1.03.200 Caterpillar G3406 Valve Setting procedure

This Policy is under development.

Purpose

The purpose of this procedure is to establish the minimum requirements for setting the engine intake and exhaust valves on Caterpillar G3406 engines as laid out in this procedure.

Procedure

This procedure applies to Flogistix skids equipped with a Caterpillar G3406 engine that is currently in service either in the Field, Test Loop, at a Repair Shop, or in Storage Yards. Flogistix Service Technicians will perform the engine intake and exhaust valve setting procedure as outlined in this procedure. This procedure will be performed for preventative maintenance, after cylinder heads have been replaced or been rebuilt, or anytime the engine intake and exhaust valves have been determined valve lash needs to be checked.

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.

Setting the Engine Intake and Exhaust Valves.

With the engine stopped and not running:

The engine intake and exhaust valves are only to be set when the engine is not running and the engine has stopped rotating. Read through all the steps before attempting to readjust the intake or exhaust valves

Valve Lash Clearance:

Intake Valve: 0.015 + or - 0.004 inch

Exhaust Valve: 0.040 + or - 0.004 inch

Checking the Valve Lash

Measure the valve lash between the rocker arm and the valve bridge. Perform checks and adjustments with the engine stopped.

The valves must be fully closed.

To determine whether the valves are fully closed determine if the #1 cylinder is at Top Dead Center using the timing mark.

An adjustment is NOT NECESSARY if the valve lash is within the tolerance that is listed above.

If the measurement is not within tolerance, adjust the valve bridge and then adjust the valve.

Valve Bridge Adjustment

The valve bridge must be adjusted before the valve lash is adjusted.

The valve bridge can be adjusted without the removal of the rocker arms and shafts.

Use the following procedure to adjust the valve bridges:

1. Ensure that the Number 1 piston is at the top center (TC) position.

2. Work the appropriate cylinders that are listed in Testing and Adjusting. "Crankshaft Positions for Valve

4. Loosen locknut (1) and adjusting screw (2)

5. Press straight down on the rocker arm (4) at the contact point for the valve bridge (3). Turn the adjusting screw (2) clockwise until the screw just contacts the valve stem.

6. Tighten adjusting screw (2) for an additional 25 degrees in order to straighten the valve bridge onto the dowel.

This also compensates for slack in the threads of the adjustment screw.

7. Hold adjusting screw (2) in position and tighten locknut (1) to 35 lb ft

8. Insure that the valve lash is correct by inserting the appropriate feeler gauge between rocker arm (3) and wear seat (4).

Valve Lash Adjustment

1. The Valve Bridge must be adjusted properly before the valve lash is adjusted

2. Ensure that the Number 1 piston is at the top center (TC) position.

3. Work on the appropriate cylinders that are listed in Testing and Adjusting. "Crankshaft Positions for Valve

4. Loosen locknut (1) and adjusting screw (2)

5. Insert the appropriate feeler gauge between rocker arm (3) and wear seat (4).

6. Hold adjusting screw (2) in place and tighten locknut (1) to a torque of 22 lb ft plus or minus 3 lb ft

7. Verify setting is correct.

After Engine has been restarted:

1. Make sure engine is running smoothly after being restarted

2. Listen for any abnormal noise from engine.

3. Listen for any misfiring of an engine cylinder

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 Caterpillar G3406 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, and rotating equipment. Risk of possible concentration of H2S. Hazardous gases could be in the units pressure vessels, cooler, or associated piping and the 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

• Long handle ratchet

• Torque wrench that can properly torque from 22 lb ft up to 35 lb ft

Approvals

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by: