Specifications For Cylinder Head Assemblies For 3500 Series Engines (0760, 0762, 1100)

3512C Engine LLB00001-UP(SEBP4365 - 41) - Systems & Components Page 1 of 26
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Product: PETROLEUM ENGINE
Model: 3512C PETROLEUM ENGINE LLB
Configuration: 3512C Engine LLB00001-UP
Special Instruction
Specifications for Cylinder Head Assemblies for 3500 Series Engines {0760, 0762, 1100}
Media Number -SEBF8155-32 Publication Date -19/02/2014 Date Updated -14/09/2017
i07161706
Specifications for Cylinder Head Assemblies for 3500 Series Engines {0760, 0762,
1100}
SMCS - 0760; 0762; 1100
Caterpillar Products
All 3500 Engines
All G3500 Engines
Introduction
Table 1
Revision Summary of Changes SEBF8155
32 Reinstated reuse of intake valves.
31 Added intake and exhaust valve statement.
30 Added surface texture and waviness specifications.
© 2017 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the
proprietary processes therein without permission may be violation of intellectual property law.
Information contained in this document is considered Caterpillar: Confidential Yellow.
This Reuse and Salvage Guideline contains the necessary information 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 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 technical questions when using this document, work with your Dealer Technical Communicator (TC).
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service
Information System (SIS Web) interface.
Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled
part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.
Important Safety Information
https://127.0.0.1:7443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 1/22/2021
Illustration 1 g02139237
Work safely. 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. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible
circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the
product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is
used, you must ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product
will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
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 which is followed by a signal word such as danger, warning, or caution. The
"WARNING" safety alert symbol is shown below.
This safety alert symbol means:
Pay attention!
Become alert!
Your safety is involved.
The message that appears under the safety alert symbol explains the hazard.
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 safety information in
this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work
methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures
will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures
will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at
the time of publication. 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, most current information before
you start any job. Caterpillar dealers can supply the most current information.
Summary
The information that is given in this guideline can be used to inspect a new cylinder head or a reconditioned cylinder head. This
process is completed to determine whether the cylinder head can be reused. If a cylinder head meets these guidelines and other
applicable guidelines, the cylinder head can be expected to give normal performance until the next overhaul, when the cylinder
head is used in the same application.
The cylinder head must be inspected for the following conditions: leaks, cracks, and flatness. The individual components must be
checked for the recommended specifications.
Refer to Reuse And Salvage Guideline, SEBF8162, "Measure Procedures and Salvage Procedures for Cylinder Head Assemblies
and Related Components" for general information on procedures, methods, and visual inspection.
Service Letters and Technical Information Bulletins
NOTICE
The most recent Service Letters and Technical Information Bulletins

that are related to this component shall be reviewed before beginning
work. Often Service Letters and Technical Information Bulletins
contain upgrades in repair procedures, parts, and safety information
that pertain to the parts or components being repaired.
References
Table 2
References
Media
Title
Number
SEBF8002 Reuse And Salvage Guideline, "Visual Inspection of Valves, Valve Springs, and Valve Bridges"
SEBF8034 Reuse And Salvage Guideline, "Valves and Valve Spring Specifications"
Reuse and Salvage Guidelines, "Measure Procedures and Salvage Procedures for Cylinder Head Assemblies
SEBF8162
and Related Components"
SEBF9066 Applied Failure Analysis"Guideline for Examining Failed Parts"
Reuse and Salvage Guidelines"Installation and Removal of the Valve Guides and Water-Cooled Valve Seat
SEBF9137
Inserts for the G3500 Series of Engines"
SEBF8187 Reuse and Salvage Guidelines"Standardized Parts Marking Procedures"
PEBJ0002 Contamination Control Guidelines"Caterpillar Dealer Contamination Control Compliance Guide"
Tooling and Equipment
NOTICE
Failure to follow the recommended procedure or the specified tooling

that is required for the procedure could result in damage to
components.
To avoid component damage, follow the recommended procedure

using the recommended tools.
Table 3
Required Tooling
Part Number Part Description Quantity
3P-1565 Collet Clamp 1
4C-3845 Grinding Wheel 1 to 2 per head
4C-8624 Mandrel 1 to 2 per head
4C-8629 Mandrel 1
5P-1729 Valve Guide Bushing 1
5P-4156 Indicator Base 1
5P-6518 Dial Indicator Fixture 1
6V-0087 Valve Stem Gauge 1
6V-2012 Depth Micrometer 1
6V-2034 Micrometer Adapter 1
6V-7059 Micrometer 1
6V-7068 Valve Guide Gauge 1
6V-7926 Dial Indicator 1
8H-8581 Feeler Gauge 1
8S-3158 Indicator Gauge 1
151-0968 Cordless Drill 1
222-3061 Air Drill 1
222-3074 Wheel Grinder 1
386-3364 Straight Edge Ruler 1
Outside Electronic Micrometer Set
473-8691 1
2-6 inch
Canceled Part Numbers and Replaced Part Numbers

