Every Service Engineers who are all in Commercial vehicle service particularly with cummins engine should have this checklist before going to dismantle Engine..
INSPECTION RECORD
JOB NO………………..
DATE………………….
1) Chassis No…………… 2) Engine No………………………………..
3) Vehicle Reg. No……………. 4) Kms………………………………………
5) Nature of failure………………………………………………………………………..
6) Kms covered after last rebuild…………………………………………………………
01. CYLINDER BLOCK
Block No…………………
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Visual inspection for damage | Only repairable Damage | ||
| 2 | Cylinder block head deck
1) Any damage 2) Flatness a) End to End b) Side to Side |
No damage
Max…….0.075 Max…….0.075 |
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| 3 | Cylinder block height front head deck top to top main bearing bore | 278.9-279.1 | ||
| 4 | Cylinder block head deck
Parallelism |
Max………..0.05 | ||
| 5 | Cam bore I.D.
1) Front bore Std………… Oversize 2) Other bores |
57.222-57.258
57.716-57.752 54.089-54.164 |
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| 6 | Cam shaft bushing dia
( Installed) |
54.107-54.146 | ||
| 7 | Cylinder bore
1) Out of round 2) Taper Max………0.076 3) Diameter a) Standard b) First rebore c) Second rebore 4) Glazed / Deglazed |
Max……….0.038
102.520+0.020 103.020+0.020 Deglazed |
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| 8 | Main bearing parent bore
1)Visual-Discoloration crack, porosity Parameter 2)Fit of main bearing cap on Cylinder block. 3)Main bearing bore ID (without shell) a) I.D. b) Out of round |
As per inspection
Press Fit 87.982-88.018 Max……………0.05 |
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| 9 | Tappet bores
1)Scoring 2)Dia |
No Scoring
16.00-16.055 |
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| 10 | Leakage | No Leakage |
02. CRANK SHAFT
Crank shaft no……………………….
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Visual:
1) Seals wear surface for Scratches or grooving 2) Main & rod journals, Scoring, overheating etc. 3) Threaded cap screw holes for damage. 4) Cracks |
No deep scratch or grooving
(Max……0.25m.m.) No deep scoring or Overheating As per inspection parameters |
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| 2 | Connection rod bearing journal
1) Dia Std R/S-1 R/S-2 R/S-3 R/S-4 2) Filler radius 3) Out of roundness 4) Taper 5) Hardness |
68.987-69.013
68.737-68.763 68.487-68.513 68.237-68.263 67.987-68.013 3.80-4.20 Max……….0.050 Max……….0.013 Min………..43HRC |
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| 3 | Main bearing journal
1) Dia Std R/S-1 R/S-2 R/S-3 R/S-4 2) Filler radius 3) Out of roundness 4) Taper 5) Hardness |
82.987-83.013
82.737-82.763 82.487-82.513 68.237-68.263 67.987-68.013 3.80-4.20 Max……….0.050 Max……….0.013 Min………..43HRC |
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| 4 | Thrust face width ( 6th main journal)
Std O/S-1 O/S-2 |
Max……….37.602
Max……….37.877 Max……….38.127 |
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| 5 | Gear journal
1) O.D 2) Run out 3) Filler radius |
63.987-64.006
Max……….0.030 1.00-3.00 |
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| 6 | Gear bore
1) I.D. 2) |
63.910-63.934
As per inspection parameter |
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| 7 | Vibration damper pilot
1) O.D. 2) Fillet radius |
18.924-19.000
Min………1.62 |
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| 8 | Rear oil seal flange :
1) O.D. 2) Diametrical concentricity |
129.975-130.025
Max………0.030 |
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| 9 | Groove depth in front oil seal Flange | Max………..0.15 | ||
| 10 | Bend :
1) Between 1&7 2) Journal to journal |
Max…….0.15
Max…………0.05 |
03. CONNECTING ROD
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Visual:
1) Connection rod & Cap for Fitting, damages etc. 2) I-beam for nick or damage 3) Bushing for damage Misalignment of oil passage And bushing |
As per inspection
Parameters -do- -do- |
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| 2 | Connecting rod bearing journal
1) Without bearing shell 2) With shells |
72.987-73.013
Std 69.051-69.103 R/S-1 68.801-68.853 R/S-2 68.551-68.603 R/S-3 68.301-68.353 R/S-4 68.051-68.103 |
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| 3 | Connecting rod small end bore Dia
1) With bush 2) Without bush |
40.053-40.076
42.987-43.013 |
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| 4 | Bend :
1) With bush 2) Without bush |
Max………0.15
Max……….0.20 |
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| 5 | Twist : With bush | Max………0.15 |
04. CYLINDER HEAD
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Visual – Localized dips or
Imperfections damages , cracks On the combustion face and Outside combustion surface |
As per inspection
Parameters. |
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| 2 | Combustion surface flatness
1) End to End 2) Side to Side |
Max……….0.30
Max……….0.076 |
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| 3 | Cylinder head parallelism | Max………..0.40 | ||
| 4 | Thickness | Min…………93.75 | ||
| 5 | Valve recess in cylinder head | 0.99-1.52 | ||
| 6 | Valve guides :
1) Scuffing/scoring 2) Bore |
No scuffing/scoring
8.091-8.090 |
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| 7 | Valve seats :
1) Cracks , Burns 2) Seat width |
As per Inspection parameter
1.5-2.0 |
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| 8 | Valves :
1) Abnormal wear on heads & stem 2) Stem dia 3) Valve tip flames 4) Bend 5) Rim thickness |
No abnormal wear
7.94-7.98 To be flat No bend Min……….0.79 |
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| 9 | Valves spring :
1) Free length 2) Inclination 3) Load to compress to 49.25 mm Other White |
White – 70.64
Other 55.63 Max………..1.00 28.91-32.12kg 64.32-69.12kg |
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| 10 | Leakage test under 2.0kg/sqcm | No leakage |
05. ROCKER LEVER/PEDASTALS/TAPPETS PUSH ROD
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Visual:
1) Bore for cracks and excessive Wear 2) Contact surface for the valve Stem for wear 3) Bore dia |
No cracks or excessive
Wear No excessive Wear 19.00-19.051 |
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| 2 | Rocker lever pedestals :
1) Pedestals shaft for damages 2) Shaft dia |
No damages
18.938-18.975 |
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| 3 | Valve Tappets :
1) Socket, stem and face for excessive Wear, crack and other damages 2) Pits on tappet face 3) Stem dia |
If NOT to accept
As per Inspection Parameters 15.936-15.977 |
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| 4 | Push rods :
1) Ball and socket for sign of Scoring 2) Crack where ball and Sockets are pressed into The tube 3) Straightness |
No deep score
Max………….0.15 |
06. CAMSHAFT
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Visual lift pump lobe, valve lobes, and bearing journal for crack.
