1.03.082 Cummins G8.3 Valve cover seal replacement

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 replacing the valve cover seal 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 cover seal replacement procedure as outlined in this procedure. This procedure will be performed during scheduled Preventative Maintenance if valve cover seal is leaking, after cylinder valve lash has been checked, or anytime the valve cover has been removed from the engine and reinstalled.

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.

Valve cover seal

If the valve cover seal is not damaged, it can be used again. If the seal is damaged, install a new seal.

New Seal replacement:

Install the rubber seal into the groove in the valve cover. Start the installation at the overlap area shown in the illustration below.

** Do Not stretch the rubber seal

If the seal has more overlap than shown in the illustration, trim the length to provide the correct overlap.

When installing the valve cover back on the engine install new o-rings on the capscrews holding down the valve cover as shown in the below illustration.

Valve cover capscrews torque value is 212 in-lb

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 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
Torque Wrench capable of 212 in-lb

Approvals

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by:

Date:

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