
(0.3135 inch) (0.0713 inch) (1.535 inch)
490-1726

252-7802 9.408 mm 2.46 mm 44.50 mm

60.75°
224-3028 (0.3704 inch) (0.097 inch) (1.752 inch)

7.962 mm 1.79 mm 39.00 mm

252-7803 60.25°
(0.3135 inch) (0.0705 inch) (1.535 inch)

255-8675
7.962 mm 1.79 mm 41.50 mm
262-2957 60.50°
(0.3135 inch) (0.0705 inch) (1.634 inch)
490-1729

309-6678 N/A N/A N/A N/A

315-3390 N/A N/A N/A N/A

6.970 mm 35.00 mm
336-5446 N/A 59.875°
(0.27441 inch) (1.37795 inch)

34.10 mm
6.955 mm 3.00 mm (1.34252 inch) to 45.25 -
435-9543
(0.2738 inch) (0.11811 inch) 33.90 mm 40.00°
(1.3346 inch)

6.955 mm 3.00 mm 37.00 ± 0.075 mm 45.25 -

435-9544
(0.2738 inch) (0.11811 inch) (1.4567 ± 0.0030 inch) 40.00°

10.986 mm 3.46 mm 56.00 mm

449-7120 70.60°
(0.43252 inch) (0.136 inch) (2.205 inch)

452-5415 10.986 mm 3.46 mm 56.00 mm

70.60°
498-1592 (0.43252 inch) (0.136 inch) (2.205 inch)

9.408 mm 2.56 mm 44.98 mm

483-2709 70.75°
(0.3704 inch) (0.101 inch) (1.771 inch)

32.32 mm
5.942 mm 2.65 mm (1.2724 inch) to 60.25 -
488-1433
(0.2339 inch) (0.1043 inch) 32.08 mm 60.00°
(1.2630 inch)

8.957 mm 46.46 mm
497-1111 N/A 60.30°
(0.35264 inch) (1.82913 inch)

6.955 mm 3.60 mm 36.00 + 0.50 mm

531-3410 45°
(0.2738 inch) (0.1417 inch) (1.4173 + 0.0197 inch)
(1) Measure the top and the bottom areas of wear.

Table 6

Specifications for Exhaust Valves

A&E B D
Part
Minimum Minimum C Angle
Number of
Stem Thickness of Diameter of the Head of the
the Valve
Diameter (1) the Lip Face

1M-0982 9.408 mm 2.24 mm 39.99 mm

60.50°
2M-7727 (0.3704 inch) (0.088 inch) (1.574 inch)

7.833 mm 2.12 mm 34.80 mm

1S-2903 45.50°
(0.3084 inch) (0.084 inch) (1.370 inch)

1W-3860 9.408 mm 2.56 mm 41.81 mm

60.75°
106-1111 (0.3704 inch) (0.101 inch) (1.646 inch)

9.408 mm
1W-1819 (0.3704 inch) 2.68 mm 57.96 mm
45.50°
(2) 9.373 mm (0.106 inch) (2.282 inch)
(0.3690 inch)

1W-1822 9.408 mm
(2) (0.3704 inch) 3.71 mm 59.69 mm
60.50°
2W-3211 9.373 mm (0.146 inch) (2.350 inch)
(2) (0.3690 inch)

9.408 mm 2.56 mm 41.81 mm

2W-2443 60.75°
(0.3704 inch) (0.101 inch) (1.646 inch)

2W-2877
9.408 mm 2.67 mm 48.16 mm
7W-7491 60.50°
(0.3704 inch) (0.105 inch) (1.896 inch)
498-1691

9.408 mm 3.95 mm 44.98 mm

3N-0516 70.50°
(0.3704 inch) (0.156 inch) (1.771 inch)

11.05 mm 1.22 mm 46.73 mm

4F-0212 45.50°
(0.435 inch) (0.048 inch) (1.840 inch)

10.998 mm 0.68 mm 42.55 mm

4F-2719 45.75°
(0.4330 inch) (0.027 inch) (1.675 inch)

15.939 mm 4.79 mm 90.00 mm

4P-3079 30.25°
(0.6275 inch) (0.189 inch) (3.543 inch)

12.55 mm 3.71 mm 59.69 mm

5S-5323 60.50°
(0.494 inch) (0.146 inch) (2.350 inch)

5S-6449
9.408 mm 2.67 mm 48.16 mm
6N-9916 60.50°
(0.3704 inch) (0.105 inch) (1.896 inch)
8N-0875

7W-2699
105-1779 7.963 mm 1.48 mm 40.00 mm
45.00°
136-0819 (0.3135 inch) (0.058 inch) (1.575 inch)
163-2432

7C-1586
109-5334
124-2693 9.408 mm 1.94 mm 42.00 mm
45.75°
133-3550 (0.3704 inch) (0.076 inch) (1.654 inch)
133-7029
157-0671

9.408 mm 2.04 mm 41.81 mm

7E-7830 45.50°
(0.3704 inch) (0.080 inch) (1.646 inch)

6.642 mm 1.26 mm 23.81 mm

7M-9595 45.83°
(0.2615 inch) (0.0500 inch) (0.937 inch)

9.408 mm 2.37 mm 48.16 mm

7N-0573 60.45°
(0.3704 inch) (0.0933 inch) (1.896 inch)

9.408 mm 2.55 mm 41.81 mm

7N-5693 60.50°
(0.3704 inch) (0.100 inch) (1.646 inch)

7W-9778 15.939 mm 4.80 mm 90.00 mm

60.13°
201-8114 (0.6275 inch) (0.189 inch) (3.543 inch)

12.55 mm 2.68 mm 57.96 mm

8H-1994 45.50°
(0.494 inch) (0.106 inch) (2.282 inch)

9.408 mm 1.31 mm 37.08 mm

8M-2552 44.15°
(0.3704 inch) (0.0515 inch) (1.460 inch)

12.55 mm 3.68 mm 59.69 mm

8N-3723 60.50°
(0.494 inch) (0.145 inch) (2.350 inch)

8N-3724 9.408 mm 2.68 mm 44.98 mm

60.50°
9M-4163 (0.3704 inch) (0.106 inch) (1.771 inch)

12.522 mm 2.28 mm 49.23 mm

8N-3737 60.50°
(0.4930 inch) (0.0900 inch) (1.938 inch)

9L-7683 (2)
9.408 mm
 9N-0185
(0.3704 inch) 1.28 mm 45.82 mm
9N-5125 45.00°
9.373 mm (0.050 inch) (1.804 inch)
119-6772
(0.3690 inch)
(2)

15.939 mm 4.79 mm 90.00 mm

9Y-6232 59.75°
(0.6275 inch) (0.189 inch) (3.543 inch)

100-4639 9.408 mm 3.37 mm 41.81 mm

70.75°
311-7555 (0.3704 inch) (0.133 inch) (1.646 inch)

100-7861 9.408 mm 2.11 mm 48.16 mm

60.75°
148-7455 (0.3704 inch) (0.083 inch) (1.896 inch)

101-8314
9.408 mm 2.81 mm 41.81 mm
212-0933 70.75°
(0.3704 inch) (0.111 inch) (1.646 inch)
358-1230

104-7184
307-4641
308-9177 9.408 mm 3.46 mm 56.00 mm
70.75°
498-1692 (0.3704 inch) (0.13622 inch) (2.205 inch)
500-8527
500-8528

115-2367 9.408 mm 1.99 mm 41.81 mm

45.75°
164-2542 (0.3704 inch) (0.078 inch) (1.646 inch)

9.408 mm 1.99 mm 41.81 mm

122-0321 45.75°
(0.3704 inch) (0.0783 inch) (1.646 inch)

15.939 mm 4.78 mm 90.00 mm

144-9992 45.00°
(0.6275 inch) (0.188 inch) (3.543 inch)

9.408 mm 1.63 mm 43.00 mm

147-8211 45.00°
(0.3704 inch) (0.064 inch) (1.693 inch)

9.408 mm 2.11 mm 48.16 mm

148-7455 60.75°
(0.3704 inch) (0.083 inch) (1.896 inch)

152-7585
153-7024
289-9231 9.408 mm 2.05 mm 41.81 mm
45.75°
391-1107 (0.3704 inch) (0.081 inch) (1.646 inch)
464-4668
490-7200

154-2417 15.939 mm 6.12 mm 90.00 mm

69.75°
319-9074 (0.6275 inch) (0.241 inch) (3.543 inch)

9.408 mm
157-7130 (0.3704 inch) 1.60 mm 43.00 mm
45.00°
(2) 9.373 mm (0.063 inch) (1.693 inch)
(0.3690 inch)

15.939 mm 5.61 mm 90.00 mm

185-1103 69.75°
(0.6275 inch) (0.221 inch) (3.543 inch)

188-3122
241-8383
246-9855 9.408 mm 1.62 mm 37.50 mm
45.75°
490-1721 (0.3704 inch) (0.064 inch) (1.476 inch)
490-1723
490-1725

194-4897(2)
443-2712 12.421 mm
(2) (0.48901 inch)
450-4379 (3) 2.86 mm 56.00 mm
45.60°
(2) 12.529 mm (0.11260 inch) (2.205 inch)
468-8825 (0.49327 inch)
498-1593 (3)
502-5058

9.408 mm 2.14 mm 41.50 mm

224-3030 45.75°
(0.3704 inch) (0.084 inch) (1.634 inch)

9.408 mm 1.94 mm 41.50 mm

248-1467 45.75°
(0.3704 inch) (0.076 inch) (1.634 inch)

255-8676 7.962 mm 1.62 mm 36.00 mm

45.75°
490-1728 (0.3135 inch) (0.064 inch) (1.417 inch)

15.939 mm 5.21 mm 90.00 mm

328-7496 69.75°
(0.6275 inch) (0.2051 inch) (3.543 inch)

6.945 mm 33.00 mm
336-5447 N/A 44.725°
(0.27342 inch) (1.29921 inch)

9.408 mm 1.94 mm 41.50 mm

394-4400 45.75°
(0.3704 inch) (0.076 inch) (1.634 inch)

6.940 mm 3.00 mm 37.50 ± 0.10 mm 45.25 -

435-9545
(0.2732 inch) (0.1181 inch) (1.47637 ± 0.00394 inch) 45.00°

6.940 mm 3.00 mm 33.00 ± 0.075 mm 45.25 -

435-9546
(0.2732 inch) (0.1181 inch) (1.2992 ± 0.0030 inch) 45.00°

9.408 mm 2.56 mm 41.81 ± 0.13 mm

483-2710 70.75°
(0.3704 inch) (0.101 inch) (1.6461 ± 0.0051 inch)

(A)
30.120 mm
5.927 mm
3.34 mm (1.1858 inch) to 45.25 -
488-1434 (0.2334 inch)
(0.1315 inch) 29.88 mm 45.00°
(E) 5.10 mm
(1.1764 inch)
(0.2008 inch)

(A)
6.970 mm
(0.2744 inch) 3.00 mm 35.00 ± 0.150 mm 59.75° -
491-1086
(E) (0.1181 inch) (1.3780 ± 0.0059 inch) 60.00°
6.00 mm
(0.2362 inch)

6.955 mm 3.90 mm 30.00 ± 0.075 mm

529-9890 45°
(0.2738 inch) (0.1535 inch) (1.1811 ± 0.0030 inch)

(A)
6.945 mm
(0.2734 inch)
to 6.960 mm Minimum
(0.2740 inch) 1.465 mm 44.45° -
563-1256
(E) (0.0577 inch) 32.850 mm 45°
6.00 mm (1.29330 inch)
(0.2362 inch)
to 5.80 mm
(0.2284 inch)
(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 63 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 64.

