Overhead Set
Contents
1. injector on the same cylinder With the set mark aligned with the pointer on the gear cover and both sets of valves closed on the cylinder loosen the locknuts on the intake and exhaust valve adjusting screws Back out the adjusting screws one or two turns select a feeler gauge for the correct valve lash specification Valve Lash Specification mm In Intake 0 36 NOM 0 014 Exhaust 0 69 NOM 0 027 Insert the feeler gauge between the top of the crosshead and the rocker lever nose pad Make sure the feeler gauge is completely under the pivoting rocker lever nose pad Tighten the adjusting screw Torque 0 6 5 in lb Value nm Page 10 of 14 9 04 09 10 11 AM Use a torque wrench and crows foot adapter to tighten the locknut Hold the adjusting screw in this position The adjusting screw must not turn when the locknut is tightened Torque 45 33 ft lb Value nm After tightening the locknut to the correct torque value remove the feeler gauge A CAUTION A To get maximum brake operating efficiency and to prevent engine damage the brake adjustment instructions must be followed For older engines locate the engine brake set marks on the outside of the vibration damper The set marks are BRAKE SET 1 6 and BRAKE SET 2 5 and BRAKE SET 3 4 BRAKE SET 1 6 Cylinder 1 or 6 adjust BRAKE SET 2 5 Cylinder 2 or 5 adjust BRAKE SET 3 4 Cylinder 3 or 4 adjust Page 11 of 14 Use the compressor drive2. or barring device to bar the engine over in the direction of rotation clockwise as viewed from the front of the engine Align the A mark on the vibration damper with the pointer on the gear cover For illustrative purposes position A is shown as the first step It is not necessary to start with position A as long as the proper sequence is followed Check the valve rocker levers on the given cylinder to see if both intake and exhaust valves are closed Both sets of valves are closed when the rocker levers and the brake lever are loose If both sets of valves are not closed rotate the compressor drive gear one complete revolution and align the A mark on the front damper with the pointer again Press the engine brake lever down to verify the camshaft follower is in contact with the camshaft Loosen the locknut on the brake lever adjusting screw and back out the adjusting screw one turn Insert the feeler gauge Part Number 3163530 between the bottom of the engine brake piston and the top of the exhaust valve pin on the exhaust valve crosshead Brake Lever Lash Specification mm in 7 00 NOM 0 276 Tighten the adjusting screw until drag on the feeler 9 04 09 10 11 AM Page 12 of 14 gauge is felt Proper drag means that there is no motion of the brake lever camshaft follower against the cam lobe Hold the engine brake lever adjusting screw and tighten the locknut Torque 20 177 in Value n m Ib Rem
3. 9 04 09 10 11 AM Overhead Set 003 004 Measure General Information All overhead lash measurements must be made when the engine is cold Stabilized coolant temperature must be at 60 C 140 F or below Remove the rocker lever cover Make sure the engine base timing is properly set before attempting to measure adjust or set the overhead Early engine vibration dampers are marked with BRAKE SET 1 6 BRAKE SET 2 5 or BRAKE SET 3 4 The engine brakes must be set at the appropriate mark on these engines Newer engine vibration dampers are marked with only A B or C and are adjusted with the valves and injector on the same cylinder Locate the valve set marks on the outside of the vibration damper Page 1 of 14 The set marks are A B and C Set to mark A to adjust cylinder 1 or 6 Set to mark B to adjust cylinder 2 or 5 Set to mark C to adjust cylinder 3 or 4 Two complete revolutions are required to set all valves engine brakes and injectors If the engine is equipped with an air compressor Remove the oil fill connector from the lower gear case cover Insert a 3 4 inch drive ratchet and extension into the air compressor drive Rotate the air compressor drive clockwise as viewed from the front of the engine A WARNING A Do not pull or pry on the fan to manually rotate the engine To do so can damage the fan blades Damaged fan blades can cause premature fan failures which can result in se
