Engineering

Standards
Engineering Standard Number
Name CASTING,GENERAL TOLERANCES

INSPECTION SPECIFICATION 16040

Identifier
(ITEM)

Abstract

This specification establishes requirements for checking dimensional accuracy and tolerances of
rough casting.

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INSPECTION SPECIFICATION 16040

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Table of Contents

Heading Page Number

Abstract .....................................................................................................................................1
Table of Contents ......................................................................................................................2
1. Scope....................................................................................................................................4
2. Applicable Documents.........................................................................................................4
3. Definitions............................................................................................................................4
4. Specifications.......................................................................................................................5
4.1. Significance and Use ...................................................................................................5
4.2. Pattern and Casting Identification................................................................................6
Table 1: Pattern and Casting Identification .........................................................................6
4.3. Dimensional Tolerances ..............................................................................................6
Table 2: Cored Passage Size Tolerance ...............................................................................7
Table 3: Wall Thickness Tolerance .....................................................................................7
Table 4: Total Casting Tolerance.........................................................................................8
4.4. Draft .............................................................................................................................8
Table 5: Draft On Sand Castings .........................................................................................8
4.5. Machining Stock ..........................................................................................................9
Table 6: Machining Stock for Aluminum and Iron Castings...............................................9
Table 7: Machining Stock for Steel Castings ......................................................................9
4.6. Smooth and Flat .........................................................................................................10
4.7. Chaplet Usage ............................................................................................................10
4.8. Chaplet Usage on Cylinder Head Castings................................................................10
4.9. Flywheel Finish Stock ...............................................................................................10
Table 8: Flywheel Finish Stock .........................................................................................10
4.10. Flywheel Housings ...................................................................................................10
Table 9: Flywheel Housing Finish Stock...........................................................................11
4.11. NH and Derivative Cylinder Blocks .........................................................................11
Table 10: General Cylinder Block Casting Tolerances .....................................................12
4.12. L10, M11 and Derivative Cylinder Blocks...............................................................12
Table 11: Cylinder Block Castings ....................................................................................12
4.13. K, KV and Derivative Cylinder Blocks ....................................................................13
Table 12: KV38/KV50 Cylinder Block Castings ..............................................................13
4.14. B & C Series Cylinder Block/Cylinder Head/Exhaust Manifold Castings ..............13
Table 13: B & C Series Cylinder Block, Cylinder Head ...................................................14

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INSPECTION SPECIFICATION 16040

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Table of Contents

Heading Page Number

Appendix A: Recommended Practices for Casting Date Codes..............................................15

Table A1: Month Code ......................................................................................................15
Appendix B: Figures ................................................................................................................16
Figure B1: “O” Flywheel ...................................................................................................16
Figure B2: “OO” Flywheel ................................................................................................17

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INSPECTION SPECIFICATION 16040

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1. Scope
This specification establishes requirements for checking dimensional accuracy and tolerances of
rough casting. This specification covers sand and permanent mold castings of all metals, and
provides dimensional tolerances for castings having standard accuracy.

Do not use this specification for new drawings. This specification is being maintained for
inspection and manufacturing tolerances on existing tooling, gages, and drawings. However, the
contents of this specification may still be used as reference in the design process. For new
drawings, refer to CES 16701.

2. Applicable Documents
Applicable documents listed below may be obtained from the respective organizations listed in
CES 10054, Standards Organizations Addresses.

a. CES 10012, Listing, Approved Source

b. CES 10054, Standards Organizations Addresses
c. CES 10056, Glossary
d. CES 16062, Defect, Visual Castings
e. CES 16083, Casting-Sand-Cast
f. CES 16257, Inspection, Cylinder Blocks and Heads
g. CES 16701, Casting, Dimensional Tolerances/Visual
h. CES 18111, Identification, Prod Item
i. SAE J435, Automotive Steel Castings
3. Definitions
Terms used in this standard that have a general definition for usage in Cummins Engineering
Standards are defined in CES 10056, Glossary.

3.1. Cast Dimensions

Cast dimensions are to theoretical sharp corners and the draft is additive to those dimensions.

3.2. Cored Passage Tolerance

Cored passage tolerance is the variation from nominal between two cast surfaces produced by the
same core.

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INSPECTION SPECIFICATION 16040

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3.3. Core Shift

Core shift is the variation from specified dimensions of a cored section due to a change in position
or misalignment of cores in an assembly.