This document does not include Canceled part numbers and replaced part numbers. Use NPR on SIS for information about
Canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.
When replacement parts are required for this product Caterpillar

recommends using Caterpillar replacement 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.
Measurement Requirements
NOTICE
Precise measurements shall be made when the component and

measurement equipment are at 20° (68° F). Measurements shall be
made after both the component and measurement equipment have had
sufficient time to soak at 20° (68° F). This will ensure that both the
surface and core of the material is at the same temperature.
Overall Size
Table 4
Part Numbers for 3500 Cylinder Head Assemblies
4P-6571
7E-5861
7E-8760
101-1175
122-5961
128-1141
131-0410
131-0411
131-0423
144-6409
145-3215
153-8397
154-1612
172-0834
172-0836
184-5496
206-1554
206-1555
206-1560
206-1563
269-0040
290-1351
295-2047
315-2630
418-9804
424-7545
462-4740
480-3132
495-2062
Nomenclature
(1) Lock
(2) Rotocoil
(3) Outer Spring
(4) Inner Spring
(5) Washer
(6) Guide
(7) Head
(8) Valve
General Procedures
Refer to Reuse and Salvage Guideline, SEBF8162, "Measure Procedures and Salvage Procedures for Cylinder Head Assemblies
and Related Components" and perform the following steps:
• Clean the cylinder head.
• Remove the gaskets.
• Check the thickness of the cylinder head.
• Measure the flatness of the surface for combustion.
• Check for cracks in the surface for combustion and the top deck.
• Inspect the surface for combustion for damage and erosion.
• Measure the depth of the valve seats.
• Inspect the valve guides.
• Inspect the cylinder head for other damage.
• Inspect the threads.
• Inspect the projection and the recession of the valve to the head.
Specific Factors for Reconditioning

The compression ratio is the critical factor that needs to be considered when the cylinder block is reconditioned or the cylinder head
is reconditioned. The compression ratio increases as the material is removed from the cylinder head.
Note: The minimum dimension means that the valve is recessed into the cylinder head. The maximum dimension means that the
valve is projecting from the cylinder head.
Material can be removed from the cylinder head without reseating the valves if the thickness of the cylinder head is at least
141.62 mm (5.576 in.). When the thickness of the cylinder head is less than the minimum thickness of the cylinder head, the valves
must be reseated to achieve the proper valve recession. These dimensions are listed in Table 17.
Cylinder Head Thickness
Measure the cylinder head thickness. Compare the dimensions to Table 5. Maintain the original specifications for flatness of the
surface of the cylinder head during the process of reconditioning.
(A) Minimum thickness of the cylinder head
Flatness of the Surface for Combustion
Maintain the original specifications for flatness of the cylinder head during the process of reconditioning the cylinder head. Refer to
Table 5 for the recommended specification for flatness.
Note: The critical factors that need to be considered during the reconditioning of the cylinder block and the cylinder head on the
3500 Series engines are the compression ratios and the clearance between the valve and the piston. The compression ratio increases
when material is removed from the cylinder block.
Flatness of the surface
(B) Diameter of the combustion chamber
(C) Cylinder head surface
(D) Combustion chamber surface
Table 5
Cylinder Head Thickness and Flatness Specifications
Flatness of
Part Diameter of Flatness of
Minimum the Sealing
Numbers the the Sealing
New Thickness of Thickness of Cylinder Surface
of the Combustion Combustion Surface
the Cylinder Head the Cylinder Head Waviness
Cylinder Chamber Chamber Texture
Head (A) Surface Spec.
Head (B) Surface (D)
(C)
4P-6571 142.00 ± 0.15 mm 141.0 mm 205.0 mm 0.10 mm 0.05 mm 3.2 µm Minimum
7E-5861 (5.591 ± 0.006 inch) (5.55 inch) (8.07 inch) (0.004 inch) (0.002 inch) (125.98 µinch) Waviness
7E-8760 (1)
Ra Height -
101-1175 Roughness 0.0125 mm
122-5961 Sampling (0.00049 inch)
128-1141 Length or per 5.0 mm
131-0410 Cutoff - (0.20 inch) of
131-0411 2.54 µm spacing (2)
131-0423 (0.1000 µinch)
144-6409
145-3215
153-8397
154-1612
172-0834
172-0836
184-5496
206-1554
206-1555
206-1560
206-1563
290-1351
295-2047
418-9804
424-7545
462-4740
495-2062 3.2 µm
269-0040 141.5 mm (125.98 µinch)
315-2630 (5.5709 inch) Ra
Roughness
Sampling
Minimum
Length or
Waviness
Cutoff -
Height -
2.54 µm
141.0 mm 0.0125 mm
480-3132 (0.1000 µinch)
(5.55 inch) (0.00049 inch)
Average
per 5.0 mm
Roughness
(0.20 inch) of
Peak
spacing(2)
to Valley
(1)
Height -
This is within an area that is outlined by an outer diameter of 205.0 mm (8.07 inch) and an inner diameter of 190.0 mm (7.48 inch) about the center of the
19.0 µm
cylinder head.
(748.03 µinch)
(2)
For waviness spacing smaller than 5.0 mm (0.20 inch) use maximum waviness height of 0.00254 PER mm (0.00010 PER inch) spacing.
Rz
Reusing Cylinder Head Bolts

3500 cylinder head bolts may be reused for a maximum of five standard rebuilds. The cylinder head bolts must be inspected for
cracks and wear during each rebuild. For the inspection procedure, refer to Reuse And Salvage Guideline, SEBF8301, "Inspection
and Reuse of Critical Fasteners Used in All Engines".
Reworking Cylinder Head Bolt Holes

This procedure machines a radius around the edges of the surface for combustion of the three bolt holes for the cylinder head.
Cracks can originate from these three holes as a result of high operating temperatures. Machining a radius around these holes can
greatly reduce the potential for cracks. These cracks could lead to failure of the cylinder head.
This procedure can only be used on heads that do not have cracks. If cracks are present, the cracks will appear on the combustion
side of the head. The cracks will radiate outward from the bolt hole. If cracks are found anywhere in the cylinder head, the cylinder
head must not be used again.
Hole Location for the Cylinder Head Bolt
The location of the three bolt holes that should be reworked.
(10) Top position
(11) Middle position
(12) Lower position
Specifications
Profile of the holes to be reworked
(13) Radius
Machine a 1.9 ± .3 mm (0.07 ± 0.01 inch) radius at location (13).
The enlarged section of radius at location (14) Refer to Illustration 7.
(C) 23.25 mm (0.915 inch) maximum
(D) 0.5 mm (0.02 inch)
(E) 1.9 ± 0.3 mm (0.07 ± 0.01 inch) radius
(14) Remove the area of the crosshatch by using a 4C-8624 mandrel.
Rework Procedure
1. Put 4C-3845 Grinding Wheel in the chuck of the air drill or in the chuck of the electric drill.
2. Operate the drill at full rated speed and lightly insert the mounted point into the bolt hole.
3. Apply a steady pressure that is equal to two times the weight of the drill for one and one half to two seconds. This should
create a 0.5 mm (0.02 inch) chamfer on the edge of the bolt hole.
4. Ensure that the chamfered diameter is not larger than 23.25 mm (0.915 inch) (C).
5. Repeat this procedure for each bolt hole.
Note: The bolt hole at the middle position may already have a chamfered diameter on some cylinder heads. This diameter
may be larger than 23.25 mm (0.915 inch) (C). Do not add an extra chamfer to this hole. Polish the hole with the
reconditioning tool that is described in the following procedure:
6. After all the holes have been reworked to have smooth corners put 4C-8629 Mandrel and 4C-8624 Mandrel in the drill.
7. Operate the drill in a clockwise direction at full rated speed. Insert the drill halfway into the bolt hole. Apply light pressure to
the chamfered edge of the hole. Steadily increase the pressure to flex the arms of the drill into the hole.
8. Insert the drill and remove the drill from each hole several times. Continue to perform this procedure until the edges of the
chamfers are removed, and a smooth radius and a polished radius is formed.
9. Clean the cylinder head thoroughly before putting the cylinder head back into service.
Valve Guides
The valve guides for the engine cylinder head must be measured for installed height from the top surface of the cylinder head and
from the inside bore diameter.
NOTICE
Do not use any valve guides with obvious damage. Do not use valve
guides with wear that is beyond the specifications that are provided.
Loose or damaged valve guides must be removed and new valve guides
must be installed. Correct any conditions that could have caused the
original damage or wear.
Install the valve guides with the 5P-1729 Valve Guide Bushing. The installed height of the valve guide for the cylinder head can be
measured by using 6V-2012 Depth Micrometer. A 152.0 mm (5.98 inch) dial caliper may also be used.
NOTICE
Do not force or turn the plug gauge into the valve guide bore. Forcing
will damage or wear the gauge. This will cause a higher replacement
rate.
The inside bore diameter of the valve guide can be measured by using one of the following:
• 6V-7068 Valve Guide Gauge
• A telescoping gauge
• A small gauge and an outside micrometer for a plug
All the valve guides should be measured on both ends 19.0 mm (0.75 inch) from the end of the bore. The measure must not be
taken in this area if the valve guide is counterbored. The bore for the valve guide is worn more than the maximum “Use again”
diameter if the plug gauge is used and the end of the gauge goes into the bore for the valve guide more than 19.0 mm (0.75 inch).
Reference: Refer to the appropriate specifications manual for the maximum inner diameter of the valve guide.
(F) Height to the top of the valve guides from the top of the head.
Precision Valve Guides
Precision machined valve guides and inserts for the valve seats are used in all 3500 engines. These parts will improve the
concentricity of the valve and concentricity of the valve seat in the cylinder head. These parts will improve the quality of cylinder
heads that are rebuilt in the field.
Valve guides with oversize outside diameters are available to replace the standard parts. These parts are 0.127 mm (0.0050 inch),
0.254 mm (0.0100 inch), 0.381 mm (0.0150 inch), and 0.508 mm (0.0200 inch) oversize outer diameter.
Table 6
Specifications for the Valve Guides
Part
Number of Part Numbers
Intake or Bore inch the Head for the Installed Height of the
the Size of Valve
Exhaust Guide Valve Guide (F)
Cylinder Guides
Head
133-9306 17.473 ± 0.008 mm
Standard
449-7117 (0.6879 ± 0.0003 inch)
7E-5861 0.127 mm 17.6 ± 0.008 mm

273-3553
7E-8760 (0.0050 inch) (0.6929 ± 0.0003 inch)
101-1175 0.254 mm 17.727 ± 0.008 mm
131-0410 Intake 273-3554
(0.0100 inch) (0.6979 ± 0.0003 inch)
131-0411
131-0423 0.381 mm 17.854 ± 0.008 mm
145-3215 301-9248
(0.0150 inch) (0.7029 ± 0.0003 inch) 26.000 ± 1.000 mm
154-1612
0.508 mm 17.981 ± 0.008 mm (1.0236 ± 0.0394 inch)
172-0834 149-1982
172-0836 (0.0200 inch) (0.7079 ± 0.0003 inch)
290-1351
295-2047 197-6995 17.473 ± 0.008 mm
Standard
462-4740 449-7118 (0.6879 ± 0.0003 inch)
480-3132 0.127 mm 17.6 ± 0.008 mm
495-2062 Exhaust 276-3875
(0.0050 inch) (0.6929 ± 0.0003 inch)
0.254 mm 17.727 ± 0.008 mm
276-3876
(0.0100 inch) (0.6979 ± 0.0003 inch)
4P-6571 Intake 17.473 ± 0.008 mm 26.000 ± 1.000 mm
Standard 191-6766
128-1141 (0.6879 ± 0.0003 inch) (1.0236 ± 0.0394 inch)
122-5961
144-6409 0.254 mm 17.727 ± 0.008 mm
206-1544
153-8397 (0.0100 inch) (0.6979 ± 0.0003 inch)
184-5496 0.508 mm 206-1545 17.981 ± 0.008 mm
206-1554 (0.0200 inch) (0.7079 ± 0.0003 inch)
17.473 ± 0.008 mm
Standard 206-1541
(0.6879 ± 0.0003 inch)
0.254 mm 17.727 ± 0.008 mm
Exhaust 206-1542
(0.0100 inch) (0.6979 ± 0.0003 inch)
206-1555 0.508 mm 17.981 ± 0.008 mm

206-1543
206-1560 (0.0200 inch) (0.7079 ± 0.0003 inch)
206-1563
424-7545 17.473 ± 0.008 mm
Standard 255-0897
(0.6879 ± 0.0003 inch)
0.254 mm 17.727 ± 0.008 mm
Exhaust 255-1261
(0.0100 inch) (0.6979 ± 0.0003 inch)
0.508 mm 17.981 ± 0.008 mm
255-1262
(0.0200 inch) (0.7079 ± 0.0003 inch)
17.473 ± 0.008 mm
Standard 191-6766
(0.6879 ± 0.0003 inch)
0.127 mm 17.600 ± 0.008 mm
322-3664
(0.0050 inch) (0.6929 ± 0.0003 inch)
Intake
0.254 mm 17.727 ± 0.008 mm
322-3665
(0.0100 inch) (0.6979 ± 0.0003 inch)
0.508 mm 17.981 ± 0.008 mm
269-0040 322-3666
(0.0200 inch) (0.7079 ± 0.0003 inch) 26.000 ± 0.5 mm
315-2630
17.473 ± 0.008 mm (1.0236 ± 0.0197 inch)
418-9804 Standard 336-1338
(0.6879 ± 0.0003 inch)
0.127 mm 17.600 ± 0.008 mm
322-3661
(0.0050 inch) (0.6929 ± 0.0003 inch)
Exhaust
0.254 mm 17.727 ± 0.008 mm
322-3662
(0.0100 inch) (0.6979 ± 0.0003 inch)
0.508 mm 17.981 ± 0.008 mm
322-3663
(0.0200 inch) (0.7079 ± 0.0003 inch)
Valves
Note: Replace all exhaust valves at PCR. DO NOT REUSE / RECONDITION / OR REMANUFACTURE EXHAUST
VALVES.
The valve stem diameter for the engine can be measured by using one of the following items:
• 6V-0087 Valve Stem Gauge
• 0 to 25.0 mm (0.98 inch) micrometer
The diameter of a valve head can be measured by using one of the following:
• A 50.0 mm (1.97 inch) to 75.0 mm (2.95 inch) micrometer
• 0 to 150.0 mm (5.91 inch) dial caliper
The thickness of the valve lip can be measured by using one of the following tools:
• 6V-7059 Micrometer (Multiple Anvil) that is used with 6V-2034 Micrometer Adapter
• 5P-6518 Dial Indicator Fixture
• 0 to 150.0 mm (5.91 inch) dial caliper
Dimensions of cylinder head valves that are used in Table 7.
Table 7
Specifications for the Intake Valves and Exhaust Valves(1) for the 3500 Engine
Diameter for the Valve Angle of the Minimum Diameter of the Minimum Thickness
Part Number for
Head Valve Face Valve Stem(2) of the Lip
the Valve
(L) (K) (G) (J)
104-7184
307-4641
308-9177
70.75° ± 0.25° 9.408 mm (0.3704 inch) 3.46 mm (0.136 inch)
498-1692
500-8527
500-8528
56.00 ± 0.15 mm 12.421 mm (0.4890 inch)(3)
194-4897 (2.205 ± 0.006 inch) 45.60° ± 0.25° 2.86 mm (0.113 inch)
498-1593 12.529 mm (0.4927 inch)(4)
210-2542
70.6° ± 0.25° 9.408 mm (0.3704 inch) 3.46 mm (0.136 inch)
468-8824
452-5415
70.6° ± 0.25° 10.986 mm (0.432 inch) 3.46 mm (0.136 inch)
498-1592
(1)
Exhaust valve dimensions are for reference only, not to qualify for reuse at overhaul.
(2)
The diameter of the valve stem must be measured approximately 12.7 mm (0.5000 inch) from the bottom of travel and 12.7 mm (0.5000 inch) from the
top of travel of the part. Do not use a combination of a valve and a guide that has a difference that is larger than 0.10 mm (0.0039 inch).
(3)
Tapered valves have two dimensions for the minimum valve stem diameter. Refer to Illustration 10 for measuring at point (H).
(4)
Tapered valves have two dimensions for minimum valve stem diameter. Refer to Illustration 10 for measuring at point (G).
Valve Seat Inserts
NOTICE
The prefinished inserts should not be ground to correct the valve

projection. Excessive valve projection indicates that the insert is not
seated or the material was not cleaned from the bottom of the
counterbore.
Table 8
Part Numbers for Valve Seat Inserts
Part Number of the
Valve Seat Inserts for Intake Exhaust Valve Seat Inserts
Cylinder Head
7E-5861
131-0410
172-0834
295-2047
172-0834
295-2047 130-2607 183-8809 130-2608 289-9745
101-1175
131-0423
145-3215
154-1612
290-1351
462-4740
456-0780
480-3132 456-0411
480-7205
495-2062
7E-8760
131-0411 130-2607 130-2608
172-0836
4P-6571
122-5961
128-1141
144-6409
153-8397
184-5496 257-9166 266-8718(1) 266-8721(2) 191-6760
206-1554
206-1555
206-1560
206-1563
424-7545
269-0040
315-2630 308-7100
418-9804
(1)
Low Swirl.
(2)
2.0 Swirl.
Table 9
Oversize Valve Seat Inserts
Standard 0.254 mm (0.0100 inch) Oversize Valve Seats 0.508 mm (0.0200 inch) Oversize Valve Seats
130-2607 - 149-1981
130-2608 - 166-5945
183-8809 - -
191-6760 206-1546 206-1547
257-9166 257-9168 257-9169
266-8718 266-8719 266-8720
266-8721 266-8722 266-8723
289-9745 - -
308-7100 322-3659(1) 322-3660(1)
(1)
Part not yet released at time of publication.
Detail views of the width of the sealing face of 3500 valve seat inserts.
(M) Width of the sealing face for 308-7100 Valve Seat Insert
(N) Width of the sealing face for 130-2607 Valve Seat Insert and 183-8809 Valve Seat Insert
(P) Width of the sealing face for 266-8718 Valve Seat Insert and 266-8721 Valve Seat Insert
(R) Width of the sealing face for 130-2608 Valve Seat Insert and 289-9745 Valve Seat Insert
(S) Width of the sealing face for 191-6760 Valve Seat Insert and 257-9166 Valve Seat
Use the following chart to determine the maximum width of the sealing face of the valve seat insert. The maximum width of the
sealing face of the valve seat insert is given in the following chart with the corresponding valve. The maximum width is found from
the corresponding valve's outer diameter of the sealing face and the valve seats insert's inner diameter of the sealing face. The angle
of the valve must be greater than the angle of the valve seat insert to ensure proper sealing.
Table 10
Maximum Width of the Valve Seat Insert's Sealing Face
Valve Valve Seat Insert Max Width
130-2607
3.4904 mm (0.1374 inch)
183-8809
210-2542
257-9166 1.8970 mm (0.0747 inch)
468-8824
266-8718
2.9804 mm (0.1173 inch)
266-8721
194-4897 130-2608 2.6640 mm (0.1049 inch)
498-1593
289-9745
104-7184 191-6760 2.4066 mm (0.0947 inch)
307-4641
308-9177
498-1692 308-7100 3.5000 mm (0.1378 inch)
500-8527
500-8528
Refer to Table 11 for dimensions of the valve seat inserts and identification.
Table 11
Specifications of the Valve Seat Insert
Inlet Valve Seat Inserts
Valve Seat Insert Part Number Valve Seat Insert Outside Diameter (T) Sealing Angle For the Valve Seat
Insert (U)
130-2607
456-0780 60.627 ± 0.015 mm (2.3869 ± 0.0006 inch) 70° ± 0.25°
480-7205
183-8809 60.627 ± 0.015 mm (2.3869 ± 0.0006 inch) 69.75° ± 0.25°
257-9166 60.640 ± .015 mm (2.3874 ± 0.0006 inch) 69.75° ± 0.25°
266-8718 (1)
60.640 ± .015 mm (2.3874 ± 0.0006 inch) 69.75° ± 0.25°
266-8721(2) 60.640 ± .015 mm (2.3874 ± 0.0006 inch) 69.75° ± 0.25°
Exhaust Valve Seat Inserts
130-2608 60.119 ± 0.015 mm (2.3669 ± 0.0006 inch) 45° ± 0.25°
289-9745 60.119 ± 0.015 mm (2.3669 ± 0.0006 inch) 45° ± 0.25°
191-6760 60.132 ± 0.015 mm (2.3674 ± 0.0006 inch) 69.75° ± 0.25°

