SEBF8002 - Valves, Valve Springs, Valve Rotators and Locks

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Reuse And Salvage Guidelines

Valves, Valve Springs, Valve Rotators and Locks
Media Number -SEBF8002-05 Publication Date -30/03/2004 Date Updated -30/03/2004
SEBF80020001
Valves, Valve Springs, Valve Rotators and Locks

SMCS - 1105; 1108; 1109
SEBF8002-05
CATERPILLAR® March 2004
SMCS Code(s): 1105, 1108, 1009
GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE OPERATIONS
Valves, Valve Springs, Valve Rotators
and Locks
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Summary of Revisions
Page Description
All Revised format.
Introduction
This guideline enables dealers and their customers to benefit from cost reductions made possible through an established parts reusability and salvage program. Every effort has been made to provide the
most current and relevant information known to Caterpillar Inc. Since the Company makes ongoing changes and improvements to its products, this guideline must be used with the latest technical
information available from Caterpillar to ensure such changes and improvements are incorporated where applicable.
For questions or additional information concerning this guideline, contact Caterpillar Service Support Division, Dealer Support (309) 494-1934.
Summary
This guideline gives reuse and salvage specifications for Caterpillar engine valves, valve springs, valve rotators, and locks by providing visual examples and “Use Again” wear specifications. It also
gives procedures to clean valves and valve components. And it gives procedures to measure valves for wear and valve springs for distortion.
Also included is a list of tools and supplies needed to measure and clean components.
This guideline must be used with the instructions given in SEBF8162, “Specifications to Measure and Salvage Cylinder Head Assemblies and Related Components”.
When used in the same application, parts that can be used again according to this guideline can be expected to give normal performance until the next overhaul.
Never install a part that this guideline shows cannot be used again. During salvage operations (reconditioning), correct any conditions that might have caused the original failure.
NOTICE
Be sure to install new exhaust valves during normal cylinder head salvage of 6.25 inch bore engines that are used in high output applications (like locomotive or marine main propulsion applications). In
other applications (like earthmoving or petroleum), all exhaust valves can be used again if they are acceptable, according to the specifications given in this guideline.
References
References
Media Number Title
SEBF8034 Valve and Valve Spring Specifications
SEBF8053 Specifications for Engine Valve Guides
SEBF8162 Specifications to Measure and Salvage
Cylinder Head Assemblies and Related
Components
SMHS6998 Instructions for 5P-6518
LEVN9063 Valve Grinding

Tooling and Equipment
Required Tools
Part Number Part Description
6V-2010 Polishing Stone
FT-1753 Valve Stem Protector
- Valve Grinder
6V-0087 Gauge
5P-6518 Fixture Group
6V-7059 Multiple Anvil Micrometer
6V-2034 Adapter
8S-2263 Valve Spring Tester
1S-0258 Soft Tip Hammer
6V-2033 Brush
6V-2032 Adapters
Glossary
Arkansas Stone: A natural stone of very fine grit used to make precision instruments sharp and to polish metal, like the 6V-2010 Polishing Stone.
Cupping: A surface that has a curve.
Discoloration: A change in color.
Erosion: To wear away.
Pits: Holes that are caused by corrosion.
Polish: To make the surface clean and shiny.
Scuffing: To become rough because of wear.
Warped: To become turned or twisted from the original shape.
Valves
Valve Nomenclature

Illustration 1
Valve with single flange keeper. Refer to Chart A for item identification.
Illustration 2
Valve with double flange keeper. Refer to Chart A for item identification.
Chart A
Valve Nomenclature
Item Description
1 Valve Spring Retainer (keeper) grooves
2 Valve Stem
3 Fillet Area
4 Valve Head
5 Valve Face
Procedure to Clean Valves

