Service Information

Document Title: Function Group: Information Type: Date:

Valves, adjusting 214 Service Information 28/04/2014
Profile:
GRD, G960 [GB]

Valves, adjusting
Valve & EGR (Exhaust Gas Recirculation) actuator, adjusting - D7
NOTE!
This procedure covers adjustments for both the valves and the EGR actuators.

Op nbr 214-012

Total procedure time (hr): 4.00

Tools:
9998681 Rotation tool
885812 Timing tool

1. Place the machine in the service position. Refer to Service position

NOTICE
Never adjust the valves with the engine running as the valves may strike the piston and cause serious damage.

WARNING
Do not carry out any work on the machine before it has cooled down. Take care with hot liquids and machine parts.
Make sure that a fire extinguisher is at hand in case of fire.

NOTE!
The engine must be allowed to cool down for at least 30 minutes (oil temperature below 80°C) before adjusting the valve
clearance!

2. Open the engine compartment doors on both sides of the machine.

Remove the right side engine door, the right rear support post, the charge air piping system and the complete muffler
assembly from under the engine hood. Refer to Silencer, removing for complete instructions.

Figure 1
Muffler assembly removed
 NOTICE
Always cover open air connections with a plastic bag and rubber bands. Gravel, dust and other particles in these
connections may result in engine failure!

3. Depending on installed options, it may be necessary to disconnect and tie back hose lines running across the top of the
engine to gain access to the cable rail and valve cover assembly.

Figure 2
Hoses & clamps, removing
Carefully remove hose holders or cut plastic tie straps only as required to gain clear access to remove the cable rail and
valve cover.

4. Remove the screws from the cable rail assembly on the top of the valve cover and carefully pull the rail and cable
harness over to the left side of the valve cover.

Figure 3
Cable rail & Oil breather, removing

A. Cable rail
B. Oil breather

NOTICE
Clean round the valve cover, intercooler and turbo to avoid oil residue and the like from getting into the engine while
work is in progress.

5. Remove the screws from the oil breather and pull the assembly away from the front of the valve cover. Cover the
opening of the oil breather with a plastic bag and rubber bands to prevent contaminates from entering the system.

6. Remove the valve cover screws and lift the valve cover off of the engine.
 Figure 4
Valve cover removed

7. Remove the cover plate for the accessory drive on the engine near the cam sensor.

Figure 5
Accessory drive, cover removed

8. Install the special engine crankshaft turning tool into the accessory drive. 9998681 Rotation tool

9. Using the rotation tool, turn the engine crankshaft until the valves at cylinder #1 are on overlap.
NOTE!
Cylinder #1 is at the flywheel end of the engine.
 Figure 6
Cylinder #1 valve position 1 & 2 on overlap
1, 3, 5, 7, 9, & 11 are exhaust valves
2, 4, 6, 8, 10, & 12 are inlet valves
NOTE!
Valve overlap implies that the exhaust valve is near opening position and the inlet valve is near closing position. None
of the push rods at cylinder #1 should be capable of hand rotation in this position.

Figure 7
Valve overlap

10. Mark the crank sensor gear wheel position when valves at cylinder #1 are on overlap.

Figure 8
Crank sensor gear wheel marked
NOTE!
Do not turn the engine from this position until further instructions.

11. Remove the mounting bolts and lift both EGR actuator control units away from above the valve rockers to gain access
for adjusting the valves.
 Figure 9
EGR units, removing

A. EGR assembly, first section

B. EGR assembly, second section
C. EGR assembly, mounting bolts

NOTE!
Install M8 x 75mm - 10.9 bolts in the holes for both EGR units on the rocker arm holders. This will keep the rockers
aligned when adjusting the valves.

12. Adjust the valves according to the valve sequence diagram for cylinders #2 exhaust, #3 intake, #4 exhaust, #5 intake, #6
exhaust and #6 intake.

Figure 10
Valve sequence diagram for Cylinder #1 on overlap
Valve clearance adjustment procedure using the angle gauge 885812Timing tool:

1. Loosen the jamnut on the rocker arm adjusting screw.

Figure 11
Valve assembly, clearance adjustment at 'X'

1. Adjusting screw
2. Adjusting screw ball end
3. Valve & spring assembly
4. Adjusting screw jamnut
2. Install the angle gauge timing tool onto the rocker arm adjusting screw.
3. Use the tool (1) to turn the adjusting screw (2) clockwise until zero clearance is obtained between the rocker
arm and valve. Adjust the angle gauge on the tool (1) to read "0".

Figure 12
 (1) 885812 Timing tool, (2) Valve adjusting screws
3. Use the tool to turn the adjusting screw counterclockwise until the angle gauge reaches: 90° for inlet valves
and 150° for exhaust valves. Refer to Valve system, specification
4. Hold the rocker arm adjusting screw in position with the tool while tightening the jamnut.

Figure 13

1. 885812 Timing tool

2. Adjusting screw & jamnut
5. Repeat this adjustment procedure for each of the valves listed in the sequence diagram for cylinder #1 on
overlap.

13. After adjusting the valves with cylinder #1 on overlap, turn the engine 360° using the special cranking tool until the
valves at cylinder #6 are on overlap.
NOTE!
Observe the mark on the crank sensor gear wheel from step 10 to ensure full 360° rotation.

14. Adjust the valves according to the valve sequence diagram for cylinders #1 exhaust, #1 intake, #2 intake, #3 exhaust, #4
intake and #5 exhaust.
 Figure 14
Valve sequence diagram for Cylinder #6 on overlap
Repeat the procedure described under point 12 until all valves have been adjusted.
NOTE!
When the valve adjustment is completed, do not change the position of the engine crankshaft. Proceed directly with
reinstalling and adjusting the EGR actuator units.

Installing and adjusting the EGR actuator units:

15. Install and lubricate new O-rings on the pipe between the two EGR units.

Figure 15
EGR assembly, O-ring location
16. Remove the retaining bolts from the EGR units mounting holes that were installed in step 11, (to keep the rockers
aligned during valve adjustment).

17. Reinstall both EGR actuator control units and torque the mounting bolts to specification.

18. With the valves at cylinder #6 on overlap, adjust the EGR exhaust valve actuator for cylinders #1, #3 and #5.
EGR clearance adjustment procedure using the angle gauge timing tool: 885812 Timing tool

1. Loosen the jamnut on the EGR actuator assembly adjusting screw (3).

Figure 16
EGR adjusting

1. EGR actuator assembly

2. Exhaust valve adjuster
3. EGR adjusting screw

2. Install the angle gauge timing tool onto the actuator assembly adjusting screw.
3. Use the tool to turn the adjusting screw clockwise until zero clearance is obtained between the EGR exhaust
rocker arm and the actuator piston, Adjust the angle gauge to read "0".

Figure 17
 Inlet & Exhaust vlaves
4. Use the tool to turn the adjusting screw counterclockwise until the angle gauge reaches: 144° - exhaust rocker
arm to actuator piston clearance.
5. Hold the actuator arm adjusting screw in position with the tool while tightening the jamnut.

Figure 18
EGR adjusting

1. 885812 Timing tool

2. Adjusting screw & jamnut

6. Repeat this adjustment procedure for each of the EGR exhaust valve actuators listed in the sequence diagram.

19. After adjusting the EGR exhaust valve actuators with cylinder #6 on overlap, turn the engine 360° using the special
cranking tool until the valves at cylinder #1 are on overlap.
NOTE!
Observe the mark on the crank sensor gear wheel to ensure full 360° rotation.

20. Repeat the procedure from step 18 to adjust the EGR exhaust valve actuator for cylinders #2, #4 and #6.

21. Remove the engine cranking tool and reinstall the accessory drive cover plate.
 Figure 19
Accessory drive, cover installed

22. When all Valves and the EGR has been adjusted, reinstall the valve cover with a new gasket. Refer to Valve cover, fitting
new gasket each.

Figure 20
Valve cover, gasket installed

23. Install hose lines back along their proper routing and secure in position with clamps and plastic tie straps as required.

Figure 21
24. Reinstall the muffler assembly, the charge air piping system, the right rear support post and the right side engine door.
Refer to Silencer, installing for complete instructions.

25. Place the machine back into service.