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NOTE: Table 5 lists all special tools required. NOTE: Current head assemblies do not use oil
deflectors. If the head being disassembled has oil
INTAKE AND EXHAUST VALVES deflectors on the intake valves, proceed with Step 2.
INTAKE AND EXHAUST VALVE REMOVAL Otherwise, go to Step 3.
2. GSI only – Remove and discard retaining rings, O-
WARNING rings, and oil deflectors from intake valves, if
equipped.
Use caution when removing or installing the valve
springs. They are under tension and can eject 3. Install spring compressor center guide stud in
from the cylinder head during the removal cylinder head.
process. Use the correct valve spring compressor Look through the holes
for this procedure. Wear safety goggles. CAUTION in the pressure plate to
Disregarding this information could result in ensure that they are aligned with the valve stems,
severe personal injury or death. threaded studs, and valve bridge guide studs. Fail-
ure to align the pressure plate properly could
Valve spring compressor (P/N 474031 or P/N 474033)
cause damage to equipment. Disregarding this
is available for use on P/N 204702 series cylinder
information could result in product damage and/or
heads. This tool is designed so that all four valve
springs can be compressed at once. Use of this tool personal injury.
greatly reduces service time for such tasks as valve
4. Position pressure plate over valve stems, threaded
stem seal replacement, valve replacement, and cylin-
studs, and valve bridge guide studs. Ensure large
der head overhaul. The tool may be used with the cyl-
diameter countersunk holes are facing up and are
inder heads on or off the engine.
aligned over valve stems (see Figure 1).
If removing the valve
CAUTION tapers, springs, or 5. Apply engine oil to threads of center guide stud.
valve stem seals with the cylinder heads on the
engine, the piston below each cylinder head must PRESSURE NUT
PLATE
be at top dead center. If each piston is not at top
dead center, the valves will fall into the combus-
tion chamber, damaging the valves. Cylinder head
removal will be required to remove the valves from
the combustion chamber. Disregarding this infor-
mation could result in product damage and/or per- THRUST
BEARING
sonal injury.
WAUKESHA ENGINE
DRESSER, INC.
Page 1 of 22
WAUKESHA, WI 53188-4999
Service Bulletin No. 7-2984B
6. Install thrust bearing and compression nut on TAPERS SPRING
center guide stud. RETAINER
7. Tighten compression nut down until pressure plate
compresses valve springs just enough to release valve
INNER VALVE
tapers (see Figure 1 and Figure 2). SPRING
8. Remove valve tapers from valve stems (see
Figure 2). OUTER VALVE
SPRING
9. Loosen and remove compression nut and thrust
bearing from center guide stud.
10. Remove pressure plate from cylinder head. VALVE SPRING
Remove two nuts and center guide stud from cylinder WASHERS
head.
VALVE STEM
SEAL
11. Remove valve spring retainers (see Figure 3).
INTAKE
VALVE GUIDE
VALVE TAPER
EXHAUST
VALVE GUIDE
VALVE TAPER
WAUKESHA ENGINE
DRESSER, INC.
Page 3 of 22
WAUKESHA, WI 53188-4999
Service Bulletin No. 7-2984B
The exhaust valve
CAUTION guides are machined
with two outside diameters and can only be 3
removed in one direction. Failure to press out the
valve guides through the bottom of the cylinder
head (piston side) can cause damage to the equip-
ment.
2
9. Using a valve guide remover (P/N 494257), press
out the valve guides. Guides must be pressed out 4
through the bottom of the cylinder head toward the
piston side.
CYLINDER HEAD CLEANING AND
INSPECTION
Generally, the cylinder head casting does not require
any unusual maintenance other than resurfacing of the 1
lower deck, if necessary (see “Cylinder Head Lower
Deck Reconditioning” on page 7). Items needing 5
6
replacement within the casting are removable fittings,
such as valve guides and valve seats. All core plugs
Figure 6. Core Plug Location – Top
and removable fittings may be removed to adequately
clean the casting.
NOTE: Core plug removal is necessary only if
excessive scale or deposits are found in the coolant
passages.
Scale buildup in a cylinder head can cause it to fail. An
accumulation of scale deposits within the cylinder
head inhibits the proper transfer of heat around critical
engine parts, causing overheating. This overheating
and expansion cause the casting to crack. Preventing
scale buildup will help prevent a cracked cylinder
head. During an engine overhaul, hot tank the compo-
nent to remove any scale.
7
When the cylinder head is cleaned and air dried,
check thoroughly for cracks. Magnaflux® products can Figure 7. Core Plug Location – Front
assist with such an inspection. When checking for
cracks, special attention must be paid to the combus-
tion side of the cylinder head. The area between the
valve inserts must be inspected carefully. Only after
the cylinder head casting is found to be free of cracks
can the removable fittings be replaced. These fittings
must also meet the required specifications. If they do
not meet the specifications or guidelines for the reuse
of used parts, replace with new genuine Waukesha
Engine parts.
1. If excessive scale or deposits are found in the
coolant passages, it may be necessary to remove the 8
eleven countersunk headless core plugs from each
Figure 8. Core Plug Location – Right
cylinder head (eight 3/4 in. NPT, three 1 in. NPT (see
Figure 6 through Figure 10).
WARNING
Use of chemical cleaning solutions should be
restricted to a well-ventilated area. Contact with
skin, clothing, and eyes could result in severe
personal injury or death.
WARNING
Compressed air can pierce the skin and cause
severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris. Wear safety goggles.
Disregarding this information could result in
severe personal injury or death.
WAUKESHA ENGINE
DRESSER, INC.
Page 5 of 22
WAUKESHA, WI 53188-4999
Service Bulletin No. 7-2984B
seven water passage openings. The rubber grommets
METAL
STRAIGHTEDGE in the head gasket point out the location of the water
EXHAUST passage openings.
VALVE SEAT
WATER OUTLET
ELBOW CONNECTION
CYLINDER HEAD
WAUKESHA ENGINE
DRESSER, INC.
Page 7 of 22
WAUKESHA, WI 53188-4999
Service Bulletin No. 7-2984B
can also cause the same type of guide wear. In addi-
tion, combustion air or fuel gas can contain abrasives
that can also wear the valve face, seat, and the lower
end of the guide.
Worn guides can cause the valves to meet the valve
seat at a variety of angles, causing a sliding motion
8.469" (215.113 mm) that will further wear the valve and its seat. This
HEIGHT (NEW HEAD) improper seating leads to blow-by of combustion
gases and seat burning or torching. Other reasons for
worn valve guides are:
• Improperly adjusted valves, which cause excessive
side thrust on the valve stems.
• Poor lubrication in the guide, either too much or too
little.
Figure 14. Cylinder Head – Intake Port Side
• Carbon deposits on the valve stem that cause the
If the lower deck is reconditioned, it may be necessary valve guide to wear into a bell-mouthed shape at the
to recut the valve seat insert counterbore depth to lower end.
maintain the proper depth of the valve heads in the • Incorrect valve or seat angle due to grinding during
cylinder head. The valve seat insert counterbore depth rebuilding.
will have to be recut to the amount as was taken off the
cylinder head. Valve Stem Scuffing
VALVE FAILURE ANALYSIS Scuffing of the valve stem can result from a lack of
lubrication and too much (or too little) stem-to-guide
The major causes for valve failures include: clearance. Poor disassembly or assembly practices
can cause damage to the surface finish of the valve
• Valve recession stem or valve guide, which will scuff the valve or guide.
• Wear Valve Deposits
• Scuffing of the valve stem Valve deposits are normal. Deposits on exhaust valves
• Excessive deposits on the valve should be dry, and white to tan in color. Deposits typi-
cally occur on the head of the valve and the blended
• Carbon buildup in the guide area between the valve head and stem. The seating
• Distortion of the valve seat surface of the valve will typically exhibit a matted
appearance with some small pockmarks due to depos-
• Incorrect valve adjustment its being caught between the valve and the seat. This
• Torching is also considered normal unless the pitting allows gas
leakage.
• Heat fatigue/cracking
Deposits will also build up on intake valves; however,
• Valve erosion they are typically darker in color and on the blended
• Other area between the head and the valve stem. They will
be black and carbonaceous with some oil present.
Valve Recession
The majority of combustion chamber deposits are
Valve recession is a normal process and is expected made up of burnt lube oil and lube oil additives. These
over time. Typically 0.0015 to 0.002 in. (0.0381 to deposits are commonly called ash, and the proper
0.0508 mm) of wear per 1000 hours of operation on amount of ash is desirable to retard valve recession or
the valve and seat faces is acceptable and will result in wear. Ash deposits should be seen on the valve face
a normal top end overhaul life. and seat.
Valve and Guide Wear Valve Guide Deposits
Abnormal component wear leads to excessive valve Deposits (carbon or lacquering) in the valve guide can
recession. Wear can occur on the valve face, valve cause the valve to stick in the guide, causing the valve
stems, valve guides, and valve seats. Valve guides to be held in the open position. Inspect the valve
typically wear from poor valve-to-seat contact, causing guides for deposits or wear. Replace worn guides.
a side thrust on the guide. Out-of-round valve seats
Valve Breaks
When a valve breaks, it generally is from a bending
fatigue or impact with the piston. Fatigue occurs usu-
ally from mechanical damage where the valve and pis-
ton have made contact, bending the valve slightly, and
over a period of time, the flexing at the stem-head
interface breaks the valve stem. Impact with the pis- Figure 15. Checking Valve Stems for Straightness
ton, if severe enough, will break the valve immediately
or induce the condition that causes a bending fatigue • Head perpendicularity: The head must be
type failure. perpendicular to the valve stem, or improper seating
will result (see Figure 16). Total runout must be
Valve Erosion within 0.002 in. (0.050 mm).
Erosion of the valve stem under the valve head can
cause valve breakage. Causes of valve erosion
include fuel gas with high hydrogen sulfide levels,
faulty combustion, or excessively high valve tempera-
tures. Improper air/fuel mixture ratios that overheat
and erode valves can cause such high-temperature
valve failure as well.
Other
Only a few of the reasons why valves fail are listed
here; there are, obviously, many others. The list above
identifies ten of the most common causes; however,
they are not necessarily in any priority of probable
occurrence.
WAUKESHA ENGINE
DRESSER, INC.
Page 9 of 22
WAUKESHA, WI 53188-4999
Service Bulletin No. 7-2984B
} RETAINER GROOVES
STEEL
WELD
HARDENED
FACE
SEAT MARGIN
ANGLE
HEAD PERPENDICULAR
TO STEM CENTERLINE
HEAD STAMPED FOR
INTAKE/EXHAUST PLUS P/N
Figure 16. Checking Head Perpendicularity
Figure 17. Cylinder Head Valve
• Stem end perpendicularity: It is important that this
surface must be flat and perpendicular to prolong 0.156" (3.96 mm) NEW VALVES
the life of the valve and tappet ball (see Figure 17). 0.128" (3.25 mm) AFTER GRINDING
INSPECT BOSS
INSPECT BOSS WARNING
Always use approved cleaning solvents in a well-
ventilated area. Avoid contact with skin. Failure to
follow proper procedures could cause severe
INSPECT OD
personal injury or death.
WAUKESHA ENGINE
DRESSER, INC.
Page 11 of 22
WAUKESHA, WI 53188-4999
Service Bulletin No. 7-2984B
Table 1. Valve Springs
INTAKE G G
J K
F*
E E
I
K*
F F
L L
B
M*
M M
N N
D, D*
C
O O
EXHAUST INTAKE
WAUKESHA ENGINE
DRESSER, INC.
Page 13 of 22
WAUKESHA, WI 53188-4999
Service Bulletin No. 7-2984B
Table 1. Valve Train Specifications
MEASUREMENT INCHES (in.) METRIC (mm)
New New
Specification Wear Limit Specification Wear Limit
WARNING
The cylinder head weighs approximately 195 lb.
(86 kg). Use a suitable lifting device and exercise
caution during removal or installation to prevent
sever personal injury or death. Figure 21. Installing Valve Guides
3. Start the new valve guides in their respective 5. Carefully remove shop towel to prevent metal
bores. Always press in the valve guides from the valve chips and debris from falling into cylinder head.
seat insert side of the cylinder head. Use a 20-ton NOTE: See service bulletin 7-2938A (or latest
hydraulic press and the valve guide removal/ revision) for checking valve guide straightness and
installation tool (P/N 494257) (see Figure 21). Any finished inside diameter using gauge tool P/N 474044.
contact between the press and the lower deck of the
cylinder head must be avoided. CYLINDER HEAD CASTING PLUG
INSTALLATION
1. Apply removable pipe thread sealant (Loctite
Removable Threadlocker 242) to the threads of the
countersunk headless core plugs (see Figure 6
through Figure 10).
