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Engine:Commercial All
3044C (S/N: 3441-UP)
C-10 (S/N: AKB1-UP; MBJ1-UP; 2PN1-UP; 3CS1-UP; 8YS1-UP; BCX1-UP)
C-12 (S/N: CPD1-UP; TME1-UP; BDL1-UP; MBL1-UP; 9SM1-UP; 1YN1-UP; 2KS1-UP; 9NS1-
UP; BCY1-UP)
C-15 (S/N: EGH1-UP; MBN1-UP; 6NZ1-UP; 9NZ1-UP)
C-16 (S/N: W1A1-UP; 7CZ1-UP)
C-18 (S/N: CJP1-UP; MDP1-UP; MEP1-UP)
C-9 (S/N: CLJ1-UP)
C11 (S/N: KCA1-UP)
C13 (S/N: KCB1-UP; LEE1-UP; JAM1-UP)
C15 (S/N: C5E1-UP; C5L1-UP; MHP1-UP; SDP1-UP; B5R1-UP; BXS1-UP; MXS1-UP; NXS1-
UP)
C18 (S/N: DKE1-UP; EJG1-UP; WJH1-UP)
C7 (S/N: JRA1-UP; JTF1-UP; FML1-UP; KAL1-UP; FMM1-UP; SAP1-UP; C7S1-UP; WAX1-
UP)
C9 (S/N: MTB1-UP; SRB1-UP; 9DG1-UP; CKP1-UP; X3R1-UP; C9S1-UP)
Engine:Truck All
Industrial Engine:with Turbochargers All
C-10 PETROLEUM (S/N: Z2B1-UP)
C-15 IND (S/N: BEM1-UP)
C-16 IND (S/N: BFM1-UP)
C11 INDUSTRIAL (S/N: GLS1-UP)
C13 INDUSTRIAL (S/N: LGK1-UP)
C15 IND (S/N: JRE1-UP)
C15 INDUSTRIAL (S/N: JAS1-UP)
C27 INDUSTRIAL (S/N: TWM1-UP)
C32 INDUSTRIAL (S/N: TLD1-UP)
C9 INDUSTRIAL (S/N: JSC1-UP; MBD1-UP; JLW1-UP)
Machine Engines: All
Marine Engine:with Turbochargers All
C-12 MARINE (S/N: 9HP1-UP)
C12 MARINE (S/N: C1Z1-UP)
C15 MARINE (S/N: RLA1-UP)
C18 MARINE (S/N: CKH1-UP; C1J1-UP; NAX1-UP; NAY1-UP)
C30 MARINE (S/N: CLX1-UP)
C32 MARINE (S/N: RXB1-UP; RNC1-UP)
C7 MARINE (S/N: C7B1-UP; C7D1-UP; C7X1-UP; C7Z1-UP)
C9 MARINE (S/N: C9B1-UP; CSN1-UP; X9X1-UP; Z9X1-UP)
Agricultural Tractor:
MT855 (S/N: A3A1-UP)
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Introduction
This Reuse and Salvage Guideline contains the necessary information in order to allow a dealer to establish a
parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit
from cost reductions. Every effort has been made in order to provide the most current information that is
known to Caterpillar. Continuing improvement and advancement of product design might have caused changes
to your product which are not included in this publication. This Reuse and Salvage Guideline must be used
with the latest technical information that is available from Caterpillar.
For additional information about this guideline, consult Repair Process Engineering of the Marketing &
Product Support Division at 1 (309) 675-5434.
Summary
This Reuse and Salvage Guideline contains the information in order to rebuild a cylinder head. Two suggested
layouts for the area of rebuild for cylinder heads are provided in the ""Recommended Layouts for the Shop" "
section of this guideline. A flow chart is provided in order to illustrate the recommended steps in the process
for the rebuild.
References
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ReferenceReuse and Salvage Guideline, SEBF8355, "Cleaning Guide Equipment and Chemical
Recommendations Reference Manual"
ReferenceReuse and Salvage Guideline, SEBF8162, "Procedure to Measure and Salvage Cylinder Head
Assemblies and Related Components"
ReferenceReuse and Salvage Guideline, SEBF8363, "Examples of Parts Cleaning Racks and Baskets"
ReferenceReuse and Salvage Guideline, SEBF9006, "Specifications for Cylinder Head Assemblies on C-
Series Engines"
ReferenceThe following web site contains the Service Operations Dealer Assessment Tool. This tool may be
helpful when the cylinder head is rebuilt.
https://productsupportglobalcontent.cat.com
The area for the rebuild should accommodate the staging of the parts while the cylinder head components are
being processed. Enough space should be available in order to rebuild the cylinder head without any
interference. The area should have access from a jib crane in order to provide an effective way of moving the
components.
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Illustration 1 g01271598
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Illustration 2 g01271599
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Illustration 3 g01380601
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cleaning area. The area for disassembly and the area for cleaning should be separated from the area for the
rebuild by a wall in order to prevent contamination to exposed parts.
Illustration 4 g01271643
(1) Lifting bar is installed.
Illustration 5 g01271645
Lifting bar is installed on a 3500 Engine.
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Illustration 6 g01271646
Specifications for the lifting bar for a 3500 Engine
Efficiency in the process for rebuilding a cylinder head begins with the removal of the head or heads
from the engine. The cylinder heads can be removed in groups on engines with multiple cylinder heads
such as the 3500 Series Engines if a lifting bar is fabricated. It is more efficient to remove multiple
cylinder heads simultaneously instead of removing each head individually. Reconditioning cylinder
heads in groups is more efficient than reconditioning cylinder heads individually.
Remove the cylinder head with the exhaust manifolds, intake manifolds, and elbows in order to reduce
the overall time of engine rebuild. The entire assembly can be disassembled and reconditioned while the
engine is being reconditioned. This procedure will enable the reconditioning of the cylinder head
assembly to be synchronized with the reconditioning of the engine so that all the parts can be ready for
engine assembly at the same time.
NOTICE
Prior to precleaning, remove or protect any component that could be
damaged by the cleaning solution.
Use a hot spray wash cabinet in order to remove the dirt, oil, and grease from the cylinder head. Refer to
Reuse and Salvage Guideline, SEBF8355, "Cleaning Guide Equipment and Chemical Recommendations
Reference Manual".
The washer should have the option for automatic washing and the option for manual washing. Caustic
solutions are effective for cleaning the ferrous parts. Do not use caustic solutions in order to clean the
nonferrous parts. Soaps that are safe for aluminum should be used for these parts.
The washer should contain a rotating table. The automatic cycle will wash most of the soap solution at
the end of the cycle. The option for the manual wash is needed in order to manually wash the parts after
the automatic wash is complete.
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Visually inspect the cylinder head for obvious defects that will cause the casting to be scrapped or
replaced. Refer to Reuse and Salvage Guideline, SEBF8162, "Procedure to Measure and Salvage
Cylinder Head Assemblies and Related Components".
Illustration 7 g01271660
(1) 9S-9087 Tool Cabinet
Illustration 8 g01271662
Adjustable work bench for cylinder heads
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Illustration 9 g01271663
Adjustable work bench for cylinder heads that can be fabricated
Disassembly requires the removal of all components from the cylinder head casting. Refer to the specific
Service Manual for the required tooling and procedures for this operation.
The disassembly should be done on a work bench at a comfortable height. The work area must be large
enough to accommodate cylinder heads when the cylinder heads are removed in groups. Make sure that
the work area has enough space in order to disassemble the cylinder heads without interference.
Use a work bench that enables the cylinder head to be rotated during the process of rebuild. The work
bench for rebuilding cylinder heads should be equipped with air supply, racks for tooling, and cabinets
for all required tooling and parts. 9S-9087 Tool Cabinet and FT-0806 Bench Gp are recommended.
Overhead lights and local lights are recommended. These lights provide enough source of light in order
to visually inspect the cylinder head and components. Overhead lights and local lights prevent shaded
areas. Fluorescent lights above the work bench also provide the necessary lighting for inspection of most
of the components.
Illustration 10 g01276782
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Abrasive buffing or blasting may be required in order to remove the exhaust manifold gaskets and the
heavy carbon from the cylinder head. High temperatures make cleaning some areas of the cylinder head
difficult. Cleaning these areas before washing often eliminates excess cycles in the washer and
contamination of components later in the process of rebuild.
Illustration 11 g01271670
Typical basket for cleaning small parts
Illustration 12 g01271671
Typical basket for cleaning small parts
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Illustration 13 g01271672
Typical basket for cleaning small parts that can be used in a high pressure wash
6. Separate the parts into wire baskets that can be put into a hot spray wash cabinet or a tank of solvent as
the cylinder head is disassembled.
These baskets can be used in high pressure cleaning systems or low pressure cleaning systems. Choose a
basket that fits the application. Refer to Reuse and Salvage Guideline, SEBF8363, "Examples of Parts
Cleaning Racks and Baskets" for more information on cleaning racks and baskets.
