Document No.
: CSA-QF-03-01-07-56
Date: 31.08.2009
Rev.: 2
ENGINE REBUILD SPESIFICATIONS
ISM, ISMe & QSM11
JOB No
ESN.
CPL.
ARTISAN SIGNATURE
ARTISAN SIGNATURE
ARTISAN SIGNATURE
CUSTOMER
Engine Rebuild Specification Limits and Check Sheet . ( QSM11 / 00 / EA / ECS ) Engine Model ISM, ISMe & QSM 11
file:///conversion/tmp/activity_task_scratch/878013803.xls Created by: N. Langenhoven
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Document No.: CSA-QF-03-01-07-56
Date: 31.08.2009
Rev.: 2
Engine Model ISM, ISMe & QSM 11
Engine Rebuild Specification Limits and Check Sheet . Job #
ENGINE SUMMARY AFTER REBUILD ESN
NOTE: 1) SIGN OFF ALL COMPLETED SECTIONS AT THE END OF EACH DAY, OR AS THEY ARE COMPLETED.
2) ALL re-used parts and rebuild components MUST meet Cummins Specifications.
Any abnormal condition to be reported to the Workshop Manager
Cylinder Block Re - used New CQ
Pistons Part Number Re - used New
Liners Part Number Re - used New
Oil Pump Part Number Re - used New RX
Camshaft Part Number Re - used New Date
Turbo Part Number Re - used New RX
Injectors Part Number Re - used New RX
Fuel Pump Code
Cylinder Heads Part Number Re - used New RX
Crankshaft Polish New CQ Grind
Oil Coolers Re - used New
Aftercoolers Re - used New
Main Bearings Std 0.010" 0.020"
Big Ends Std 0.010" 0.020"
Head gaskets Std 0.010" 0.020"
Liner Shims Std 0.002" 0.004"
Liner Size Std 0.010" 0.020"
NB. If a new camshaft was installed engrave date on side of camshaft
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Document No.: CSA-QF-03-01-07-56
Date: 31.08.2009
Rev.: 2
Engine Rebuild Specification Limits and Check Sheet . Engine Model ISM, ISMe & QSM 11
ENGINE SUMMARY AFTER REBUILD
Main Bearing Thickness UPPER SHELLS LOWER SHELLS Machanic/Fitter
STANDARD 1
3.894mm - 3.945mm or 0.1533"- 0.1553" 2
3
4
5
6
7
Connecting Rod Bearing Thickness UPPER SHELLS LOWER SHELLS Machanic/Fitter
STANDARD 1
2.430mm - 2.473mm or 0.0957"- 0.0974" 2
3
4
5
6
Main Bearing Clearance 1 Machanic/Fitter
Min. 0.0483mm or 0.0019" 2
Max. 0.221mm or 0.0087" 3
4
5
6
7
Big End Bearing Clearance 1 Machanic/Fitter
Min. 0.0152mm or 0.0006" 2
Max. 0.211mm or 0.0083" 3
4
5
6
file:///conversion/tmp/activity_task_scratch/878013803.xls Created by: N. Langenhoven
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Document No.: CSA-QF-03-01-07-56
Date: 31.08.2009
Rev.: 2
Engine Rebuild Specification Limits and Check Sheet . ( ISM, ISMe & QSM11 / 00 / EA / ECS ) Engine Model ISM, ISMe & QSM 11
Torque Wrench
Feature Specification / Torque Number Actual Reading Mechanic / Fitter
Calibrate torque wrench before job
Block Height NOT LESS THAN 305.30mm or 12.019"
Cylinder Liner to block Clearance 0.25mm Min 0.010"
Liner Protrusion 0.00mm - 0.12mm or .000"-.0047"
Liner Ovality 0.10mm Max 0.004"
1) Main Bearing Capscrews
Step 1 68 N.m or 50 ft-lb
Step 2 Loosen Completely
Step 3 68 N.m or 50 ft-lb
Step 4 Rotate 180 Degrees
2) Main Bearing Capscrews Blocks stamped TTY on The Rear
Step 1 68 N.m or 50 ft-lb
Step 2 Loosen Completely
Step 3 135 N.m or 100 ft-lb
Step 4 Rotate 180 Degrees
file:///conversion/tmp/activity_task_scratch/878013803.xls Created by: N. Langenhoven
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Document No.: CSA-QF-03-01-07-56
Date: 31.08.2009
Rev.: 2
Torque Wrench
Feature Specification / Torque Number Actual Reading Mechanic / Fitter
Crankshaft end float 0.10mm - 0.56mm or .004"-.022"
Big End Capscrews
Step 1 68 N.m or 30 ft-lb
Step 2 142 N.m or 105 ft-lb
Step 3 210 N.m or 155 ft-lb
Step 4 Loosen Completely
Step 5 Repeat Steps 1 to 3
Connecting Rod Side Clearance 0.10mm - 0.30mm or 0.004" - 0.012"
Gear Housing - Step 1 20 N.m or 15 ft-lb
68 N.m or 50 ft-lb
Idler Gear Holddown Bolts
Step 1 61 N.m or 45 ft-lb
Step 2 Rotate 60 Degrees
Idler Gear backlash 0.08mm - 0.38mm or 0.003" - 0.015"
Idler Gear end Clearance 0.30mm - 0.53mm or 0.012" - 0.021"