(1)
Low Swirl.
(2)
2.0 Swirl.
Inner diameter and depth of the bore for the valve seat inserts for the cylinder head.
(V) Depth of the bore for valve seat inserts.
(W) Diameter of the bore for the valve seat insert
Table 12
Dimensions for the Bore inch the Cylinder Head for the Valve Seat Insert
Depth of the bore Inside diameter of the Bore for 0.254 mm Bore for 0.508 mm
Part Intake or
for the valve seat bore for the valve seat (0.0100 inch) oversize (0.0200 inch) oversize
Number Exhaust
(V) insert (W) valve seats (W) valve seats (W)
7E-5861
7E-8760 Intake 14.00 ± 0.15 mm 60.508 ± 0.025 mm 60.762 ± .025 mm 61.016 ± .025 mm
131-0410 (0.551 ± 0.006 inch) (2.3822 ± 0.0010 inch) (2.3922 ± 0.0010 inch) (2.4022 ± 0.0010 inch)
131-0411
172-0834 14.00 ± 0.15 mm 60.000 ± 0.025 mm 60.254 ± .025 mm 60.508 ± 0.025 mm
172-0836 Exhaust (0.551 ± 0.006 inch) (2.3622 ± 0.0010 inch) (2.3722 ± 0.0010 inch) (2.3822 ± 0.0010 inch)
295-2047
4P-6571
101-1175
122-5961
128-1141
131-0423 Intake 16.00 ± 0.15 mm 60.508 ± .025 mm 60.762 ± .025 mm 61.016 ± .025 mm
144-6409 (0.630 ± 0.006 inch) (2.3822 ± 0.0010 inch) (2.3922 ± 0.0010 inch) (2.4022 ± 0.0010 inch)
145-3215
153-8397
154-1612
184-5496
206-1554
206-1555
206-1560
206-1563 16.00 ± 0.15 mm 60.000 ± 0.025 mm 60.254 ± .025 mm 60.508 ± 0.025 mm
290-1351 Exhaust (0.630 ± 0.006 inch) (2.3622 ± 0.0010 inch) (2.3722 ± 0.0010 inch) (2.3822 ± 0.0010 inch)
418-9802
424-7545
480-3132
495-2062
Specifications of the Valve Seat Insert for 256-4407 Cylinder Head
Cross Section view of the bore for the valve seat insert for 256-4407 Cylinder Head.
(W) Upper bore of the head for the valve seat insert.
(X) Lower bore of the head for the valve seat insert.
Table 13
Dimensions for the Bore of the Cylinder Head Valve Seat for 256-4407
Size Bore at location (W) Bore at location (X)
60.000 ± 0.025 mm 55.000 ± 0.025 mm
Standard
(2.3622 ± 0.0010 inch) (2.1654 ± 0.0010 inch)
0.254 mm (0.0100 inch) oversize valve seat 60.254 ± 0.025 mm 55.254 ± 0.025 mm
inserts (2.3722 ± 0.0010 inch) (2.1753 ± 0.0010 inch)
0.508 mm (0.0200 inch) oversize valve seat 60.508 ± 0.025 mm 55.508 ± 0.025 mm
inserts (2.3822 ± 0.0010 inch) (2.1853 ± 0.0010 inch)
Water-cooled valve seat insert for 269-0040 Cylinder Head and the 315-2630 Cylinder Head
(Y) Upper Diameter
(Z) Lower Diameter
Table 14
Dimensions for the Inlet and Exhaust Valve Seat Insert for Cylinder Head 256-4407
Sealing Angle
Valve Seat Insert Upper Diameter (Y) Lower Diameter (Z)
(U)
308-7100
60.115 ± 0.015 mm 55.108 ± 0.015 mm
203-0843
(2.3667 ± 0.0006 inch) (2.1696 ± 0.0006 inch)
Standard
322-3659
60.369 ± 0.015 mm 55.362 ± 0.015 mm
0.254 mm (0.0100 inch) 20.25° ± 0.25°
(2.3767 ± 0.0006 inch) (2.1796 ± 0.0006 inch)
oversize
322-3660
60.623 ± 0.015 mm 55.616 ± 0.015 mm
0.254 mm (0.0100 inch)
(2.3867 ± 0.0006 inch) (2.1896 ± 0.0006 inch)
oversize
Contact Area for the Valve and Valve Seat
In the past, cylinder heads could be rebuilt so that the insert for the valve seat contacts the sealing face of the valve head at the
middle of the sealing face of the valve. Then, the 3500 engine was introduced. Currently, the traditional sealing area for the valve
moved to a location that was close to the edge of the valve. More recently, premachined inserts for the seat and precision valve
guides have moved the sealing area. This distance is now at 0.51 mm (0.020 inch) to 1.02 mm (0.040 inch) from the outside
diameter of the valve head. New, premachined valve seat inserts may be installed during the rebuild of a cylinder head. Do not
machine the sealing faces of the inserts or grind the sealing faces of the inserts. Modern manufacturing processes make machining
after installation unnecessary.
Installation
1. Freeze the insert to −60 °C (−76 °F).
2. Install the insert with a hammer and a drive plate. Make sure that the insert is fully seated in the counterbore.
3. After installation, use a 0.038 mm (0.0015 inch) feeler gauge to ensure that the insert is in contact with the bottom of the
counterbore for the cylinder head. If the gauge goes into a gap under the insert, reseat the insert.
Premachined Valve Seat Inserts
Premachined valve seat inserts are used on all gas and diesel 3500 engines except for the G3500A landfill applications. Do not
machine premachined valve seat inserts. These parts will improve the concentricity of the valve and valve seat in the cylinder head.
This will also improve the quality of cylinder heads that are rebuilt in the field.
Typical cylinder head assembly
(15) Valve seat insert for the exhaust valve
(16) Valve seat insert for the intake valve
NOTICE
The valve seat inserts are similar in size. Make sure that the correct
insert is placed in the appropriate counterbore. Damage can be caused
to the head and damage could be caused to the insert.
Specifications for the Machinable Valve Seats for the 3500 Gas Engine
Valve seats for the 3500 Gas engine
See Illustration 19 and Illustration 20 for details about Area (AA).
Specifications for the Valve Seats for the Standard Gas Engine
Detail (AA) from Illustration 18 of double angle valve seats for intake valves and exhaust valves.
Table 15
Specifications for the valve seats for G3500A Cylinder Heads for Landfill Applications
Two Angles
Item Intake Valve and Exhaust Valve
(AB) 20.25 ± 0.25 degrees
(AC) 10.0 ± 0.5 degrees
(AD) 52.0 mm (2.05 inch) gauge diameter
(AE) 55.8 mm (2.20 inch) gauge diameter
(AF) 0.6 ± 0.05 mm (0.02 ± 0.002 inch)
(AG) 5.3 ± 0.10 mm (0.21 ± 0.004 inch)
(17) Gauge Plane
Runout of the 20.25° angle is 0.065 mm (0.0026 inch) maximum relative to the centerline of the valve guide bore in the cylinder
head.
Specifications for the Valve Seat for the G3500A Landfill Gas Engine
Table 16
Specifications for the Valve Seats on the Cylinder Head for the G3500A Landfill Applications
Three Angles
Item Intake and Exhaust
(AB) 60.00 ± 0.50 degrees
(AC) 20.25 ± 0.50 degrees
(AD) 52.0 mm (2.05 inch) gauge diameter
(AE) 55.8 mm (2.20 inch) gauge diameter
(AF) 0.61 ± 0.05 mm (0.024 ± 0.002 inch)
(AG) 5.3 ± 0.10 mm (0.21 ± 0.004 inch)
(AH) 49.00 ± 0.15 mm (1.929 ± 0.006 inch) diameter
(AJ) 54.0 mm (2.13 inch)
(AK) 15.00 ± 0.50 degrees
(17) Gauge Plane
Recession of the Valve
After the cylinder head has been reconditioned, the cylinder head must be measured for the recession of the valves. The recession
of the valves is measured from the surface of the cylinder head that is exposed to combustion to the valve head. This measurement
is taken when the valve is closed.
Refer to Table 17 for measurements of the recessed valve.
A positive value for the recession of a valve represents a recessed valve as it relates to the cylinder head surface. The valve head is
below the surface.
Measurement for Recession
The recession of the valve can be measured by using any of the following:
1. 3P-1565 Collet Clamp, 8S-3158 Dial Indicator, and 5P-4156 Indicator Base.
Note: The above tools are part of the 5P-4165 Dial Indicator.
2. 6V-2012 Depth Micrometer
3. 8H-8581 Feeler Gauge and a 150.0 mm (6.0 inch) straight edge
6V-7926 Indicator Gauge
(18) 3P-1565 Collet Clamp
(19) 8S-3158 Indicator Gauge
(20) 5P-4156 Indicator Base
The minimum and the maximum dimensions for intake and exhaust valves are listed in Table 17. The table lists the dimensions for
the following minimum permissible recession, maximum recession, and maximum recession for reusability. The maximum
recession for reusability applies when the cylinder head has been machined or the valve has been ground. For the minimum
recession for reusability, refer to the minimum permissible recession. A valve that projects too far can contact the piston during
normal engine operation. A valve that is recessed too much will not adjust. A valve that is recessed too much will create the
following conditions:
• Binding in the guide
• Abnormal wear
• Poor engine performance
NOTICE
The prefinished inserts should not be ground to correct the valve

