Remove/install valves

AR05.30-W-3511A

Remove/install valves

09.01.2014

ENGINE

902.9 in MODEL 957

with CODE MS8 (Natural gas engine)

ENGINE

904.9 in MODEL 375, 673, 674, 676, 970, 972, 975, 976

ENGINE

904.9 in MODEL 668, 670

ENGINE

906.9 in MODEL 374, 375, 950, 952, 953, 954

ENGINE

906.9 in MODEL 957

ENGINE

906.9 in MODEL 970, 972, 974, 975, 976

1

Valve locks

2

Valve spring retainer

3

Valve springs

4

Valve spring

5

Cylinder head

6

Intake valves

7

Exhaust valve

8

Valve lifter

9

Valve stem seals

12.1

Assembly cartridge guide

12.2

Assembly cartridge

12.3

Detent part

12.4

Thrust fork

5

Cylinder head

6

Intake valves

7

Exhaust valve

10

Mount dial indicator

11

Dial indicator holder

A

Valve seat angle

B

Valve disk dia.

C1

Valve length

C2

Valve length

E

Valve stem dia.

F

Valve seat width on the valve disk

G

Valve seat face dia.

H

Valve seat face machining dimension



Remove

1

Remove cylinder head (5)

Model 374, 375, 673, 674, 676, 950, 952, 953, 954, 970, 972, 975, 976, model 957 without code MS8 (Natural gas engine)

AR01.30-W-5800A

Model 957 with code MS8 (Natural gas engine)

AR01.30-W-5800H

Model 668, 670

AR01.30-D-5800D



Exhaust valve spring, exhaust valve and exhaust valve seat ring modified

BT05.30-N-0004-01RH

2.1

Remove nozzle holder combinations

Except code MS8 (Natural gas engine)

Engine 904.9 up to engine end no. 040487 in model 668, 670, 673, 674, 676

AR07.03-W-6831A

Engine 904.9 as of engine end no. 040488 in model 668, 670, engine 904.9, 906.9 in model 374, 375, 950, 952, 953, 954, 957, 970, 972, 974, 975, 976

AR07.03-W-6831C

2.2

Remove spark plugs

Model 957 with code MS8 (Natural gas engine)

ENGINE 902.9, 906.9

AR15.12-W-1010H

3

Measure and note valve setback in relation to cylinder head (5)

Engine 902.9 in model 957 with code MS8 (Natural gas engine), engine 904.9 in model 375, 673, 674, 676, 970, 972, 975, 976, engine 904.908/914/923/936 in model 668, 670, engine 906.9 in model 374, 375, 950, 952, 953, 957, 970, 972, 974, 975, 976

AR05.30-W-4100-01C

Valve setback relative to cylinder head contact surface

*BE05.30-N-1001-01B

Permissible difference of intake valves measured between cylinder head and valve stem end

*BE05.30-N-1014-01B

 Dial gage

*001589532100

 Dial indicator holder

*363589022100

 Dial indicator holder

*343589004000

If the measurements lie outside the permissible tolerance:



Replace cylinder head.

4

Remove valve spring retainer (2) and valve springs (3, 4)

Remove with valve lifter (8). Model 374, 375, 668, 670; model 957 with code MS8 (Natural gas engine)

AR05.30-W-3510-03C

Remove with valve tool kit. Model 668, 670, 673, 674, 676, 950, 952, 953, 954, 970, 972, 974, 975, 976, model 957 without code MS8 (Natural gas engine)

AR05.30-W-3510-03D

 Magnetic pin

*210589004000

 Valve lifter

*442589003100

 Adapter piece

*904589003100

 Valve tool case

*541589006100

5

Measure difference for intake valves (6) between cylinder head and valve stem end and note result

Permissible difference of intake valves measured between cylinder head and valve stem end

*BE05.30-N-1014-01B

If the measurements lie outside the permissible tolerance:



Replace cylinder head (5).

6

Mark intake valves (6) and exhaust valve (7) and remove upwards out of cylinder head (5)

 Mark installation location for intake valves (6) and the exhaust valve (7).

7

Pull off valve stem seals (9)

8

Check valve seat rings

 Measure valve seat width on all valve seat rings.

Valve seat width on valve seat ring

*BE05.30-N-1007-03B

The measurement values lie outside the tolerance:



Replace cylinder head (5).

