(/qs3/pubsys2/xml/en/manual/4021528/4021528-titlepage.

html)

Preparatory Steps
with Mechanically Actuated Injector

 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.

 WARNING 
When the engine is operating with the rocker lever covers
removed, oil splashing can cause personal injury. To reduce
the possibility of personal injury, wear eye and face protection.

 WARNING 

To reduce the possibility of personal injury, avoid direct

contact of hot oil with your skin.

 WARNING 

Some state and federal agencies have determined that used

engine oil can be carcinogenic and cause reproductive
toxicity. Avoid inhalation of vapors, ingestion, and prolonged
contact with used engine oil. If not reused, dispose of in
accordance with local environmental regulations.

Disconnect the batteries. Refer to Procedure 013-009 (Battery

Cables and Connections) in Section 13.
(/qs3/pubsys2/xml/en/procedures/99/99-013-009.html)
Remove the rocker lever cover. Refer to Procedure 003-011
(Rocker Lever Cover) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-011-tr.html)
Remove the rocker levers. Refer to Procedure 003-009 (Rocker
Lever Assembly) in Section 3.
 (/qs3/pubsys2/xml/en/procedures/28/28-003-009-tr.html)
Remove the crossheads.Refer to Procedure 002-001
(Crosshead) in Section 2.
(/qs3/pubsys2/xml/en/procedures/28/28-002-001-tr.html)
Remove the push rods. Refer to Procedure 004-014 (Push
Rods or Tubes) in Section 4.
(/qs3/pubsys2/xml/en/procedures/28/28-004-014-tr.html)
Remove the cam follower covers. Refer to Procedure 004-002
(Cam Follower Cover) in Section 4.
(/qs3/pubsys2/xml/en/procedures/28/28-004-002-tr.html)

Disconnect the batteries. Refer to Procedure 013-009 (Battery

Cables and Connections) in Section 13.
(/qs3/pubsys2/xml/en/procedures/99/99-013-009.html)
Disconnect the air/gas supply to the air starter if equipped.
Refer to Procedure 012-022 (Air Starting Motor) in Section 12.
(/qs3/pubsys2/xml/en/procedures/28/28-012-022-tr-gc.html)
Drain the lubricating oil from the engine. Refer to Procedure
007-037 (Lubricating Oil System) in Section 7.
(/qs3/pubsys2/xml/en/procedures/28/28-007-037-tr-gc.html)
Disconnect the spark plug wires from the spark plugs. Refer to
Procedure 013-014 (Spark Plug Wire (Non-Shielded)) in
Section 13. (/qs3/pubsys2/xml/en/procedures/103/103-013-
014.html)
Disconnect the spark plug wires from the spark plugs. Refer to
Procedure 013-045 (Spark Plug Wire (Shielded)) in Section 13.
(/qs3/pubsys2/xml/en/procedures/103/103-013-045-om-
gc.html)
Remove the rocker lever cover. Refer to Procedure 003-011
(Rocker Lever Cover) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-011-tr-gc.html)
Remove the rocker lever assembly. Refer to Procedure 003-
009 (Rocker Lever Assembly) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-009-tr-gc.html)
Remove the crossheads. Refer to Procedure 002-001
(Crossheads) in Section 2.
(/qs3/pubsys2/xml/en/procedures/28/28-002-001-tr-gc.html)

with Electronically Actuated Injector

 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.
 Disconnect the batteries. Refer to Procedure 013-007
(Batteries) in Section 13.
(/qs3/pubsys2/xml/en/procedures/99/99-013-007.html)
Remove the crankcase breather. Refer to Procedure 003-001
(Crankcase Breather) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-001-tr.html)
Remove the wiring harness. Refer to Procedure 019-043
(Wiring Harness) in the Troubleshooting and Repair Manual
Electronic Control System, QSK50 and QSK60 Modular
Common Rail System, Bulletin 4021533.
(/qs3/pubsys2/xml/en/procedures/05/05-019-043.html)
Remove the fuel supply lines. Refer to Procedure 006-024
(Fuel Supply Lines) in Section 6.
(/qs3/pubsys2/xml/en/procedures/28/28-006-024-tr.html)
Remove the rocker lever cover. Refer to Procedure 003-011
(Rocker Lever Cover) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-011-tr.html)
Remove the rocker levers and the STC injector link. Refer to
Procedure 003-009 (Rocker Lever Assembly) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-009-tr.html)
Remove the crossheads. Refer to Procedure 002-001
(Crosshead) in Section 2.
(/qs3/pubsys2/xml/en/procedures/28/28-002-001-tr.html)
Remove the push rods. Refer to Procedure 004-014 (Push
Rods or Tubes) in Section 4.
(/qs3/pubsys2/xml/en/procedures/28/28-004-014-tr.html)
Remove the cam follower covers. Refer to Procedure 004-002
(Cam Follower Cover) in Section 4.
(/qs3/pubsys2/xml/en/procedures/28/28-004-002-tr.html)