The most effective baskets allow each part to have the direct impact of the cleaning solution. Direct
impact of the cleaning solution eliminates a second cycle of cleaning. Baskets should be designed to be
transported with a crane rather than a lift truck in order to reduce time of transport, labor, and space in
the shop.
Illustration 14 g01271682
Design of a fixture for cleaning valves
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Illustration 15 g01271684
Valves in the fixture
Components of the cylinder head such as the valves, valve lifters, valve springs, keepers, valve
rotators, and other parts can be cleaned in a separate system from the cylinder head casting. Clean
these parts prior to inspection in order to allow easier identification of defects unless obvious
defects are visible.
Cleaning fixtures can be designed to work with cleaning equipment that will result in a more
efficient cleaning and a better quality of rebuild.
A variety of different equipment is available for cleaning small parts. Refer to Catalog,
NENG2500, "Dealer Service Tool Catalog" or Shop Review, SEBF8360, "Spec Shop" for
information on cleaning equipment and suppliers.
The valves, valve springs, lifters, and rotators must be inspected. Refer to Reuse and Salvage
Guideline, SEBF8162, "Procedure to Measure and Salvage Cylinder Head Assemblies and
Related Components".
All valves must be ground in order to ensure proper seating between the valve and the insert. A
variety of grinding valves are available.
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Illustration 16 g01271920
Rack for the cylinder head that will fit in a washer
Illustration 17 g01271921
Rack with a cylinder head
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Illustration 18 g01271924
Cradle for the cylinder head with a stand for a washer
7. Clean the cylinder head casting in a hot spray wash cabinet. Refer to Shop Review, SEBF8359, "Main
Shop" for more information on a variety of washers.
Note: The most effective washers for cleaning cylinder heads are hot spray wash cabinets.
8. Remove the gaskets and carbon deposits from the cylinder head.
Remove the gaskets and joint seals immediately after washing. The gaskets will typically be loosened
from the wash. Abrasive cleaning will then remove the gaskets. The gaskets can be removed easily if the
gaskets are scraped immediately after the cycle of wash.
The carbon deposits may need to be removed by hand after the first cycle of cleaning. A second cycle of
cleaning may then be necessary in order to rinse the remaining carbon deposits.
Flush the internal passages. Blow out the internal passages and the blind cavities. Apply a rust inhibitor
to the cylinder head after rinsing.
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Illustration 19 g01271962
Serdi SPT1500 Cylinder Head Pressure Tester
Note: Refer to Reuse and Salvage Guideline, SEBF8162, "Procedure to Measure and Salvage Cylinder
Head Assemblies and Related Components" for detailed procedures on reconditioning techniques,
inspecting cylinder heads, checking cylinder head thickness and combustion surface for flatness, and
checking for cracks and erosion.
Make sure that the cylinder head meets the specifications for thickness and criteria for reusability in the
specific reusability guideline for the cylinder head.
Pressure test the cylinder head casting for internal cracks when the cylinder head is tested for integrity.
The operating conditions and temperatures of a cylinder head need to be simulated during the pressure
test in a heated tank under pressure. Steel plates must be fabricated in order to cover the openings in the
head during testing. Gaskets, seals, and fittings are needed in order to connect the air supply.
The tank must be big enough to hold the largest cylinder head that will be tested. The dimensions in
Table 1 are reference dimensions for the tank for the corresponding engine models. The water in the tank
needs to be heated to a temperature of 82 °C (180.0 °F). A minimum air supply of 415 kPa (60.0 psi) is
required for the testing.
Note: The dimensions in Table 1 are not reconditioning dimensions for cylinder heads. Use the
dimensions in order to determine the correct size of a tank for the pressure test.