9

Use feeler gauge to inspect valve guides for wear

 Drift

*102589002300

If the side of the drift marked "+" can be inserted in the valve guide:



For engine without code MS8 (Natural gas engine) the valve guide must be replaced.

Engine 904.9, 906.9 without code MS8 (Natural gas engine)

AR05.30-W-3731A

For engine with code MS8 (Natural gas engine) the cylinder head (5) is replaced.

10

Check hardness at valve stem end.

 Replace respective intake valve (6) or exhaust valve (7) if necessary.

Hardness at valve stem end

*BE05.30-N-1010-01B

 Hardness tester

*000589202100

11

Check whether intake valves (6) and exhaust valve (7) can to re-used.

 Intake valves (6) or exhaust valve (7) may be used again if no surface damage is recognizable on the valve stem ends, the chrome layer on the valve stems is intact, the valve retainer grooves are not worn out or the valve seats are not burnt.

12

Check intake valves (6) and exhaust valve (7) for smooth operation and for specified dimensions

Valve seat angle

*BE05.30-N-1003-01B

Valve disk Ø

*BE05.30-N-1004-01B

Valve seat width on the valve disk

*BE05.30-N-1005-01B

Valve length

*BE05.30-N-1006-01B

Valve stem Ø

*BE05.30-N-1007-01B

Intake valve seat surface machined dimension (H) relative to valve seat surface dia. (G)

*BE05.30-N-1008-01B

Exhaust valve seat surface machined dimension (H) relative to valve seat surface dia. (G)

*BE05.30-N-1009-01B

Concentricity of valve seat to valve stem

*BE05.30-N-1011-01B

13

Check valve springs (3, 4)

 Replace damaged valve springs (3, 4).



Install

14

Grind intake valves (6) and exhaust valve (7) if necessary

Only for engine without code MS8 (Natural gas engine)

AR05.30-W-4202A

15

Insert intake valves (6) and exhaust valve (7) into cylinder head (5)

 Note marking.

16

Install new valve stem seals (9)

Engine 902.9 in model 957 with code MS8 (Natural gas engine), engine 904.9 in model 375, 673, 668, 670, 674, 676, 970, 972, 975, 976, engine engine 906.9 in model 374, 375, 950, 952, 953, 954, 957, 970, 972, 974, 975, 976

AR05.30-W-3510A

17

Install valve spring retainer (2) and valve springs (3, 4)

Installation with valve lifter (8). Model 374, 375, 668, 670; model 957 with code MS8 (Natural gas engine)

AR05.30-W-3510-03C

Installation with valve tool kit. Model 668, 670, 673, 674, 676, 950, 952, 953, 954, 970, 972, 974, 975, 976, model 957 without code MS8 (Natural gas engine)

AR05.30-W-3510-03D

 Magnetic pin

*210589004000

 Valve lifter

*442589003100

 Adapter piece

*904589003100

 Valve tool case

*541589006100

18.1

Install nozzle holder combinations

Except code MS8 (Natural gas engine)

Engine 904.9 up to engine end no. 040487 in model 673, 674, 676, 668, 670

AR07.03-W-6831A

Engine 904.9 as of engine end no. 040488 in model 668, 670, engine 904.9, 906.9 in model 374, 375, 950, 952, 953, 954, 957, 970, 972, 974, 975, 976

AR07.03-W-6831C

18.2

Install spark plug

Engine with code MS8 (Natural gas engine)

ENGINE 902.9, 906.9

AR15.12-W-1010H

19

Install cylinder head (5)

Model , 374, 375, 950, 952, 953, 954, 970, 972, 974, 975, 976, model 957 except code MS8 (Natural gas engine)

AR01.30-W-5800A

Model 957 with code MS8 (Natural gas engine)