2. Install eleven core plugs in each cylinder head
(eight 3/4 in. NPT, three 1 in. NPT). Tighten the core
plugs to 600 in-lb (68 N·m).
WAUKESHA ENGINE
DRESSER, INC.
Page 15 of 22
WAUKESHA, WI 53188-4999
Service Bulletin No. 7-2984B
VALVE SEAT INSERT INSTALLATION Install the valve seat
CAUTION insert with the beveled
side facing outward. Disregarding this information
DANGER could result in product damage.
Comply with the liquid nitrogen manufacturer’s NOTE: The insert warms up rapidly and must be
recommendations for proper use and handling of properly installed before its diameter increases to the
liquid nitrogen. Improper handling or use of liquid point where installation becomes too difficult.
nitrogen will result in severe personal injury or
3. Use a wire bent in the shape of a hook to pick up
death.
the valve seat insert and position it into the
counterbore with the beveled side facing outward (see
Figure 22).
WARNING
BEVEL
Liquid nitrogen is -320° F (-196° C) and will cause
severe burns if it comes into contact with human
skin. To prevent burns to the skin, wear protective
equipment when working with liquid nitrogen.
Disregarding this information could result in
severe personal injury or death.
NOTE: Use of the Hall-Toledo EDP valve seat grinder TYPE STONE ANGLE TOOL P/N
(P/N 494277) is a factory-approved service method of
Seat Angle 20 Degrees 494014
grinding valve seats (an eccentric grinder, diamond
dresser, stand, and necessary wrenches are 494305
Seat Angle 30 Degrees
included). Other commercially available devices such (current wide bridge heads)
as the SERDI machining system may be used.
Machining accuracy
CAUTION depends upon the fit of
the pilot mandrel. The pilot mandrel should fit
snugly in the guide and in the hub of the grinder
stone. Be sure that the upper end of the mandrel TIGHTEN PILOT
MANDREL
does not wobble during the grinding procedure.
Upper end movement will produce a seat that is
not ground true, causing damage to equipment.
Disregarding this information could result in prod-
uct damage and/or personal injury.
WAUKESHA ENGINE
DRESSER, INC.
Page 17 of 22
WAUKESHA, WI 53188-4999
Service Bulletin No. 7-2984B
2. Install a light lifting spring over valve stem. Apply a
WARNING small amount of lubricating oil into valve guide bore
and slide valve into cylinder head. The spring should
Compressed air can pierce the skin and cause just barely hold the valve off its seat.
severe personal injury or death. Never use your
hand to check for leaks or to determine air flow 3. Press down until valve is seated. Rotate valve a
rates. Wear safety glasses to shield your eyes from quarter turn, first in one direction, then in the other. Do
flying dirt and debris. Disregarding this this three or four times.
information could result in severe personal injury 4. Release pressure on valve stem, so that the spring
or death. lifts valve straight off its seat. Turn valve about 10 to 15
degrees clockwise and repeat grinding procedure.
Continue this operation until valve has been rotated a
WARNING complete 360 degrees and all grinding compound has
Always use approved cleaning solvents in a well- been rubbed off valve seat.
ventilated area. Contact with skin could result in Ensure that all lapping
severe personal injury or death. CAUTION compound is com-
pletely removed from the valve and valve seat.
7. Use compressed air to blow away all loose dust. Failure to completely clean all lapping compound
Wipe down valve seat and seat insert surfaces with a from the valve and valve seat could cause damage
non-volatile cleaning solution or solvent and dry with a
to equipment. Disregarding this information could
clean cloth.
result in product damage and/or personal injury.
VALVE SEAT LAPPING
5. Remove valve and spring from cylinder head and
1. Apply a good fine grinding compound sparingly thoroughly clean valve and valve seat insert of any
around entire valve face. lapping compound.