Table 1
C7
848 mm (33.4 inch) 305 mm (12.0 inch) 158 mm (6.2 inch)
C9 2007
871 mm (34.3 inch) 345 mm (13.6 inch) 163 mm (6.4 inch)
C9
C-9 890 mm (35.0 inch) 300 mm (11.8 inch) 130 mm (5.1 inch)
C-10
C-12 972 mm (38.3 inch) 320 mm (12.5 inch) 105 mm (4.1 inch)
C11
997 mm (39.3 inch) 395 mm (15.6 inch) 165 mm (6.5 inch)
C13
972 mm (38.3 inch) 397 mm (15.6 inch) 165 mm (6.5 inch)
C15
C-15
C16
C-16 1118 mm (44.0 inch) 360 mm (14.2 inch) 250 mm (9.8 inch)
C18
C-18
C27
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C32 1185 mm (46.7 inch) 455 mm (18.0 inch) 250 mm (9.8 inch)
C30
1185 mm (46.7 inch) 320 mm (12.5 inch) 114 mm (4.5 inch)
3044C
478 mm (18.8 inch) 216 mm (8.5 inch) 85 mm (3.3 inch)
3066
343 mm (13.5 inch) 205 mm (8.0 inch) 100 mm (3.9 inch)
3114
590 mm (23.2 inch) 252 mm (9.9 inch) 105 mm (4.1 inch)
3116
840 mm (33.0 inch) 252 mm (9.9 inch) 105 mm (4.1 inch)
3126
840 mm (33.0 inch) 252 mm (9.9 inch) 105 mm (4.1 inch)
3126E
848 mm (33.4 inch) 285 mm (11.2 inch) 160 mm (6.3 inch)
3145
3150
632 mm (24.9 inch) 290 mm (11.4 inch) 140 mm (5.5 inch)
3160
3176
972 mm (38.3 inch) 320 mm (12.6 inch) 130 mm (5.1 inch)
3196
972 mm (38.3 inch) 320 mm (12.6 inch) 130 mm (5.1 inch)
3204
632 mm (24.9 inch) 290 mm (11.4 inch) 140 mm (5.5 inch)
3208
632 mm (24.9 inch) 290 mm (11.4 inch) 140 mm (5.5 inch)
3304
662 mm (26.1 inch) 350 mm (13.8 inch) 100 mm (3.9 inch)
3306
960 mm (37.8 inch) 375 mm (14.8 inch) 100 mm (3.9 inch)
G3304
662 mm (26.1 inch) 330 mm (13.0 inch) 100 mm (3.9 inch)
G3306
960 mm (37.8 inch) 350 mm (13.8 inch) 100 mm (3.9 inch)
3304B
3306B
3306BH 662 mm (26.1 inch) 350 mm (13.8 inch) 100 mm (3.9 inch)
3306C
3406
3406B
1118 mm (44.0 inch) 368 mm (14.5 inch) 114 mm (4.5 inch)
3406C
3406E
1118 mm (44.0 inch) 345 mm (13.6 inch) 250 mm (9.8 inch)
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G3406
1118 mm (44.0 inch) 368 mm (14.5 inch) 114 mm (4.5 inch)
3408
3408B
3408C
845 mm (33.3 inch) 320 mm (12.6 inch) 114 mm (4.5 inch)
3408E
G3408
3412
3412C
3412D 1185 mm (46.7 inch) 320 mm (12.6 inch) 114 mm (4.5 inch)
3412E
3456
1118 mm (44.0 inch) 345 mm (13.6 inch) 250 mm (9.8 inch)
3508
3508B
268 mm (10.6 inch) 408 mm (16.0 inch) 145 mm (5.7 inch)
3508C
3512
G3512 268 mm (10.6 inch) 455 mm (18.0 inch) 145 mm (5.7 inch)
3512B
3512C 268 mm (10.6 inch) 408 mm (16.0 inch) 145 mm (5.7 inch)
3516
268 mm (10.6 inch) 455 mm (18.0 inch) 145 mm (5.7 inch)
3516B
3516C 268 mm (10.6 inch) 408 mm (16.0 inch) 145 mm (5.7 inch)
3524B
268 mm (10.6 inch) 408 mm (16.0 inch) 145 mm (5.7 inch)
3606
750 mm (29.5 inch) 420 mm (16.5 inch) 280 mm (11.0 inch)
3608
750 mm (29.5 inch) 420 mm (16.5 inch) 280 mm (11.0 inch)
3612
750 mm (29.5 inch) 420 mm (16.5 inch) 280 mm (11.0 inch)
3616
750 mm (29.5 inch) 420 mm (16.5 inch) 280 mm (11.0 inch)
3618
615 mm (24.2 inch) 420 mm (16.5 inch) 280 mm (11.0 inch)
2. Cover the openings on the cylinder head with a steel plate and seals or gaskets.
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4. Use a hoist and a lift in order to submerge the cylinder head in the tank so that the water level covers all
surfaces.
5. Apply a constant air pressure of 415 kPa (60.0 psi) minimum to the submerged cylinder head for one
hour.
6. Observe the submerged cylinder head for any signs of air bubbles during the one hour test.
Note: If no air bubbles are observed during the test, the cylinder head does not have any internal leaks.
7. Coat the cylinder head with a rust preventive in order to prevent rusting. Refer to the ""Storage
Procedures" " section.
8. Inspect the valves, valve seat inserts, and the valve guides. If necessary, replace any components that do
not meet the Reuse and Salvage Guidelines.
Note: Refer to Reuse and Salvage Guideline, SEBF8162, "Procedure to Measure and Salvage Cylinder
Head Assemblies and Related Components" for information on procedures, criteria for inspection, and
tooling.
Illustration 20 g01272410
Fabricated hydraulic puller for valve seat inserts
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Illustration 21 g01272411
Pulling a valve seat insert with a fabricated puller
9. Remove the valve seat inserts from the cylinder head. Refer to Catalog, NENG2500, "Dealer Service
Tool Catalog" for a listing of pullers. Pullers may also be fabricated in order to remove the valve seat
inserts.
10. Inspect the valve seat inserts for reusability. If the valve seat insert is cracked or damaged, replace the
valve seat insert.
11. Install the valve seat inserts into the cylinder head. Refer to Catalog, NENG2500, "Dealer Service Tool
Catalog" for a list of tooling in order to install the valve seat inserts.
Illustration 22 g01272433
Serdi 100 Valve Seat and Guide Cutting Machine
12. Machine the valve seat inserts or the bores for the valve seat inserts.
Note: Some valve seats cannot be machined. Refer to Reuse and Salvage Guideline, SEBF9006,
"Specifications for Cylinder Head Assemblies on C-Series Engines" in order to determine if a
valve seat can be machined. Specialized manufacturing processes were used on these parts.
Machining these parts will significantly decrease the life of the engine.
Cutting tools for the valve seats are more effective than grinding in several ways. Cutters are faster and
more accurate than grinding stones. Cutters maintain the dimensions longer. However, cutters are more
expensive.
Stones for grinding wear every time of use. Stones for grinding periodically need to be shaped resulting
in additional labor for each job and one more step for error. Grinding produces dust and debris which
adds more contamination to the process of reconditioning.
The cylinder head must be protected from corrosion, external damage, and dirt after cleaning if the
cylinder head is stored. Refer to the ""Storage Procedures" " section.
Note: Refer to Reuse and Salvage Guideline, SEBF8162, "Procedure to Measure and Salvage Cylinder
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Head Assemblies and Related Components" for more information on salvage procedures and testing
procedures.
Assemble the cylinder head after all necessary parts were replaced and all components were thoroughly
inspected, tested, cleaned, and salvaged. Refer to Reuse and Salvage Guideline, SEBF8162, "Procedure
to Measure and Salvage Cylinder Head Assemblies and Related Components".
14. Measure the projection of the valve. Refer to the appropriate Reuse and Salvage Guideline for your
machine for the specifications for the projection of the valve.
The vacuum test will identify a good seal between the valve and the valve seat. The cylinder head must
be completely assembled before the vacuum test can be performed. Refer to Reuse and Salvage
Guideline, SEBF8162, "Procedure to Measure and Salvage Cylinder Head Assemblies and Related
Components" for more information of the tools and procedure for a vacuum test of the valves.
SERDI
www.serdi.com
1 800-447-3790
Kwik-Way Products
www.kwik-way.com
1 800-553-5953
Sunnen
www.sunnen.com
1 (314) 781-2100
Storage Procedures
Proper protection of the cylinder head and components from corrosion is very important. Corrosion will start
in as little as one hour after the cylinder head and components have been cleaned.
When the cylinder head and components will not be inspected for one hour or less the cylinder head and
components should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The cylinder
head and components should be individually wrapped in order to prevent contamination, and the cylinder head
and components should be stored in a protected area in order to avoid damage. See Illustration 23.
When the cylinder head and components will not be inspected in two days or more the cylinder head and
components should be coated with a rust or corrosion inhibitor or coated with clean engine oil and the cylinder
head and components should be individually wrapped. The wrapped cylinder head and components should be
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placed in a container which is clean and structurally solid. The container should be covered or wrapped in
plastic in order to prevent damage and contamination to the cylinder head and components. See Illustration 24.
Illustration 23 g01272481
Example of protection for a component that is stored for a shorter term
Illustration 24 g01272483
Example of protection for a component that is stored for a longer term
Table 2
Hard film
Up to one year storage
222-3121 355 mL (12 oz) Rust Preventive
Aerosol Outside conditions for
storage
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Film of wax
1U-8801 3.79 L (1 US gal)
Up to one year storage
Caterpillar 4A Rust Preventive Oil
Copyright 1993 - 2009 Caterpillar Inc. Tue Mar 17 10:59:40 EST 2009
Todos los derechos reservados.
Red privada para licenciados del SIS.
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