Illustration 3
Valves before (left) and after (right) cleaning with the sodium bicarbonate method.
Solvents
If there is only a small amount of carbon on the valves, use a good parts cleaning solvent to clean the valves. Use one or more of the methods that follow to clean hard carbon deposits.
Sodium Bicarbonate Method
Use the sodium bicarbonate method to remove oils, grease and carbon deposits from the fillet areas, valve faces and valve heads. Use the sodium bicarbonate blast media of a crystal size of 70 microns.
For best results, it is recommended to use the "Turbine Formula" 163-3951, which is specially formulated to remove deeply imbedded carbon deposits. Use a number 4 nozzle with a blast pressure
between 70 to 80 psi (483 to 550 kPa), that will require approximately 75 cfm (35 L/s) of compressed air. Set the differential pressure at 1 lb (4.45 N) to control media flow in the range of ¾ lb (3.34 N)
per minute.
There are benefits to using sodium bicarbonate as the blast media. Unlike other blast media, it is not necessary to wash grease and oil from the valves before blasting them with sodium bicarbonate.
Sodium bicarbonate is water-soluble which provides options for waste disposal. Spent sodium bicarbonate can be used to buffer waste treatment systems or be used to neutralize acids in other plant
operations, thereby reducing waste disposal costs. Sodium bicarbonate is an environmentally friendly chemical making it safe for workers, parts and the environment.
NOTICE
Do not use glass bead or steel shot in a cabinet

configured for sodium bicarbonate. These media will
not tolerate grease or oils on the valves and require a
wash cycle prior to blast cleaning.
Glass Bead Method
Use the glass bead method to remove heavy carbon deposits from fillet areas, valve faces and valve heads. Use glass beads that are 88 to 150 microns (size 10) with 80 to 90 psi (550 to 620 kPa) air
pressure. Use size 10 glass beads for best results. Size 9 glass beads [125 to 177 microns (.0049 to .0070 in)] through size 11 glass beads [74 to 125 microns (0.0029 to 0.0049 in)] are acceptable.
Never use glass beads larger than 230 microns (0.0091 in). Protection of valve stems from glass beads and steel shot is necessary at all times. Do not use aluminum oxide or any other material instead of,
or mixed with, glass beads.
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 very
important.
Steel Shot Method
Use the steel shot method to remove heavy carbon deposits from fillet areas, valve faces and valve heads. Use size S170 cast steel shot for best results. Larger size shot can damage the valve.
NOTICE
The steel shot will not give an acceptable finish on the

valve stem; to protect it, use an FT-1753 Valve Stem
Protector or similar type of hose on the valve stem.
6V-2033 Brush and 6V-2032 Adapters
Illustration 4
6V-2033 Brush and 6V-2032 Adapters

One way to clean valve stems is with a 6V-2033 Brush and 6V-2032 Adapters as shown in Illustration 4. The 6V-2033 Brush is a flap-brush, 203 mm (8.0 in) in diameter, 50 mm (2.0 in) wide and has a
76 mm (3.0 in) center hole. The 6V-2032 Adapters fit the 6V-2033 Brush and have a 12 mm (0.5 in) center hole that can be made larger.
Personal injury or death can occur from not following the

proper procedure or the recommended tooling.
To prevent the possibility of injury or death, follow the
established procedure using the recommended tooling.
Using a 6V-2033 Brush at speeds greater than 2100 rpm could cause the brush to fly apart and cause injury to the operator.
The best speed for the 6V-2033 Brush is 2100 rpm. Do not use a 3450 rpm motor. A 1725 rpm motor is acceptable, if the motor does not slow down while cleaning the valves.
One source of variable speed motors is:
Somaca-Rockford
405 Lonergan Drive
Rockford, IL 61109 U.S.A.
Telephone: (815) 874-9411
If the 6V-2033 Brush is not available, use only a Scotch-Brite Finishing Flap Brush, Fiber Core, Type 5A, Fine Grade. Use of other grades or brushes from another supplier can result in too smooth or too
rough a surface. For more information on Scotch-Brite brushes, contact the Caterpillar Service Technology Group.
Vibratory Cleaning
A vibratory type of cleaner can also be used to clean valves if it gives the correct final surface finish to the valve stem.

Illustration 5
Typical vibratory cleaner.
Note: The valve stem must be 0.30 to 0.51 micrometers (12 to 22 microinches) smooth.
For more information on vibratory-type cleaners and surface analyzers, contact the Caterpillar Service Technology Group.
The size and type of pellet used in a vibratory cleaner have an effect on the surface finish of the valves. If necessary, polish the valve stem with Scotch Brite material to get the correct surface finish. If
you do not use Scotch Brite material, check the surface finish on the valves often.
NOTICE
Inspect the retainer groove area of the valves for discoloration before you use a vibratory-type cleaner. After cleaning, put clean oil on the valves to prevent rust.
NOTICE
It is no longer recommended to use a grinder with a Scotch Brite abrasive to clean the valves. This process creates airborne particles that contaminate areas of the specialization shop.
NOTICE
Do not use a wire brush or wire wheel to remove carbon deposits from valves. These will make scratches on the valves, which can cause a valve failure.
Valve Inspection
To save time, check the condition of the valves before they are cleaned, ground or measured.
Retainer Groove Area
Illustration 6
Remove any raised edge with the Scotch Brite method or use a fine grade polishing (Arkansas) stone, like the 6V-2010 Polishing Stone.
Use again