projection. Excessive valve projection indicates that the insert is not
seated or the material was not cleaned from the bottom of the
counterbore.
Table 17
Recession of the Cylinder Head Valve (AL)
Part Intake Valves Exhaust Valves

Number of Maximum Maximum
Cylinder Minimum Maximum Minimum Maximum
Recession for Recession for
Head Recession Recession Recession Recession
Reusability Reusability
7E-5861
7E-8760
131-0410
0.080 mm 0.920 mm 2.010 mm 0.100 mm 0.900 mm 2.590 mm
131-0411
(0.0031 inch) (0.0362 inch) (0.0791 inch) (0.0039 inch) (0.0354 inch) (0.1020 inch)
172-0834
172-0836
295-2047
101-1175
131-0423
2.008 mm 2.920 mm 4.010 mm 2.100 mm 2.900 mm 4.590 mm
145-3215
(0.0819 inch) (0.1150 inch) (0.1579 inch) (0.0827 inch) (0.1142 inch) (0.1807 inch)
154-1612
290-1351
4P-6571
122-5961
128-1141
144-6409
153-8397 +0.155 mm -0.654 mm 2.031 mm +0.155 mm -0.654 mm 2.031 mm
184-5496 (+0.00610 inch) (-0.0258 inch) (0.0800 inch) (+0.00610 inch) (-0.0258 inch) (0.0800 inch)
206-1554
206-1555
206-1560
206-1563
269-0040 +0.115 mm -0.685 mm 1.860 mm +0.115 mm -0.685 mm 1.860 mm
315-2630 (+0.0045 inch) (-0.0270 inch) (0.0732 inch) (+0.0045 inch) (-0.0270 inch) (0.0732 inch)
Valve Springs
Note: Do not reuse the following valve springs. 194-4901 Outer Spring, 194-4902 Inner Spring, 281-6157 Outer Spring, 316-
5976 Outer Spring, 316-5977 Inner Spring, 450-0908 Outer Spring, and 450-0909 Inner Spring.
This section has the “Use again” specifications for the valve springs for the 3500 engine cylinder head. See Reuse And Salvage
Guideline, SEBF8162 for a description of the tools needed to measure the dimensions for the valve springs.
Dimensions are for valve springs. Refer to Table 18 for identification of the items.
Table 18
Valve Spring Specifications
Outer Inner
Dimensions
7N-1904 7N-1903
Approximate free length (AS) 62.5 mm (2.46 inch) 51.5 mm (2.03 inch)
Approximate outside diameter (AN) 44.0 mm (1.73 inch) 29.24 mm (1.151 inch)
Assembled length or test length (AR) 56.4 mm (2.22 inch) 45.5 mm (1.79 inch)
Minimum load at assembled length 212.0 N (47.66 lb) 104.0 N (23.38 lb)
Length at valve open position (AP) 42.1 mm (1.66 inch) 31.3 mm (1.23 inch)
Minimum load at valve open position 733.0 N (164.79 lb) 382.0 N (85.80 lb)
The spring must be square with ends within dimension (AM). 2.2 mm (0.09 inch) 1.8 mm (0.07 inch)
Straightness of the Spring (AT) 90° NA
These specifications do not apply to the “B” series of diesel engines.
Valve Rotocoils
Note: Do not reuse any valve rotocoils.
Vacuum Test for the Valves

Refer to Reuse And Salvage Guideline, SEBF8162 for the methods and procedures for testing of the valves with a vacuum.
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Specifications For Cylinder Head Assemblies For 3500 Series Engines (0760, 0762, 1100)

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3512C Engine LLB00001-UP(SEBP4365 - 41) - Systems & Components Page 1 of 26

Information contained in this document is considered Caterpillar: Confidential Yellow.

Canceled Part Numbers and Replaced Part Numbers

Important Safety Information

Improper operation, lubrication, maintenance or repair of this product

Do not operate or perform any lubrication, maintenance or repair on

This safety alert symbol means:

Your safety is involved.

Service Letters and Technical Information Bulletins

The most recent Service Letters and Technical Information Bulletins

Tooling and Equipment

Failure to follow the recommended procedure or the specified tooling

To avoid component damage, follow the recommended procedure

Canceled Part Numbers and Replaced Part Numbers

When replacement parts are required for this product Caterpillar

Failure to heed this warning can lead to premature failures, product

Precise measurements shall be made when the component and

Specific Factors for Reconditioning

Cylinder Head Thickness

Flatness of the Surface for Combustion

Reusing Cylinder Head Bolts

Reworking Cylinder Head Bolt Holes

Hole Location for the Cylinder Head Bolt

5. Repeat this procedure for each bolt hole.

• 6V-7068 Valve Guide Gauge

• A small gauge and an outside micrometer for a plug

Precision Valve Guides

7E-5861 0.127 mm 17.6 ± 0.008 mm

206-1555 0.508 mm 17.981 ± 0.008 mm

• 6V-0087 Valve Stem Gauge

• 0 to 25.0 mm (0.98 inch) micrometer

• A 50.0 mm (1.97 inch) to 75.0 mm (2.95 inch) micrometer

• 0 to 150.0 mm (5.91 inch) dial caliper

• 5P-6518 Dial Indicator Fixture

• 0 to 150.0 mm (5.91 inch) dial caliper

Valve Seat Inserts

The prefinished inserts should not be ground to correct the valve

191-6760 60.132 ± 0.015 mm (2.3674 ± 0.0006 inch) 69.75° ± 0.25°

Specifications of the Valve Seat Insert for 256-4407 Cylinder Head

Contact Area for the Valve and Valve Seat

1. Freeze the insert to −60 °C (−76 °F).

Premachined Valve Seat Inserts

(15) Valve seat insert for the exhaust valve

(16) Valve seat insert for the intake valve

See Illustration 19 and Illustration 20 for details about Area (AA).

Recession of the Valve

Measurement for Recession

2. 6V-2012 Depth Micrometer

3. 8H-8581 Feeler Gauge and a 150.0 mm (6.0 inch) straight edge

(18) 3P-1565 Collet Clamp

(19) 8S-3158 Indicator Gauge

(20) 5P-4156 Indicator Base

• Binding in the guide

• Poor engine performance

The prefinished inserts should not be ground to correct the valve

Part Intake Valves Exhaust Valves

These specifications do not apply to the “B” series of diesel engines.

Vacuum Test for the Valves

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