Cummins India Limited - Distribution Business Unit

HHP Rebuild Center

ASSEMBLY CHECKSHEET K19
DATE: ………………….. ENGINE NUMBER: ……………………………………..
MODEL ……………….…

JOB NO:……………….. HHPRC NUMBER: ………………………………..

APPLICATION:…………….....

CUSTOMER : …………..…...……………………………………..………………………………………
SO NUMBER….......................................

CYL.BLOCK SR.NO.:……………………...

CRANKSHAFT Sr.No.:……….…………… NEW/REGROUND/LAPPED

SIZE OF CRANK MJ ……….U/S, CP …..….U/S TR-F……….O/S TR-R ………O/S

CAMSAHFT Sr.No. ……………………….. PART NUMBER……………..

CPL ……………. INJECTION TIMING …………………… TO ……………………
NOTE: Please write Sub-Assemblies source (ReCon India or SMP or In-house Built)
FUEL PUMP Sr.No. ……………………. CODE ………………………… NEW/RECON

COMPRESSOR Sr.No. ……………….. PART No. ……………………. NEW/RECON

GOVERNOR Sr.No. …………………… PART No. ……………………. NEW/RECON

TURBOCHARGER Sr.No. ……………. PART No. ……………………. NEW/RECON

PISTON P/No. …………………………… INJECTOR …………………… NEW/RECON

RC PLATE SINGLE LIP P/No. RC PLATE DOUBLE LIP P/No.

STC VALVE P/No. STC VALVE SR. NO.

PT PUMP TYPE : PTG AUTO / PTR AUTO / PTG MVS / PTG EFC /
Customer Requirement Form referred during this engine rebuilding - Yes / No.
Engine assembly completeness - Verified By :
EXH MFD (F) ………..… EXH MFD (C) …………... EXH MFD (R) …………...

OIL PAN P/No…..………...…………………. O.G.BRACKET P/No. …...…………...……

DIPSTICK P/No. ….…….…………..………. VIBRATION DAMPER P/No. ……..………

PULLEY CRANKSHAFT P. No ………..……...…. WTR PUMP P.No…….. .…....……..

FLANGE CRANKSHAFT No ………..……...….

SPECIAL REMARKS IF ANY ……………………………………………………………………………….

………………………………………………………………………………………….……………………..
Note: This engine FINAL INSPECTION for completeness is done by:
(Attach customized checksheet with this checksheet for customers - WCL & JNPT)

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CHECK POINTS SPECIFIED ACTUAL OPERATOR
FIRST STAGE
A. CYLINDER BLOCK
1. CLEANING VISUAL
2. CHECK CAM BUSH OIL HOLE VISUAL
ALIGNMENT
3. CHECK OIL GALLERY PLUGS

B. CRANKSHAFT
1. CLEANING VISUAL
2. MJ/CP FOR DENTS VISUAL
3. TORQUE MAIN BRG.C/SCREWS 200-450 Ft-lbs. Loose & Repeat
4. CHECK CRANK SHAFT FOR
FREE ROTATION
5. CHECK & RECORD END PLAY 0.004" to 0.016" (Refer foot note)

SECOND STAGE
A. LINER, PISTON & CON ROD
INSTALLATION Liner Protrusion
1. CHECK LINER PROTRUSION 0.0055" to 0.0078" 1
2
2. CONNECTING ROD TORQUE 75-145-215-270 Ft-Lbs. 3
3. CHECK CONNECTING ROD SIDE 4
CLEARANCE 0.008" to 0.014" 5
4. NOTE CON ROD SIDE CLEARANCE 6
1 2 3 4 5 6

B. CHECK & RECORD LINER BEFORE

SIZE AND OVALITY Setting Ring 6.2500"
1" FROM TOP Minus 0.0035" to Plus 0.001"
3" FROM TOP Minus 0.0015" to Plus 0.001"
6" FROM TOP Minus 0.0015" to Plus 0.001"
FREE LINER ID minus 0.0005" to Plus 0.001"
LINER OVALITY
AFTER INSTALLATION 0.0025"
Cyl.No. TOP MIDDLE BOTTOM
THRUST ANTI TH. THRUST ANTI TH. THRUST ANTI TH.
1
2
3
4
5
6

THIRD STAGE
A. CYLINDER HEAD INSTALLATION
1. CHECK FOR CLEANLINESS VISUAL
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2. CHECK FOR PROPER INSTALLATION
OF GASKET
3. TORQUE AS PER THE SEQUENCE 70-170-250-370 Ft-lbs.
50-150-210/220 + 90 Deg
Please maintain crank shaft end play 0.010" and below during engine rebuilding.

CHECK POINTS SPECIFIED ACTUAL OPERATOR

B. GEAR END HSG INSTALLATION
1. CHECK FOR CLEANLINESS
2. PROPER INSTALLATION OF GASKET
3. CHECK PROTRUSION W.R.T. PAN RAIL 0.010"
4. HSG. PROTRUSION W.R.T. BLOCK Plus 0.004" or Minus 0.004"
5. PROTRUSION FOR PLATE TYPE HSG Plus 0.002" or Minus 0.002"
C. IDLER GEARS INSTALLATION
1. CHECK IDLER SHAFTS FOR DENTS, VISUAL
SCORING, RUST ETC.
2. INSPECT GEAR FOR PITTING AND VISUAL
SCORING IN BUSH.
3. INSTALL THRUST WASHERS ON
EITHER SIDE OF GEAR PROPERLY
4. IDLER SHAFT CAPSCREW TORQUE 220 Ft-lbs.
5. END PLAY CAM IDLER 0.004" - 0.014"
6. BACKLASH CAM IDLER 0.003" - 0.012"
7. W/P IDLER GEAR END PLAY 0.004" - 0.014"
8. W/P IDLER GEAR BACKLASH 0.003" - 0.012"

D. CAMSHAFT ASSLY.
1. INSPECT FOR DENTS/PITTING
2. USE LOCATOR FOR INSTALLATION
3. CHECK THRUST PLATE FOR FOULING
WITH GEAR END HOUSING
4. THRUST PLATE TORQUE 30-35 Ft-lbs.
5. INSTALL DUMMY GEAR OF CAM
6. CHECK TIMING MARK ALIGNMENT
7. CHECK INJECTION TIMING AS PER CYL. No. TIMING
CPL AND ADJUST OFFSET KEY 2
(REFER DATA OF OFFSET KEY) 5
8. INSTALL NEW GEAR
(OVEN TEMPRATURE : 375 Deg F)
9. CHECK GEAR BACKLASH 0.003" - 0.012"
10.CHECK GEAR END PLAY 0.006" - 0.013"
11.RECHECK INJECTION TIMING
12.BEND LOCK PLATES OF CAM THRUST
E. LUB OIL PUMP INSTALLATION
1. CHECK FOR FREE ROTATION
2. CHECK "O" RINGS FOR PROPER
INSTALLATION
3. TORQUE TO CAPSCREWS 30-35 Ftl-bs.
4. CHECK GEAR BACK LASH 0.003" - 0.012"
F. GEAR CASE COVER INSTALLATION
1. CHECK FOR CLEANLINESS
2. INSTALL NEW BUSHES
3. TORQUEAS PER SEQUENCE 30-35 Ft-lbs.
G. CAM FOLLOWER INSTALLATION
1. CHECK FREENESS OF ROLLERS

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2. POSITION CAM FOLLOWER ASSLY
OVER RING DOWELS ON BLOCK.
3. TORQUEAS PER SEQUENCE 29-31 Ft-Lbs.
4. INSTALL CAM FOLLOWER COVERS 25-35 Ft-lbs.
5. FAN HUB END PLAY 0.004" TO 0.016"

