Guideline For Reusable Parts And Salvage Operations

Rocker Arm, Rocker Arm Shafts, and Bridge Assemblies for 3500 Engines

Media Number -SEBF8174-05 Publication Date -12/02/2003 Date Updated -12/02/2003

   
SEBF81740001

Rocker Arm, Rocker Arm Shafts, and Bridge Assemblies for

3500 Engines
SMCS - 1102; 1121; 1123

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SEBF8174-05
January 2003
SMCS Code: 1102, 1121, 1123

 
 
 
 

GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE OPERATIONS

Rocker Arm, Rocker Arm Shafts, and

Bridge Assemblies for 3500 Engines
 

Summary of Revisions

Page Description

All Updated information

4 Updated dimensions in Chart B

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 Service Operations (309) 636-5833.

Summary
The information given in this guideline will assist in determining the reusability of the
rocker arms, rocker arm shafts, and bridge assemblies for the 3500 Family of Engines.

During the operation of the engine, each rocker arm, rocker arm shaft, and bridge
assembly 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, rocker arm shaft, and bridge assembly must be installed in its original
position. If the rocker, rocker arm shaft, and bridge assemblies are not installed in the
same location, the difference in the wear patterns will result in a faster rate of wear or
possible failure.

Rocker arms, rocker arm shafts, and bridge assemblies 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.

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When replacement parts are required for

this product Caterpillar recommends
using Caterpillar 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.

Tooling and Equipment

Required Tools

Part Number Part Description

1P-0510 Driver Group

Inspection
Check the rocker arm assembly for excessive wear at the bearings. Also check for wear
at the point between the rocker arm adjusting screw and all push rods (valve and
injector).

Check all the parts for surface damage. There must not be any pits, corrosion, or
smeared material on the contact surfaces. If the parts show only signs of normal wear
patterns and the surfaces are free of defects, "Use again". Excessive wear patterns are
visible and can be felt with the fingernail. Excessive wear patterns indicate "Do not use
again."

Check the rocker arm shaft for excessive wear. One indication of excessive wear is that
the rocker arm feels loose on its mating shaft. If this condition exists, "Do not use
again".

Check for wear at the contact surfaces between the rocker arm assembly and the
bridge. Normally, excessive wear is not present in this area.

Nomenclature
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Illustration 1

Rocker arm, rocker arm shaft, and bridge assembly nomenclature. Refer to Chart A.

Chart A.

Nomenclature

Item Description

1 Hollow Pin, Pin Opening

2 Rocker Arm Shaft Assembly

3 Adjusting Screw
 4 Cover Base Assembly

5 Jam Nut

6 Valve Rocker Arm Assembly

7 Injector Rocker Arm Assembly

8 Injector Arm Socket

9 Retainer Ring

10 Button

11 Sleeve Bearing

12 Gasket

13 Valve Arm Socket

 
Specifications for Rocker Arms and
Assembly
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Illustration 2

Rocker arm and rocker arm shaft specifications. Refer to Chart B for specifications.

Chart B.

Rocker Arm and Rocker Arm Shaft Specifications

3500A 3500B

Item Description

Max Min Max Min

Sleeve 40.402 40.362 48.318 48.278

A
Bearing (OD) (1.591) (1.589) (1.902) (1.901)

40.302 48.218
Rocker Arm
40.332 48.248
B (Valve &
(1.588) (1.569) (1.900) (1.898)
Injector)

45.071 45.041
37.155 37.125
C Bearing (ID)
(1.463) (1.462) (1.774) (1.773)

Arm Socket 7.970 7.870 7.970 7.870

D
Radius (.3138) (.3098) (.3138) (.3098)
 37.097 37.071 45.013 44.987
Rocker Arm
E
Shaft (1.461) (1.460) (1.772) (1.771)

16.510 16.250 19.812 19.532

Dowel Pin
(OD) (.650) (.640) (.780) (.769)

F
15.951 15.824 19.120 18.990
Shaft Pin
Hole (ID) (.628) (.623) (.753) (.748)

Dowel Pin 6.000 6.000

G
Height (.2362) (.2362)

Note: All dimensions are mm (inch).

Note: Rocker arm bearing to shaft clearance is 0.056 ± 0.028 mm (0.002 ± 0.001
inch).

Chart C.

Maximum Surface Texture

Description Surface Finish

Rocker Arm Shaft 0.125 (5)

Bearing 0.80 (32)

Note: Specifications are micrometers (microinches).

Rocker Shaft Assembly

Disassembly
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Illustration 3

Remove shaft (1) from rocker arms (2).

1. Slide shaft assembly (1) out of rocker arms (2). If necessary, remove the dowel
from shaft assembly (1).

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2. Illustration 4
3. Remove adjustment screw (4) and socket (3) from rocker arm (2).

4. Remove adjustment screw (4) and the nut from rocker arm (2).
5. Use a hammer and punch to push socket (3) out of rocker arm (2).

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6. Illustration 5
7. Remove ring (5) from socket (3).

8. Remove the ring that holds button (5) in socket (3), and remove the button from
the socket.

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 9. Illustration 6
10. Remove bearing (6) from rocker arm (2).

11. Use 1P-0510 Driver Group to remove bearing (6) from rocker arm (2).

Assembly
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Illustration 7

Install bearing into rocker arm (1) using driver (A).

1. Align the oil hole (slot) in the bearing with the oil passage in rocker arm (1). Use
1P-0510 Driver Group (A) to install the bearing in rocker arm (1). Make sure the
joint in the bearing is toward the top of the rocker arm.
2. After installing bearing, machine the inside diameter to the specifications given in

Chart B.

Note: The inside surface of the bearing must be machined to 100% cleanup. If
cleanup is not obtained, install a new bearing and re-machine.

3. Clean bearing, bearing groove, and oil passages to remove all machining debris.

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4. Illustration 8
5. Install socket.
(1) Rocker arm
(2) Socket
(3) Button
(4) Ring

6. Align the scribe mark on socket (2) with the mark on rocker arm (1). Install the
socket in the rocker arm to the full depth. The scribe mark on the socket must be
within ± 5 degrees of the mark on the arm.
7. Install ring (4) in socket (2) and seat button (3) past the ring to hold button (3) in
socket (2).

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8. Illustration 9
9. Install adjustment screw.
(1) Rocker arm
(5) Screw
(6) Nut

10. 6. Install adjustment screw (5) and nut (6) on rocker arm (1).

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 11. Illustration 10
12. Install rocker arms (1) on shaft (7).

13. If the dowel was removed from shaft assembly (7), install the new dowel into the
shaft until it is 6.00 mm (0.236 inch) above the surface of the shaft.
14. Put clean engine oil on the rocker arm bearings and shaft assembly (7). Install
rocker arms (1) on shaft assembly (7).

Bridge Assembly
Valve Mechanism Group

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Illustration 11

109-3824 Valve Mechanism Group.

(1) 7C-0204 Rocker Arm Adjusting Screw and 3J-9196 Nut.
(2) 9Y-1714 Rocker Arm Assembly (Valve).
(3) 129-4181 Bridge Assembly.
(4) 2N-5842 Bridge Adjusting Screw and 9L-7712 Nut.
Bridge Adjusting Screw

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Illustration 12

Bridge Adjusting Screw. Inspect surface (1) for wear from valve stem.

Do not use again -

if the bridge adjusting screw seating surface to valve stem area (1) shows wear steps or
shows scuffing or seizure marks.

Bridge Assembly

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llustration 13
Bridge Assembly
(1) Valve Bridge, (2) Wear Seat, (3) Inspect surface for wear from rocker button, (4) Make sure oil supply hole is open and clear, (5) Inspect
bore for wear from valve stem,
(6) Inspect bore for wear.

Inspection of the bridge assembly must include guide bore (6), the bridge contact seats with
valve stems (5), and rocker contact seat (3). If guide bore (6) shows any scuffing or
seizure marks on the inside diameter or if the bore diameter shows excessive wear
[diameter larger than 11.15 mm (0.439 inch)], the bridge assembly should not be used
again. If the bridge contact seat (7) or bore (5) shows any significant wear or if any part
of the bore is scuffed or seized, do not use again. If the rocker contact seat shows
scuffing or seizure marks or if a polished wear step area is excessive, the bridge
assembly should not be used again.

Rocker Arm Adjusting Screw

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Illustration 14

Rocker arm adjusting screw. Inspect surface (1) for wear on valve push rods and injector push rod.

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