Remove
with Mechanically Actuated Injector
Remove the cam followers.
Note : The capscrews are slotted.
Remove the capscrews. Remove the cam follower shaft from the
ring dowels. The ring dowels do not have to be removed unless
they are damaged.

with Electronically Actuated Injector

Remove the capscrews and plain washers.
 Remove the cam follower assembly by pulling it straight out.

Disassemble
with Mechanically Actuated Injector
Remove the retaining ring. Pull the shaft out.

Mark and tag the parts for installation identification.

with Electronically Actuated Injector

Remove the retaining ring and pull the shaft out.

Mark and tag the parts for installation identification.

Clean and Inspect for Reuse

with Mechanically Actuated Injector

 WARNING 
When using solvents, acids, or alkaline materials for cleaning,
follow the manufacturer's recommendations for use. Wear
goggles and protective clothing to reduce the possibility of
personal injury.

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

Use solvent to clean the cam followers.

Dry with compressed air.

Use compressed air to check the oil drillings. Be sure the three
drillings in the shaft are not blocked.
Note : Each end of the shaft must contain a cup plug. The
plugs prevent oil leakage and force oil through the shaft oil
drillings.

Check the rollers for damage. The rollers must be replace if

damaged. Refer to Procedure 004-005 ( Cam Follower Roller and
Pin) in Section 4. (/qs3/pubsys2/xml/en/procedures/28/28-004-005-
tr.html)

The roller must rotate easily.

Roller Clearance
mm in
(1) 0.23 MIN 0.009
  0.61 MAX 0.024
(2) 0.076 MIN 0.003
  0.178 MAX 0.007

If the clearances are not within specifications. Refer to Procedure

004-005 (Cam Follower Roller and Pin) in Section 4.
(/qs3/pubsys2/xml/en/procedures/28/28-004-005-tr.html)

Measure the lever bore inside diameter, replace if worn or

damaged. Refer to Procedure 004-005 (Cam Follower Roller and
Pin) in Section 5. (/qs3/pubsys2/xml/en/procedures/28/28-004-005-
tr.html)
 Lever Bore Inside Diameter
mm in
22.225 MIN 0.875
22.276 MAX 0.877

Inspect the push rod socket for an even seating pattern or

excessive wear.

When parallel grooves and scratches are observed or the contact

area extends into the oil hole chamfer of the socket, the socket
must be replaced.

Check the shaft for damage or roughness. Measure the outside

diameter.

Shaft Outside Diameter

mm in
22.174 MIN 0.8730
22.200 MAX 0.8740

with Electronically Actuated Injector

 WARNING 

When using solvents, acids, or alkaline materials for cleaning,

follow the manufacturer's recommendations for use. Wear
goggles and protective clothing to reduce the possibility of
personal injury.

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

Use solvent to clean the cam followers.

Dry with compressed air.

Use compressed air to check the oil drillings. Be sure the three
drillings in the shaft are not blocked.

Note : Each end of the shaft must contain a cup plug. The
plugs prevent oil leakage and force oil through the shaft oil
drillings.

Check the rollers for damage. The roller(s) must be replaced if

damaged. Refer to Procedure 004-005 (Cam Follower Roller and
Pin) in Section 4. (/qs3/pubsys2/xml/en/procedures/28/28-004-
005.html)

The roller must rotate easily.