Illustration 7
Damage or wear in the grooves.
Do not use again
Illustration 8
Surface wear, but no damage to the sides or bottom of the grooves.
Use again –
If desired, use the Scotch Brite method to polish the area.
Valve Stem

Illustration 9
Valve with discoloration before being cleaned. Do not clean or use valves that have discoloration that goes into the retainer groove area.
Use again
Illustration 10
Valve after cleaning (same valve as shown in Illustration 9)
Use again

Illustration 11
Erosion on valve stem.
Do not use again
Illustration 12
Rust can be removed by cleaning.

Use again
Illustration 13
Small mark or scratch, but no raised or sharp edge. The mark must not be deeper than the part number stamp.
Use again
Illustration 14
Mark or scratch with a raised or sharp edge after cleaning with the Scotch Brite or vibratory method.
Do not use again
NOTICE
Do not use a valve if normal cleaning methods will not

remove a raised edge on the part of the stem that moves
inside the valve guide.
Illustration 15
Grooves cannot be felt with the fingernail.
Use again

Illustration 16
Grooves can be felt with the fingernail.
Do not use again

Illustration 17
The line, indicated by arrow, shows where the valve is welded. It cannot be felt with the fingernail.
Use again

Illustration 18
Valve stem with scuffing or seizure.
Do not use again
Illustration 19
Valve stem with scuffing or seizure.
Do not use again

Illustration 20
Worn chromium coating. (Only a small number of Caterpillar valves have a chromium coating on the stems.)
Do not use again
Illustration 21
Some valves, like those in later 6.25 inch bore engines; have a change in diameter above the fillet area. This is acceptable, if similar to the other valves from the same engine.
Use again

Illustration 22
Some valve stems are smaller at this point so the fillet area and stem surface come together smoothly.
Use again
Illustration 23
Change in diameter of valve stem.

Do not use again
Illustration 24
Change in diameter of valve stem.
Do not use again
Illustration 25

Valve stem is bulged (larger than new) from engine operation.
Do not use again
Stem Measurements
Illustration 26
Always measure wear on valve stems.
Use a 6V-0087 Gauge or micrometer to measure the diameter of the valve stem. Measure the top and bottom area that moves inside the valve guide.
If a micrometer is used to check the diameter of the valve stem, adjust the micrometer to the "Use again" diameter. If the micrometer or correct gauge slides easily over the stem at any position on the
stem, the valve is worn and must be replaced. (The micrometer should be set and locked at minimum diameter.)
Note: Some valve stems have a taper (measurements at the top and bottom are different).
NOTICE
Do not use force or roll the valve stem into the gauge or micrometer. This can cause early wear of the gauge and incorrect measurements.

Illustration 27
The micrometer slides over the stem.
Do not use again
Illustration 28

Use a 6V-0087 Gauge to check the diameter of the valve stem. Gauge will not slide easily over the stem.
Use again
Fillet Area
Illustration 29
Cracks in fillet area
Do not use again

Illustration 30
Normal bond between valve head and valve face material.
Use again
Illustration 31
Do not use any valve with nicks, burrs or deep scratches in fillet area that can be felt with the fingernail.
Do not use again

NOTICE
Be careful to prevent damage to the fillet area when the valve is installed, ground, or handled. If used, damaged valves can result in engine damage.
Illustration 32
Erosion in fillet area.
Do not use again

Illustration 33
Foreign material (aluminum) on fillet area.
Do not use again
Note: Illustrations 34 and 35 show valves where part of the rust has been removed by the Scotch Brite cleaning method.
Illustration 34
Rust covers pits, scale, and erosion.
Do not use again

Illustration 35
Rust is removed when valve is cleaned and there are no pits, deposits, scale or erosion under the rust.
Use again
Valve Head
Illustration 36

Large or deep marks; also some marks are near the edge of the valve head.
Do not use again
Illustration 37
Small marks are not near the edge of the valve head and are not deeper than the part number stamp.
Use again

Illustration 38
Damaged valve head.
Do not use again
Illustration 39
Damaged valve head.
Do not use again

Illustration 40
Small amount of erosion. Do not use a valve with more erosion than shown in this illustration.
Use again
Illustration 41
Too much erosion.
Do not use again

Illustration 42
If cupping of the valve head is more than 0.25 mm (0.010 in), do not use the valve again.
Do not use again
Illustration 43
A small amount of cupping is normal even on new valves. Use a straight edge and a feeler gauge to check for cupping.
Use again

Valve Face
Illustration 44
Grind all valves even if wear cannot be felt after grinding.
Use again
Illustration 45
Too much wear on valve face.