AR01.30-W-5800H

Model 668, 670

AR01.30-D-5800D

Check values for valves

Number

Designation

ENGINE 902.9, 906.9 with CODE MS8

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

BE05.30-N-1001-01B

Valve setback relative to cylinder head contact surface

Inlet

mm

1,1...1,5

1,1...1,5

Outlet

mm

1,3...1,7

1,1...1,5

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1001-01B

Valve setback relative to cylinder head contact surface

Inlet

mm

1,1...1,5

Outlet

mm

1,1...1,5

Check values for valves

Number

Designation

ENGINE 902.9, 906.9 with CODE MS8

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

BE05.30-N-1003-01B

Valve seat angle

Inlet

°

20

20

Outlet

°

20

36

Outlet

°

36

45

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1003-01B

Valve seat angle

Inlet

°

20

Outlet

°

36

Outlet

°

45

Check values for valves

Number

Designation

ENGINE 902.9, 906.9 with CODE MS8

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

BE05.30-N-1004-01B

Valve disk Ø

Inlet

mm

33,9...34,1

33,9...34,1

Outlet

mm

37,8...38,2

37,9...38,1

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1004-01B

Valve disk Ø

Inlet

mm

33,9...34,1

Outlet

mm

37,9...38,1

Check values for valves

Number

Designation

ENGINE 902.9, 906.9 with CODE MS8

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

BE05.30-N-1005-01B

Valve seat width on the valve disk

Inlet  20°

mm

3,19

3,19

Outlet  20°

mm

3,50...4,30

–

Outlet  36°

mm

3,63

3,63

Outlet  45°

mm

–

3,35

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1005-01B

Valve seat width on the valve disk

Inlet  20°

mm

3,19

Outlet  20°

mm

–

Outlet  36°

mm

3,63

Outlet  45°

mm

3,35

Check values for valves

Number

Designation

ENGINE 902.9, 906.9 with CODE MS8

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

BE05.30-N-1006-01B

Valve length

Inlet

mm

128,45...129,05

125,70...126,10

Outlet

mm

152,50...152,90

152,20...152,90

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1006-01B

Valve length

Inlet

mm

128,45...129,05

Outlet

mm

152,20...152,90

Check values for valves

Number

Designation

ENGINE 902.9, 906.9 with CODE MS8

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

BE05.30-N-1007-01B

Valve stem Ø

Inlet

mm

7,935...7,950

7,935...7,950

Outlet

mm

7,925...7,940

7,925...7,940

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1007-01B

Valve stem Ø

Inlet

mm

7,935...7,950

Outlet

mm

7,925...7,940

Test specifications for valve seat rings

Number

Designation

ENGINE 902.9, 906.9 with CODE MS8

ENGINE 904.9, ENGINE 906.9 except CODEMS8

BE05.30-N-1007-03B

Valve seat width on valve seat ring

Inlet  20°

mm

1,5...2,5

1,5...2,5

Outlet  20°

mm

1,9...3,0

–

Outlet  36°

mm

2,0...3,0

2,0...3,0

Outlet  45°

mm

–

1,8...3,0

Check values for valves

Number

Designation

ENGINE 902.9, 906.9 with CODE MS8

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

BE05.30-N-1008-01B

Intake valve seat surface machined dimension (H) relative to valve seat surface dia. (G)

Dimension G

mm

31,0

31,0

Dimension H

mm

2,7...3,1

2,7...3,1

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1008-01B

Intake valve seat surface machined dimension (H) relative to valve seat surface dia. (G)

Dimension G

mm

31,0

Dimension H

mm

2,7...3,1

Check values for valves

Number

Designation

ENGINE 902.9, 906.9 with CODE MS8

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

BE05.30-N-1009-01B

Exhaust valve seat surface machined dimension (H) relative to valve seat surface dia. (G)

Dimension G

mm

36,0

36,0

Dimension H

mm

2,7...3,0

2,5...3,2

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1009-01B

Exhaust valve seat surface machined dimension (H) relative to valve seat surface dia. (G)

Dimension G

mm

36,0

Dimension H

mm

2,5...3,2

Check values for valves

Number

Designation

ENGINE 902.9, 906.9 with CODE MS8

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

BE05.30-N-1010-01B

Hardness at valve stem end

Inlet

HRC

54...60

54...60

Outlet

HRC

54...60

54...60

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1010-01B

Hardness at valve stem end

Inlet

HRC

54...60

Outlet

HRC

54...60

Check values for valves

Number

Designation

ENGINE 902.9, 906.9 with CODE MS8

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

BE05.30-N-1011-01B

Concentricity of valve seat to valve stem

Inlet

mm

0,03

0,03

Outlet

mm

0,03

0,03

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1011-01B

Concentricity of valve seat to valve stem

Inlet

mm

0,03

Outlet

mm

0,03

Check values for valves

Number

Designation

ENGINE 902.9, 906.9 with CODE MS8

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

BE05.30-N-1014-01B

Permissible difference of intake valves measured between cylinder head and valve stem end

mm

0,3

0,3

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1014-01B

Permissible difference of intake valves measured between cylinder head and valve stem end

mm

0,3