Roller Clearance
mm in
(1) 0.23 MIN 0.009
  0.61 MAX 0.024
(2) 0.076 MIN 0.003
  0.178 MAX 0.007

If the clearances are not within specifications. Refer to Procedure

004-005 (Cam Follower Roller and Pin) in Section 4.
(/qs3/pubsys2/xml/en/procedures/28/28-004-005.html)

Measure the lever bore inside diameter, replace if worn or

damaged.Refer to Procedure 004-005 (Cam Follower Roller and
Pin) in Section 4. (/qs3/pubsys2/xml/en/procedures/28/28-004-
005.html)

Lever Bore Inside Diameter

mm in
22.225 MIN 0.875
22.276 MAX 0.877

Inspect the push rod socket for an even seating pattern or

excessive wear.
 When parallel grooves and scratches are observed or the contact
area extends into the oil hole chamfer of the socket, the socket
must be replaced.

Check the shaft for damage or roughness. Measure the outside

diameter.

Shaft Outside Diameter

mm in
22.174 MIN 0.8730
22.200 MAX 0.8740

Assemble
with Mechanically Actuated Injector

 CAUTION 
The use of the standard cam follower shaft on K2000E,
K1800E, K1500E, and QSK50 engines will result in shaft failure
and engine damage.

The K2000E, K1800E, K1500E, and QSK50 cam follower shaft can
be identified by the part number stamped on the shaft end.

 CAUTION 

The use of the standard injector cam follower on K2000E,

K1800E, K1500E, and QSK50 engines will result in cam
follower failure and engine damage.

The K2000E, K1800E, K1500E and QSK50 injector cam follower

lever can be identified by the roller width, 28.07 mm [1.105 inch].

Use clean engine oil. Lubricate the shaft and the bores of the
levers.

Slide the levers on the shaft. Install the parts as illustrated.

The shaft must rotate easily after assembly.

 If resistance is apparent, disassemble and check for burrs on the
shaft.

with Electronically Actuated Injector

Use clean engine oil. Lubricate the shaft and the bores of the
levers.

Slide the levers on the shaft. Install the parts as illustrated.

The shaft must rotate easily after assembly.

If resistance is apparent, disassemble and check for burrs on the

shaft.

Install
with Mechanically Actuated Injector

 WARNING 

When using solvents, acids, or alkaline materials for cleaning,

follow the manufacturer's recommendations for use. Wear
goggles and protective clothing to reduce the possibility of
personal injury.

 CAUTION 

Service replacement cam followers are coated withy a heavy

preservative to prevent rust. This preservative must be
removed completely with solvent before the parts are installed
in the engine.
  CAUTION 

On engines built previous to March 1986 (ESN 33112109), the

cam follower mounting capscrews are special. They have a
slot that allows oil to flow to the cam follower assembly. The
oil drilling intersects with the right capscrew hole. The use of
standard capscrews will result in failure.

If a new component is installed, it must be cleaned, prior to

installation, to remove the manufacturer's preservative.

 CAUTION 

Starting with Engine Serial Number (ESN) 33112109 and after

(March 1987 to present), the drilling (1) intersects with the
shank of the capscrew. This allows the use of standard
capscrews in mounting the cam follower shafts.

The drilling (2) on KV blocks prior to Engine Serial Number (ESN)

33112109 delivered oil directly to the end of the capscrew and
required the use of a grooved capscrew.

Grooved Cam Follower Capscrew Torque Value

n.m ft-lb
39 MIN 29
42 MAX 31

Hexagon Head Cam Follower Capscrew Torque Value

n.m ft-lb
50 MAX 37

Twelve Point Head Cam Follower Capscrew Torque Value

n.m ft-lb
70 MAX 52

with Electronically Actuated Injector

 CAUTION 

The washer is hardened and prevents the capscrew from

bottoming out in the hole. Omitting the washer will result in
engine damage.

Install the cam follower assembly.

 Use clean engine oil to lubricate the capscrew threads,

Install the special capscrews and washers.

