1.03.080 Cummins G8.3 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 G8.3 engines as laid out in this procedure.

Procedure

This procedure applies to all Cummins G8.3 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 Valve Lash Guide Steps

When setting the valve lash on the Cummins G8.3 the engine needs to be set to #1 cylinder Top Dead Center (TDC).  The #1 cylinder on the G8.3 will be the farthest forward cylinder on the engine from the flywheel.    

The crankshaft rotation looking at the front of the engine will be Clockwise.  

Rotate the vibration damper Clockwise until the mark on the vibration damper pulley is aligned with the pointer.

Using the  Cummins rotating tool as illustrated below to rotate the engine vibration damper to the desired position.  

The engine is at top dead center (TDC) #1 if both cylinder number 1 intake and exhaust valves are closed.  When the valves are closed there should be some valve lash clearance between the rocker arm and the valve stem.

If not, rotate the engine until the exhaust valve and intake valve are both open to number 6 cylinder.  Watch for the exhaust valve to begin to close.  Once it is almost closed, the intake will start to open. At this point, the engine will be at top dead center (TDC) on cylinder #1. 

The G8.3 engine firing order is 1-5-3-6-2-4

Adjustment

Check and set valves with the engine cold - below 140 deg F

Intake Rocker arm:    .012

Exhaust Rocker arm: .024

**The clearance is correct when some resistance is felt when the feeler gauge is slipped between the valve stem and the rocker lever.

Check and adjust the valves indicated for STEP A (shown below)

STEP A valve adjustment equals

• • • Cylinder #1 intake

    • Cylinder #2 intake

    • Cylinder #3 Exhaust

    • Cylinder #4 intake

    • Cylinder #5 Exhaust

After adjusting and tightening the rocker lever locknut, check the valve clearance to make sure the valve clearance has NOT changed.

The rocker lever locknut torque value is 212 in-lb

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

The engine should then be at #6 cylinder TDC.

Check and adjust the valves indicated for STEP B (shown below)

Step B valve adjustment equals

• • Cylinder #6 Exhaust

  • Cylinder #6 Intake

  • Cylinder #5 Intake

  • Cylinder #4 Exhaust

  • Cylinder #3 Intake

    • Cylinder #2 Exhaust 

After adjusting and tightening the rocker lever locknut, check the valve clearance to make sure the valve clearance has NOT changed.

The rocker lever locknut torque value is 212 in-lb

After the previous steps have been completed the engine valves should be set to their proper valve setting and no rocker lever locknuts 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 locknuts on each cylinder.

After setting the correct valve lash replace the engine valve cover according to procedure: 1.3.82 Cummins G8.3 Valve cover seal replacement

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 4021489 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 G8.3 style Natural Gas Engines equipped with adjustable rocker levers 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

• 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

• Feeler gauge(s) .012 and .024

• Torque wrench capable up to 212 in-lb

Approvals

Field Service approved by:

Date:

Engineering approved by: 

Date: 

EHSS approved by:

Date: