21/10/2023, 18:12 QuickServe Online | (4021375) QSK23 Troubleshooting and Repair Manual

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Select Service Tools

Recommended Cummins® Service Tools
Dial indicator, Part Number 3824564
Overheard adjustment kit, Part Number 5298979
Additional Service Items
Feeler gauge
Magnetic block with extension arm

General Information
Cummins Inc. has found that engines in most applications
will not experience significant valve/injector train wear. It is
recommended that the valve and injector adjustment be
performed only when the injectors are removed, when other
repairs disturb the valve train, or, when the valves or
injectors are checked and found out of adjustment.

Valves and injectors must be correctly adjusted for the

engine to operate efficiently. Valves and injector adjustment
must be performed using the values listed in this section.

Injector and Valve overhead must be checked for clearance

at specified maintenance interval. Use the following section
in the QSK23 Operation and Maintenance Manual, Bulletin
4021374. Refer to Section 6.

The cylinders are numbered from the front of the engine.

Firing order for the QSK23 engine is 1-5-3-6-2-4.

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The crankshaft rotation is clockwise when viewed from the

front of the engine.

Each cylinder has three rocker levers. When facing the

cylinder head from the intake side of the engine, the lever on
the left is the intake rocker lever, and the lever on the right is
the exhaust rocker lever. The center rocker lever is for the
injector.

The engine has valve and injector adjustment marks on the

vibration damper.

Valve and injector marks must be aligned with the pointer, or

a false adjustment can occur.

One pair of valves and one injector are adjusted at each

vibration damper index mark.

Two crankshaft revolutions are required to adjust all of the

valves and injectors.

This illustration shows the engine barring device. To use the

device, remove the clip and push the device towards the
flywheel. The barring device must be rotated
counterclockwise to turn the flywheel and crankshaft in the
direction of normal rotation.

Preparatory Steps
Remove the rocker lever covers. Refer to Procedure
003-011 (Rocker Lever Cover) in Section 3.
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Measure
Remove the retaining clip on the barring device and using
the barring device, rotate the crankshaft in the direction of
normal rotation until the pointer on the front of the engine
aligns with the 1 to 6 top line on the crankshaft pulley.
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Refer to vibration damper mark determination chart in this

procedure.

Cylinder number one should now be at top dead center

compression. With the piston in this position both valves are
closed and the valve rocker arms for cylinder number one
should be loose. Observe the injector pushrods for cylinders
two and five. Cylinder two injector pushrod should be higher
and the injector plunger bottomed in the cup. If this is the
case, the valves on cylinder one can be checked and the
injector lift is done on cylinder two. If the valves are not loose
on cylinder number one, check the valves on cylinder six.
Those valves should be loose and number five injector
pushrod should be higher than two. If this is true check the
injector lift on cylinder two and the valves on number one.

Injector Lift:

To determine which cylinder is ready for checking, identify

the cylinders that would be in position for injector lift
checking, refer to the Valve and Injector Adjustment
Determination chart in this procedure. For example, if the
engine was barred to the “1.6 TOP” mark, cylinder 2 or 5
would be in position for injector plunger lift check.

To check injector plunger lift the engine cylinder 1 and 6

must be at Top Dead Center (TDC).

Set dial gauge (1) to the head of the plunger to be checked.

Use dial gauge with a stroke of at least 30 mm or 1.181 in.

Crank the crankshaft and measure lift (see letter “c”) of the
plunger at the point where deflection on the dial gauge is
maximum. If measurement is not within specified value, go
to Adjust section in this procedure.

If injector lift “c” is within specified value, proceed to Valve

Check.

Valve Lash:

To determine which cylinder valve is ready for checking,

identify the cylinders that would be in position for valve
checking, refer to the Valve and Injector Adjustment
Determination chart in this procedure. For example, if the

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engine was barred to the “1.6 TOP” mark, cylinder 1 or 6

would be in position for intake and exhaust valve clearance
check.

The engine must be cold to perform the overhead set

checking procedure.