4. adjusting screw locknut on the cylinder Do not use a click type torque wrench 9 04 09 10 11 AM Page 8 of 14 Use a dial type torque wrench with a range of O to 150 in lb to tighten the injector rocker lever adjusting screw If the screw chatters during setting repair the screw and lever as required Back out the adjusting screw one or two turns Hold the torque wrench in a position that allows you to look in a direct line at the dial This is to make sure the dial will be read accurately Make sure the parts are aligned and squeeze the oil out of the valve and injector train by tightening the adjusting screw Use this initial adjustment to preload the valve train and injector Tighten the injector lever adjusting screw Torque 71 in lb Value nm Back the adjusting lever screw out 1 or 2 turns Tighten the injector lever adjusting screw Torque 71 in lb Value Hold the injector lever adjusting screw and tighten the adjusting screw locknut Torque 75 55 ft lb Value n m After setting the injector on a cylinder set the valves and engine brakes on the same cylinder Early engine vibration dampers are marked with BRAKE SET 1 6 BRAKE SET 2 5 or BRAKE SET 3 4 The engine brakes must be set at the appropriate mark on these engines Newer engine vibration 9 04 09 10 11 AM Page 9 of 14 9 04 09 10 11 AM dampers are marked with only A B or C and are adjusted with the valve and
5. ive purposes position A is shown as the first step It is not necessary to start with position A as long as the proper sequence is followed Use the compressor drive or barring device to bar the engine over in the direction of engine rotation clockwise as viewed from the front of the engine Align the A mark on the vibration damper with the pointer on the gear cover Check the valve rocker levers on the given cylinder to see if both intake and exhaust valves are closed Both sets of valves are closed when the rocker levers and the brake lever are loose If both sets of valves are not closed rotate the compressor drive gear one complete revolution and align the A mark on the front damper with the pointer again Valve Lash Use feeler gauges to measure the amount of clearance lash between the crosshead and the rocker lever nose Measure and record the intake exhaust and brake valve lash If the valve lash is not within the specifications listed below the valve must be adjusted See the adjust step in this procedure Press the brake lever down to verify the camshaft follower is in contact with the camshaft prior to measurement of the brake lash ISX OSX Series Valve Lash Recheck Limits intake ozs mm minimum ooon 9 04 09 10 11 AM Page 4 of 14 9 04 09 10 11 AM Brake 7 13 mm maximum 0 281 In Brake Running Clearance Rotate the brake lever to the detent neutral position Check the clearance bet
6. lve rocker lever 3 The engine brake rocker lever 4 The intake valve rocker lever is always the long lever on the valve rocker lever shaft Early engine vibration dampers are marked with BRAKE SET 1 6 BRAKE SET 2 5 or BRAKE SET 3 4 The engine brakes must be set at the appropriate mark on these engines Newer engine vibration dampers are marked with only A B or C and are adjusted with the valves and injector on the same cylinder The valves brakes and injectors on the same cylinder are adjusted at the same index mark on the vibration damper injector o 9 04 09 10 11 AM Page 7 of 14 tei ie Advance to A le e e Firing Order 1 5 3 6 2 4 NOTE For illustrative purposes position A is shown as the first step It is not necessary to start with position A as long as the proper sequence is followed Use the compressor drive or barring device to bar the engine over in the direction of engine rotation clockwise as viewed from the front of the engine Align the A mark on the vibration damper with the pointer on the gear cover Check the valve rocker levers on the given cylinder to see if both intake and exhaust valves are closed Both sets of valves are closed when the rocker levers and the brake lever are loose If both sets of valves are not closed rotate the compressor drive gear one complete revolution and align the A mark on the front damper with the pointer again Loosen the injector
7. ove the feeler gauge A CAUTION A Engine damage can occur if the running clearance is not within specifications Check the running clearance O Rotate the engine brake rocker lever to the detente neutral position 1 Check the clearance 1 between the engine brake lever actuator piston and the crosshead guide pin Engine Brake Rocker Lever Running Clearance mm in 0 635 MIN 0 025 2 790 MAX 0 110 If the running clearance does not meet specification loosen but do not remove the rocker shaft capscrews and rotate the shaft in the direction required to bring the running clearance within the listed specification It is critical that this clearance be set and verified on all six brake levers Engine damage can result if this task is not completed Check the brake running clearance Ne 9 04 09 10 11 AM Page 13 of 14 9 04 09 10 11 AM The rocker lever shafts must be adjusted so that all three engine brake levers fall within the given running clearance specification Repeat the process to adjust all injectors engine brakes and valves according to the chart shown below jz ei i favenceto a C E Firing Order 1 5 3 6 2 4 Last Modified 28 Apr 2008 Page 14 of 14
8. ration damper The set marks are A B and C Set to mark A to adjust cylinder 1 or 6 Set to mark B to adjust cylinder 2 or 5 Set to mark C to adjust cylinder 3 or 4 Two complete revolutions are required to set all valves engine brakes and injectors If the engine is equipped with an air compressor Remove the oil fill connector from the lower gear case cover Insert a 3 4 inch drive ratchet and extension into the air compressor drive Rotate the air compressor drive clockwise as viewed from the front of the engine A WARNING A Do not pull or pry on the fan to manually rotate the engine To do so can damage the fan blades Damaged fan blades can cause premature fan failures which can result in serious personal injury or property damage The crankshaft rotation is clockwise as viewed from the front of the engine The cylinders are numbered from the front of the 9 04 09 10 11 AM Page 6 of 14 engine 1 2 3 4 5 6 The engine firing order is 1 5 3 6 2 4 If the engine is not equipped with an air compressor Loosen the capscrews and rotate the cover or remove the oil fill tube if equipped Use a 1 inch socket to push the barring gear into the gear mesh and rotate the barring adapter counterclockwise to bar the engine Rock the barring device back and forth until it disengages Each cylinder has four rocker levers The exhaust valve rocker lever 1 The injector rocker lever 2 The intake va
9. rious personal injury or property damage The crankshaft rotation is clockwise as viewed from the front of the engine The cylinders are numbered from the front of the engine 1 2 3 4 5 6 The engine firing order is 1 5 3 6 2 4 If the engine is not equipped with an air compressor Loosen the cover plate capscrews and rotate the cover or remove the oil fill tube if equipped 9 04 09 10 11 AM Page 2 of 14 Use a 1 inch socket to push the barring gear into the gear mesh and rotate the barring adapter counterclockwise to bar the engine Rock the barring device back and forth until it disengages Each cylinder has four rocker levers The exhaust valve rocker lever 1 The injector rocker lever 2 The intake valve rocker lever 3 The engine brake rocker lever 4 The intake valve rocker lever is always the long lever on the valve rocker lever shaft Early engine vibration dampers are marked with BRAKE SET 1 6 BRAKE SET 2 5 or BRAKE SET 3 4 The engine brakes must be set at the appropriate mark on these engines Newer engine vibration dampers are marked with only A B or C and are adjusted with the valves and injector on the same cylinder The valves brakes and the injectors on the same cylinder are adjusted at the same index mark on the vibration damper js ei i Advance to A le e e I 9 04 09 10 11 AM Page 3 of 14 Firing Order 1 5 3 6 2 4 NOTE For illustrat
10. ween the engine brake actuator piston and the cross head guide pin 1 If the brake running clearance is not within the specifications listed below the running clearance must be adjusted See the Adjust step in this procedure Brake Running Clearance mm in 0 635 MIN 0 025 2 79 MAX 0 110 Injector Lash There is no service procedure to check the injector free load Install the rocker lever cover Adjust Read the entire procedure for overhead adjustment before attempting to perform this operation Valves injectors and engine brakes if equipped must be correctly adjusted for the engine to operate efficiently Valve injector and engine brake adjustment must be performed using the values listed in this section After an engine rebuild or any major repair where the injector and valve setting must be disturbed set all of the valves injectors and brakes Valve Brake and Injector Adjustment Values Injector Adjustment is 8 Nem 70 in Ib Intake Valve 0 35 mm 0 014 in Page 5 of 14 Exhaust Valve 0 68 mm 0 027 in Engine Brake 7 00 mm 0 276 in Early engine vibration dampers are marked with BRAKE SET 1 6 BRAKE SET 2 5 or BRAKE SET 3 4 The engine brakes must be set at the appropriate mark on these engines Newer engine vibration dampers are marked with only A B or C and are adjusted with the valves and injector on the same cylinder Locate the valve set marks on the outside of the vib
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