Guideline For Reusable Parts And Salvage Operations

Valves, Valve Springs, Valve Rotators and Locks

Media Number -SEBF8002-05 Publication Date -30/03/2004 Date Updated -30/03/2004

Valves, Valve Springs, Valve Rotators and Locks

SMCS - 1105; 1108; 1109

ILLAR®

INE FOR
BLE PARTS
LVAGE OPERATIONS
alve Springs, Valve Rotators

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 Title
Number

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 Part Description

Number

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

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Illustration 1

Valve with single flange keeper. Refer to Chart A for item identification.

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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
Procedure to Clean Valves
4 Valve Head
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5 Valve Face

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

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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.

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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.

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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

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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

 
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Illustration 7

Damage or wear in the grooves.

Do not use again

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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

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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

 
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Illustration 10

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

Use again

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Illustration 11
Erosion on valve stem.

Do not use again

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Illustration 12

Rust can be removed by cleaning.

Use again

 
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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

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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.

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Illustration 15

Grooves cannot be felt with the fingernail.

Use again

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Illustration 16

Grooves can be felt with the fingernail.

Do not use again

 
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Illustration 17

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

Use again

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Illustration 18

Valve stem with scuffing or seizure.

Do not use again

 
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Illustration 19

Valve stem with scuffing or seizure.

Do not use again

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Illustration 20

Worn chromium coating. (Only a small number of Caterpillar valves have a chromium coating on
the stems.)

Do not use again

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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

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Illustration 22

Some valve stems are smaller at this point so the fillet area and stem surface come together
smoothly.

Use again

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Illustration 23

Change in diameter of valve stem.

 Do not use again

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Illustration 24

Change in diameter of valve stem.

Do not use again

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Illustration 25

Valve stem is bulged (larger than new) from engine operation.

Do not use again

Stem Measurements

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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.

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Illustration 27

The micrometer slides over the stem.

Do not use again

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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

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Illustration 29

Cracks in fillet area

Do not use again

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Illustration 30

Normal bond between valve head and valve face material.

Use again

 
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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.
View Image

Illustration 32

Erosion in fillet area.

Do not use again

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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.

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Illustration 34

Rust covers pits, scale, and erosion.

Do not use again

 
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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
View Image

Illustration 36

Large or deep marks; also some marks are near the edge of the valve head.

Do not use again

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Illustration 37

Small marks are not near the edge of the valve head and are not deeper than the part number stamp.

Use again

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Illustration 38

Damaged valve head.

Do not use again

 
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Illustration 39
Damaged valve head.

Do not use again

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Illustration 40

Small amount of erosion. Do not use a valve with more erosion than shown in this illustration.

Use again

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Illustration 41

Too much erosion.

Do not use again

 
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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

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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

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Illustration 44

Grind all valves even if wear cannot be felt after grinding.

Use again

 
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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
View Image

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.

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Illustration 47

Put valve in chuck.

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

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Illustration 48

Adjust carriage stop.

3.      Adjust the carriage stop for maximum movement to the left.

 
View Image

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.

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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.

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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

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Illustration 52

Before valve stem is ground.

View Image

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.

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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

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Illustration 55

Lip thickness of the valve. Use either of the two methods that follow to check lip thickness.
 
View Image

Illustration 56

Use of 5P-6518 Fixture Group to measure valve lip thickness.

 

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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.

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Illustration 58

Nicks (deep grooves or notches) and deep scratches.

Do not use again

View Image

Illustration 59

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

Use again

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Illustration 60

Rust deposits.

Do not use again

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Illustration 61

Notches at the end of the spring are not acceptable.

Do not use again

 
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Illustration 62

Wear on valve spring between coils and on end.

Do not use again

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Illustration 63

Wear on the valve spring sides.

Do not use again

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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

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Illustration 65

Using the 8S-2263 Valve Spring Tester to test springs

Valve Rotators and Locks

Nomenclature
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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.

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Illustration 67

Cross-section of a typical valve rotator. If dirt gets inside, the parts wear quickly. Wash in clean
solvent only.

Inspection

Rotators

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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.

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Illustration 69

Tap valve six to eight times.

 
View Image

Illustration 70

If rotocoil rotates, operation of rotator is correct.

 

Note: Refer to Caterpillar Service Training Videotape LEVN9063, "Valve Grinding", for more
information.

Locks

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Illustration 71

Locks do not show heavy wear, cracks or gouges.

Use again
  

 
 

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illustration 72

Locks must mate (fit) correctly with the valve and rotator.

Use again