Blocks - Cylinder HHP

General Policy - Core Acceptance Block Core Acceptance Standards

Cummins ReCon Core Acceptance Standards
relies on returned core to continuously supply
customers with the correct high quality
remanufactured components. To support this goal,
it is requested that cores be returned on a like-for-
like or style-for-style basis.
Core is acceptable without additional billing if core
inspection indicates the following:
1. Core exchange like for like; no swapping accepted
2. Final decision for the acceptance criteria will be
taken by the repair facility

1. Cores damaged as a result of improper 3. Freight expense is responsibility of distributor/

packaging may be subject to rejection. It is the dealer/customer except as provided in Cummins
shipper's responsibility to properly package core. Warranty Memo 0715 (latest version)

2. Core that is damaged by non-operational causes
such as rough handling, fire, improper removal
or improper protection during storage is not
acceptable.
3. Rust that occurs on exterior surfaces of
components exposed to weather conditions
from normal operating conditions is acceptable.
Interior surfaces and components, such as rods,
or any machined surface can only have light
flash rust. Heavy rust due to improper storage is
not acceptable.
4. Assemblies must be complete and contain their
original component parts.
5. No attempts to rebuild or make an assembly
from mismatched parts is acceptable.
IMPROPER REMOVAL, STORAGE OR
PACKAGING OF CORE COULD RESULT IN
THE REJECTION OF THE COMPONENT.
4. If the block is declared non-repairable there will be
no credit for the block core.
5. If a dealer or distributor would like a non-repairable
block to be returned to his shop, they will be
responsible for freight costs
6. Additional billing is established at the time of
inspection based on missing parts, damaged parts,
fluids and current block pricing policy.
Please Note:
Removal of camshaft bushings, dowel pins or rings,
plugs is not required.
Block and crankshaft can be shipped together if
the crankshaft is also being returned as acceptable
core.
Do not return connecting rods, pistons, liners,
front gear train components or cylinder head cap
screws. All these parts must be removed before
the block is returned.
All main bearing caps and main bearing cap screws
are to be returned regardless of degree of damage.

Core Block Shipment Address

The block needs to be shipped
to the following address:
Attention: David Bowne
B&G Machine Inc.
6400 Corson Avenue S.
Seattle, WA 98108
Phone: (800) 645-2384
david.bowne@bandgmachine.com

HHPB-1
REV: 02-09
 Blocks - Cylinder HHP

KT/KTA/KTTA/QSK38/QSK50 Block Core Identification

Block Assy. Service Block Acceptable
Bare Block Number Comments as core*
Number Number
KT/KTA/KTTA/QSK38
Drilled for rear gear drive. Replaced by Yes
3178911 3177639 3177802 3639181.
3639181 3177639 3177802 Drilled for rear gear drive. Current. Yes
Not drilled for rear gear drive. Replaced Yes
3052563 3177638 4955577 by 3639185.
Released for QSK38 MCRS but used on Yes
3639185 3177638 4955577 all 38 liter engines. Not drilled for rear
gear drive. Current.
KT/KTA/KTTA/QSK50
Drilled for rear gear drive. Replaced by Yes
3178910 3177641 3040191 3637658.
3178803 Yes
3637658 3637659 Drilled for rear gear drive. Current.
3637667
Not drilled for rear gear drive. Replaced Yes
3632803 3632807 by 3049291.
Not drilled for rear gear drive. Re- Yes
3049291 3177640 placed by 4927511.
Released for QSK50 MCRS but used on Yes
4927511 4927512 4955242 all 50 liter engines. Not drilled for rear
gear drive. Current.
*ONLY BLOCKS THAT PROVIDE FOR CENTER MOUNT PISTON COOLING NOZZLES ARE ACCEPTABLE