Do not use again
Procedure to Grind Valves
Note: After a valve has been ground, inspect the face and measure the lip thickness. Refer to the "Procedure to Measure Valve Lip Thickness" in this guideline.
Grind all valves even if wear cannot be felt.
All specifications for grinding valves are given in the Guideline for Reusable Parts, SEBF8034, “Valve and Valve Spring Specifications”.
Valve Face
Illustration 46
Adjust the angle of the valve grinder.
1. Adjust the valve grinder carriage to the correct valve face angle given in the specifications.

Illustration 47
Put valve in chuck.
2. Follow the manufacturer's instructions for installation of the valve into the chuck.
Illustration 48
Adjust carriage stop.
3. Adjust the carriage stop for maximum movement to the left.

Illustration 49
Dress the grinding wheel.
4. Always dress (to make straight and smooth) the grinding wheel so it has no nicks, grooves or foreign material.
Illustration 50
Valve face that is not ground evenly.
Do not use again

5. As the valve turns in the grinding machine, look at it to see if it is warped or bent. A grind that is not even (as shown in Illustration 50) can be caused by a warped valve or bad maintenance of the
valve grinding machine. A valve that is warped must not be used again unless the lip thickness is correct after it is ground smooth and even.
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. Grind all valves wet.
7. Use the manufacturer's instructions to grind the valve.
Note: Refer to Caterpillar Service Training Videotape, LEVN9063, "Valve Grinding" for more information.
Illustration 51
Inspect valve face after grinding.
8. After the valve is ground, inspect the valve face. There must be no grooves, pits, machine marks or burns on the face.
NOTICE
If the maintenance on a valve grinding machine is not correct, it can cause bad results and possible valve failure. 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 (.001 in). If the dial indicator shows too much runout, the chuck is damaged and needs repair or the bearings are
bad or loose.
Also, check the ways (channels) that the valve grinding machine slides in. If any movement can be felt, the ways 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.
Repair to End of Valve Stem

Illustration 52
Before valve stem is ground.
Illustration 53
After valve stem is ground.
Use again
The end of the valve stem must be very smooth [maximum of 0.81 micrometers or (32 microinches)] and level. Normally, only a small amount of material must be removed. Remove
only 0.025 mm (0.001 in) with each grind; then inspect the stem.

Note: All valves do not have to be the same length.
Illustration 54
Grinding (repair of the end of the valve stem).
Use the valve again, if any part of the original chamfer can be seen. Remove sharp edges with the Scotch Brite method or with an Arkansas stone.
Procedure to Measure Valve Lip Thickness

Illustration 55
Lip thickness of the valve. Use either of the two methods that follow to check lip thickness.
Illustration 56
Use of 5P-6518 Fixture Group to measure valve lip thickness.
Illustration 57
Use of the 6V-7059 Multiple Anvil Micrometer with

6V-2034 Adapter.
Valve lip thickness can be measured with either a 5P-6518 Fixture Group (Illustration 56) or a 6V-7059 Multiple Anvil Micrometer used with a 6V-2034 Adapter (Illustration 57). Refer to the “Tool
Guide for Caterpillar Dealers” and Special Instruction, SMHS6998, “Instructions for the Use of 5P-6518 Fixture Group for Parts Reusability of Turbocharger Shaft”, for more information.

Note: Remove any burrs from the V-blocks on the fixture group with a small 6V-2010 Arkansas Stone. Burrs can damage the valve stems.
Refer to SEBF8034 for correct lip thickness.
Note: Some difference in lip thickness is permissible, but if the thickness is less than the minimum specification at any point, do not use the valve again.
Valve Springs
Cleaning and Inspection
Use a good solvent to clean all valve springs.
Illustration 58
Nicks (deep grooves or notches) and deep scratches.
Do not use again

Illustration 59
Light wear in the first 180 degrees of turn is acceptable.
Use again
Illustration 60
Rust deposits.
Do not use again

Illustration 61
Notches at the end of the spring are not acceptable.
Do not use again
Illustration 62
Wear on valve spring between coils and on end.

