CUMMINS DE LOS ANDES S.A.

CODE
REPORT ASSEMBLED ENGINES ISB4.5, ISB6.7, ISD4.5 and ISD6.7
VERSION
CM2150
TECHNICAL SUPPORT PAGE
CLIENTE: No. O.T.
LICENSE PLATE: MOTOR: No. SERIES:
CPL: DATE: ADVISOR:
TECHNICIAN CITY
INSTALLATION OF THE CRANKSHAFT
1. Check the machining report of the Block.

2. Wash the block and check the condition and cleanliness of the following parts of the block:

Main lubrication gallery, cooling galleries, head screw threads, sleeve housing.

3. Visually inspect the bench tunnel and camshaft tunnel for damage and dents.

4. Rectified surface of the block: YES________. NO_________ MEASURE:___________

5. Measurement of crankshaft journal bearings. 6. Measurement of crankshaft connecting rod journals

STUMP A B M/F STUMP A B F/M

1 1
2 2
3 3
4 4
5 5
6 6
7

Standard journal diameter in the crankshaft Diameter of the connecting rod journal in the crankshaft
mm Flea. mm Flea.
98,006 MIN. 3,8585 76,000 MIN. 2,9921
98,032 MAX. 3.8595 76,026 MAX. 2,9931

Ovaling of the Main Bearing Stub of the Crankshaft Ovaling of the Crankshaft Connecting Rod Stub
mm Flea. mm Flea.
0.050 MAX. 0.002 0.050 MAX. 0.002

Taper of the Main Bearing Journal of the Crankshaft Taper of the Connecting Rod Journal
mm Flea. mm Flea.
0.013 MAX. 0.0005 0.013 MAX. 0.0005

6. Width of the Crankshaft Thrust Face (Standard).

Width of the pushing face of the pusher.

mm Flea.
37,475 MIN. 1,475
37,576 MAX. 1,576
7. Check the contact areas of the rear oil seal of the crankshaft.

Worn groove of the front and rear seal

of crankshaft oil
mm in
0.25 MAX 0.010

8. What is the outer diameter of the rear oil seal flange of the crankshaft?

Wear groove of the front and rear seal

of the crankshaft oil.
mm Flea.
129.98 MIN. 5,117
130.03 MAX. 1,119

9 What is the outer diameter of the crankshaft damper pilot.

Outer diameter of the crankshaft damper pilot.

mm in
23.92 MIN. 0.942
24.00 MAX. 0.945

10. Install the crankshaft and accessories in the block as specified in the repair manual. Torque the bolts.
bench covers according to specification.

New screws Used screws

120nm [89ft-bl] 60 n.m (44 ft-lb)
Completely relax 2. 80 n.m (59 ft-lb)
3. 60nm [44ft-lb] 3. Turn 90 degrees.
4. 85nm [63ft-lb]
Turn 120 degrees.

11. Measure the axial play of the crankshaft.

Crankshaft axial play.

mm Flea
0.102 Min. 0.004
0.432 MAX. 0.017

Axial game measured:

NOTE: if the axial play of the crankshaft is greater than indicated
It is necessary to change the crankshaft.

12. Measure the thickness of the bearing pads.

Dimensions of connecting rod bearings.
mm Flea.
Installation 2,456 Min. 0.0967
2,464 MAX. 0.097
About a measurement of 0.25 mm [0.010 in] 2,706 Min. 0.1067
2,714 MAX. 0.1170
About a measurement of 0.50 mm [0.020 in] 2,956 Min. 0.1167
2,964 MAX. 0.117
About a measurement of 0.75 mm [0.030 in 3,206 Min. 0.1267
3,214 MAX. 0.127
About a measurement of 1.00 mm [0.040 in] 3,456 Min. 0,1367
 3,464 MAX. 0.137

PROCESS CONTROL 1
Date / Time Workshop Manager / Support Engineer
TECHNICIAN:
OBSERVATIONS

BLOCK
13. Inspect the block for cracks.
If you find any crack, it is necessary to change the block.

Ok OBSERVACIONES:
No Ok

14. Measure the separation of the piston rings.

ARTICULATED PISTON
Separation of the upper ring (fire ring)
mm Flea.
0.30 Min. 0.012
0.46 MAX. 0.018
Separation of the intermediate ring coated with phosphate (scraping ring)
mm Flea.
0.82 Min. 0.032
1.18 MAX. 0.047
Separation of the intermediate ring coated with chrome
mm Flea.
0.52 Min. 0.021
0.88 MAX. 0.034
Oil ring separation
mm Flea.
SEPARATION OF THE RINGS 0.22 Min. 0.010
INTERMEDIATE TOP SHIRT OIL 0.58 MAX. 0.023
1
2
3
4
5
6
CRANKS
15. Measure the inner diameter of the crankshaft hole in the connecting rods.