CHECK POINTS SPECIFIED ACTUAL OPERATOR

H. CROSS HEAD INSTALLATION
1. CHECK FREENESS IN GUIDE
2. LOCK NUT TORQUE. 25-30 Ft-lbs.
3. ADAPTOR PLATE INSTALLATION
4. PROTRUSION OF ADAPTOR PLATE 0.005" Max
I. INJECTOR INSTALLATION
1. PART NUMBER AS PER CPL/EBR
2. INSTALL TIP SEAL (COPPER)
3. LUBRICATE "O" RINGS
4. TORQUE TO HOLD DOWN C/S. 11-13 Ft-lbs.
J. ROCKER HOUSING &
WATER MANIFOLD INSTALLATION
1. LUBRICATE "O" RINGS ON WTR MFD.
2. TORQUE TO CAPSCREWS 60-70 Ft-lbs.
3. LUBRICATE BALL AND SOCKET END
OF PUSH RODS.
4. INSTALL ROCKER LEVER ASSLY.
5. ENSURE PROPER SEATING OF
ADJ. SCREWS IN PUSH RODS.
6. TORQUE TO CAPSCREWS 60-70 Ft-lbs.
K. ACC DRIVE INSTALLATION
1. ALIGN TIMING MARK 'A' WITH IDLER
2. TORQUE TO NUT 310 Ft-lbs.
3. CHECK GEAR BACK LASH 0.003" - 0.012"
4. CHECK END PLAY 0.002" - 0.012"
5. WOORWARD DRIVE END PLAY 0.0001"
6. TORQUE TO FUEL PUMP
MOUNTING CAPSCREW 30-35 Ft-lbs.
L. WATER PUMP DRIVE &
WATER PUMP INSTALLATION
1. CHECK OIL HOLE IN THE GAKSET
2. BLIND PLUG SHOULD BE PRESS
FITTED IN THE DRIVE SHAFT.
3. CHECK END PLAY 0.007" - 0.015"
INSTALL BARRING MECHANISM
1. TORQUE TO MTG. CAPSCREWS 30-35 Ft-lbs.
A. INJ. & VALVE ADJUSTMENT
1. INJECTOR PLUNGER TRAVEL 0.304"
(Plus 0.001" or Minus 0.001")
2. VALVE CLEARANCE INTAKE 0.017"
EXHAUST 0.029"
FOR INJECTOR SETTING OBC Method IBC Method
1. ADJUST INJECTOR BY OBC METHOD MARK SET VALVE SET INJ. MARK VALVE INJECTOR
ONLY. A 5 4 A 5 3
2. TORQUE - 90 In-lbs. B 3 1 B 3 6
3. USE DIAL TYPE TORQUE WRENCH. C 6 5 C 6 2

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 A 2 3 A 2 4
B 4 6 B 4 1
C 1 2 C 1 5
B. ROCKER COVER & BREATHER ASSLY
1. VISUAL INSPECTION
2. TORQUE TO ROCKER COVER BOLTS 30-35 Ft-lbs.
C.FUEL MFD. & CONN BLOCK INSTALL
1. CHECK FOR CLEANLINESS
2. TORQUE TO CAPSCREWS 80-90 In-lbs.
D.OIL FILTER HEAD
1. CHECK FOR CLEANLINESS
2. TORQUE TO MOUNTING CAPSCREW 30-35 Ft-lbs
E.THERMOSTAT HOUSING MOUNTING
1. CHECK FOR CLEANLINESS
2. TORQUE TO MOUNTING CAPSCREW 30-35 Ft-lbs
CHECK POINTS SPECIFIED ACTUAL OPERATOR
D. PISTON COOLING NOZZLE
INSTALLATION
1. VISUAL INSPECTION
2. LUBRICATE "O" RINGS.
3. TORQUE TO CAPSCREWS 10-15 Ftlbs.
E. OIL COOLER ASSLY.
1. INSPECT FOR CLEANLINESS
2. TORQUE TO COVER 25-30 Ft-lbs.
F. INTAKE MFD. ASSEMBLY
1. INSPECT FOR CLEANLINESS
2. TORQUE TO MTG. CAPSCREWS 25-30 Ft-lbs.
3. TORQUE TO COVERS 20-25 Ft-lbs.
G. EXH. MANIFOLD INSTALLATION
1. INSPECT FOR CRACKS
2. TORQUE TO CAPSCREWS 40-45 Ft-lbs.
H. TURBO INSTALLATION Check turbo axial and radial plays and compare with specification sheet.
1. INSPECT FOR FREE ROTATION
2. ENSURE ALIGNMENT WITH AIR
COMPRESSOR
3. TORQUE DRAIN CONN. FLANGE 30-35 Ft-lbs.
4. TURBO MTG. NUT TORQUE. 30-35 Ft-lbs.
I. VIB. DAMPER INSTALLATION
1. INSPECT FOR BURR / NICKS ON
MOUNTING FACE OF DAMPER
2. TORQUE FLANGE TO CRANK 320-340 Ft-lbs.
CAPSCREWS
3. TOQUE TO DAMPER TO FLANGE 65-70 Ft-lbs.
4. CHECK T.I.R. OF DAMPER FACE - 0.010" & Dia - 0.010"
5. HYD.PUMP DRIVE END PLAY 0.004" to 0.019"
J. OIL PAN ADAPTOR AND SUMP
ASSEMBLY INSTALLATION
1. RECHECK CON ROD TORQUE 220 Ft-lbs.
2. LUBE OIL PUMP SUCTION TUBE 60 Ft-lbs.

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 CAPSCREW TORQUE
3. LUBE PUMP TURBE CLAMP 30-35 Ft-lbs.
CAPSCREW TORQUE
4. INSTALL TWO RECTANGULAR
SEALING STRIPS IN THE SLOT
AT REAR END OF ADAPTOR
5. TORQUE AS PER SEQUENCE 30-35 Ft-lbs.
6. O.G. BRACKET AS PER EBR
7. DIPSTICK AS PER EBR
8. FLYWHEEL HOUSING INSTALLATION 150-160 Ft-lbs
9. FLYWHEEL HOUSING T.I.R. Bore & Face - 0.010"
10. OIL SEAL BORE IN FLYWHEEL HSG 0.008"
11. R.C.PLATE OIL SEAL BORE T.I.R. 0.008"
12. R.C.PLATE PROTRUSION 0.005" Max.
13. FLYWHEEL INSTALLATION 100-220 Ft-Lbs
14. FLYWHEEL T.I.R. Face:0.010", Bore:0.012"
OFF SET KEY DATA STRAIGHT KEY : S-302
KEY 216294 200711 216782 200709 200704 200708
Off Set 0.0035" 0.0070" 0.011" 0.015" 0.0197" 0.023"
Change 0.0017" 0.0033" 0.0055" 0.0070" 0.0095" 0.0110"
in Travel

KEY 3000491 200706 3000492 200714 3000493 3000494 3000495

Off Set 0.027" 0.0328" 0.036" 0.039" 0.043" 0.047" 0.0510"
Change 0.0135" 0.0155" 0.0180" 0.0185" 0.0215" 0.0235" 0.0256"
in Travel

FIRST STAGE : REMARKS

ASSEMBLY : REMARKS

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TESTING : REMARKS

ReCon India Built Cylinder Heads Serial Number Data

Cylinder Head P/No.
Injector Copper Sleeve Size & P/No.*
0.010" (P/N0. )
0.020" (P/N0. )
0.030" (P/N0. )

Cyl No.
Cylinder Head Sr No.
(RB)
1
2
3
4
5
6
Remarks:

Operator Sign
* Please tick mark on oversize injector sleeve size & note P/No. only if comustion face milled cylinder heads used.
Con rod Serial number
Con rod serial number details *
SR No Number on Rod Number on Cap

1
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 2
3
4
5
6

Injector Serial Number :

Injector serial number details *
SR No Injector Serial number

1
2
3
4
5
6

Oil Pan Rail Except Rail

Adaptor Plate and Oil pan Cover

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Cylinder head and Rocker Housing

Gear End Housing and Gear Cover

Flywheel housing and Oil Cooler Cover

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Cyl. Top Middle Bottom
No.
Thrust Anti-Thrust Thrust Anti-Thrust Thrust Anti-Thrust
1 0.00 0.00 0.00 0.00 0.00 0.00
2 0.00 0.00 0.00 0.00 0.00 0.00
3 0.00 0.00 0.00 0.00 0.00 0.00
4 0.00 0.00 0.00 0.00 0.00 0.00
5 0.00 0.00 0.00 0.00 0.00 0.00
6 0.00 0.00 0.00 0.00 0.00 0.00