Do not use again
Illustration 63
Wear on the valve spring sides.
Do not use again

Illustration 64
Use a square or straight edge and a feeler gauge to check each valve spring for distortion.
Use again –
If the spring meets the “use again” specifications.
NOTICE
Do not use a valve spring again if it has more distortion than the dimensions given in SEBF8034
Valve Spring Test Procedure
1. Adjust stop at top of valve spring tester to compress (push) only to the "Length at Valve Open Position".
2. Put the spring under compression until it is at the "Assembled Length." Make a record of the force needed to hold the spring at this length.
3. Continue to compress the spring until it is at the "Length at Valve Open Position." Make a record of the force needed to hold the spring at this length.
4. Make a comparison of the results to the specifications given in SEBF8034

Illustration 65
Using the 8S-2263 Valve Spring Tester to test springs
Valve Rotators and Locks
Nomenclature
Illustration 66

Rotocoils (rotators) and locks nomenclature.
Chart B
Valve Rotator and Lock Nomenclature
Item Description
1 Inner part
2 Rotators
3 Outer part
4 Three-piece locks
5 Two-piece locks
Procedure to Clean
Be very careful as you clean the rotator. Do not take it apart; it can be damaged easily.
Use a good, clean solvent to clean rotators and locks. The clearances inside the rotators are very tight and foreign material can easily damage the rotators. Keep the solvent clean with the use of a filter.
Illustration 67
Cross-section of a typical valve rotator. If dirt gets inside, the parts wear quickly. Wash in clean solvent only.
Inspection
Rotators

Illustration 68
Rotation of the inner part of the rotator is smooth and there is no damage like deep grooves or notches.
Note: Some new rotators can be tight and this test will not work on many new rotators.
At assembly, make a mark on the rotator parts with chalk. Tap (lightly hit) the valve, in a straight downward motion, with a 1S-0258 Soft Tip Hammer, six to eight times. If the rotocoil rotates the valve,
operation of the rotator is correct.
Illustration 69
Tap valve six to eight times.

Illustration 70
If rotocoil rotates, operation of rotator is correct.
Note: Refer to Caterpillar Service Training Videotape LEVN9063, "Valve Grinding", for more information.
Locks
Illustration 71
Locks do not show heavy wear, cracks or gouges.
Use again

Illustration 72
Locks must mate (fit) correctly with the valve and rotator.
Use again
© 2004 Caterpillar
Printed in the U.S.A
All Rights Reserved
Copyright 1993 - 2007 Caterpillar Inc. Wed Feb 7 07:44:55 UTC+0700 2007 Wed Feb 7 07:44:14 UTC+0700 2007
All Rights Reserved.
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Reuse And Salvage Guidelines

Valves, Valve Springs, Valve Rotators and Locks

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Tooling and Equipment

Cupping: A surface that has a curve.

Discoloration: A change in color.

Erosion: To wear away.

Pits: Holes that are caused by corrosion.

Polish: To make the surface clean and shiny.

Scuffing: To become rough because of wear.

Warped: To become turned or twisted from the original shape.

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Procedure to Clean Valves

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Sodium Bicarbonate Method

Do not use glass bead or steel shot in a cabinet

Glass Bead Method

Do not use the glass bead method to clean the valve

Steel Shot Method

The steel shot will not give an acceptable finish on the

6V-2033 Brush and 6V-2032 Adapters

6V-2033 Brush and 6V-2032 Adapters

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Personal injury or death can occur from not following the

One source of variable speed motors is:

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Typical vibratory cleaner.

Retainer Groove Area

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Damage or wear in the grooves.

Do not use again

Surface wear, but no damage to the sides or bottom of the grooves.

If desired, use the Scotch Brite method to polish the area.

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Valve after cleaning (same valve as shown in Illustration 9)

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Erosion on valve stem.

Do not use again

Rust can be removed by cleaning.

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Do not use again

Do not use a valve if normal cleaning methods will not

Grooves cannot be felt with the fingernail.

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Grooves can be felt with the fingernail.

Do not use again

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Valve stem with scuffing or seizure.

Do not use again

Valve stem with scuffing or seizure.

Do not use again

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Do not use again

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Change in diameter of valve stem.

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