Rocker Lever Assembly Page 1 sur 16

003-009 Rocker Lever Assembly

Preparatory Steps

Remove the air piping

from the intake
manifold.
Remove the rocker
lever cover. Refer to
Procedure 003-011 in
Section 3.
Remove the engine
brakes, if equipped.
Refer to Procedure
020-024 in Section 20.
Remove the push rods
and push tubes. Refer
to Procedure 004-014
in Section 4.

Remove

NOTE: This action applies

only to engines built with
cast-iron supports.

Install a piece of 1/4-inch key

stock 457 mm [18 in] long on
top of the four front rocker
lever assembly supports.
Use four M10 - 1.50 x 25
flange head capscrews to
secure the bar stock to the
supports.

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The capscrews on the two

end supports fasten to the
engine brake mounting holes
on one side of the bar stock.
The capscrews on the two
center supports fasten to the
engine brake mounting holes
on the opposite side of the
bar stock.

Loosen, but do not remove,

the eight rocker shaft
capscrews. The capscrews
hold the rocker lever
assemblies together.

NOTE: Engines with cast-

iron supports: Grasp the
bar stock and lift the front
rocker lever assembly
from the engine. Do not lift
the assemblies by
grasping the rocker levers
and shaft. The shaft and
levers can lift out of the
supports allowing the
levers to slide off the
shaft.

NOTE: Engines with

aluminum supports: Grasp
the assembly by the rocker
levers and shaft and lift
them from the engine. The
shafts can not lift out of
the supports.

Repeat the process to

remove the rear rocker lever
assembly.

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Remove the crossheads.

NOTE: Be sure to note the

crosshead location so they
can be installed in the
same location.

Disassemble

Mark each rocker lever,

shaft, and support with their
relative position in the
engine.

The rocker lever assemblies

must be installed in the
same position from which
they were removed.

Remove the rocker shaft

capscrews (1) and retaining
blocks (2).

If the supports are cast-iron,

lift the shaft and levers out of
the supports (3).

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If the supports are

aluminum, slide the end
supports and levers off the
end of the shafts.

Remove the rocker levers (4)

from both shaft assemblies.

Remove the locknuts and

the adjusting screws from
each rocker lever.

Clean

WARNING
When using a steam
cleaner, wear safety glasses
or a face shield, as well as

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protective clothing. Hot

steam can cause serious
personal injury.

WARNING
Wear appropriate eye and
face protection when using
compressed air. Flying
debris and dirt can cause
personal injury.

Use steam or solvent to clean

the parts. Dry with compressed
air.

Be sure to blow out the oil

passages.

Inspect the rocker levers for

cracks, excessive pitting, or
unusual wear.

Inspect the adjusting screws

and locknuts for damaged
threads.

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Inspect the adjusting screw

threads in the rocker levers
for damaged threads.

Measure each rocker lever

bushing bore inside
diameter.

Rocker Lever Bushing

Inside Diameter
(Installed)
mm in
34.887 MIN 1.3735
34.990 MAX 1.3776

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Inspect the rocker lever

shafts for pitting, scoring, or
other damage.

Measure each rocker lever

shaft outside diameter.

Rocker Lever Shaft

Outside Diameter
mm in
34.837 MIN 1.3715
34.864 MAX 1.3726

If worn or damaged parts are

found, or the rocker lever
bushings or shafts are not
within the specifications
given, the rocker lever
assemblies must be rebuilt.

Inspect the sockets in the

injector rocker levers for
wear or damage.

Inspect the valve rocker lever

pads for wear, cracks, or
other damage.

If wear, cracks, or other

damage is found, the rocker
lever must be replaced.

Use crack detection kit, Part

Number 3375432, to inspect
the rocker lever supports for
cracks or damage.

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WARNING
Wear appropriate eye and
face protection when using
compressed air. Flying
debris and dirt can cause
personal injury.

Use crack detection cleaner,

Part Number 3375433, to clean
the rocker levers and shaft
supports. Dry with compressed
air.

Use crack detection

penetrant, Part Number
3375435, to spray the rocker
levers and shaft supports.

NOTE: Do not dry with

compressed air.

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Allow the penetrant to dry for 15

minutes.

Remove the excess penetrant

with a dry cloth.

Use crack detection

developer, Part Number
3375434, to spray the rocker
levers and shaft supports.

Inspect the levers and

supports.

Cracks will appear as a solid,

bright line.

Cavitation in the casting will

appear as a small round
mark.

If cracks or cavitation are

found, the part must be
replaced.

Assemble

CAUTION

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Make sure the rocker lever

shafts are installed with the
arrow on the end of the
shafts pointing DOWN.
When the arrow points up,
cross-drilling to the rocker
levers are orientated
differently, which has an
adverse affect to rocker lever
oiling.

The rocker lever shafts are

labeled front (or "F") and rear
on the end of the shafts (1). The
arrows on the shafts (2) must
be pointed downward to
maintain an oil flow to the
rocker levers.

The shaft end supports are not

interchangeable.

Use clean 15W-40 engine oil

to lubricate both shafts.

On cast-iron supports, install

the shaft into the front end
support. Install the retaining
block, washer, and capscrew
through the support.

On aluminum supports,
install the support by sliding
it onto the end of the shaft.
Install a washer and
capscrew through the
support.

Install the rocker levers in

the correct sequence, as
shown.

NOTE: The rocker levers

must be installed so they
will be in the same
position in the engine as

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when they were removed.

Install one of the two shaft

center supports on the shaft.

On cast-iron supports, install

the retaining block, washer,
and capscrew through the
center support.

Install the remaining levers

and supports with the intake
(l) and exhaust (E) valve
levers in the correct position,
as shown.

On cast-iron supports, install

the remaining retaining
blocks, washers, and
capscrews.

On cast-iron supports only,

install the key stock used to
remove the rocker levers on
top of the supports.

Install

The rocker lever assemblies

must be installed in the
engine so they are in the
same position as they were
removed from.

Install the assemblies on the

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engine.

NOTE: Hand-tighten the

mounting capscrews. The
rocker lever side clearance
must be adjusted before
the capscrews are
tightened to their final
torque value.

Rocker Lever Installation

Side Clearance
mm in
0.50 NOM 0.020

Push or use a hammer to tap

the number 5 rocker lever
support toward the front of
the engine.

Tighten the mounting

capscrews to 5 N•m [44 in-
lb].

Install a 0.50 mm [0.020 in]

feeler gauge between the
number 5 support and the
intake lever for the number 4
cylinder.

Push or use a hammer to tap

the number 6 support toward
the front of the engine.

Tighten the mounting

capscrews to 5 N•m [44 in-
lb].

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Install a 0.50 mm [0.020 in]

feeler gauge between the
number 6 support and the
exhaust lever for the number
5 cylinder.

Push or use a hammer to tap

the number 7 support toward
the front of the engine.

Tighten the mounting

capscrews to 5 N•m [44 in-
lb].

Install a 0.5 mm [0.020 in]

feeler gauge between the
number 7 support and the
intake lever for the number 6
cylinder.

Push or use a hammer to tap

the number 8 support toward
the front of the engine.

Tighten the number 5, 6, 7,

and 8 support capscrews to
their final torque value.

Torque
Value: 122 n.m [90 ft-lb]

Push or use a hammer to tap

the number 4 support toward
the rear of the engine.

Tighten the mounting

capscrews to 5 N•m [44 in-
lb].

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Install a 0.50 mm [0.020 in]

feeler gauge between the
number 4 support and the
intake lever for the number 3
cylinder.

Push or use a hammer to tap

the number 3 support toward
the rear of the engine.

Tighten the mounting

capscrews to 5 N•m [44 in-
lb].

Install a 0.50 mm [0.020 in]

feeler gauge between the
number 3 support and the
exhaust lever for the number
2 cylinder.

Push or use a hammer to tap

the number 2 support toward
the rear of the engine.

Tighten the mounting

capscrews to 5 N•m [44 in-
lb].

Install a 0.50 mm [0.020 in]

feeler gauge between the
number 2 support and the
intake lever for the number 1
cylinder.

Push or use a hammer to tap

the number 1 support toward
the rear of the engine.

Tighten the number 1, 2, 3,

and 4 support capscrews to

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their final torque value.

Torque
Value: 122 n.m [90 ft-lb]

Check the front and rear

assemblies for the correct
clearance. Check the
support capscrews for the
correct torque value.

Install the valve crossheads.

NOTE: The crossheads

must be installed in the
same location from which
they were removed.

Engines Equipped with

Engine Brakes:

Install the six engine brake

crossheads on the exhaust
valves. Verify the actuator
pins are facing the camshaft
side of the engine.

Verify the crossheads are

fully seated on the valve
stems.

Finishing Steps

Install the push rods

and push tubes. Refer
to Procedure 004-014
in Section 4.
Adjust the valves and
injectors. Refer to
Procedure 003-004 in
Section 3.
Install the engine

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brakes, if applicable.
Refer to Procedure
020-024 in Section 20.
Install the rocker lever
cover. Refer to
Procedure 003-011 in
Section 3.
Install the air piping to
the intake manifold.
Refer to the
manufacturer's
specifications for the
correct torque value.
Operate the engine
and check for proper
operation.

Last Modified: 11-Feb-2009

Copyright © 2000-2010 Cummins Inc. All rights reserved.

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