HHPB-2
REV: 02-09
 Blocks - Cylinder HHP

QSK45/QSK60/QSK60 MCRS/QSK78 Block Core Identification

Block Assy. Service Block Acceptable
Bare Block Number Comments as core*
Number Number
QSK45
3410333 34110334 3410334 Changed front dowels. No
Must be modified to use straight split Yes
4016528 4016526 4001051 rods. Replaced by 3640531.
Casting changed for straight split rods. Yes
3640531 3640734 3640781 Current.
Rail. Must be modified to used straight Yes
4101418 4101419 4101419 split rods.
Rail. Casting changed for straight split Yes
3640528 3640532 3650736 rods. Current.
QSK60/QSK60 MCRS
3410335 3410336 Changed front dowels. No
Must be modified to use straight split Yes
4016529 4016527 4001053 rods. Replaced by 3640533.
Casting changed for straight split rods. Yes
3640533 3640735 3640782 Current.
? ? 3082443 3640530D Yes
QSK78
Interim casting change. Replaced by No
4007169 4007168 3630441.
Casting change on head deck. No
4007169 3640441 Replaced by 3640435.
3640435 3640432 4089095 Current. Yes

HHPB-3
REV: 02-09
 Blocks - Cylinder HHP

QSK 60 Block Core Acceptance Illustration 3640530D

Casting #3082443

HHPB-4
REV: 02-09
 Blocks - Cylinder HHP
Examples Of Acceptable/Not Acceptable Block Damage
This and the following pages provide examples of common block along with descriptive criteria.
It is not possible to provide examples or criteria for every form of damage possible.
If the user of this publication is not sure as to whether or not the block is acceptable as core,
please contact the supplier with digital photos to further determine if the block is acceptable.
Contact: david.bowne@bandgmachine.com
Phone: (800) 645-2384

Missing Skirt Material Over Main Support Hole in Block Skirt

Not acceptable Acceptable if pan rail is not broken out and little to no material
Too much material missing over main missing over main bearing webs.
bearing support causing loss of strength Not acceptable if pan rail is broken out as shown above.
and no place for stitch pins.

Cracks Between Cylinders At Head Deck

Not acceptable if cracks at upper

counterbore area or in packing ring bore.
Acceptable if crack is in water jacket wall
between cylinders if both ends of crack
are visible in both cylinders. HHPB-5
REV: 02-09
 Blocks - Cylinder HHP
Examples Of Acceptable/Not Acceptable Block Damage

BLOCK HEIGHT K38/K50/QSK38/QSK50

Block height minimum:
From crank centerline (18) 482.194 mm (18.984 in)
From top of main bore (19) 397.790 mm (15.561 in)
Both banks must meet minimum height for the full
length of block

BLOCK HEIGHT QSK45/QSK60

Block height minimum:
From crank centerline (18) 528.69 mm (20.814 in)
From top of main bore (19) 432.21 mm (17.016 in)
Both banks must meet minimum height for the full
length of the block.

BLOCK HEIGHT QSK78

Block height minimum:
From crank centerline (18) 529.20 mm (20.835 in)
From top of main bore (19) 432.72 (17.036)
Both banks must meet minimum height for the full
length of the block.

HHPB-6
REV: 02-09

Examples Of Acceptable/Not Acceptable Block Damage
Water Jacket Damage Repair In
Cam Follower Cavity
Acceptable if cracks do not reach a radius and
both ends of all cracks are visible on both sides of
the wall.
The damage shown above is not acceptable
because it extends into the cam bore web to the
right, and the top end of the crack closest to the
cam bore web is not visible at the top.
Block Ventilation At Hand Hole Cover
Acceptable if cracks do not reach a radius and
Acceptable UNLESS the damage extends into the
outboard piston cooling oil rifle (QSK45, QSK60,
QSK60 (MCRS), QSK78.
Blocks - Cylinder HHP
Crack In Hand Hole Cover Area
Top of block
Acceptable if both ends of crack that extends
upward are visible inside and outside the wall.
Acceptable if crack as shown at right is in pan rail
but nothing is missing from pan rail.
Not acceptable if the crack extends upward into
the outboard piston cooling oil rifle (QSK45/60,
QSK60 (MCRS), QSK78)
Head Bolt Boss Break out in Casting
Generally acceptable and repairable with blind end
insert.
If cracked due to impact from rod/piston failure
then see criteria for breakout of water jacket
between cylinders or into cam follower cavity.
HHPB-7
REV: 02-09

Examples Of Acceptable/Not Acceptable Block Damage
Heat Damaged Main Bore or Cam Bore
Acceptable if there are no cracks.
Block will be magnetic crack checked at supplier.
Cracks that extend to the block skirt or main cap
saddle are probably not acceptable. Contact the
supplier.
Head Deck Fretting
Acceptable as long as block height is acceptable.
Blocks - Cylinder HHP
Front Gear Train Idler Face and Bore
Fretting to the face of the block is acceptable.
Damage to cap screw holes and shaft or dowel
ring bore is acceptable.
Gouges in front face of block from gear train
failures are acceptable as long as both ends of any
cracks are visible inside and outside the casting.
Bad Welds and Field Repairs
Conditionally Acceptable
Contact the supplier with complete information
and digital photographs before shipping. HHPB-8
REV: 02-09
 Blocks - Cylinder HHP
Examples Of Acceptable/Not Acceptable Block Damage
Crack in Camshaft Bore Block Broken in Push Rod Area

Acceptable as long as the upper cylinder bore is

not involved and the criteria for water jacket cracks
Cracks in the camshaft bore are acceptable. in cam follower cavity are met.
Photo at left shows new section from another block
that will be inserted and pinned in place.

Cracked Accessory Mounting Bolt Holes Bad Welds and Field Repairs

Acceptable if cracked to exterior as shown.

Acceptable as long as cracks do not extend into

oil rifles. HHPB-9
REV: 02-09
 Blocks - Cylinder HHP
Examples Of Acceptable/Not Acceptable Block Damage
Cracked Flywheel Housing Bolt Hole Cracked Main Bearing Saddle

Cracks in the cap screw hole or the radius are

Acceptable as long as crack does not extend into acceptable as long as they do not intersect
oil rifle. another hole in the block or a coolant or oil
passage.

Pulse Cavitation, Pinholes and other Small Holes Pulse Cavitation, Pinholes and other Small Holes

Acceptable as long as casting is not cracked into

Acceptable. adjacent cylinder packing ring bore.

HHPB-10
REV: 02-09
 Blocks - Cylinder HHP
Examples Of Acceptable/Not Acceptable Block Damage
Lower Liner Stop and Piston Cooling Nozzle
Pad Damage Cylinder to Cylinder Water Jacket Damage

Liner stop damage:

Acceptable as long as any missing section is not
Acceptable.
larger than 3 inch x 3 inch, does not intersect a radius
Liner stops will not be restored to remanufactured above packing ring bore or below upper counterbore,
blocks as engine can be operated without the a caps screw hole and does not extend into the cam
protrusions. follower cavity (crankcase).
Sometimes called liner catchers.
Piston cooling nozzle pad damage:
Not acceptable if chunks missing as shown Counterbore and Head Deck Cracks
above.
Simple nicks and dings acceptable.

Main Bearing Saddle Damage

Fretting of pad surface around cap screw hole
is acceptable.
Fretting of press fit area is acceptable.

Upper Counterbore Wear

Wear beyond published reuse limits is
acceptable.

Fretting on Flywheel Housing Face

Same as block front face fretting.

Gear Housing or Flywheel Housing

Dowel Pin Damage
Radial cracks in the counterbore radius are
Oversize or ovalized holes are acceptable
acceptable.

Exterior Coolant Hole Erosion Damage Cracks across the counterbore ledge are acceptable.
Acceptable Cracks from the counterbore diameter to a coolant
hole or cylinder head cap screw hole are not
acceptable. HHPB-11
REV: 02-09