421-1011 Valve Recession Tool Group used on G3500 C, E, ; H Engines{0374, 0599, 0701, 0703, 1100} Caterpillar

Engine: All 3500 Engines

Introduction

Important Safety Information

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Think Safety

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

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

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

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

Literature Information

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

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

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

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

Safety Section

The Safety Section lists basic safety precautions.

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

General Information Section

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

Operation Section

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

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

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

Maintenance Section

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

Safety Section

Safety Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

Hazard Avoidance

Crushing Hazard (foot)

Crushing Hazard (hand)

Pinch Point

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

USA: 800-542-8665, Option 1

International: 1-309-578-7372

Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.

References

For more information on using the 421-1011 Valve Recession Tool Group refer to the appropriate Disassembly and Assembly Manual.

General Information Section

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The 421-1011 Valve Recession Tool Group is used to accurately measure valve recession on G3500 C, E, and H Engines.

The 421-1011 Valve Recession Tool Group comes in a foam lined, heavy-duty carrying case.

Nomenclature

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Operation Section

The operation section illustrates components and describes the operation of the 421-1011 Valve Recession Tool Group on the G3500 Series Engine.

Note: This standard work will describe the most consistent way to zero and measure valve recession on the G3500/C/E/H product line.

1. Zero the gauge.

   1. Ensure that all couplings are adequately tightened so gauges are fixed.
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   Valve Recession Gauge and Valve Recession Tool Components

   2. Place gauge stand on zeroing gauge as seen in Illustration 5.

      Note: For best results, always locate the gauge stand legs toward the front of the gauge zeroing base guides. This will ensure that minimal amount of variation is experienced while zeroing the gauge.

   3. Loosen the screw on the upper right corner of each gauge and rotate until the large dial is aligned with "0".

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2. Remove rocker arm shaft assembly and bridges from all heads. (See illustration 6.)

3. Place the gauge stand on the head by aligning the dowels with the two guides on the bottom of the gauge stand. (See Illustration 7)

   1. Ensure that all three legs are touching the head with no debris below them.

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Measurement of Valves

4. Record measurement from each gauge noting the location of each measurement (in board, outboard, intake, exhaust).

5. Repeat steps 3 and 4 for all other heads on the engine.

6. Periodically put gauge stand back onto gauge block, and verify that all of the dial indicators still zero.

Maintenance Section

Inspection

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Inspect and clean all of the parts on the 421-1011 G3500 Engine Tool Group before each use. Contaminants can cause rapid engine wear and shortened component life.

If components are worn or damaged, they must be replaced.

1. Inspect all welds and check for damaged, cracked, or bent components.

2. Inspect the thrust bearing. Clean and lubricate, as needed for smooth operation.

3. Check for cracks and damaged or galled threads.

4. Clean the threads on the spring compression rod assembly frequently and lubricate with a high-pressure lubricant to prevent thread galling.

5. Have tools inspected annually by an approved dealership inspector. Maintain a written record of all inspections.

Cleaning

Clean tools using a high quality cleaning fluid. Allow to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on tools, which can result in contamination of precision engine components.

Storage

Store tool in the 4C-3975 Case . Store indoors in a clean, dry location to prevent rust or corrosion. Tooling and threads can be damaged by moisture or high humidity.

Tool Disposal

At the end of the operational life of the tool, destroy the tool and dispose of as scrap.