Standard Diameter of the Drill for Crankshaft in the Connecting Rod with Installed Bearings
mm Flea.
69.05 Min. ##
69.10 MAX. ##
Drill Diameter for Crankshaft in the Connecting Rod, Bearings Removed
mm Flea.
72.99 Min. ##
73.01 MAX. ##

WHITE A B C F/E
1
2
3
4
5
 6

Dimensions of the Bearing Block.

mm Flea.
On a measure of 0.25 mm [0.010 in] 68.80 Min. 2,709
68,85 MAX. 2,711
About a measurement of 0.50 mm [0.020 in] 68.55 Min. 2,699
68.60 MAX. 2,701
About a measurement of 0.75 mm [0.030 in 68.30 Min. 2,689
68.35 MAX. 2,691
About a measurement of 1.00 mm [0.040 in] 68.05 Min. 2,680
68.10 MAX. 2,681

16. What is the inner diameter for the piston bolt hub?
Interior Diameter of the Hub for Piston Pin in the Connecting Rod.
mm Flea.
40,019 Min. 1.5756
40,042 MAX. 1,5765

WHITE A B F/E
1
2
3
4
5
6

17. Assemble the connecting rod, connecting rod cap, Valor de Torque: 100 n.m [74 ft-lb]
and screws.

PISTON

18. What is the tolerance of the piston ring.

Piston Ring Tolerance.

mm Flea.
Intermediate 0.040 MIN. 0.0016
0.110 MAX. 0.0043
Control of 0.040 MIN. 0.0016
aceite: 0,085 MAX. 0.0032

19. Measure the skirt diameter of the piston at 21.4 mm [0.84 in] (A) from the bottom of the piston.

Standard diameter of the piston skirt.

mm Flea.
106,878 MIN. 4,2078
106,892 MAX. 4.2083

Oversized diameter of the piston skirt

mm Flea.
107,378 MIN. 4.2275
107,392 MAX. 2.2280
PISTON MEASURE A MEASURE B OBSERVATIONS
1
2
3
4
5
6
20. Measure the bore of the piston pin.
Piston pin bore.
mm Flea.
40,006 Min. 1.5750
40,012 MAX. 1,5749

BOLT A B OBSERVATIONS
1
2
3
4
5
21. Diameter of the piston pin. 6
mm Flea.
39,997 Min. 1,5747
40,003 MAX. 1.5749
Bolt A B OBSERVATIONS
1
2
3
4
5
6

22. Install the rings on the pistons.

The separation of each of the rings should not be

aligned with the piston bolt nor with any other ring.

23. Measure the piston protrusion with the depth gauge assembly.

Piston Protrusion
mm Flea.
0.151 MIN. 0.006
0.485 MAX. 0.019

24. Install the piston cooling nozzle in a cylinder.

Tighten the screw.

Torque Valué:
Type J screw
1. 15 n.m [133 in-lb]

25. Inspect the connecting rod caps for damage.

Replace any cap with the following damage:

Sting
Shelling
 Corrosion
Damage to the closure flap
Stripes (deep enough to feel with your fingernail).

26. Measure the thickness of the connecting rod bearing with an outside micrometer.
Dimensions of connecting rod bearings.
mm Flea.
Installation 1,955 Min. 0,0770
1,968 MAX. 0.0775
About a measurement of 0.25 mm [0.010 in] 2,080 Min. 0.0819
2,093 MAX. 0.0824
About a measurement of 0.50 mm [0.020 in] 2,205 Min. 0.0868
2,218 MAX. 0.0873
About a measurement of 0.75 mm [0.030 in] 2,330 Min. 0.0917
2,343 MAX. 0.00922
About a measurement of 1.00 mm [0.040 in] 2,455 Min. 0.0967
27. Install the connecting rod bearings, lubricate the bearings and bolts.
28. Install the rod - piston assembly on the crankshaft. Torque the connecting rod bolts according to the sequence.

Value of torque

1. 45 n.m [33ft-lb]
2. Turn 90 degrees clockwise

29. What is the lateral separation of the connecting rod.

Lateral separation of the connecting rod
mm Flea.
0,100 Min. 0.004
0.330 MAX. 0.013

Lateral separation of the connecting rod

White 1 White 4
White 2 White 5
White 3 White 6

30. Install the block reinforcement plate.

Apply torque to the ten screws of the plate.

Torque value

43 n.m [32ft-bl]

31. Install the oil pump with the respective washers, tighten the four screws according to specification.

Torque value

8n.m [70in-lb]
2. 24n m[212in-lb

32. Check the meshing of the crazy gear and oil pump driven.
Play limits between the gear of the new oil lubricant pump.
mm Flea.
0.150 MIN 0.005
0,250 MAX 0,009

Limits of play between the driven gear of the oil pump new pump.
 mm Flea.
0.300 MIN 0.012
0.500 MAX 0.019

33. Install the oil pan.

34. Tighten the 32 screws of the crankcase in the indicated sequence.

Torque value

28 n.m [248 in-lb]

PROCESS CONTROL 2
Fecha / Hora Workshop manager / Support engineer
TECHNICIAN
OBSERVATIONS

HEAD
35. Measure the length of the screws.

