1.03.040 GM 8.1 (496) Setting Valve Lash

This Policy is completed and is waiting on Field Service, Engineering, and Safety approval.

Purpose

The purpose of this procedure is to establish the minimum requirements for setting the engine valve lash on General Motors 8.1 (496) Vortec style engines equipped with hydraulic roller lifters as laid out in this procedure.

Procedure

This procedure applies to all General Motors 8.1 (496) Vortec style engines equipped with hydraulic roller lifters with the GM LS firing order of 1, 8, 7, 2, 6, 5, 4, 3. Flogistix skids equipped with General Motors 8.1 Vortec engine drive units that are currently in service in the Field, Test Loop, at a Repair Shop, or in Storage Yards. Flogistix Service Technicians will perform the valve lash setting procedure as outlined in this procedure. This procedure will be performed after cylinder heads have been replaced, or removed from the engine and reinstalled or anytime the engine valves need to be checked or reset.

Before any work is performed a JSA needs to be done according to Flogistix procedure along with any Customer requirements before any work is started.

Initial set up of Engine to set Valve lash guide steps

When setting the valve lash on the GM 8.1 the engine needs to be set to #1 cylinder at Top Dead Center (TDC). The #1 cylinder on the GM 8.1 will be the farthest forward cylinder on the engine, and will be on the left side of the engine. If there is a timing mark turn the engine until the timing mark is at TDC. To determine #1 cylinder is on TDC when turning the engine at the standard rotation of counterclockwise, the intake and exhaust valves will not be moving when the timing mark is coming up to TDC. This can also be done by removing the #1 cylinder sparkplug and holding your thumb over the sparkplug hole. While turning the engine and the timing mark starts to come up to the TDC mark, pressure will push against your thumb as the engine is being turned. Once determined that #1 cylinder is at TDC the first step can be performed in setting the valve lash.

1. With the engine at #1 cylinder TDC the Intake valves on #1, #3, #4, #5 and Exhaust valves on #1, #2, #7, #8 can be set

2. Setting the Valve Lash. Make sure the rocker arms are loose on valves that are to be set. With the rocker arm loose, spin the pushrod on the valve being adjusted as the rocker arm nut is tightened. When zero lash occurs, the pushrod will not run freely. Once at zero lash, then turn or tighten the rocker nut an additional 1/4 to 1/2 turn.

3. Continue this process until all the Intake and Exhaust valves for the #1 TDC sequence are set.

4. Rotate the engine 360 degrees (One full Turn) untill the timing mark is at the TDC indicator mark.

5. The engine should then be at #6 cylinder TDC.

6. With the engine at #6 cylinder TDC, the Intake valves on #2, #6, #7, #8 and Exhaust valves on #3, #4, #5, #6 can be set

   1. Follow the same procedure as step two for setting the valves on cylinder #6 TDC sequence. (step 6)

After the previous steps have been completed the engine valves should be set to their proper valve setting and no rocker arms should be loose on any valves. Look over the engine on both sides on the cylinder heads. Verify that about the same amount of threads are showing above the rocker arm adjustment nuts on each cylinder.

When the engine is started listen for any valve train noise or for any ticking coming from the valve train. If new lifters were used there maybe some ticking noise from the engine when first started but should quit once lifters have been primed from proper engine oil pressure.

Responsibilities

Management - Management is responsible for implementing, supporting, and enforcing the requirements of this procedure to their respective locations/area.

EHSS - Responsible to assist in the implementation of this procedure and to review for effectiveness.

Employees, Contractors, Vendors, ETC. - Are responsible to follow the follow the requirements outlined in this procedure and ask for assistance

Scope

This procedure applies to all General Motors 8.1 Vortec style Natural Gas Engines equipped with hydraulic roller lifters and is applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

Employees need to be aware of the possibility of extremely hot exhaust pipe surfaces, potential exposure and the inhalation of engine exhaust. Employees should be aware that units could contain flammable and toxic gasses. Potential for the possible hazards of gas ignition or fire, hot surfaces & fluids, rotating equipment. Risk of possible concentration of H2S. Hazardous gases could be in the units pressure vessels, cooler, or associated piping and risk of inhalation of hazardous gas fumes.

Safety

All Personal Protective Equipment (PPE) for normal Field Mechanical duties apply for this procedure.

Four Gas Monitor, which is outlined in the Flogistix EHSS Manual, PPE Section 8, Procedure 8.3

This procedure applies to all units in service in the field, at a service shop, or in any storage yard.

Insure Flogistix personnel have proper safety certification or site orientation if required by the Flogistix Customer.

Insure Flogistix personnel adhere to all Customers safety practices.

Proper use of required tools

Training

All employees shall be initially trained on the following topics:

• Employee Personal Protective Equipment (PPE)

• Lock Out Tag Out (LOTO) procedure according to Flogistix policy

• Emission set up knowlege for Natural Gas Engines

• Methods and Observations that may be used to detect the presence or release of a hazardous chemicals or gas in the work place

Tools & Equipment Required

All employees performing this procedure shall be required to have the listed tools to perform job tasks:

• All required PPE according to Flogistix Safety Policy

• Lock Out Tag Out LOTO items to properly perform LOTO procedure according to Flogistix policy

• Basic Hand Tools

Approvals

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by:

Date: