M11 Plus Series Engines Operation and Maintenance Manual – 003-004   Overhead Set

All valve and injector adjustments must be made when the engine is cold (any stabilized coolant temperature at 60°C [140°F] or below).

Remove the rocker lever cover and gasket.

WARNING  Do not straighten a bent fan blade or continue to use a damage fan. A bent or damaged fan blade can fail during operation and cause personal injury or property damage.

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

Use the accessory driveshaft to rotate the crankshaft.

The crankshaft rotation is clockwise when viewed from the front of the engine.

The cylinders are numbered from the front gear housing end of the engine.

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

Each cylinder has three rocker levers:

• The long rocker lever (E) is the exhaust lever.
• The center rocker lever is the injector lever.
• The short rocker lever (l) is the intake lever.

Reference the accompanying graphic for valve rocker lever locations.

The adjustment can begin on any valve set mark. In the following example, the adjustment will begin on the “A” valve set mark with cylinder number 1 valves closed and ready for adjustment.

Rotate the accessory drive clockwise until the “A” valve set mark on the accessory drive pulley is aligned with the pointer on the gear cover.

When the “A” mark is aligned with the pointer, the intake and exhaust valves for cylinder number 1 must be closed. If these conditions are not correct, cylinder number 6 injector and valves must be ready to set. Set the injector and valves on the cylinder so that both the intake and exhaust valve rocker lever arms are loose and can be moved from side-to-side.

Both valves are closed when both rocker levers are loose and can be moved from side-to-side.

NOTE: Do not use excessive force when bottoming the plunger.

Loosen the injector adjusting screw locknut. Using a screwdriver (box end wrench if equipped with engine brakes) and the adjusting screw, bottom the injector plunger three or four times to remove the fuel.

Turn the adjusting screw in until you can feel it just bottom the plunger.

Back out the adjusting screw two flats, 120 degrees. Hold the adjusting screw, and tighten the locknut.

After setting the injector, set the valves on the same cylinder.

With the “A” valve set mark aligned with the pointer on the gear cover and both valves closed on the cylinder to be adjusted, loosen the adjusting screw locknuts on the intake and exhaust valves.

Select a feeler gauge for the correct valve lash specification.

Insert the feeler gauge between the top of the crosshead and the rocker lever pad.

Two different methods for establishing valve lash clearance are described below. Either method can be used; however, the torque wrench method has proven to be the most consistent. It eliminates the need to feel the drag on the feeler gauge.

• Torque Wrench Method: Use the inch-pound torque wrench, Part Number 3376592, or equivalent, normally used to set preload on top-stop injectors, and tighten the adjusting screw.

• Touch Method: Tighten the adjusting screw until a slight drag is felt on the feeler gauge.

Hold the adjusting screw in this position. The adjusting screw must not turn when the locknut is tightened.

• Without torque wrench adapter

• With torque wrench adapter, Part Number 3163196, or equivalent

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.

If using the touch method, attempt to insert a feeler gauge that is 0.03-mm [0.001-in] thicker between the crosshead and the rocker lever pad. The valve lash is not correct when a thicker feeler gauge will fit.

If the engine is equipped with an engine brake.

After adjusting the injector, valves, and engine brakes (if equipped) on the appropriate cylinder, rotate the accessory drive pulley, and align the next valve set mark with the pointer on the gear cover.

If the valve cover gasket was not damaged, it can be used again. If the gasket was damaged, it must be discarded and a new one used.

Install the gasket on the cover.

Install the cover on the rocker lever housing.

Install the 16 isolators, spacers, and capscrews in the cover.

Tighten the capscrews in the sequence shown.

NOTE: To obtain maximum brake operating efficiency and prevent engine damage by piston-to-valve contact, complete the following instructions carefully.

After adjusting the exhaust valves on the appropriate cylinder, insert a feeler gauge 0.38 mm [0.015 in] between the slave piston and the actuating pin in the crosshead.

CAUTION  Do not tighten the adjusting screws too tightly. The engine can be damaged.

Turn the slave piston adjusting screw down until it touches the feeler gauge.

Hold the screw in position, and tighten the locknut.

• Without torque wrench adapter

• With torque wrench adapter, Part Number 3163196, or equivalent:

CAUTION  Failure to have the correct clearance can damage the engine.

After the slave piston adjusting screw locknut is tightened to the correct torque value, check the clearance with the feeler gauge again.