Illustration 64 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 65 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

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component

life.

Illustration 66 g03774568
Removing Lockers

1. Use 5S-1330 Valve Spring Compressor

tooling, compress the valve springs.

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)

Illustration 67 g03776099

4. Secure Support Assembly (8) in a vice. Use a

breaker bar or ratchet, remove Retainer (13).

Illustration 68 g03776143

5. Use adequate tooling, remove, and discard

Retainer Seal (13) from the retainer.

Illustration 69 g03776164

6. Clean the retainer and inspect the top

surface for damage.

Illustration 70 g03776293

7. Using the tool made from Illustration 64, 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

Illustration 71 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 72 g01338022
Nicks and deep scratching on the valve spring.

Do not use the spring again.

Illustration 73 g03155598
Light wear in the first 180 degrees of turn is acceptable.

Use the spring again.

Illustration 74 g01338028
Rust deposits on the spring.

Do not use the spring again.

Illustration 75 g03155618
Notches at the end of the spring are not acceptable.

Do not use the spring again.

Illustration 76 g01338033
Wear on the valve spring between the coils and on the end
of the spring.

Do not use the spring again.

Illustration 77 g03155696
Spring has wear on the sides and cannot be reused.

Do not use the spring again.

Illustration 78 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 7.

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 79 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 7.

Valve Spring Specifications

Illustration 80 g01420828
(E) Spring within tolerance
(F) Outside Diameter
(G) Minimum operating length
(H) Assembled length
(J) Approximate free length
(K) 90 degree angle

Table 7

Specifications for Valve Springs

Dimensions

Minimum
Approximate Outside Assembled Minimum Minimum Spring Within
Part Operating
Number Free Length Diameter Length Load Load Tolerance
Length

J F H H G E
G

1B-9704 88.90 mm 26.87 mm 61.12 mm 39.0 N 46.83 mm 3.10 mm

N/A
Spring (3.500 inch) (1.058 inch) (2.406 inch) (8.77 lb) (1.844 inch) (0.122 inch)

1C-6765
48.40 mm 39.96 mm 39.70 mm 187 N 29.0 mm 2.30 mm
Spring N/A
(1.90551 inch) (1.57323 inch) (1.56299 inch) (42.03947 lb) (1.14173 inch) (0.09055 inch)
(Outer)

1C-6766
Spring
(Outer) 65.38 mm 43.51 mm 56.36 mm 253.5 N 41.00 mm 736.5 N 2.28 mm
9M-5350 (2.574 inch) (1.713 inch) (2.219 inch) (56.99 lb) (1.614 inch) (165.57 lb) (0.090 inch)
Spring
(Outer)

1W-1748
114.00 mm 68.0 mm 84.87 mm 667.5 N 58.37 mm 1376.0 N 3.98 mm
Spring
(4.490 inch) (2.68 inch) (3.341 inch) (150.06 lb) (2.298 inch) (309.34 lb) (0.157 inch)
(Outer)

1W-1749
107.00 mm 47.92 mm 79.25 mm 318.0 N 52.75 mm 664.0 N 3.74 mm
Spring
(4.210 inch) (1.887 inch) (3.120 inch) (71.49 lb) (2.077 inch) (149.27 lb) (0.147 inch)
(Inner)

1W-4259 50.70 mm 39.62 mm 45.77 mm 186.6 N 29.63 mm 735.0 N 1.77 mm

Spring (1.996 inch) (1.560 inch) (1.802 inch) (41.95 lb) (1.167 inch) (165.24 lb) (0.070 inch)

2S-4213 58.67 mm 37.74 mm 49.53 mm 206.5 N 37.34 mm 595.5 N 2.05 mm

Spring(1) (2.310 inch) (1.486 inch) (1.950 inch) (46.42 lb) (1.470 inch) (133.87 lb) (0.081 inch)

2S-5627
Spring 67.31 mm 32.57 mm 59.44 mm 229.6 N 46.84 mm 2.35 mm
N/A
9H-9164 (2.650 inch) (1.282 inch) (2.340 inch) (51.61 lb) (1.844 inch) (0.093 inch)
Spring

2S-7339 53.85 mm 25.99 mm 48.11 mm 186.9 N 37.44 mm 589.4 N 1.88 mm

Spring (2.120 inch) (1.023 inch) (1.894 inch) (42.02 lb) (1.474 inch) (132.50 lb) (0.074 inch)

3S-3018
Spring 49.78 mm 30.86 mm 44.15 mm 180.0 N 31.95 mm 596.0 N 1.74 mm
159-7303 (1.960 inch) (1.215 inch) (1.738 inch) (40.47 lb) (1.258 inch) (133.99 lb) (0.069 inch)
Spring

4F-5408 61.52 mm 41.66 mm 49.61 mm 220.3 N 34.26 mm 2.15 mm

N/A
Spring (2.422 inch) (1.640 inch) (1.953 inch) (49.53 lb) (1.349 inch) (0.085 inch)

4F-5409 59.92 mm 29.09 mm 48.82 mm 117.1 N 33.48 mm 2.09 mm

N/A
Spring (2.359 inch) (1.145 inch) (1.922 inch) (26.33 lb) (1.318 inch) (0.082 inch)

4N-5906 62.74 mm 31.75 mm 54.99 mm 291.5 N 42.93 mm 836.0 N 2.19 mm

Spring (2.470 inch) (1.250 inch) (2.165 inch) (65.53 lb) (1.690 inch) (187.94 lb) (0.086 inch)

4W-2471
59.46 mm 37.31 mm 53.24 mm 211.1 N 38.96 mm 765.0 N 2.08 mm
Spring
(2.341 inch) (1.469 inch) (2.096 inch) (47.46 lb) (1.534 inch) (171.98 lb) (0.082 inch)
(Outer)

4W-2472
65.70 mm 25.13 mm 50.24 mm 155.1 N 35.97 mm 326.0 N 2.29 mm
Spring
(2.587 inch) (0.989 inch) (1.978 inch) (34.87 lb) (1.416 inch) (73.29 lb) (0.090 inch)
(Inner)

5B-6030
91.95 mm 34.29 mm 73.15 mm 62.99 mm
Spring N/A N/A N/A
(3.620 inch) (1.350 inch) (2.880 inch) (2.480 inch)
(Outer)

5F-3111
46.04 mm 28.35 mm 38.89 mm 66.1 N 28.18 mm 1.61 mm
Spring N/A
(1.813 inch) (1.116 inch) (1.531 inch) (14.87 lb) (1.109 inch) (0.063 inch)
(Inner)

5F-3112
48.42 mm 37.05 mm 39.69 mm 184.3 N 28.97 mm 1.69 mm
Spring N/A
(1.906 inch) (1.459 inch) (1.563 inch) (41.44 lb) (1.141 inch) (0.067 inch)
(Outer)

6I-2307 81.00 mm 28.66 mm 70.80 mm 568.5 N 59.00 mm 1259.0 N 2.83 mm

Spring (3.189 inch) (1.128 inch) (2.787 inch) (127.81 lb) (2.323 inch) (283.04 lb) (0.111 inch)

7C-4273 71.00 mm 28.81 mm 65.86 mm 185.5 N 50.70 mm 815.0 N 2.48 mm

Spring (2.795 inch) (1.134 inch) (2.593 inch) (41.70 lb) (1.996 inch) (183.22 lb) (0.098 inch)

7N-1903
51.54 mm 29.24 mm 45.49 mm 104.0 N 31.27 mm 388.0 N 1.80 mm
Spring
(2.029 inch) (1.151 inch) (1.791 inch) (23.38 lb) (1.231 inch) (87.23 lb) (0.071 inch)
(Inner)

7N-1904
62.50 mm 43.96 mm 56.36 mm 212.5 N 42.13 mm 800.0 N 2.18 mm
Spring
(2.460 inch) (1.731 inch) (2.219 inch) (47.77 lb) (1.659 inch) (179.85 lb) (0.086 inch)
(Outer)

7N-7713 53.3 mm 35.60 mm 47.20 mm 195 N 36.8 mm 568 N 1.90 mm

Spring (2.09842 inch) (1.40157 inch) (1.85826 inch) (43.83795 lb) (1.44882 inch) (127.69208 lb) (0.07480 inch)

7S-7144
Spring 52.07 mm 35.21 mm 44.86 mm 217.0 N 32.28 mm 658.0 N 1.82 mm
394-8211 (2.050 inch) (1.386 inch) (1.766 inch) (48.78 lb) (1.271 inch) (147.93 lb) (0.072 inch)
Spring

7S-6323 66.37 mm 43.98 mm 56.36 mm 351.3 N 41.00 mm 2.32 mm

N/A
Spring (2.613 inch) (1.732 inch) (2.219 inch) (78.98 lb) (1.614 inch) (0.091 inch)

7W-7082
Spring
(Outer)
214-0586
62.70 mm 34.00 mm 52.95 mm 274.0 N 37.40 mm 811.0 N 2.19 mm
Spring
(2.469 inch) (1.339 inch) (2.085 inch) (61.60 lb) (1.472 inch) (182.32 lb) (0.086 inch)
(Outer)
332-2152
Spring
(Outer)

7W-7083
Spring
(Inner) 64.10 mm 23.24 mm 50.47 mm 128.5 N 34.92 mm 367.0 N 2.24 mm
224-4441 (2.524 inch) (0.915 inch) (1.987 inch) (28.89 lb) (1.375 inch) (82.51 lb) (0.088 inch)
Spring
(Inner)

8H-9488 59.92 mm 31.63 mm 53.19 mm 181.3 N 42.06 mm 2.09 mm

N/A
Spring (2.359 inch) (1.245 inch) (2.094 inch) (40.75 lb) (1.656 inch) (0.082 inch)

9L-9172
47.12 mm 25.35 mm 43.56 mm 50.3 N 30.86 mm 315.6 N 1.65 mm
Spring
(1.855 inch) (0.998 inch) (1.715 inch) (11.32 lb) (1.215 inch) (70.95 lb) (0.065 inch)
(Inner)

9L-9190
9N-3387
47.09 mm 36.58 mm 42.04 mm 191.1 N 26.63 mm 730.0 N 1.64 mm
9N-3617
(1.854 inch) (1.440 inch) (1.655 inch) (42.96 lb) (1.048 inch) (164.11 lb) (0.065 inch)
Spring
(Outer)(2)

9M-5349
55.35 mm 28.57 mm 45.49 mm 78.0 N 30.15 mm 214.0 N 1.93 mm
Spring
(2.179 inch) (1.125 inch) (1.791 inch) (17.54 lb) (1.187 inch) (48.11 lb) (0.076 inch)
(Inner)

9N-5495
48.77 mm 26.67 mm 45.77 mm 76.4 N 27.23 mm 289.5 N 1.70 mm
Spring
(1.920 inch) (1.050 inch) (1.802 inch) (17.18 lb) (1.072 inch) (65.08 lb) (0.067 inch)
(Inner)

9N-5496
51.77 mm 39.62 mm 45.77 mm 155.0 N 30.23 mm 589.0 N 1.81 mm
Spring
(2.038 inch) (1.560 inch) (1.802 inch) (34.85 lb) (1.190 inch) (132.41 lb) (0.071 inch)
(Outer)

9Y-3326
69.04 mm 42.61 mm 53.24 mm 469.0 N 38.96 mm 942.0 N 2.41 mm
Spring
(2.718 inch) (1.678 inch) (2.096 inch) (105.44 lb) (1.534 inch) (211.77 lb) (0.095 inch)
(Outer)

9Y-3327
70.90 mm 29.83 mm 50.42 mm 238.0 N 36.14 mm 423.0 N 2.48 mm
Spring
(2.790 inch) (1.174 inch) (1.985 inch) (53.50 lb) (1.423 inch) (95.09 lb) (0.098 inch)
(Inner)

103-2454 54.37 mm 35.56 mm 44.93 mm 350.6 N 31.43 mm 864.6 N 1.90 mm

Spring (2.141 inch) (1.400 inch) (1.769 inch) (78.81 lb) (1.237 inch) (194.36 lb) (0.075 inch)

119-3045 76.00 mm 28.91 mm 65.86 mm 426.5 N 50.70 mm 1083.0 N 2.65 mm

Spring (2.992 inch) (1.138 inch) (2.593 inch) (95.89 lb) (1.996 inch) (243.47 lb) (0.104 inch)

137-6718
Spring 92.08 mm 28.82 mm 80.27 mm 610.5 N 66.27 mm 1387.0 N 3.24 mm
391-9854 (3.625 inch) (1.135 inch) (3.160 inch) (137.25 lb) (2.609 inch) (311.81 lb) (0.128 inch)
Spring

140-6188
Spring 67.50 mm 28.59 mm 60.40 mm 266.0 N 46.40 mm 862.5 N 2.36 mm
391-9855 (2.658 inch) (1.126 inch) (2.378 inch) (59.80 lb) (1.827 inch) (193.90 lb) (0.093 inch)
Spring

165-7585
107.40 mm 49.51 mm 81.70 mm 343.0 N 55.20 mm 706.0 N 3.75 mm
Spring
(4.230 inch) (1.949 inch) (3.220 inch) (77.11 lb) (2.170 inch) (158.72 lb) (0.148 inch)
(Inner)

165-7586
115.90 mm 69.0 mm 84.90 mm 723.0 N 58.40 mm 1351.0 N 4.05 mm
Spring
(4.560 inch) (2.72 inch) (3.340 inch) (162.54 lb) (2.300 inch) (303.72 lb) (0.159 inch)
(Outer)

190-6115
57.80 mm 23.18 mm 36.50 mm 197.0 N 24.50 mm 301.0 N 2.02 mm
Spring
(2.276 inch) (0.913 inch) (1.437 inch) (44.29 lb) (0.965 inch) (67.67 lb) (0.080 inch)
(Inner)

190-6117
57.80 mm 31.79 mm 37.70 mm 333.0 N 25.70 mm 574.0 N 2.02 mm
Spring
(2.276 inch) (1.252 inch) (1.484 inch) (74.87 lb) (1.012 inch) (129.04 lb) (0.080 inch)
(Outer)

211-3122
Spring
(Inner) 71.70 mm 25.17 mm 60.14 mm 119.5 N 44.02 mm 382.0 N 2.50 mm
390-0989 (2.823 inch) (0.991 inch) (2.368 inch) (26.87 lb) (1.733 inch) (85.88 lb) (0.098 inch)
Spring
(Inner)

211-3123
Spring
(Outer)
247-9908
76.70 mm 36.30 mm 67.12 mm 288.0 N 51.00 mm 848.0 N 2.68 mm
Spring
(3.020 inch) (1.429 inch) (2.643 inch) (64.75 lb) (2.008 inch) (190.64 lb) (0.106 inch)
(Outer)
392-4530
Spring
(Outer)

224-4441
64.10 mm 23.24 mm 50.47 mm 128.5 N 34.92 mm 367.0 N 2.24 mm
Spring
(2.524 inch) (0.915 inch) (1.987 inch) (28.89 lb) (1.375 inch) (82.51 lb) (0.088 inch)
(Inner)

241-8385
67.69 mm 28.56 mm 44.00 mm 300.0 N 32.00 mm 441.0 N 2.36 mm
Spring
(2.665 inch) (1.124 inch) (1.732 inch) (67.44 lb) (1.260 inch) (99.14 lb) (0.093 inch)
(Outer)

241-8386
56.68 mm 21.34 mm 42.80 mm 146.0 N 30.80 mm 275.5 N 1.98 mm
Spring
(2.232 inch) (0.840 inch) (1.685 inch) (32.82 lb) (1.213 inch) (61.94 lb) (0.078 inch)
(Inner)

255-8677
Spring
(Inner) 74.60 mm 21 mm 46.15 mm 221.0 N 34.15 mm 333.5 N 2.61 mm
349-5303 (2.937 inch) (0.824 inch) (1.817 inch) (49.68 lb) (1.345 inch) (74.97 lb) (0.103 inch)
Spring
(Inner)

255-8678
Spring
(Outer) 77.90 mm 29.4 mm 47.35 mm 442.0 N 35.35 mm 640.2 N 2.72 mm
349-5307 (3.067 inch) (1.157 inch) (1.864 inch) (99.37 lb) (1.392 inch) (143.92 lb) (0.107 inch)
Spring
(Outer)

35.00 mm 21.70 mm 30.40 mm 75.00 N 22.90 mm 200.00 N 0.25 mm

477-8828
(1.3781 inch) (0.8543 inch) (1.1969 inch) (16.8608 lb) (0.9016 inch) (44.9620 lb) (0.0098 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 81 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 82 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.

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 83 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 84 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 85 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 86 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 87 g01352432
No pitting, raised material, waving, or wear steps on top of
the bridge.
Use the bridge again.

Illustration 88 g01352475
Pitting, raised material, waving, or a wear step on top of the
bridge.

Do not use the bridge again.

Illustration 89 g01352479
No pitting, raised material, waving, or wear steps in the
pocket for the valve stem.

Use the bridge again.

Illustration 90 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 91 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 92 g01352491
Pitting, raised material, waving, or a wear step on top of the
bridge.

Do not use the bridge again.

Illustration 93 g01352492
No pitting, raised material, waving, or wear steps in the
pocket of the valve stem.

Use the bridge again.

Illustration 94 g01352493
Pitting, raised material, waving, or a wear step in the pocket
for the valve stem.

Do not use the bridge again.

Illustration 95 g02157060
Bridge button (or elephants foot) cannot be replaced.

Note: If button does not meet reuse

specifications, the bridge assembly cannot be
reused.

3406, 3408, and 3412 Bridges

Illustration 96 g01352505
No pitting, raised material, waving, or wear steps on top of
the bridge.
Use the bridge again.

3500 Bridges
Type 1

Illustration 97 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
(29) Bridge Assembly

Illustration 98 g02142927
109-3824 Valve Mechanism Group
(30) Adjustment Screw and Jam Nut
(31) Rocker Arm
(32) Bridge Assembly
(33) Screw and Nut
Illustration 99 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

Bridge Adjustment Screw

Illustration 100 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

Bridge Assembly

Illustration 101 g01210351

(39) Valve Bridge
(40) Wear Seat
(41) Surface for Wear
(42) Oil Supply Hole
(43) Valve Stem Seat
(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

Type 2

Illustration 102 g06209444

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

Bridge Assembly

Illustration 103 g06209447

(12) Surface for Wear
(13) Oil Supply Hole
(14) Oil Supply Hole
(15) Valve Stem Seat
(16) Valve Stem Seat
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.

Inspection of Bridges

Illustration 104 g01352495

No pitting, raised material, waving, or wear steps on top of
the bridge.
Use the bridge again.

Illustration 105 g01352497

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

Do not use the bridge again.

Illustration 106 g01352498

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

Use the bridge again.

Illustration 107 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 108 g06209505

Illustration 109 g06209509

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

Illustration 110 g02920157

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

Illustration 111 g06209513

Illustration 112 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 mustnever
be 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 113 g06267073

Location of the Lifter Guide Spring

Illustration 114 g06267075

Do Not Use Again

Illustration 115 g06267077

Do Not Use Again

Illustration 116 g06267078

Do Not Use Again

Illustration 117 g06267079

Do Not Use Again

Illustration 118 g03688601

Do Not Use Again

This spring shows signs of metal that has moved,

possibly because of smearing, fretting, or
scuffing.

Illustrations 114,115,116,117, and 118 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.

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.

Illustration 119 g07538739

Example of an edge impact without a protrusion on the
Outside Diameter (OD) of roller lifters.
OK TO USE AGAIN

Illustration 120 g07538753

Example of an edge impact with a protrusion on the
Outside Diameter (OD) of roller lifters.
DO NOT USE AGAIN
Illustration 121 g07539590
Example of surface scratch on roller lifters.
DO NOT USE AGAIN

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 10 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 exposed 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

Illustration 122 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.

Illustration 123 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.

Illustration 124 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 124. If the
stamped arrow is not pointing straight up,
the pin is not aligned correctly.

Illustration 125 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 125. 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.

Illustration 126 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.

Illustration 127 g06266668

Roller Lifter
(5) Roller
(6) Pin

Illustration 128 g03353393

Pushrod insert.

12. The pushrod 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 129 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 130 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 131 and 132 show corrosion from
poor storage procedures.

Illustration 131 g01745733

Rust on the body near the roller
Reuse the lifter.

Illustration 132 g01745893

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

Illustration 133 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 134 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 11.
Reuse the lifter only if scratches or dents are
shallow.

Illustration 135 g01746855

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

Wear of the Roller

Illustration 136 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 137 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 138 g01746973

Normal wear on the roller
Reuse the lifter.

Illustration 139 g01748013

Normal wear on the roller
Reuse the lifter.

Illustration 140 g01748074

Typical example of light circumferential wear
Reuse the lifter.

Illustration 141 g01748258

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

Illustration 142 g01748700

Typical example of heavy pitting or galling
Do not reuse the lifter.
Illustration 143 g01748997
Typical example of pitting. The pitting is not heavy, but is
still unacceptable.
Do not reuse the lifter.

Illustration 144 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 145 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 146 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 147 g01750994

Typical wear of the body
Reuse the lifter.

Illustration 148 g01751698

Typical wear of the body
Reuse the lifter.

Slipper Followers
Visual Inspection
Illustration 149 shows the condition of the
contact surface in a new slipper follower.
Illustrations 150, 151, 154, and 155 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 149 g06266631

The contact surface is convex on a new slipper follower.

Illustration 150 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 151 g01995593

The contact surface of this slipper follower is concave.

Reuse the follower if the follower meets the

specifications in Illustration 152.

Illustration 152 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 153 g01996053

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

Illustration 154 g01996134

The follower has a normal amount of circumferential wear.

Reuse the follower.

Illustration 155 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 156 g01996974

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

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 156 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 156.

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 8.

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 157 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.

a. Put the tip of the indicator at point (8)

while the follower is on the grinder.

b. Turn the follower from (8) to (10). The

dial indicator must not move more than
the specification for total indicated
runout shown in Table 8.

2. Check the correct amount of radius or

“crown”.

a. Put the follower on a surface plate.

b. Install a 3P-1568 Dial Indicator on a

magnetic base and measure the height
between location (9) and locations (8)
and (10).

c. The difference must be acceptable

according to the specifications in Table
8.

Table 8

Reference Dimensions

Minimum Approximate
Part Diameter Checking
Reusable Radius on T.I.R. Height of Crown
Number of the ball Diameter
Length Face

123.22 mm 11.910 mm 11940.00 mm 0.038 mm 38.10 mm 0.005 mm - 0.025 mm

102-1561
(4.851 inch) (0.469 inch) (470.078 inch) (0.0015 inch) (1.500 inch) (0.0002 inch - 0.0010 inch)

133.53 mm 11.910 mm 11940.00 mm 0.038 mm 38.10 mm 0.005 mm - 0.025 mm

5S-1220
(5.257 inch) (0.469 inch) (470.078 inch) (0.0015 inch) (1.500 inch) (0.0002 inch - 0.0010 inch)

59.44 mm 2032.00 mm 0.025 mm 25.40 mm 0.030 mm - 0.051

5M-2277 N/A
(2.340 inch) (78.000 inch) (0.0010 inch) (1.000 inch) (0.0012 inch - 0.0020)

165.28 mm 11.910 mm 11940.00 mm 0.038 mm 38.10 mm 0.005 mm - 0.025 mm

2H-3069
(6.507 inch) (0.469 inch) (470.078 inch) (0.0015 inch) (1.500 inch) (0.0002 inch - 0.0010 inch)

54.69 mm 11.113 mm 3962.00 mm 0.0191 mm 19.05 mm 0.0076 mm - 0.0152 mm

9N-5786
(2.153 inch) (0.438 inch) (155.984 inch) (0.00075 inch) (0.750 inch) (0.00030 inch - 0.00060 inch)

66.55 mm 11.113 mm 2032.00 mm 0.020 mm 25.40 mm 0.031 mm - 0.051 mm

7S-3161
(2.620 inch) (0.438 inch) (78.000 inch) (0.0008 inch) (1.000 inch) (0.0012 inch - 0.0020 inch)

Roller Followers
Nomenclature

Illustration 158 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 9, replace the lifter assembly.

Illustration 159 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 9 for the correct specifications.
(1) Valve roller follower
(2) Injector roller follower

Table 9

Maximum Allowable Movement of Roller

Follower and Minimum Diameter of Lifter
Shaft Assembly

Minimum
Maximum Maximum
Outside
Movement in Movement in
Diameter of
Direction A Direction B
Shaft

0.165 mm 0.165 mm 15.60 mm

(0.0065 inch) (0.0065 inch) (0.6142 inch)

Roller Lifters

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 160 g06266661

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

Lubricating Ports

Illustration 161 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 161.

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 lifter. 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 162 through 164 to determine
reusability.

Illustration 162 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 10

Maximum Allowable Total Movement for Reusability

C D E
Engine Direction of Direction of Direction of
movement movement movement
 C7
3114 0.40 mm 0.40 mm 0.80 mm
3116 (0.016 inch) (0.016 inch) (0.032 inch)
3126

0.116 mm 0.116 mm 0.499 mm

C9
(0.00457 inch) (0.00457 inch) (0.01965 inch)

C15
C18 0.116 mm 0.116 mm 0.375 mm
C27 (0.0046 inch) (0.0046 inch) (0.0148 inch)
C32

0.178 mm 0.178 mm 0.508 mm

3208
(0.0070 inch) (0.0070 inch) (0.0200 inch)

0.115 mm 0.115 mm 0.375 mm

3306B
(0.0045 inch) (0.0045 inch) (0.0148 inch)

0.178 mm 0.178 mm 0.508 mm

3400
(0.0070 inch) (0.0070 inch) (0.0200 inch)

Illustration 163 g06267067

Refer to Table 11 for specifications on maximum allowable
movement.

Note: For directions (A) and (B), measure along

the centerline of the roller.

Table 11

Maximum Allowable Movement and Minimum

Diameter

Injector
Valve Lifter
Lifter from
from 3500B
Location 3500A(1) 3500B and
and C Series
C Series
Engines
Engines

Direction 0.38 mm 0.71 mm 0.38 mm

A (0.015 inch) (0.028 inch) (0.015 inch)

Direction 0.38 mm 0.71 mm 0.38 mm

B (0.015 inch) (0.028 inch) (0.015 inch)

Direction 0.71 mm 0.71 mm 0.71 mm

C (0.028 inch) (0.028 inch) (0.028 inch)

Minimum
OD of
29.882 mm 29.890 mm 34.932 mm
Body
(1.1765 inch) (1.1768 inch) (1.3752 inch)

Minimum
OD of
34.940 mm
Body at 29.890 mm 29.890 mm
(1.3756 inch)
Length (1.1768 inch) (1.1768 inch)
(2)

E
(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 164 g06267068

Table 12

Valve from 3500B Injector from

Location 3500A and C Series 3500B and C
Engines Series Engines

150.00 ± 1.00 mm 146.50 ± 1.00 mm 146.50 ± 1.00 mm

F
(5.906 ± 0.039 inch) (5.768 ± 0.039 inch) (5.768 ± 0.039 inch)

87.30 ± 0.30 mm 87.30 ± 0.30 mm 78.00 ± 0.50 mm

G
(3.437 ± 0.012 inch) (3.437 ± 0.012 inch) (3.070 ± 0.017 inch)

63.00 ± 0.50 mm 59.80 ± 0.30 mm 58.00 ± 0.50 mm

H
(2.480 ± 0.020 inch) (2.354 ± 0.012 inch) (2.283 ± 0.197 inch)

17.00 ± 0.50 mm 17.00 ± 0.50 mm 17.00 ± 0.50 mm

I
(0.669 ± 0.020 inch) (0.669 ± 0.020 inch) (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 11.

C175 Lifter Assembly Mechanism

Illustration 165 g06209516

(A) Housing
(B) Lifter assembly
(C) Lifter shaft

Lifter Housing

Illustration 166 g06319943

Bottom view and inspection surface of 384-5330 Housing
Assembly

Illustration 167 g06319949

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

Illustration 168 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 168
(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 169 g06219123

Cover orientation

Mark the lifter shaft cover similar to

Illustration 169 (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 170 g06219125

The cover can be reused if the hollow dowel

is damaged as shown in Illustration 170.

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 13

Caterpillar Channel 1

Title: "C175 Lifter Housing Rework"

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

Illustration 171 g06353192

1U-9570 Dowel Puller Group

Illustration 172 g06353200

Hollow dowels from the housing.

1. Remove the two hollow dowels from the

housing using 1U-9570 Dowel Puller Group.

Illustration 173 g06353210

2. Mill 0.26 mm (0.01024 inch) (A) from both

lifter shaft abutment pads on the housing.

Illustration 174 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.

Illustration 175 g06353232

4. Thoroughly flush internal threads and oil

passage within the housing to ensure that
there are no machining chips remaining

Illustration 176 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.

Illustration 177 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 178 g06209518

(F) Roller

Illustration 179 g02921337

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

Illustration 180 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 14

Specifications for Lift Lever Assembly

Location Description Dimension

Inner
38.1 ± 0.013 mm
Diameter of
(1.50 ± 0.0005 inch)
Bushing

Surface
D Texture of 0.8 µm (31.50 µinch)
Bushing

Installation
0.5 ± 0.25 mm
Depth of
(0.020 ± 0.010 inch)
Bushing

Do not reuse the lift

lever assembly if the
Indicator mark (E) on the roller
E
Mark has rotated more
than 5 degrees past
the vertical plane.

Shaft
Visual check for any nicks and dings.

Illustration 181 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. The 357-4823 Shaft
Assembly has been canceled and replaced
by the 550-7773 Shaft Assembly.

Illustration 182 g06271518

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

Illustration 183 g06271556

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

Illustration 184 g06271537

Table 15

Lift Lever Shaft

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

Surface 0.125 µm
Texture (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 185 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 186 g06267086

Illustration 187 g06267087

Table 16

Chart A
1W-2470 Valve Lifter Group

Part
Location Qty. Description
Number

1 4 8D-7941 Bolt

2 1 1W-0020 Lifter Guide

3 2 194-0629 Valve Lifter As

Unit Injector Lifter

4 1 194-0630
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 188 g06267088

Table 17

Chart D
Valve Lifter Body

Minimum Maximum
Location Description
Reuse Reuse

Lifter body 41.870 mm

A N/A
diameter (1.6484 inch)

Roller 60.00 mm
B N/A
diameter (2.362 inch)

Injector Lifter Body

Illustration 189 g06267089

Table 18

Chart E
Injector Lifter Body

Minimum Maximum
Location Description
Reuse Reuse

Lifter body 55.860 mm

A N/A
diameter (2.1992 inch)

Roller 80.00 mm
B N/A
diameter (3.148 inch)

Lifter Guide Housing

Illustration 190 g06267090

Table 19

Chart F
Lifter Guide Housing

Location Maximum Reuse

A
56.050 mm (2.2067 inch)
Injector Lifter Bore

B
42.050 mm (1.6555 inch)
Valve Lifter Bore

Visual Inspection of Rocker

Arms
Check the rocker arm assembly for excessive
wear at the bearings. Check for wear at the point
between the rocker arm adjustment screw and
all pushrods. This includes the pushrods for the
valves and injectors.

Inspect the parts for damage on the surface.

Parts with the following defects should not be
reused:

Pits

Corrosion

Contact Surfaces That Are Deformed

The parts can be used again if the parts show

only signs of normal wear patterns and the
surfaces are free of defects.

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.

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 for wear at the contact surfaces between

the rocker arm assembly and the bridge.
Typically excessive wear is not present in this
area.

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, pushrods and
injector rocker arms, and adjusting screws and
buttons. If one of the two parts in these pairs
needs to be replaced, both must be replaced. 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, with
a brass pin, onto a new camshaft or premature
wear can result. For C27/ C32 machine engines,
rocker arms with DLC pins can be reused on new
or old camshafts, if the camshaft lobes and
rollers do not exhibit any signs of scuffing,
pitting, or skidding. Tracking lines are acceptable
and do not indicate camshaft failure and should
not affect DLC pin reusability. Refer to Special
Instruction, REHS9247 “Improved Camshafts,
Rocker Arm Assemblies, and High-Pressure Oil
Pumps Are Now Used on C27 and C32 Machine
Engines” for additional information on DLC pin
rocker arms.

Rocker Arms for 3176, 3196, C-

10, C-11, 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
191 through 193, however the same use again
criteria applies to the intake valve rocker arms.

Illustrations 191 through 193 show progressive

stages of wear to the rocker arm pad.

Illustration 191 g06267424

Minimal wear. The wear area is shown in white.

Use again if all other reusability requirements

are met.

Illustration 191 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 192 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 192 covers

approximately 60 percent or 8 mm (0.3 inch) of
the pad, which is the maximum allowable
amount of wear.

Illustration 193 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 193 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 194 g06267432

Maximum allowable wear on exhaust valve rocker arm.

Use again if all other reusability requirements

are met.

Illustration 194 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 195 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 195 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 196 g06267441

Rocker arm pad with raised material.

Do not use again

The rocker arm pad in Illustration 196 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 197 g06267442

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

Do not use again

Illustration 197 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 198 g06267444

Raised material on tip of rocker arm pad.

Do not use again

Illustration 199 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 200 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 201 g06267451

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

Do not use again

Injector Rocker Arm Adjusting

Screw and Button

Illustration 202 g06267454

Adjusting screw.
Use again if unblemished, with no sharp edges,
and measures greater than 12.6 mm (0.50 inch)
in diameter. See Illustration 204.

Illustration 203 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 204 g06267460

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

Illustration 205 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.

Pushrod and Injector Rocker Arm

Insert

Illustration 206 g06267465

Top view of injector pushrod. If the injector pushrod 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 207 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)

Specifications for C9, C-9, and C9.3

Engines
Table 20

Specifications for 155-7927 Valve Mechanism

Part Maximum Minimum

Location Description
Number Diameter Diameter

183-4365 Adjusting 8.40 mm 8.00 mm

2
260-7524 Screw (0.331 inch) (0.315 inch)

7.089 mm 7.063 mm
5 161-3394 Insert
(0.279 inch) (0.278 inch)

8.06 mm 8.02 mm
6 164-5671 Button
(0.317 inch) (0.316 inch)

Shaft
28.063 mm 28.037 mm
7 164-5669 Support
(1.105 inch) (1.104 inch)
(End)

19.38 mm
8 8F-6575 Plug (0.763 inch)
Average

Rocker Arm
28.063 mm 28.037 mm
9 161-3392 (Intake
(1.105 inch) (1.104 inch)
valve)

29.98 mm
Spring I.D. (1.180 inch)
10 163-2459
Spring O.D. 34.80 mm
(1.370 inch)

Rocker Arm
28.063 mm 28.037 mm
11 161-3391 (Exhaust
(1.105 inch) (1.104 inch)
valve)

Rocker Arm 28.013 mm 27.987 mm

Shaft (O.D.) (1.1029 inch) (1.1019 inch)
12 161-3389 Rocker Arm
19.12 mm 19.18 mm
Shaft (I.D.
(0.753 inch) (0.755 inch)
for plug)

Shaft
28.063 mm 28.037 mm
13 176-5913 Support
(1.105 inch) (1.104 inch)
(Middle)

Shaft
28.063 mm 28.037 mm
14 176-5914 Support
(1.105 inch) (1.104 inch)
(Oil)

133-6379 Pushrod 11.201 mm 11.049 mm

N/A
264-6156 (Int/Exh) (0.4409 inch) (0.4350 inch)

Table 21

Specifications for 348-9896 and 242-0447 Valve

Mechanisms

Part Maximum Minimum

Item Description
Number Diameter Diameter

Adjusting 8.40 mm 8.00 mm

2 260-7524
Screw (0.331 inch) (0.315 inch)

7.089 mm 7.063 mm
5 260-9576 Insert
(0.279 inch) (0.278 inch)

8.05 mm 8.01 mm
6 260-9575 Button
(0.31693 inch) (0.31535 inch)

13.0 mm
8 0L-1026 Plug (0.51181 inch)
Average

Rocker Arm
21.561 mm 21.535 mm
9 255-8670 (Intake
(0.84886 inch) (0.84783 inch)
valve)

Rocker Arm
21.561 mm 21.535 mm
11 347-8749 (Exhaust
(0.84886 inch) (0.84783 inch)
valve)

Rocker Arm 21.487 mm 21.513 mm

Shaft (O.D.) (0.84594 inch) (0.84697 inch)
12 274-5874 Rocker Arm
12.777 mm 12.827 mm
Shaft (I.D.
(0.50303 inch) (0.50500 inch)
for plug)

Pushrod 11.201 mm 11.049 mm

N/A 261-0205
(Int/Exh) (0.4409 inch) (0.4350 inch)

Surface Texture
Table 22

Surface Texture

Description Specification

0.50µm
Rocker Arm Shaft
(19.690 µinch)

0.80 µm
Rocker Arm
(31.4960 µinch)

Nomenclature for 3044 Engines

Illustration 208 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 209 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 210 g06270822

(1) Rocker Arm Shaft
(2) Rocker Arm Bushing
(3) Rocker Arm

Table 23

Valve Mechanism Group for 3054, and 3056 Engines

Maximum Minimum
Location Description
Diameter Diameter

19.04 mm 19.01 mm
1 Arm Shaft
(0.74960 inch) (0.74842 inch)

Rocker Arm
Bushing 22.31 mm 22.28 mm
Outside (0.87834 inch) (0.87716 inch)
Diameter

Rocker Arm
Bushing 19.01 mm 19.06 mm
Inside (0.74842 inch) (0.75039 inch)
Diameter

Clearance
2 Between the
0.09 mm 0.03 mm
Rocker Arm
(0.00354 inch) (0.00118 inch)
Bushing and
Rocker Shaft

Maximum
Permissible
Clearance
0.13 mm
Between the N/A
(0.00512 inch)
Rocker Arm
Bushing and
Rocker Shaft

22.26 mm 22.23 mm
3 Rocker Arm
(0.87638 inch) (0.87520 inch)

Surface Texture
Table 24

Surface Texture

Location Specification

Rocker Arm Shaft 0.80 µm

Rocker Arm (31.4960 µinch)

Nomenclature for 3064, and 3066

Engines

Illustration 211 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.

Specifications for 3044, 3046, 3064

and 3066 Engines
Clearance For The Rocker Arm Bushing and
Rocker Shaft

Illustration 212 g01239077

Measure the inside diameter of the rocker arm
bushing (21) and measure the diameter of the
shaft assembly (22). See Illustration 212.
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 25 and 26. 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 25

Specifications for 3044 and 3046 Valve Mechanism Group

Part
Nominal Maximum Minimum Repair Limit
Description

Rocker arm
bushing
The bore
19 mm 19.030 mm 19.010 mm
dimension N/A
(0.7480 inch) (0.7492 inch) (0.7484 inch)
of the rocker
arm
bushing

Rocker arm
shaft
19 mm 19.000 mm 18.980 mm
Diameter of N/A
(0.7480 inch) (0.7480 inch) (0.7472 inch)
the rocker
arm shaft

Clearance of
the rocker
0.050 mm 0.010 mm 0.070 mm
arm bushing N/A
(0.0020 inch) (0.0004 inch) (0.0028 inch)
and the
shaft

Table 26

Specifications for 3064 and 3066 Valve Mechanism Group

Part
Nominal Maximum Minimum Repair Limit
Description

Rocker arm
bushing
The bore
20 mm 20.094 mm 20.011 mm
dimension N/A
(0.7874 inch) (0.7911 inch) (0.7878 inch)
of the rocker
arm
bushing

Rocker arm
shaft
20 mm 19.984 mm 19.966 mm
Diameter of N/A
(0.7874 inch) (0.7868 inch) (0.7861 inch)
the rocker
arm shaft

Clearance of
the rocker
0.128 mm 0.27 mm 0.15 mm
arm bushing N/A
(0.0050 inch) (0.0106 inch) (0.0059 inch)
and the
shaft

Replacement Of The Rocker Arm Bushing

Illustration 213 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 214 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 214.

Pushrods
Note: Do Not reuse C175 pushrods. There is no
reuse criteria for C175 pushrods.

Illustration 215 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 27

Pushrod for 3046 and

Standard
3046 Engines

0.3 mm
Runout of pushrod (0.012 inch) or
less

Table 28

Pushrod for 3064 and

Standard
3066 Engines

0.4 mm (0.0157 inch)

Runout of the pushrod
maximum

Tappet

Illustration 216 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 216.

Note: Investigate the causes of abnormal wear

and correct the conditions that caused the
abnormal wear.

Illustration 217 g01239109

Measure the outside diameter of each tappet

(31) and measure the corresponding tappet bore
(32) in the cylinder block. See Illustration 217.
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 29 and 30. If the dimension is more than
the repair limit, replace the tappet.

Table 29

3044 and
Service
3046 Standard Repair Limit
Limit
Engines

Inside
diameter
of the
tappet 14.000 to 14.018 mm 14.100 mm
N/A
bore in (0.5512 to 0.5519 inch) (0.5551 inch)
the
cylinder
block

Clearance
between
the
tappet
and the 0.016 to 0.052 mm 0.08 mm
N/A
tappet (0.0006 to 0.0021 inch) (0.0031 inch)
bore in
the
cylinder
block

Table 30

3064 and
3066 Standard Repair Limit Service Limit
Engines

Inside
diameter
of tappet
22.000 to 22.021 mm 22.100 mm
bore in N/A
(0.86614 to 0.86697 inch) (0.87008 inch)
the
cylinder
block

Clearance
between
the
tappet
and the 0.035 to 0.086 mm 0.120 mm
N/A
tappet (0.0014 to 0.00339 inch) (0.0047 inch)
bore in
the
cylinder
block

Nomenclature for 3114, and 3116

Engines

Illustration 218 g06270823

Nomenclature for 107-7722, 115-4186, and 119-2910 Valve
Rocker Arm Groups

Illustration 219 g06270825

Nomenclature for 115-4180 Valve Rocker Arm Groups

Table 31

Specifications for 107-7722 Rocker Arm Group

Part Maximum Minimum

Description
Number Diameter Diameter

Rocker Arm
24.828 mm 24.788 mm
6I-0586 (Exhaust
(0.97748 inch) (0.97590 inch)
Valve)

Rocker Arm
24.828 mm 24.788 mm
6I-0586 (Intake
(0.97748 inch) (0.97590 inch)
Valve)

Rocker Arm 27.937 mm 27.897 mm

105-1775
(Injector) (1.09988 inch) (1.09830 inch)

24.765 mm 24.745 mm
7W-4138 Arm Shaft
(0.97500 inch) (0.97421 inch)

Bearing
inside
24.822 mm 24.782 mm
7W-3980 diameter
(0.97724 inch) (0.97567 inch)
after
machining

Table 32

Specifications for 115-4186 Rocker Arm Group

Part Maximum Minimum

Description
Number Diameter Diameter

Rocker Arm
24.828 mm 24.788 mm
115-4191 (Exhaust
(0.97748 inch) (0.97590 inch)
Valve)

Rocker Arm
24.828 mm 24.788 mm
115-4191 (Intake
(0.97748 inch) (0.97590 inch)
Valve)

Rocker Arm 27.937 mm 27.897 mm

105-1775
(Injector) (1.09988 inch) (1.09830 inch)

24.765 mm 24.745 mm
7W-4138 Arm Shaft
(0.97500 inch) (0.97421 inch)

Bearing
inside
24.822 mm 24.782 mm
7W-3980 diameter
(0.97724 inch) (0.97567 inch)
after
machining

Table 33

Specifications for 119-2910 Rocker Arm Group

Part Maximum Minimum

Description
Number Diameter Diameter

Rocker Arm
24.828 mm 24.788 mm
115-4191 (Exhaust
(0.97748 inch) (0.97590 inch)
Valve)

Rocker Arm
24.828 mm 24.788 mm
115-4191 (Intake
(0.97748 inch) (0.97590 inch)
Valve)

Rocker Arm 27.937 mm 27.897 mm

105-1775
(Injector) (1.09988 inch) (1.09830 inch)

24.765 mm 24.745 mm
7W-4138 Arm Shaft
(0.97500 inch) (0.97421 inch)

Bearing
inside
24.822 mm 24.782 mm
7W-3980 diameter
(0.97724 inch) (0.97567 inch)
after
machining

Table 34

Specifications for 115-4180 Rocker Arm Group

Part Maximum Minimum

Description
Number Diameter Diameter

Rocker Arm
24.828 mm 24.788 mm
115-4191 (Exhaust
(0.97748 inch) (0.97590 inch)
Valve)

Rocker Arm
24.828 mm 24.788 mm
115-4191 (Intake
(0.97748 inch) (0.97590 inch)
Valve)

24.765 mm 24.745 mm
7W-4138 Arm Shaft
(0.97500 inch) (0.97421 inch)

Surface Texture
Table 35

Surface Texture

Location Specification

0.125 µm
Rocker Arm Shaft
(4.92126 µinch)

0.80 µm
Bearing
(31.4960 µinch)

Nomenclature for 3176, 3196, C-

10, C-11, and C-12 Engines

Illustration 220 g06267468

Nomenclature for valve rocker arm group. Refer to Table 36
for item identification.

Table 36

Valve Rocker Arm Group Nomenclature for

3176, 3196, C-10, C-11, and C-12 Engines

Location 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 pushrod

15 Valve pushrod

Illustration 221 g06267472

Nomenclature for unit injector rocker arm assembly. Refer
to Table 37 for item identification.

Table 37

Unit Injector Rocker Arm Group

Nomenclature

Location 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 222 g06267474

Bearing nomenclature. Refer to Table 38 for item
identification.

Table 38

Bearing Nomenclature

Location Description

16 Bearing

17 Bearing joint

19 Oil holes

20 Oil groove

Specifications for 3176, 3196, C-

10, C-11 ,and C-12 Engines
Tables 39, 40, and 41 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 39

Specifications for the 7W-7818 Rocker Arm Group

Part Maximum Minimum

Location Description
Number Diameter Diameter

Rocker Arm
30.090 mm 30.060 mm
1 7E-7588 (Exhaust
(1.1846 inch) (1.1835 inch)
valve)

Arm
13.2 mm 12.6 mm
3 7C-1798 Adjustment
(0.52 inch) (0.50 inch)
Screw

Rocker Arm
30.090 mm 30.060 mm
6 7W-6448 (Intake
(1.1846 inch) (1.1835 inch)
valve)

Rocker Arm
30.065 mm 30.035 mm
7 7E-8872 Assembly
(1.1837 inch) (1.1825 inch)
(Injector)

Rocker Arm 33.02 mm 32.98 mm

7 7E-8531
(Injector) (1.300 inch) (1.298 inch)

30.01 mm 29.99 mm
10 7E-3982 Arm Shaft
(1.182 inch) (1.181 inch)

7E-6887 13 mm 13 mm
12 Bridge As
144-2916 (0.5 inch) (0.5 inch)

7W-7235 18.15 mm 17.85 mm

13 Button
258-8721 (0.715 inch) (0.703 inch)

Pushrod 20.25 mm 19.75 mm

14 7W-5401
(Injector) (0.797 inch) (0.778 inch)

Valve
16.25 mm 15.75 mm
15 7W-5402 Pushrod
(0.640 inch) (0.620 inch)
Int/Exh

Bearing
Joint (A)
5 Degrees 5 Degrees
Inside
16 7W-6452 30.065 mm 30.035 mm
diameter (B)
(1.1837 inch) (1.1825 inch)
after
machining

Table 40

Specifications for 6I-1616 Rocker Arm Group

Part Maximum Minimum

Location Description
Number Diameter Diameter

Rocker Arm
32.090 mm 32.060 mm
1 6I-1618 (Exhaust
(1.2634 inch) (1.2622 inch)
valve)

Arm
13.2 mm 12.6 mm
3 7C-1798 Adjustment
(0.52 inch) (0.50 inch)
Screw

Rocker Arm
32.090 mm 32.060 mm
6 6I-1617 (Intake
(1.2634 inch) (1.2622 inch)
valve)

Rocker Arm
32.065 mm 32.035 mm
7 6I-1623 As
(1.2624 inch) (1.2612 inch)
(Injector)

Rocker Arm 35.02 mm 34.98 mm

7 6I-1624
Injector (1.379 inch) (1.377 inch)

Rocker Arm 32.01 mm 31.99 mm

10 6I-1622
Shaft (1.260 inch) (1.259 inch)

6I-1659
115-9407
Valve Bridge 13 mm 13 mm
12 138-2554
As (0.5 inch) (0.5 inch)
144-2913
176-4168

7W-7235 18.15 mm 17.85 mm

13 Button
258-8721 (0.715 inch) (0.703 inch)

Pushrod 20.25 mm 19.75 mm

14 7W-5401
(Injector) (0.797 inch) (0.778 inch)

Valve
16.25 mm 15.75 mm
15 7W-5402 Pushrod
(0.640 inch) (0.620 inch)
Int/Exh

Bearing
Joint (A)
5 Degrees 5 Degrees
Inside
16 6I-1625 32.065 mm 32.035 mm
diameter (B)
(1.2624 inch) (1.2612 inch)
after
machining

Table 41

Specifications for 115-9397 Rocker Arm Group

Part Maximum Minimum

Location Description
Number Diameter Diameter

Rocker Arm
34.090 mm 34.060 mm
1 115-9398 (Exhaust
(1.3421 inch) (1.3409 inch)
valve)