Pitting or scoring |
As per Inspection
Parameters |
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| 2 | Gear teeth for pitting, cracks at the root of the teeth. | If so not acceptable | ||
| 3 | Dia at the peak of the lob
1) Intake 2) Exhaust. 3) Lift pump |
47.040-47.492
46.770-47.222 35.50-36.26 |
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| 4 | Bearing journal Dia. | 53.962-54.013 |
07. VIBRATION DAMPER
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Mis alignment of index line | Max…………1.59 | ||
| 2 | Deterioration and missing piece below metal surface | Max…………3.18 |
08. PISTON PIN
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Damage and excessive wear on
Top, ring grooves, skirt and pin bore |
If so not to reuse | ||
| 2 | Skirt dia | 101.823-101.887 | ||
| 3 | Ring clearances in groove with
New rings a) Top ring b) Intermediate c) Oil control |
Not to check
0.075-0.150 0.040-0.130 |
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| 4 | Pin bore dia 40.006-40.025 | |||
| 5 | Piston Pin
1) Nick and excessive wear 2) Pin dia 39.99-40.003 |
If so not to reuse |
09. OIL FILTER HEAD
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Plunger bore for nicks or scratches | If not to reuse | ||
| 2 | Plunger freeness in the bore | To bi free | ||
| 3 | Pressure regulator valve spring
Load Height 44.50 mm 41.15 mm |
Min………10.5kg
Min………13.7kg |
10. OIL COOLER
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Soldered joints for corrosion or cracks | If not to reuse | ||
| 2 | Leakage at 5kg/sqcm | No leakage |
11. OIL PUMP
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Pump gears for chips, cracks or excessive wear | If so not to reuse | ||
| 2 | Gerotor planetary for excessive wear or scoring | If so not to reuse | ||
| 3 | Pump housing and Gerotor drive for excessive wear | If so not to reuse | ||
| 4 | Gerotor and Gerotor drive Tip clearance | Max……….0.178 | ||
| 5 | Gerotor drive / Gerotor planetary to port plate clearance | Max……….0.127 | ||
| 6 | Gerotor planetary to body bore clearance | Max……….0.381 | ||
| 7 | Gear backlash | 0.076-0.33 |
12. WATER PUMP
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Impeller blades for wear and corrosion | If so replace pump | ||
| 2 | Free rotation of pump | To rotate freely | ||
| 3 | Check any tell tail sign of water leakage | Replace seal |
13. FAN HUB
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Free rotation of fan hub shift | To rotate freely | ||
| 2 | Check for any leakage of lubricant | If rebuilt or replace | ||
| 3 | Fan hub bearing for wear | No wear | ||
| 4 | Side to side or end play | To be minimum |
14. BELT TENSIONER
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Pilot tube area for excessive wear
( elongated hole ) |
If so replace | ||
| 2 | Bearing for free rotation and rough spot | To be free and smooth |
15. THERMOSTAT
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Damages | If so to be replace | ||
| 2 | Opening temp :
Start to open…….. Fully open……….. |
83 degree C.
95 degree C. |
16. TURBO CHARGER
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | Damages on housing | If so replace | ||
| 2 | Turbine wheel and compressor
Wheel for fretting, cracked or Broken vanes |
If so replace
Turbo charger |
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| 3 | Free rotation of Turbine shaft | If not. Replace Turbo | ||
| 4 | Turbine shaft end play | 0.03-0.08 | ||
| 5 | Compressor impeller radial clearance | 0.30-0.46 |
17. EXHAUST MANIFOLD
| Sl. No. | Inspection parameter | Specifications | Observed | Remarks |
| 1 | For cracks burr outer damages | If so replace | ||
| 2 | Flatness of manifold surface | Max……..0.20 mm | ||
| 3 | Flatness Turbo charger surface | Max……..0.13 mm |
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