Select a feeler gauge for the correct valve lash specification.

Valve Clearance - Check

mm in
Exhaust
0.60 MIN 0.024
valves (A)
0.64 MAX 0.025
Intake
0.30 MIN 0.012
valves (B)
0.34 MAX 0.013

Insert the feeler gauge between the top of the crosshead and
the rocker lever nose pad. Verify the feeler gauge is
completely under the pivoting rocker lever nose pad.

Continue Checking Injector Lift and Valve Clearance:

Bar the engine to next damper timing mark and (refer to the chart in this procedure) to the
determine the next injector cylinder and valve cylinder to check . If the rocker lever assemblies
were not removed, identify the cylinders that are in position for injector plunger lift check. On
these two cylinders, identify the injector push rod which is higher in relation to the top of the
rocker lever housing. This is the cylinder ready for injector lift checking. Refer to the chart in
this section to determine the corresponding valve clearance check cylinder. Repeats steps
above until all cylinders are checked for injector lift and valve clearance.

Once all injector plunger lift and valve clearance checks have been found to be within
specification in this procedure, proceed to Finishing Steps section. If injector plunger or valve
clearance does not meet specification, proceed to the Adjust section for adjusting the
overhead.

Adjust
If the rocker lever assemblies were removed for this repair,
use this step to determine the correct cylinder to set.

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Lubricate the adjusting screw threads with clean engine oil

prior to making valve and injector adjustments.

All adjusting screws must be loose on all cylinders and the

push rods must remain in alignment.

Bar the engine to the next valve set mark on the damper.
Setting can begin on any valve set mark.

To determine which cylinder is ready for setting, identify the

cylinders that would be in position for injector setting, refer to
the chart in this procedure. For example, if the engine was
barred to the “1.6 TOP” mark, cylinder 2 or 5 would be in
position for injector setting.

For these two cylinders, turn the injector adjusting screws

and locknuts down until the injector rocker is in contact with
the push rod and injector link. Perform the injector setting on
the cylinder which has the most visible threads above the
locknut on the injector adjusting screw.

Prior to barring the engine, the injector which had less visible
threads and was not set in the previous step must have the
injector adjusting screw backed out until there are at least as
many threads above the adjusting nut as for the injector that
was set.

To determine which cylinder is ready for valve setting, refer

to the chart in this section and identify the cylinder which
corresponds to the injector set cylinder from the previous
step. For example, if cylinder 2 injector was set, then cylinder
1 would be ready for valve setting.

Note : The engine must be cold to perform the

overhead set procedure.
Crosshead adjustment must always be made before
attempting to adjust the valves.

Adjust the crossheads on the cylinder that is ready for valve

setting.

Loosen the crosshead adjusting screw locknuts on the intake

and exhaust valve crossheads.

Use the following procedure to adjust both the intake and

exhaust crossheads.

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Turn the adjusting screw counterclockwise at least one

turn.

Hold the crosshead down against the guide.

Turn the adjusting screw clockwise until it touches the top of

the valve stem, but does not raise the crosshead.

Hold the adjusting screw in this position. The adjusting screw

must not turn when the locknut is tightened to its torque
value.

Tighten the locknut.

The following torque values are given with and without a
torque wrench adapter, Part Number 3163196.

Torque Value:
With adapter
1. 60 n•m [ 44 ft-lb ]

Torque Value:
Without adapter
1. 65 n•m [ 48 ft-lb ]

Bar the engine to the next damper timing mark and (refer to
the chart in this procedure) to determine the next injector
cylinder and valve cylinder to set.

If the rocker lever assemblies were not removed, identify the

cylinders that are in position for injector setting.

On these two cylinders, identify the injector push rod which is

higher in relation to the top of the rocker lever housing. This
is the cylinder ready for injector setting.

Refer to the chart in this section to determine the

corresponding valve set cylinder.

Valve and Injector Adjustment Determination

Valve Injector
Vibration Adjustment on Adjustment on
Damper Mark Cylinder Cylinder
Number Number
1.6 TOP 1 2
2.5 TOP 5 4
3.4 TOP 3 1

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Valve and Injector Adjustment Determination

Valve Injector
Vibration Adjustment on Adjustment on
Damper Mark Cylinder Cylinder
Number Number
1.6 TOP 6 5
2.5 TOP 2 3
3.4 TOP 4 6

Valve Adjustment

Valve Clearances - Initial Set

mm in
Exhaust
0.62 MAX 0.024
valves (A)
Intake
0.32 MAX 0.013
valves (B)
Valve Clearances - Check
mm in
Exhaust
0.60 MIN 0.023
valves (A)
0.64 MAX 0.025
Intake
0.30 MIN 0.012
valves (B)
0.34 MAX 0.013
The Torque Wrench Method and Screwdriver Method are
used to set valve lash clearance. Both are described below.
Either method can be used; however, the Torque Wrench
Method has proven to be the most consistent.

Make sure the crossheads have been adjusted and are firmly
in place on the valve stems.

Make sure the feeler gauge is under the center of the rocker
lever or incorrect adjustment can result.

The adjustment screws must turn freely or a false reading or

setting can occur.

Select the proper feeler gauge for the valves being set. Use
feeler gauge set, Part Number 3823557, or equivalent.

Valve Adjustment - Torque Wrench Method

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Make sure parts are aligned and squeeze the oil out of the
valve train by tightening the adjusting screw.

Loosen the adjusting screw at least one revolution.

Insert the feeler gauge between the rocker lever and the
crosshead.

Use torque wrench, Part Number 3376592, to tighten the

adjusting screw.

Torque Value: 0.68 n•m [ 6 in-lb ]

Remove the feeler gauge.

The adjusting screw must not turn when the locknut is

tightened. Locknut torque can be applied with or without the
torque wrench adapter, Part Number 3163196.

Tighten the locknut.

Torque Value:
With adapter
1. 48 n•m [ 35 ft-lb ]
Torque Value:
Without adapter
1. 68 n•m [ 50 ft-lb ]

Attempt to insert a feeler gauge that is 0.03 mm [0.001 in]

thicker. The valve lash is not correct if the thicker feeler
gauge will fit.
Repeat the adjustment process until the proper lash is
obtained.

Valve Adjustment - Screwdriver Method

Make sure the parts are aligned and squeeze the oil out of
the valve train by tightening the adjusting screw.

Loosen the adjusting screw at least one revolution.

Insert the feeler gauge between the rocker lever and the
crosshead.

Tighten the adjusting screw until the rocker lever touches the
feeler gauge.

The adjusting screw must not turn when the locknut is

tightened. Locknut torque can be applied with or without a
torque wrench adapter, Part Number 3163196.
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Tighten the locknut.

Torque Value:
With Adapter
1. 48 n•m [ 35 ft-lb ]

Torque Value:
Without Adapter
1. 68 n•m [ 50 ft-lb ]

Attempt to insert a feeler gauge that is 0.03 mm [0.001 in]

thicker. The valve lash is not correct if the thicker feeler
gauge will fit.

Repeat the adjustment process until the proper lash is

obtained.

Injector Lever Adjustment

Either a click type or a dial type torque wrench can be used

to tighten the injector rocker lever adjusting screw. The
specified adjusting screw torque must fall near the center of
the operating range for the torque wrench used. If the screw
chatters during setting, repair the screw and lever as
required.

Tighten the adjusting screw.

Torque Value: 32 n•m [ 24 ft-lb ]

Loosen the adjusting screw at least one revolution.

Tighten the adjusting screw again.

Torque Value: 32 n•m [ 24 ft-lb ]

When tightening the adjusting screw locknut, do not hold the

adjusting screw in position.

Tighten the injector adjusting screw locknut.

Torque Value: 225 n•m [ 166 ft-lb ]

Finishing Steps
Install the rocker lever covers. Refer to Procedure 003-
011 (Rocker Lever Cover) in Section 3.
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Operate the engine and check for leaks.

Last Modified: 13-Sep-2023

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