6. Carefully inspect mating surfaces. A properly
lapped valve will show a gray, frosty seating surface
located either near center of valve face for 30° valves,
or near valve head end for 20° valves. If properly
lapped, the lapped surface width will equal valve seat
width values listed in Table 3.
7. Repeat lapping procedure if necessary. Regrind
valve seat insert if results are not acceptable.
VALVE
FACE
WIDTH OF
PRUSSIAN BLUE
TRANSFER
NOTE: See Service Bulletin 7-2949C (or latest 4. Position the valve stem seal installation tool (P/N
revision) when selecting application specific TL82158) over the valve stem and seal. The tool bore
components. allows insertion of the valve stem, while the
counterbore fits over the valve stem seal.
1. Apply a small amount of lubricating oil into the
valve guide bores and install the valves in the cylinder 5. With the palm of your hand, lightly strike the end of
head, in the locations from which they were removed. the tool to seat the seal evenly on the valve guide.
To distribute the lubricating oil around the valve stem, 6. Install two washers over the valve guide shoulders
hand spin the valves as they are installed. Work the until they come to rest on the cylinder head casting.
valves back and forth to verify that they slide smoothly The washers are needed to retain proper tension on
and seat properly. the inner spring (see Figure 27).
2. Clean inner and outer valve springs, washers,
retainers, and tapers in a non-volatile cleaning solution
or solvent. Inspect for damage, rust pits, or excessive
wear. Replace as necessary (see Table 1).
To avoid cracking the
CAUTION valve stem seals,
always use the proper valve stem seal installation
tool. See Table 6 for proper valve stem installation
tool selection. Use of an ordinary socket may dam-
age the seals, resulting in leakage around the
valve stem and excessive oil consumption.
NOTE: See Service Bulletin 7-2949C (or latest
revision) for valve stem seal applications.
3. Position the new valve stem seal on top of each
valve guide with the outer band facing downward (see
Figure 26). The outer band holds the seal in place on
the guide, while the spring maintains even tension on
the valve stem.
WAUKESHA ENGINE
DRESSER, INC.
Page 19 of 22
WAUKESHA, WI 53188-4999
Service Bulletin No. 7-2984B
Table 4. Valve Spring Reference
TAPERS
SPRING DIRECTION OF HELIX
RETAINER VALVE COLOR
(TOP TO BOTTOM)
PRESSURE NUT
PLATE
Figure 27. Cylinder Head Assembly
WARNING
Use caution when removing or installing the valve
springs. They are under tension and can eject THRUST
BEARING
from the cylinder head during the removal
process. Use the special valve spring compressor
tools for this procedure. Wear safety goggles.
Failure to take adequate precautions can result in
severe personal injury. CENTER
GUIDE STUD
7. Install the inner and outer valve springs on the
intake and exhaust valve guides. The intake valve Figure 28. Position Pressure Plate Compression Nut
springs are dyed orange. and Thrust Bearing
NOTE: Do not intermix the intake and exhaust valve 11. Apply engine oil to threads of center guide stud.
springs. Intake valve springs can be distinguished
12. Install thrust bearing and compression nut on
from the exhaust valve springs by the direction of the
center guide stud.
helix (see Table 4 for valve spring reference).
TAPERS SPRING
RETAINER
CYLINDER HEAD
VALVE SPRING
WASHERS
WATER PASSAGES
VALVE GUIDE
Figure 30. Assembled Cylinder Head – Cross Sectional View of Exhaust Valve
WAUKESHA ENGINE
DRESSER, INC.
Page 21 of 22
WAUKESHA, WI 53188-4999
Service Bulletin No. 7-2984B
Table 5. Special Tools
DESCRIPTION P/N
Valve Spring Compressor (G/GSI) 474031
Valve Spring Compressor (GL) 474033
Valve Guide Reamer 474046
20 Degrees Seat Angle Grinding Stone 494014
Valve Guide Removal/Installation Tool 494257
Valve Seat Grinder 494277
Dial Indicator Gauge (thousandths) 494278
Magnaflux® Dye Penetrant 494283
Valve Adjusting Wrench 494287
30 Degree Seat Angle Grinding Stone 494305
Pilot Mandrel 494344
Valve Stem Seal Installation Tool TL82158
Valve Seat Installation Tool TL982981
Straightness and Finished I.D. Gauge 474044