ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 004-015   Tappet

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

NOTE: On Marine applications, prior to starting this procedure, make sure that there is adequate clearance in front of the engine. This procedure requires the camshaft to be removed. Make sure there is adequate clearance from the front gear housing face to any obstruction in the camshaft area to remove the camshaft. If there is not enough clearance, the engine must be removed from the vessel.

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Remove the crankcase breather tube and drain tube, external crankcase breather only. Refer to Procedure 003-018 in Section 3.
• Remove the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Remove the engine brake assembly, if equipped. Refer to Procedure 020-004 in Section 20.
• Remove the rocker levers. Refer to Procedure 003-008 in Section 3.
• Remove the push rods or tubes. Refer to Procedure 004-014 in Section 4.
• Remove the belt guard, if equipped. Refer to Procedure 008-001 in Section 8.
• Remove the drive belt. Refer to Procedure 008-002 in Section 8.
• Remove the vibration damper.Refer to Procedure 001-052 in Section 1.
• Remove the gear cover.Refer to Procedure 001-031 in Section 1.

Use tappet removal tool kit, Part Number 3822513, to remove the tappets.

Push a wooden dowel rod into each tappet. It will probably be necessary to push the dowel into the tappet with a soft-face hammer.

Pull each valve tappet up until it makes contact with the cylinder block. Put a rubber band around two dowels. This will hold the tappets up off the camshaft.

Remove the camshaft. Refer to Procedure 001-008 in Section 1.

Insert the trough to the full length of the camshaft bore.

Make sure the trough is positioned so it will catch the tappet when the wooden dowel is removed.

Only remove one (1) tappet at time. Remove the rubber band from the two (2) companion tappets, securing the tappet not to be removed with the rubber band.

Pull the wooden dowel from the tappet bore and allow the tappet to fall into the trough.

When the tappet is dropped into the trough, most of the time it will fall over. However, if it doesn’t, gently shake the trough just enough to allow the tappet to fall over before removing.

When removing the Number 6 cylinder tappets, special care must be taken not to knock or shake the tappet over the end of the trough.

Carefully pull the trough and tappet from the camshaft bore and remove the tappet. Repeat the process until all tappets are removed.

Mark each tappet to indicate its location if the tappets are to be reused.

Use tappet removal tool kit, Part Number 3165088, to remove the tappets.

Insert the tappet extractor tool (2) into the tappet bore. Turn the top knob counterclockwise while holding the bottom knob to expand and secure the tool into the tappet.

Raise the tappet extractor (2) until it stops, and push the metal tab down against the head surface to secure the tool and captured tappet in the up position.

Repeat for the remaining tappets.

Remove the camshaft. Refer to Procedure 001-008 in Section 1.

Make sure the holes are in the up position.

Insert the tappet holder to the full length of the camshaft bore.

Lower the tappet extractor, and seat the tappet into the tappet holder. Turn the top knob clockwise while holding the bottom knob to disengage the extractor from the tappet. Repeat the step for the remaining tappets.

Carefully pull the tappet holder and tappets from the camshaft bore. If the tappets will be reused, be sure to note their position. Do not install a tappet in a different position.

Inspect the socket, stem and face for excessive wear, cracks and other damage.

Pit marks on the tappet face are acceptable.

The following criteria defines the size of the pits allowed.

1. A single pit can not be greater than 2 mm [0.078 in].
2. Interconnection of pits is not allowed.
3. Total pits when added together must not exceed 6 mm [0.236 in] diameter or a total of 4 percent of the tappet face.
4. No pitting is allowed on the edges of the wear face of the tappet.

Measure the valve tappet stem.

Valve Tappet Stem Diameter

Inspect the tappet body for cracks or other damage.

Inspect the roller for flat spots or pitting. Refer to Camshaft Reuse Guidelines for Cummins® Engines with Roller Followers or Roller Tappets, Bulletin 3666052. If excessive wear is found, replace the tappet, and inspect the camshaft.

The roller must rotate freely. If it does not, replace the tappet.

Inspect the tappet body guide screw groove for damage.

If damage to the groove is found, remove the guide screw from the cylinder block.

Inspect the guide screw and guide screw hole for thread condition and cracks.

NOTE: Damage to the tappet body guide screw is not common.

Install the tappet guide screw and tighten.

CAUTION  Anytime a camshaft or tappets are replaced in a B or C series engine with sliding tappets, that has more than 250 hours or 5000 miles, the camshaft, tappets, and push tubes must be replaced with new.

Insert the trough the full length of the camshaft bore.

Do not use worn tappets with a new camshaft.

Lower the tappet installation tool down the push tube hole, through the tappet bore, and into the trough.

Feed the installation tool through the camshaft bores by carefully pulling the plastic trough or installation tool out the front. The barrier at the rear of the trough will pull the tool out most of the time.

Lubricate the tappets with Lubriplate™ 105, Part Number 3163087, or equivalent.

Insert the installation tool into the tappet.

To aid in removing the installation tool after the tappet is installed, work the tool in and out of the tappet several times before installing the tappets.

Slide the trough into the camshaft bore.

Pull the tool and tappet through the camshaft bore and up into the tappet bore.

If difficulty is experienced in getting the tappet to make the bend from the trough up to the tappet bore, pull the trough out enough to allow the tappet to drop down and align itself, then pull the tappet up into the bore.

After the tappet has been pulled up into position, slide the trough back into the camshaft bore and rotate it one-half turn. This will position the round side of the trough up, and will hold the tappet in place.

Remove the installation tool from the tappet.

Install a wooden dowel into the top of the tappet. Wrap rubber bands around the wooden dowels to secure the tappets.

Repeat this process until all tappets have been installed.

Install the camshaft. Refer to Procedure 001-008 in Section 1.

Lubricate the tappets with Lubriplate™ 105, Part Number 3163087, or equivalent.

Make sure the tappets are installed with the pin slots toward the outside of the block.

Insert the tappets into the tappet holder.

NOTE: If the tappets are being reused, be sure to install them in their original position.

Insert the tappet holder the full length of the camshaft bore.

Insert the tappet extractor tool (2) into the tappet bore. Turn the top counterclockwise to expand and secure the tool into the tappet.

Raise the tappet extractor (2) until it stops, and push the metal tab down against the head surface to secure the tool in the up position.

NOTE: Some manipulation may be necessary to get the tappet to enter the bore. When the tappet enters the bore, attempt to rotate the extractor while applying light upward pressure. If the tool will not rotate, the tappet has engaged the guide pin. If the tool does rotate, continue until the tappet engages the guide pin.

Repeat for the remaining tappets.

Remove the tappet holder.

Install the camshaft. Refer to Procedure 001-008 in Section 1.

Lower the tappet extractor, and seat the tappet into the camshaft. Turn the top knob clockwise while holding the bottom knob to disengage the extractor from the tappet. Repeat the step for the remaining tappets.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the gear cover. Refer to Procedure 001-031 in Section 1.
• Install the vibration damper. Refer to Procedure 001-052 in Section 1.
• Install the drive belt. Refer to Procedure 008-002 in Section 8.
• Install the belt guard, if equipped. Refer to Procedure 008-001 in Section 8.
• Install the push rods or tubes. Refer to Procedure 004-014 in Section 4.
• Install the rocker levers. Refer to Procedure 003-008 in Section 3.
• Adjust the valves. Refer to Procedure 003-004 in Section 3.
• Install the engine brake assembly, if equipped. Refer to Procedure 020-004 in Section 20.
• Install the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Install the crankcase breather tube and drain tube, external crankcase breather only. Refer to Procedure 003-018 in Section 3.
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Operate the engine and check for leaks.