Torque Value:  70  n•m    [ 52 ft-lb ]

Finishing Steps
with Mechanically Actuated Injector

 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 cam follower covers. Refer to Procedure 004-002

(Cam Follower Cover) in Section 4.
(/qs3/pubsys2/xml/en/procedures/28/28-004-002-tr.html)
Install the push rods.Refer to Procedure 004-014 ( Push Rods
or Tubes) in Section 4. (/qs3/pubsys2/xml/en/procedures/28/28-
004-014-tr.html)
Install the crossheads.Refer to Procedure 002-001 (Crosshead)
in Section 2. (/qs3/pubsys2/xml/en/procedures/28/28-002-001-
tr.html)
Install the rocker levers and the STC injector link. Refer to
Procedure 003-009 (Rocker Lever Assembly) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-009-tr.html)
Adjust the overhead.Refer to Procedure 003-006 (Overhead
Set (OBC)) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-006-tr.html)
Install the rocker lever cover.Refer to Procedure 003-011
(Rocker Lever Cover) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-011-tr.html)
Connect the batteries.Refer to Procedure 013-007 (Batteries) in
Section 13. (/qs3/pubsys2/xml/en/procedures/99/99-013-
007.html)
Operate the engine and check for leaks.

Install the crossheads. Refer to Procedure 002-001

(Crossheads) in Section 1.
(/qs3/pubsys2/xml/en/procedures/28/28-002-001-tr-gc.html)
Install the rocker lever assembly. Refer to Procedure 003-009
(Rocker Lever Assembly) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-009-tr-gc.html)
 Install the rocker lever cover. Refer to Procedure 003-011
(Rocker Lever Cover) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-011-tr-gc.html)
Connect the spark plug wires from the spark plugs. Refer to
Procedure 013-045 (Spark Plug Wire (Shielded)) in Section 13.
(/qs3/pubsys2/xml/en/procedures/103/103-013-045-om-
gc.html)
Connect the spark plug wires from the spark plugs. Refer to
Procedure 013-014 (Spark Plug Wire (Non-Shielded)) in
Section 13. (/qs3/pubsys2/xml/en/procedures/103/103-013-
014.html)
Fill the lubricating oil from the engine. Refer to Procedure 007-
037 (Lubricating Oil System) in Section 7.
(/qs3/pubsys2/xml/en/procedures/28/28-007-037-tr-gc.html)
Connect the batteries. Refer to Procedure 013-009 (Battery
Cables and Connections) in Section 13.
(/qs3/pubsys2/xml/en/procedures/99/99-013-009.html)
Connect the air/gas supply to the air starter if equipped. Refer
to Procedure 012-022 (Air Starting Motor) in Section 12.
(/qs3/pubsys2/xml/en/procedures/28/28-012-022-tr-gc.html)
Operate the engine and check for leaks.

with Electronically Actuated Injector

 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 cam follower covers. Refer to Procedure 004-002

(Cam Follower Cover) in Section 4.
(/qs3/pubsys2/xml/en/procedures/28/28-004-002-tr.html)
Install the push rods. Refer to Procedure 004-014 ( Push Rods
or Tubes) in Section 4. (/qs3/pubsys2/xml/en/procedures/28/28-
004-014-tr.html)
Install the crossheads. Refer to Procedure 002-001
(Crosshead) in Section 2.
(/qs3/pubsys2/xml/en/procedures/28/28-002-001-tr.html)
Install the rocker levers. Refer to Procedure 003-009 (Rocker
Lever Assembly) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-009-tr.html)
Adjust the overhead. Refer to Procedure 003-006 (Overhead
Set (OBC)) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-006-tr.html)
 Install the rocker lever cover. Refer to Procedure 003-011
(Rocker Lever Cover) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-011-tr.html)
Install the fuel supply lines. Refer to Procedure 006-024 (Fuel
Supply Lines ) in Section 6.
(/qs3/pubsys2/xml/en/procedures/28/28-006-024-tr.html)
Install the wiring harness. Refer to Procedure 019-043 (Engine
Wiring Harness) (/qs3/pubsys2/xml/en/procedures/05/05-019-
043.html) in the Troubleshooting and Repair Manual Electronic
Control System, QSK50 and QSK60 Modular Common Rail
System, Bulletin 4021533.
Install the crankcase breather. Refer to Procedure 003-001
(Crankcase Breather (External)) in Section 3.
(/qs3/pubsys2/xml/en/procedures/28/28-003-001-tr.html)
Connect the batteries. Refer to Procedure 013-007 (Batteries)
in Section 13. (/qs3/pubsys2/xml/en/procedures/99/99-013-
007.html)
Operate the engine and check for leaks.

Last Modified:  24-Sep-2015