Arm
13.2 mm 12.6 mm
3 7C-1798 Adjustment
(0.52 inch) (0.50 inch)
Screw

Rocker Arm
34.090 mm 34.060 mm
6 115-9399 (Intake
(1.3421 inch) (1.3409 inch)
valve)

Rocker Arm
34.065 mm 34.035 mm
7 115-9400 As
(1.3411 inch) (1.3400 inch)
(Injector)

Rocker Arm 37.02 mm 36.98 mm

7 115-9401
Injector (1.4575 inch) (1.4559 inch)

Rocker Arm 34.01 mm 33.99 mm

10 115-9404
Shaft (1.339 inch) (1.338 inch)

138-2554
Valve Bridge 13 mm 13 mm
12 144-2913
As (0.5 inch) (0.5 inch)
176-4168

7W-7235 18.15 mm 17.85 mm

13 Button
258-8721 (0.715 inch) (0.703 inch)

104-3568 Pushrod 20.25 mm 19.75 mm

14
341-8889 (Injector) (0.797 inch) (0.778 inch)

Valve
104-3567 14.5 mm 13.5 mm
15 Pushrod
341-8888 (0.571 inch) (0.531 inch)
Int/Exh

Bearing
Joint (A)
5 Degrees 5 Degrees
Inside
16 115-9402 34.065 mm 34.035 mm
diameter (B)
(1.3411 inch) (1.3400 inch)
after
machining

Table 42

Specifications for 260-0252 Rocker Arm Group

Part
Location Description Maximum Diameter Minimum Diameter
Number

Rocker Arm
34.09 mm 34.060 mm
1 261-2294 (Exhaust
(1.342 inch) (1.341 inch)
valve)

Arm
7.7 mm 7.7 mm
3 260-7524 Adjustment
(0.303 inch) (0.303 inch)
Screw

Rocker Arm
261-2291 34.09 mm 34.060 mm
6 (Intake
385-5474 (1.342 inch) (1.341 inch)
valve)

Rocker Arm
36.98 mm 37.02 mm
7 260-0251 As
(1.455 inch) (1.458 inch)
(Injector)

9.50 mm by 11.35 9.70 mm by 11.65

12 237-7253 Bridge As
(0.374 inch by .449 inch) (.382 inch by 459 inch)

236-5422 18.15 mm 17.85 mm

13 Button
258-8721 (0.715 inch) (0.703 inch)

Pushrod 20.25 mm 19.75 mm

14 319-0271
(Injector) (0.797 inch) (0.778 inch)

Valve
246-6563 13.5 mm 14.5 mm
15 Pushrod
319-0270 (0.531 inch) (0.570 inch)
Int/Exh

Bearing
Joint (A)
5 Degrees 5 Degrees
Inside
16 7W-6452 33.113 mm 33.087 mm
diameter (B)
(1.304 inch) (1.302 inch)
after
machining

Table 43

Specifications for 396-4102 Rocker Arm Group

Part
Location Description Maximum Diameter Minimum Diameter
Number

Rocker Arm
34.09 mm 34.060 mm
1 261-2294 (Exhaust
(1.342 inch) (1.341 inch)
valve)

Arm
7.7 mm 7.7 mm
2 260-7524 Adjustment
(0.303 inch) (0.303 inch)
Screw

Rocker Arm
34.09 mm 34.060 mm
6 385-4639 (Intake
(1.342 inch) (1.341 inch)
valve)

Rocker Arm
36.98 mm 37.02 mm
7 260-0251 As
(1.455 inch) (1.458 inch)
(Injector)

9.50 mm by 11.35 9.70 mm by 11.65

12 237-7253 Bridge As
(0.374 inch by .449 inch) (.382 inch by 459 inch)

236-5422 18.15 mm 17.85 mm

13 Button
258-8721 (0.715 inch) (0.703 inch)

Pushrod 20.25 mm 19.75 mm

14 319-0271
(Injector) (0.797 inch) (0.778 inch)

Valve
246-6563 13.5 mm 14.5 mm
15 Pushrod
319-0270 (0.531 inch) (0.570 inch)
Int/Exh

Bearing
Joint (A)
5 Degrees 5 Degrees
Inside
16 7W-6452 33.113 mm 33.087 mm
diameter (B)
(1.304 inch) (1.302 inch)
after
machining

Surface Texture
Table 44

Surface Texture

Description Specification

0.125 µm
Rocker Arm Shaft
(4.92126 µinch)

0.80 µm
Bearing
(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 223 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 224 g06267535

Section view of 115-9402 Bearing and oil hole location
specifications. Refer to Illustration 225 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 225 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 226 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 226. 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.

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 23, 40,
and 41. 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 227 g03684911

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

Specifications for Rocker Arms and

Assembly

Illustration 228 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 45

Surface Texture

Description Specification

0.125 µm
Rocker Arm Shaft
(4.92126 µinch)

0.80 µm
Bearing
(31.4960 µinch)

Disassembly and Assembly of the

Rocker Shaft
Disassembly

Illustration 229 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 230 g03690778

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

Assembly

Illustration 231 g03690779

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

Illustration 232 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 233 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 234 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 235 g06267370

The roller has a concentrated area of pitting or

galling.

Illustration 236 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 237 g06267381

The roller of the rocker arm has light

circumferential scratches. These scratches are
known as tracking.

Illustration 238 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 239 g03175776

Reuse
Surface roughness cannot be felt with a finger tip.

Illustration 240 g03176096

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

Rocker Arm Adjustment Screw

Illustration 241 g01950447

(11) Wear surface for the adjustment screw

Engine Brake Rockers

Brake Socket Wear

Illustration 242 g03177349

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

Illustration 243 g03177777

Do not reuse
Damage area in the socket

Illustration 244 g03177790

Do not reuse
Wear on cone area near socket.

Illustration 245 g03177816

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

Illustration 246 g03177080

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

Illustration 247 g03177255

Reuse
Broken edge wear. Deburr the socket edge and reuse.

Illustration 248 g03177271

Reuse
Material damage wear. Deburr the socket and reuse.

Illustration 249 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 250 g03177964

Reuse
Light polishing with smooth wear.
Illustration 251 g03177982
Do not reuse
Excessive pitting damage.

Nomenclature for 3500 Rocker

Arm Assemblies
Check the rocker arm assembly for excessive
wear at the bearings. Check for wear at the point
between the rocker arm adjustment screw and
all pushrods. This includes the pushrods for the
valves and injectors.

Illustration 252 g01208242

(1) Pin Hole
(2) Shaft
(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
(13) Socket of the Valve Rocker Arm

Specifications

Illustration 253 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 254 g06267545

1W-8465 Valve Mechanism Gp
(H) Spacer
Refer to Table 46 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 46. 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) for 3500A, G3520C,
G3520E, G3500, and G3520B.
The allowable clearance between the shaft and
the bearing is 0.077 ± 0.028 mm
(0.0030 ± 0.0011 inch) for the 3500B, 3500C,
and 3500E.

Table 46

Part
Location 3500A 3500B G3520C and G3520E G3500 and G3520B
Description

Sleeve 40.382 ± 0.020 mm 48.298 ± 0.020 mm 40.382 ± 0.020 mm 40.382 ± 0.020 mm

A
Bearing (1) (1.5898 ± 0.0008 inch) (1.9015 ± 0.0008 inch) (1.5898 ± 0.0008 inch) (1.5898 ± 0.0008 inch)

Rocker Arm
Inside 40.317 ± 0.015 mm 48.233 ± 0.015 mm 40.317 ± 0.015 mm 40.317 ± 0.015 mm
B
Dimension (1.5873 ± 0.0006 inch) (1.8989 ± 0.0006 inch) (1.5873 ± 0.0006 inch) (1.5873 ± 0.0006 inch)
(2)

1W-4594
37.140 ± 0.015 mm 37.140 ± 0.015 mm
Sleeve N/A N/A
(1.4622 ± 0.0006 inch) (1.4622 ± 0.0006 inch)
Bearing (3)

230-2620
Sleeve
Bearing (3) 45.077 ± 0.015 mm
C N/A N/A N/A
Refer to (1.7747 ± 0.0006 inch)
Illustration
253.

201-8300
37.140 ± 0.015 mm
Sleeve N/A N/A N/A
(1.4622 ± 0.0006 inch)
Bearing (3)

8N-7197
Replace With New
D Arm Replace With New Part Replace With New Part Replace With New Part
Part
Socket(4)

Rocker Arm 37.084 ± 0.013 mm 45.000 ± 0.013 mm 37.084 ± 0.013 mm 37.084 ± 0.013 mm
E
Shaft (1.4600 ± 0.0005 inch) (1.7717 ± 0.0005 inch) (1.4600 ± 0.0005 inch) (1.4600 ± 0.0005 inch)

16.380 ± 0.130 mm 19.672 ± 0.140 mm 16.380 ± 0.130 mm 16.380 ± 0.130 mm

F1 Dowel Pin
(0.6449 ± 0.0051 inch) (0.7745 ± 0.0055 inch) (0.6449 ± 0.0051 inch) (0.6449 ± 0.0051 inch)

Dowel Pin
Hole in the 15.8875 ± 0.06255 mm 19.055 ± 0.062 mm 15.8875 ± 0.06255 mm 15.8875 ± 0.06255 mm
F2
Rocker (0.62549 ± 0.00256 inch) (0.7502 ± 0.0024 inch) (0.62549 ± 0.00256 inch) (0.62549 ± 0.00256 inch)
Shaft

Installed 6.000 mm 6.000 mm 6.000 mm

G N/A
Dowel Pin (0.2362 inch) (0.2362 inch) (0.2362 inch)

Inside
37.155 ± 0.030 mm
Diameter of N/A N/A N/A
(1.4628 ± 0.0012 inch)
H the Spacer

Width of the 38.750 ± 0.010 mm

N/A N/A N/A
Spacer (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 253. This part should be replaced.
This part should not be reused.

Surface Texture
Table 47

Surface Texture

Description Specification

0.125 µm
Rocker Arm Shaft
(4.92126 µinch)

0.80 µm
Bearing
(31.4960 µinch)

Disassembly and Assembly of the

Rocker Shaft
Table 48

Required Tools

Tool Part Number Part Description Qty

A 1P-0510 Driver 1

Disassembly

Illustration 255 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.