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Document No.: CSA-QF-03-01-07-56
Date: 31.08.2009
Rev.: 2
Torque Wrench
Feature Specification / Torque Number Actual Reading Mechanic / Fitter
Piston Cooling Nozzle 28 N.m or 21 ft-lb
Block Stiffener Plate 47 N.m or 35 ft-lb
Camshaft lockplate Capscrews 47 N.m or 35 ft-lb
Camshaft end float .13mm - .33mm or .005"-.013"
Cam Follower 47 N.m or 35 ft-lb
Front Cover Bolts
Bolts 1 - 22 20 N.m or 15 ft-lb
Bolts 23 - 28 68 N.m or 50 ft-lb
Cam Follower Side Clearance 0.76mm Min. 0.030"
Cylinder Head Capscrews
Step 1 68 N.m or 50 ft-lb
Step 2 136 N.m or 100 ft-lb
Step 3 Rotate 180 Degrees
7 Capscrews Fuel Pump Side of Head 68 N.m or 50 ft-lb
Oil Suction Tube Capscrew 61 N.m or 45 ft-lb
Oil Pan 54 N.m or 40 ft-lb
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Document No.: CSA-QF-03-01-07-56
Date: 31.08.2009
Rev.: 2
Torque Wrench
Feature Specification / Torque Number Actual Reading Mechanic / Fitter
Rocker lever housing 34 N.m or 25 ft-lb
61 N.m or 45 ft-lb
Internal Engine Harness 10 N.m or 15 ft-lb
Rocker Lever Cover 15 N.m or 130 inch-lb
Rocker lever Support Capscrews 81 N.m or 60 ft-lb
Injector Clamps
1 Bolt Type 75 N.m or 55 ft-lb
See Adjusting sequence on last page
Valve Clearance
Inlet .36mm or .014"
Exhaust .71mm or .027"
Injector Setting Turn Adjusting Screw Until It Just
Bottom The Plunger - back Out 2 Flats
( 120 Degrees ) - Lock 61 N.m or 45ft-lb
Jacobs Brake InstallationCapscrews 81 N.m or 60 ft-lb
Jacobs Brake Clearance 0.38mm or 0.015" Min.
Rocker Lever Adj. Nut 61 N.m or 45 ft-lb
file:///conversion/tmp/activity_task_scratch/878013803.xls Created by: N. Langenhoven
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Document No.: CSA-QF-03-01-07-56
Date: 31.08.2009
Rev.: 2
Torque Wrench
Feature Specification / Torque Number Actual Reading Mechanic / Fitter
Flywheel Housing
Step 1 68 N.m or 50 ft-lb
Step 2 129 N.m or 95 ft-lb
Step 3 197 N.m or 145 ft-lb
Flywheel 183 N.m or 135 ft-lb
Water Header Plate 54 N.m or 40 ft-lb
Vibration Damper 203 N.m or 150 ft-lb
Turbo Mounting Capscrews
Normal 88 N.m or 65 ft-lb
Wastegate 61 N.m or 45 ft-lb
Rear Crankseal Housing
Step 1 6 N.m or 50 inch-lb
Step 2 34 N.m or 25 ft-lb
Exhaust Manifold
Step 1 27 N.m or 20 ft-lb
Step 2 47 N.m or 35 ft-lb
Intake Manifold 47 N.m or 35 ft-lb
Front Engine Mounting 68 N.m or 50 ft-lb
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Document No.: CSA-QF-03-01-07-56
Date: 31.08.2009
Rev.: 2
Torque Wrench
Feature Specification / Torque Number Actual Reading Mechanic / Fitter
Oil Pump Mtg. Capscrews 41 N.m or 30 ft-lb
Oil Filter Head 47 N.m or 35 ft-lb
Oil Cooler 47 N.m or 35 ft-lb
Water Pump 47 N.m or 35 ft-lb
Thermostat Housing 54 N.m or 40 ft-lb
Acc Drive To Block 47 N.m or 35 ft-lb
Pin at 12 "o" Clock
Compressor Must be Timed to The Acessory Drive
Compressor Bolts
Cummins 44 N.m or 33 ft-lb
Holset 68 N.m or 50 ft-lb
Fuel Pump & Bracket 47 N.m or 35 ft-lb
ECM Cooling Plate Screws 40 N.m or 30 ft-lb
ECM Bolts 20 N.m or 15 ft-lb
Fan Hub Bracket Bolts 75 N.m or 55 ft-lb
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Document No.: CSA-QF-03-01-07-56
Date: 31.08.2009
Rev.: 2
Torque Wrench
Feature Specification / Torque Number Actual Reading Mechanic / Fitter
Sump Plug 88 N.m or 65 ft-lb
Valve and Injector Setting - STC
Firing Order 1-5-3-6-2-4
Pulley Position Injector Valve
Start A 3 5
B 6 3
C 2 6
A 4 2
B 1 4
C 5 1
Valve and Injector Setting - Non STC
Firing Order 1-5-3-6-2-4
Pulley Position Injector Valve
Start A 1 1
B 5 5
C 3 3
A 6 6
B 2 2
C 4 4
Specs. Taken From Bulletin No. 3666322, ISM, ISMe & QSM 11 Service manual on Quickserve
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Rev Changes made Effective Date
level
0 New CPB work instruction ###
1 Add columns in to reflect main and big end bearing sizes Monday, June 8, 2009
2 Add artisan and signature coulombs to front page ###
10
04 QF 003B Page 11 of 11