Free length of the screw.

mm in
152.1 MAX ##

36. Record the injector protrusion for each injector.

Injector Protuberance
mm Flea.
1,630 Min. 0,064
1,980 MAX. 0.078

37. Record the depth of the valve for each valve.

Installed Intake Valve Depth
mm Flea.
0,584 Min. 0,023
1,092 MAX. 0.043
Depth of the Exhaust Valve (Installed).
mm Flea.
0.965 Min. 0.038
1,473 MAX. 0.058
38. What is the Flatness of the Cylinder Block. Flatness of the Cylinder Block
mm Flea.
End to end 0.075 Min. 0.003
Side by side 0.075 MAX. 0.002

39. Measure the inner diameter of the boring for the valve seat insert in the cylinder head.

Inner Diameter (I.D.) of the Drill for Insert in the Cylinder Head.
mm Flea.
34,847 Min. 1,3719
34,863 MAX. 1,3726

40. What is the outer diameter of the valve stem.

Valve Stem Diameter

mm Flea.
6.96 Min. 0.2740
7.01 MAX. 0.2760

41. Measure the thickness of the rim to determine if there is enough material left on the rim.

Limit of Valve Flange Thickness

mm Flea.
0.79 Min. 0.031

42. 34 Install a new head gasket.

43. Apply the torque to the head bolts in the indicated sequence.

Tighten the cylinder head screws.

Torque Valué:

90 n.m [66 ft-lb]

2. Loosen and Re-tighten
90 n.m [66 ft-lb]
4. Turn 90 degrees clockwise.

For 4 cylinders.
Tighten the cylinder head bolts.
 Torque Valué:

1. 90 n.m [66 ft-lb]

2. Loosen and Tighten
3. 90 n.m [66 ft-lb]
4. Turn 90 degrees clockwise.

PROCESS CONTROL 3
Date / Time Workshop Manager / Support Engineer
TECHNICIAN
OBSERVATIONS

CAMSHAFT.
44. What roundness.

The area of deterioration at the edge should not be larger.

that the equivalent area of a circle of 2 mm [0.079 in]
at ±20 degrees from the nose of the camshaft lobe.

45. Measure the diameter of the camshaft bearing pins.

Diameter of the camshaft stub.

mm Flea.
53,095 Min. 2.0904
54,045 MAX. 2,1278

STUMP A B
1
2
3
4
5
6
7

46. Measure the peaks of the valve lobes of the camshaft.

Diameter of the camshaft stub.

mm Flea.
stump A B Admission 47,175 Min. 1,857
1 47,855 MAX. 1,884
2 Escape 45,632 Min. 1,797
3 46,312 MAX. 1,823
4
5
6
7

47. Install the camshaft.

Rear gear train
.

48. Install the camshaft.

49. Install the push plate.

Torque value

24 nm [212 in -lb]

PROCESS CONTROL 4
Date / Time Workshop Manager / Support Engineer
TECHNICIAN
OBSERVATIONS

45. Install the rear gear housing.

Torque value:

M12
1. 50nm [37ft-lb]

M10
47nm [35fl-lb]

M8
24nm [212in-lb]
CAMSHAFT GEAR.
46. Measure the outer diameter of the crankshaft gear pin.
 Outer diameter of the crankshaft gear hub.
mm Flea.
75,987 Min. 2.9916
76,006 MAX. 2.9924

47. Install the screws of the camshaft gear and tighten.

Torque value

36 n.m [27 ft-lb]

48. Check the camshaft clearance. Check the gear play of the camshaft.

Axial game of the camshaft.

mm Flea.
0.100 Min. 0.004
0.361 MAX. 0.014

Camshaft gear game

mm Flea.
0.076 Min. 0.003
0.280 MAX. 0.011
PROCESS CONTROL 5
Date / Time Workshop Manager / Support Engineer
TECHNICIAN
OBSERVATIONS

49. Install the front gear cover.

Install on the mounting screws of the engine block and the oil pan.

50. Check that the new injector seal washer is the correct thickness.

Thickness of the injector seal washer.

mm in
## NAME. ##

ROCKER ARM ASSEMBLY

51. What does the rocker drill do?

Swing hammer drill

mm Flea.
 22,027 MAX. 0.867

Admission rocker arms Escape balancers

No A B No A B
1 1
2 2
3 3
4 4
5 5
6 6

52. What is the diameter of the rocker arm shaft?

Rocking shaft
mm Flea.
21,965 Min. 0.865

AXIS 1 AXIS 1
1 2 3 1 2 3

53. Install the rocker cover.

54. Position the rockers on the pedestal.

55. Install the rocker assemblies and pedestals in their original position.

Tighten the pedestal mounting screws

Valor de Torque:

36 n.m [27 ft-lb]

PROCESS CONTROL 6
Date / Time Workshop Manager / Support Engineer
TECHNICIAN
OBSERVATIONS

57. Apply the preliminary torque to the retaining nut of the fuel connector.

Valor de Torque:15 n.m (133 in-lb)

58. Install the injectors with sealing washers inside the cylinder head.

Alternate between screws, turning 90 degrees per turn until reaching:

Valor de Torque: 8 n.m [71 in-lb]

59. Measure the injector protrusion for each injector.

Injector protuberance.
mm Flea.
1.63 Min. 0.064
1,680 MAX. 0.068

60. Valve and injector calibration.

61. What does the game of the following seesaws 1A, 1E, 2A, 3E, 4A, and 5E measure?

Game review limits.

mm in
 Admission 0.152 MIN. 0.006
0.381 MAX. 0.015
Escape 0.381 MIN. 0.015
0.762 MAX. 0.030

62. Measure the game by inserting a line between the crossbar and the bushing of the rocker.

Tighten the lock nut and measure it.

Valor de Torque: 24 n.m [212 in-lb]

63. Measure the game for the following seesaws.

Four cylinders
2E, 3A, 4E and 4A.

Six cylinders
2E, 3A, 4E, 5A, 6A, and 6E.

(E = escape, I = admission)

PROCESS CONTROL 7
Date / Time Workshop Manager / Support Engineer
TECHNICIAN
OBSERVATIONS

64. Install the valve cover along with the gasket.

Torque value

24 n.m [212 in-lb]

65. Install the thermostat inside the thermostat housing.

66. Install the water outlet connection and the mounting screws.
 Torque value

10 n.m [89 in-lb]

67. Install the exhaust manifold and tighten the bolts in the sequence shown.

Torque value 43 n.m [32ft-lb]

68. Assemble the cover, screws, gaskets, of the lubricating oil cooler, and the oil cooler.

69. Low assembly. High assembly.

70. Install the turbo.

Torque value

43nm [32ft-lb]

71. Install the intake tube and the air inlet connection and tighten the clamp.

Valor de torque: 8 n.m (71 in-lb)

PROCESS CONTROL 8
Date / Time Workshop Manager / Support Engineer
TECHNICAL
OBSERVATIONS

72. Install the water pump.

Torque value

30n.m [22ft-lb]

73. Install the steering wheel casing.

Torque Value:
M10
1. 49 n.m (36 lb-ft)

M12
85 n.m (63 ft-lb)

74. Install the steering wheel on the guide pins.

Install two guide pins M12 x 1.25 x 90 mm apart

180 degrees, at the crankshaft flange.

75. Install the six screws.

Tighten the screws in a star pattern.

Torque Valué:

1. 30 nm [22ft-lb]
2. More turn of 60 degrees.
77. Eccentricity of the inner hole of the wheel.

Eccentricity of the inner hole of the steering wheel.

mm Flea.
0.127 MAX. 0.005

78. Measurement of the steering wheel face wobble.

Steering wheel radio:

Measured value:

79. Install the front engine mount.

For Front Mounting, install the front mounting bracket and screws.
Torque Valué:
Grade 8.8
1. 80 n.m [60 ft-lb]
Torque Value:
Grade 10.9
1. 115 n.m [85 ft-lb]
Torque value
Grade 12.9
125 n.m [95 ft-lb]

Same for the side support.

80. For engines that are not Cummins

Valor de Torque:

350 n.m [258 ft-lb]

PROCESS CONTROL 9
Fecha / Hora Workshop Chief / Support Engineer
TECHNICIAN
OBSERVATIONS
 INSTALLATION OF THE ENGINE IN THE UNIT
81. Inspect the engine mounts
82. Inspect the screws and mounting holes on the unit.
83. Install the engine in the chassis.
84. Condition the transmission in the engine (clutch and transmission)
85. Install accessories (alternator, starter motor)
86. Install the oil filter and fuel filters.
87. Add oil to the engine.
88. Condition the radiator and pipes of the cooling system.
Add coolant to the engine cooling system.
PROCESS CONTROL 10
Date / Time Workshop Manager / Support Engineer
TECHNICIAN
Observations

Start the engine

90. Check for oil and coolant leaks
91. Check for noises
92. Oil pressure (vehicle control panel) DATA OBTAINED

93. Low oil pressure at idle at nominal motor speed

cap psi cap psi
69 MIN. 10 ## MIN. 30 DATA OBTAINED

Cooling system
Thermostat modulation range 180 - 200 Degrees Fahrenheit