Illustration 256 g06209412

(5) Jam Nut
(6) Valve Rocker Arm assembly
(10) Button
(11) Sleeve Bearing
(14) Adjustment Screw
(16) Socket for the Rocker Arm
(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

Illustration 257 g06209414

Oil holes
(6) Valve Rocker Arm assembly
(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.

Illustration 258 g06209416

(6) Valve Rocker Arm Assembly
(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).

Illustration 259 g06209419

(6) Valve rocker arm assembly, (10) Button, (14)
Adjustment screw, (16) Socket for the rocker arm and
(17) Retainer ring
(6) Valve Rocker Arm Assembly
(14) Adjustment Screw
(16) Socket for the Rocker Arm
(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).

Illustration 260 g06209422

(2) Shaft for the Rocker Arm Shaft Assembly
(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 261 g06209468

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

Specifications

Illustration 262 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 263 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 49

Rocker Arm, Bearing, Shaft, and Support Block

Part
Dimension New
Description

Inner Bore
53.233 ± 0.02 mm
of Rocker A
(2.0958 ± 0.001 inch)
Arm

Inside
Diameter of
Bushing
AFTER 50.086 ± 0.015 mm
B
Installation (1.9719 ± 0.0006 inch)
and
machining
to size

Diameter of
the 50.000 ± 0.013 mm
C
Rocker Arm (1.9685 ± 0.0005 inch)
Shaft

Thickness of
the Rocker
Arm Shaft D 34.1 mm (1.34 inch)
Between
Flats

Installation
Depth of .5 ± 0.25 mm
E
Rocker Arm (0.02 ± 0.010 inch)
Bearing

Table 50

Maximum Surface Texture

Description Specification

C
0.125 µm (4.9212 µinch)
Rocker Arm Shaft

0.8 µm (31.50 µinch)

Rocker Arm
Bearing

Rocker Arm Shaft

When engines come in for PCR, ensure that the
depth of 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 264 g06369734

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

Illustration 265 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.

3500 Pushrod

Measure pushrod runout using V-blocks and a

dial indicator. If the pushrod measurement is
more than 1.0 mm out, you must replace the
pushrod

Illustration 266 g01239103

Example of a pushrod cup with acceptable wear.

Reuse

Illustration 267 g06505951

Smooth polished surface, light discoloration acceptable.

Illustration 268 g06505956

Smooth polished surface, light discoloration acceptable.

Example of a pushrod cup with unacceptable

wear. Replace

Illustration 269 g06505947

Visible wear, scuffing, scratching, pitting, or corrosion not
acceptable. Should not be able to feel wear with fingernail.

Rocker Arm Adjustment Screw

The following criteria applies to only 3500
adjusting screws including 358-0768 Adjusting
Screw, 358-0769 Adjusting Screw & 380-4843
Adjusting Screw

Matching wear patterns are formed on rocker

arms, rocker shafts, valve bridges, pushrods, and
adjusting screws & buttons. If one of the two
parts in these pairs is replaced, so must the
other. In case of reuse, mated pushrods and
adjustment screws should be marked and
reassembled together and in the same position.

Acceptable Wear: Polish on interface between

screw head and Cup. The interface area should
be reflective and smooth. No bumps or
scratches should be felt on the interface
surfaces. Small depressions which contain the
zinc phosphate coating are acceptable. Slight
discolorations (streaks) are acceptable as long as
they are cosmetic and cannot be felt.
Discoloration, or bluing, of parts as a result of
high heat may also be present. Discoloration
without abrasive and / or adhesive wear is
acceptable.

Unacceptable Wear: Abrasive and / or adhesive

wear on interface between screw head and Cup.
The interface surfaces will not be reflective or
smooth. Grooves, bumps, and scratches are not
acceptable on the interface location.
Discoloration of parts, or bluing, as a result of
high heat is not acceptable.

Thread condition of a screw should be

inspected. Screws that have been run on engine
need to conform to the torque requirements
outlined in 1E0500 section 4.3. If the screws are
not damaged and pass the torque requirements,
then the screws can be reused.

The oil holes need to be checked for continuity

(if present). Compressed air or oil can be used to
check for continuity. Follow safety protocols
when using compressed air. If the fluid flows
freely from the opposite end as to which it is
applied, then the screw can be reused

3500 Adjusting Screw

Illustration 270 g06267454

Acceptable: Adjusting Screw can have a defined wear area
boundary, polish visible at the interface surface, flat still
present at the oiling hole. There may also be visible small
depressions with zinc phosphate coating in them.

Illustration 271 g06267456

Not Acceptable: Adjusting Screw cannot have wear present
on the entire head, or a lack of flat at the oil hole. Abrasive
or Adhesive wear are directional marks that are prominent
and can be felt by touch.

3500 Lifters

Lifter reusability should be based on the

inspection of the pushrod ball end. If the ball
end of the pushrod does not display adverse
wear, then it can be reused along with the lifter.
If adverse wear is present on the pushrod ball
end, then the lifter has to be replaced along with
the pushrod.

G3500 Adjusting Screw and HLA

Cup Reusability
The following information pertains to G3500
engines that are equipped with HLA Pushrods.

Acceptable Wear: Polish on interface between

screw head and HLA Cup. The interface area
should be reflective and smooth. No bumps or
scratches should be felt on the interface
surfaces. Small depressions which contain the
zinc phosphate coating are acceptable. Slight
discolorations (streaks) are acceptable as long as
they are cosmetic and cannot be felt.
Discoloration, or bluing, of parts as a result of
high heat may also be present. Discoloration
without abrasive and / or adhesive wear is
acceptable.

Illustration 272 g06596094

(1) Wear Area has a defined boundary.
(2) Polish at interface surface.
(3) Small depressions with zinc phosphate coating.
(4) Flat is present.

Illustration 273 g06596017

(1) Flat is present.
(2) Wear area has a defined boundary.
(3) Polish at interface surface.

Illustration 274 g06596024

(1) Polished area. Streaks are allowed if they are not
prominent.
(2) Discoloration may or may not be present.

Illustration 275 g06596029

(1) Polished area.
(2) Discoloration may or may not be present.

Unacceptable Wear: Abrasive and / or adhesive

wear on interface between screw head and HLA
Cup. The interface surfaces will not be reflective
or smooth. Grooves, bumps, and scratches may
be present on the interface location.

Illustration 276 g06596033

(1) Lack of flat on adjusting screw.
(2) Wear is present on the entire head.
(3) Abrasive / adhesive wear. Directional marks are
prominent and can be felt by touch.

Illustration 277 g06596109

(1) Lack of flat on adjusting screw.
(2) Wear is present on the entire head.
(3) Abrasive / adhesive wear. Directional marks are
prominent and can be felt by touch.

Illustration 278 g06596134

(1) Abrasive / adhesive wear. Directional marks are
prominent and can be felt by touch.
(2) Discoloration may or may not be present.

Illustration 279 g06596138

(1) Discoloration may or may not be present.
(2) Abrasive / adhesive wear. Directional marks are
prominent and can be felt by touch.

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.

Illustration 280 g06110690

Illustration 281 g06110743

1. Place the rocker arm lightly into a vice.

Remove the rocker arm adjustment nut.
Remove the rocker arm adjusting screw.

Illustration 282 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)

Illustration 283 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.

Illustration 284 g06110764

Illustration 285 g06110783

Illustration 286 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

Illustration 287 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).

Illustration 288 g06111208

Illustration 289 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 are free of debris.

Illustration 290 g06110690

Illustration 291 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.

Illustration 292 g06111224

 Illustration 293 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.

Illustration 294 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.

Illustration 295 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.

Illustration 296 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.

Illustration 297 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).

Illustration 298 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.

Illustration 299 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.

Illustration 300 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.

Illustration 301 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.

Illustration 302 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

Illustration 303 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.

Illustration 304 g06111233

Illustration 305 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.

Illustration 306 g06111238

Illustration 307 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).

Illustration 308 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.

Illustration 309 g06111623

Illustration 310 g06111624

4. Once the bearing is pressed in place, be

sure that the lubrication ports are open and
not being blocked by the bearing.

Illustration 311 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).

Illustration 312 g06114960

Illustration 313 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.

Illustration 314 g06111643

Illustration 315 g06111649

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

Illustration 316 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.

Illustration 317 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.

Illustration 318 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.

Illustration 319 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.

Illustration 320 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.

Note: C175 rocker arm adjustment screws Must

Be Replaced during every rebuild.

Illustration 321 g06234638

1. Place the rocker arm into a vice with brass

jaws. Remove the adjusting screw.

Illustration 322 g06234642

2. Remove the button from the insert using

plastic jawed pliers. This practice will reduce
the risk of damaging the button.

Illustration 323 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.

Illustration 324 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.

Illustration 325 g06234656

Illustration 326 g06234657

5. Inspect the bearing bore for damage. The

bearing bore should measure
53.233 ± 0.02 mm (2.0958 ± 0.0008 inch).

Illustration 327 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.

Illustration 328 g06236278

Illustration 329 g06236280

7. Once the bearing is installed into the rocker

arm, be sure that the lubrication ports are
aligned.

Illustration 330 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).

Illustration 331 g06111208

Rocker arm lubrication ports being flushed.

Illustration 332 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.

Illustration 333 g06235821

Illustration 334 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.

Illustration 335 g06235827

11. Install the button onto the insert. Use a

rubber mallet to drive the button onto the
insert.

Illustration 336 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.

3600 Rocker Arm

For 129-4859 Rocker Arm Aswith replacement
bushing 6I-0578 Bushing. Once installed 6I-
0578 Bushing must be machined. The ID
dimensions required after installation of bearing
are 70.0 ± 0.015 mm (2.75590 ± 0.00059 inch).
The surface texture must be a maximum of
1.6 mm (62.992µinch) The depth of the
circumferential groove in bearing ID after boring
must not be less than 1.3 mm (0.0512 inch)

Storage Procedures
Proper protection of the components from
corrosion is important. Corrosion will start in as
little as 1 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
337.

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 338.

Refer to SEHS9031 Special Instruction,

"Storage Procedure for Caterpillar Products" for
more information.

Illustration 337 g06278538

Example of protection for a component that is stored for a
shorter term

Illustration 338 g06278539

Example of protection for a component that is stored for a
longer period

PSP-00063872
2023/04/13
05:35:39+03:00
i02656121
© 2023 Caterpillar Inc.
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