1.03.070 Cummins G855 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 Cummins G855 engines as laid out in this procedure.

Procedure

This procedure applies to all Cummins G855 engines on Flogistix skids 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 during scheduled Preventative Maintenance or 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 Crossheads and Valve Lash Guide steps

** New style G855 Cummins engines Do Not have adjustable crossheads. For new style engines disregard the following steps for adjusting the crossheads on this procedure. On new style engines Only adjust the Valve rocker levers.

Use the accessory drive shaft nut to rotate the crankshaft. The crankshaft rotation is clockwise when viewed from the front of the engine.

The valve set marks are located on the accessory drive pulley. The marks align with a pointer on the gear cover.

Rotate the accessory drive clockwise until the 1-6 VS mark on the accessory drive pulley is aligned with the pointer. (as shown in the example below)

Note : One full revolution of the crankshaft is required to adjust all of the valves.

Check the valve rocker levers on cylinder number 1 to see if both the intake and exhaust valves are closed.

Both the intake and exhaust valves are closed when both levers are loose and can be moved from side to side. ( as shown in the example below)

If both valves are not closed, rotate the accessory drive one complete revolution and align the A or 1-6 VS mark on the accessory drive pulley with the pointer.

The cylinders are numbered from the front of the engine. The firing order is 1-5-3-6-2-4.

Crossheads

Note : Crosshead adjustments must always be made before attempting to adjust the valves.

With the 1-6 VS valve set mark aligned with the pointer and both valves closed on cylinder number 1, loosen the crosshead adjusting screw locknuts for:

• Cylinder #1 exhaust

• Cylinder #1 intake

• Cylinder #2 intake

• Cylinder #3 exhaust

• Cylinder #4 intake

• Cylinder #5 exhaust

Note : The procedure is the same for both the intake and exhaust crossheads.

Step 1: Turn the adjusting screw out one turn. (As shown in the example below)

Step 2: Hold the crosshead down against the guide.

Step 3: Turn the adjusting screw in until it touches the top of the valve stem, but does Not raise the crosshead. (As shown in the example below)

Step 4: Hold the adjusting screw in this position. The adjusting screw must not turn when the locknut is tightened. (As shown in the example below)

Step 5: Tighten the locknut. (As shown in the example below)

Step 6: Torque Value on crosshead adjustment nut: 30 ft-lb

When using a torque wrench adapter like shown in the example above, tighten to the following value. Torque Value: 26 ft-lb

Step 7: Adjust the intake and exhaust valves on the cylinder listed before rotating the accessory drive to the next valve set mark. See the following information for valve lash adjustment.

Valve Adjustment

Intake Rocker Lever (Arm): .014

Exhaust Rocker Lever (Arm): .034

Each cylinder has two rocker levers. The two levers closest to the center of each rocker housing are the intake levers (2). The two levers closest to the ends of the rocker housing are the exhaust levers (1). (As shown in the example below)

Step 2: Use the appropriate feeler gauge when adjusting the valve lash.

Intake Rocker Lever (Arm): .014

Exhaust Rocker Lever (Arm): .033

Tighten the adjusting screw until a slight drag is felt on the feeler gauge.

Step 3: Once adjusted to a slight drag with the feeler gauge, Hold the adjusting screw in this position then tighten the adjusting screw locknut. The adjusting screw must not turn when the locknut is tightened.

Torque Value for adjuster screw locknut: if using an adapter, 40 ft-lb

Torque Value: Without Adapter 50 ft-lb

Step 4: After tightening the locknut to the correct torque value, check to make sure the feeler gauge will slide backward and forward between the crosshead and the rocker lever, with only a slight drag. To make sure the correct valve lash is set, attempt to insert a feeler gauge that is 0.001 thicker between the crosshead and rocker lever pad. The feeler gauge must not be able to slide between the crosshead and rocker lever pad.

The lash is not correct if a thicker gauge will fit.

Step 5: After adjusting the valves listed in step 1, rotate the accessory drive 360 degrees ( One full turn) counterclockwise to the 1-6 VS mark.

Adjust the crossheads first and adjust and then adjust the valves on:

• Cylinder #2 exhaust

• Cylinder #3 intake

• Cylinder #4 exhaust

• Cylinder #5 intake

• Cylinder #6 exhaust

• Cylinder #6 intake.

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.

This procedure complies with QuickServe Online procedure 4021507 of the Cummins G8.3 Operation and Maintenance Manual

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 Cummins G855 style Natural Gas Engines equipped with or without adjustable crossheads 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

• Torque wrench capable of 50 ft-lb

Approvals

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by:

Date: