Repair Procedure: 3600 Series Cylinder Heads - Blended Fuel{1100} Caterpillar

Introduction

This procedure outlines the repair for a 3600 series cylinder head used in a residual fuel application. All information needed to complete the repair of the cylinder head is included in this document with the exception of the "Guideline for Reusable Parts and Salvage Operations." Further references can be made to the 3600 series service manuals.

References

For further detail on rebuild procedures and reconditioning operations, see the Guidelines for Reusable Parts and Salvage Operations listed in the following chart.

Tooling and Equipment

Before starting the rebuild procedure on a 3600 series cylinder head, it is important to obtain the correct tooling and equipment. The various tooling listed will accomplish the outlined task.

Rebuild Procedure Disassemble Cylinder Head 1100-015

1. Bolt cylinder head on the 8T-2826 Fixture and 1U-9352 Engine Stand.

2. Inspection: Inspect the cylinder head for external damage such as large cracks in the combustion surface between the valve seat pockets and the injector hole, pitting and erosion of the combustion surface or damaged caused by separated valve heads. This type of damage requires replacement of the cylinder head.

3. Clean the combustion surface of the cylinder head using the 1U-5780 Angle Grinder with the 5P-9709 Metal Reconditioning Disk and the 5P-9718 Disk Pad. The combustion surface should be cleaned to a bare metal finish. When cleaning the combustion surface take care to ensure that no metal is removed from the cylinder head casting.

4. Inspection: Measure the thickness of the cylinder head casting using the outside micrometer. The minimum allowable thickness of the cylinder head casting is 279.0 mm (10.98 in). If the cylinder head does not meet specifications, or has pitting on the combustion surface that will require machining below tolerance, the cylinder head must be replaced.

5. To locate the sealing surface area, place the spacer plate on the combustion surface aligned with the cylinder head stud holes. Using a permanent marker, draw a line around the inside diameter of the spacer plate.

6. With the spacer plate still on the combustion surface, place the sealing ring on the combustion surface and draw a line around the inside diameter. The area between the two lines, after the spacer plate and sealing ring have been removed, is the combustion sealing ring area. The inner diameter of the combustion sealing surface is 330.0 ± 1.0 mm (12.99 ± .04 in), the outer diameter of the combustion sealing surface is 380.0 ± 1.0 mm (14.96 ± .04 in).

NOTE: If the engine does not have a spacer plate, create a template with the above dimensions that aligns with the injector hole in the cylinder head.

7. Inspection: Measure the flatness of the combustion surface and the combustion sealing ring surface with the straight edge and the 8H-8581 Feeler Gauges. The combustion surface flatness must not exceed a maximum of 0.10 mm per 100.00 mm (0.004 in per 4.000 in) length except within the combustion sealing ring area. Within the combustion sealing ring area the surface flatness must not exceed 0.05 mm (0.002 in). If the combustion sealing surface is out of tolerance the cylinder head casting will have to be machined or replaced.

8. Place the dealer fabricated plate over the injector hole on the valve spring side of the cylinder head and put the 8T-2679 Pulling Rod through the injector hole.

9. Install 8T-3109 Retainer Plate over the Pulling Rod and use the 1D-4720 Nut to hold the Retainer Plate to the combustion surface.

10. If valve reuse is expected, mark the valves so that they can be returned to their original location. Using an 8T-2664 Lever Group (part of 9U-5100 Cylinder Head Repair Tool Group), compress the valve springs and remove the two valve retainers.

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Do not remove valve retainers with your fingers. The spring can move and cause personal injury.

11. Decompress the valve springs. Remove the valve rotator, the outer valve spring, and the inner valve spring (not shown). Remove the valve spring guide.

12. Repeat steps 10 and 11 for the remaining valves.

13. Remove the 1D-4720 Nut, the Dealer Fabricated Plate, the 8T-2679 Pulling Rod (part of 9U-5100 Cylinder Head Repair Tool Group) and 8T-3109 Retainer Plate. When the Retainer Plate is removed the two intake valves and the two exhaust valves can be removed from the cylinder head.

14. Inspection: Use the 9U-6401 Valve Guide Gauge to measure the internal diameter of the valve guides. If the valve guides do not meet dimensional specification they should be removed and replaced.

15. Inspection: Use the 130-2534 Bridge Dowel Gauge to measure the outside diameter and the height of the bridge dowels. The diameter of the bridge dowel must be within 19.055 ± 0.003 mm (0.7502 ± 0.0001 in). The height of the bridge dowel must not exceed 105.0 ± 2.0 mm (4.10 ± 0.08 in). If the bridge dowels do not meet dimensional specifications remove the bridge dowels

16. Use the 9U-5099 Puller Group (part of 9U-5100 Cylinder Head Repair Tool Group) to remove the bridge dowels and dowel plugs from the cylinder head casting.

NOTE: When the bridge dowels are removed the bridge dowel plugs should also be removed and the O-ring seals replaced. If the plugs are not removed when the dowels are removed, the plugs will have to be threaded in order to be removed from the casting.

17. Roll the cylinder head over so that the combustion face is up. Using the 1U-5778 Die Grinder with the 1U-9942 Wire Brush remove any carbon deposits from the valve seat insert sealing surface.

18. Inspection: Inspect the four valve seat inserts for cracks, erosion or other damage. Take special note of the exhaust valve inserts. If any erosion is present on or below the insert sealing face it will require replacement.

19. Using the 9U-5099 Puller Group (part of 9U-5100 Cylinder Head Repair Tool Group) remove intake valve inserts and exhaust valve inserts.

NOTE: It may be necessary to apply heat to the exhaust valve inserts in order to break the bond of the retaining compound and remove the inserts.

20. Using the 1U-5778 Die Grinder with the 1U-9942 Wire Brush remove any retaining compound that might be present and polish the valve insert bore.

21. Remove the cylinder head casting from the rollover stand adapter plate and place in a hydraulic press on the combustion surface. When the cylinder head is placed in the press, ensure that the combustion surface is not damaged.

22. Using the 8T-2676 Valve Guide Driver (part of 9U-5100 Cylinder Head Repair Tool Group) and a Hydraulic Press, press the four valve guides out of the casting.

NOTE: The threaded holes used to connect exhaust manifold may need to be re-threaded with a 4C-4979 Bottoming Tap to remove any carbon buildup before the cylinder head can be put into service.

NOTE: If the combustion surface requires machining, proceed with the machining process at this time.

23. Clean parts and inspect for reusability before reassembly. The recommended method for cleaning the cylinder head casting and components is a cabinet washer with a caustic cleaner 1U-9490, Hydrosolv 4165 (5 Gal. Container). This method of cleaning will require the least amount of time and should remove the carbon buildup from the components. All carbon residue must be removed from the exhaust passages.

Assembly Procedure 1100-016

NOTE: There is more than one possible method for assembling the cylinder head assembly. The tooling in the assembly and disassembly tooling list will accomplish the task outlined.

24. Insure that the cylinder head casting is free of carbon residue and that the internal passages are free of contamination that might be present from machining before beginning the assembly process.

25. Place the cylinder head in a hydraulic press on the combustion surface. When the cylinder head is placed in the press, ensure that the combustion surface is not damaged.

26. Place new O-ring seals on the bridge dowel plugs and apply a light coat of oil to the seals before installing the bridge dowel plugs.

27. Place the bridge dowel plugs in the plug bore and use a 4C-8540 Driver (part of 9U-5100 Cylinder Head Repair Tool Group) to drive the plugs into the casting.

28. Using the 4C-8540 Driver and the 8T-2673 Stop Sleeve (part of 9U-5100 Cylinder Head Repair Tool Group) drive the bridge dowels into the bridge dowel plugs.

NOTE: Cool the valve guides before installation.

29. Place the valve guide into the valve guide bore and use the 8T-2676 Driver (part of 9U-5100 Cylinder Head Repair Tool Group) to drive the valve insert into the cylinder head casting.

30. Inspection: Using the 9U-6401 Valve Guide Gauge, measure the internal diameter of the valve guides. If the valve guide internal diameter has been reduced upon installation it will have to be removed and replaced, or honed to the proper diameter.

31. Inspection: Using the 130-2534 Bridge Dowel Gauge, measure the external diameter and the height of the bridge dowel.

32. Place the cylinder head in the press on the upper side of the cylinder head.

NOTE: Before installing the valve seat inserts, ensure that the insert bore is thoroughly clean and that there are no sharp edges remaining from the surface grinding procedure.

33. Place the intake valve insert into the valve insert bore and press into place using the 8T-2674 Driver (part of 9U-5100 Cylinder Head Repair Tool Group).

34. Wipe clean the exhaust valve insert bore with a rag and prime the surface with 6V-1541 Quick Cure Primer. Apply 4C-9507 Retaining Compound to the insert bore along the sealing surfaces.

35. Place the exhaust valve insert in the insert bore and press into the cylinder head casting using the 8T-2674 Driver (part of 9U-5100 Cylinder Head Repair Tool Group).

NOTE: If the valve seat inserts are to be reused they will need to be lightly ground with the 4C-4706 Grinder. When grinding the valve inserts do not remove any more material that necessary.

36. Inspection: Using the 147-2285 Valve Gauge Group measure the valve to insert interference angle. The valve seat insert angle is 30.75 degrees ± 0.25 degrees. The valve to valve insert interface should be line contact around the outside edge of the valve and valve seat.

37. Inspection: Measure the valve lip thickness using the 6V-7059 Micrometer and the 6V-2034 Adapter. The minimum valve lip thickness is 4.80 mm (0.190 in). The angle of the valve seating surface is 30.25 degrees ± 0.10 degrees.

38. Inspection: Measure the valve recession using the valve projection tooling. The maximum valve recession of the intake valves is 2.00 mm (0.079 in). The maximum recession of the water cooled exhaust valve is 7.00 mm (0.276 in). Maximum valve projection is 0.5 mm (0.02 in). If the valve projection exceeds the specifications the valve seat insert will need to be ground.

39. Remove the cylinder head from the press and place on the cylinder head adapter and rollover stand.

40. Install two intake valves and two exhaust valves into the cylinder head. Install the 8T-3109 Retainer Plate, the 8T-2679 Pulling-Rod, the Dealer Fabricated Plate and the 1D-4720 Nut to retain the valves in the cylinder head.

41. Install four valve spring guides over the valve stems.

42. Place four inner valve springs over the valve stems.

43. Place four outer valve springs over the valve stems and inner springs.

44. Place the four valve rotators on the outer valve springs.

45. Compress the valve springs using the 8T-2664 Lever Group and install the eight valve retainers, two on each valve stem.

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Do not install valve retainers with your fingers. The springs can move and cause personal injury.

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The locks can be thrown from the valve when spring compressor is released if they are not in their correct position on the valve stem. To prevent possible personal injury, be sure to stay away from the area in front of the valve retainer and springs. Always wear protective glasses.

46. Inspection: Vacuum check the valve to insert interface seal using the FT-1742 vacuum tester. If the seal does not meet specifications the valve interface needs to be checked. The interface must be capable of achieving a maximum of 76 kPa (11 psi) vacuum. The vacuum must not decay any faster than 5 kPa (.5 psi) per second following removal of the vacuum source.

47. Inspection: Place a mark on both halves of the valve rotators and hit the valve stem with a rubber hammer to test the action of the valve rotators. If the marks on the rotators do not change position in relation to each other the rotators will have to be removed and replaced.

48. Place the cylinder head on a wooden palate and coat with oil or grease. Shrink wrap the cylinder head assembly to prevent contamination of the cylinder head assembly until installation.