3.4. Largest Overall Cast Dimension

The largest overall cast dimension is the largest linear dimension of the casting, including
machining stock. Addition of several drawing dimensions and machining stock may be necessary
to determine largest overall cast dimension, but diagonal calculations do not apply.

3.5. Mold Shift

Mold shift is a casting condition that results when a casting mold does not match at the parting line.

3.6. Smooth and Flat

Local areas on castings may be designated as “smooth and flat” to accommodate machining
locators, clamps or for other functions that are sensitive to surface roughness or angularity.

3.7. Total Casting Tolerance

Total casting tolerance is the maximum deviation of cast surfaces from nominal dimension.
Generally, these are measured from initial machining locators; however, tolerances applied to each
cast surface are not additive. Any two cast surfaces shall be within total casting tolerance of
each other.

4. Specifications
4.1. Significance and Use

This specification applies to most cast components. Specific sections of this standard for cylinder
blocks, cylinder heads, flywheels or other components take precedence over the general
tolerance specifications.

Note: For casting appearance requirements refer to CES 16062. Refer to CES 16257 for cleanliness
requirements of cylinder block and cylinder head castings, and refer to CES 16083 for inspection
of rough castings made from precision patterns.

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INSPECTION SPECIFICATION 16040

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4.2. Pattern and Casting Identification

4.2.1. All castings shall have information identified on the casting in accordance with Table 1:
Pattern and Casting Identification on page 6.

Table 1: Pattern and Casting Identification

All Castings Critical Castings (1)

Part number CES 18111 CES 18111

Engineering revision level Recommended Required
Pattern number Recommended Required
Supplier identification per Required Required
CES 18111
Cast date Recommended Required
Shell mold date Optional Required
Mold cavity number Recommended Required
Heat code Optional Required
Note (1): Critical castings are identified by reference to CES 10012 on the drawing.

4.2.2. Recommended practices for date codes are described in Appendix A: Recommended
Practices for Casting Date Codes on page 15.

4.3. Dimensional Tolerances

Dimensional tolerances in this section shall apply to castings which do not have tolerances
specified in Section 4.11. NH and Derivative Cylinder Blocks on page 11 through Section 4.14. B
& C Series Cylinder Block/Cylinder Head/Exhaust Manifold Castings on page 13 of this standard.

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INSPECTION SPECIFICATION 16040

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4.3.1. Cored Passage Size Tolerance

The variation from nominal between any two cast surfaces formed by the same core or mold
section shall be in accordance with Table 2: Cored Passage Size Tolerance on page 7.

Table 2: Cored Passage Size Tolerance

Nominal Size of Cored Dimension Tolerance

0 - 254 mm [0 - 10 in] ± 0.76 mm [0.030 in]

Over 254 mm [10 in] ± 1.15 mm [0.045 in]

4.3.2. Wall Thickness Tolerance

Wall thickness tolerance, independent of how the wall is formed, shall be in accordance with Table
3: Wall Thickness Tolerance on page 7. The tolerance is determined by the largest overall casting
dimension, independent of the local wall thickness.

Table 3: Wall Thickness Tolerance

Largest Overall Cast Dimension Tolerance

0 - 457 mm [0 - 18 in] ± 0.76 mm [0.030 in]

Over 457 mm [18 in] ± 20% of specified wall thickness

4.3.3. Fillet and Round Tolerance

Maximum fillet and round radius is 1.3x specified. Minimum fillet and round radius is
0.8x specified.

4.3.4. Angular Tolerance

Angular tolerance for all castings shall be ± 1°.

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4.3.5. Total Casting Tolerance

For characteristics not specified in Sections 4.3.1. Cored Passage Size Tolerance on page 7 through
4.3.4. Angular Tolerance on page 7 of this specification, the tolerance shall be in accordance with
Table 4: Total Casting Tolerance on page 8. Any two cast surfaces shall be within total casting
tolerance of each other. The tolerance in all directions is determined by the largest overall
cast dimension.

Table 4: Total Casting Tolerance

Largest Overall Cast Dimension Total Tolerance

0 - 152 mm [0 - 6 in] ± 1.02 mm [0.040 in]

Over 152 - 610 mm [6 - 24 in] ± 1.5 mm [0.060 in]
Over 610 - 1220 mm [24 - 48 in] ± 1.90 mm [0.075 in]
Over 1220 mm [48 in] ± 2.3 mm [0.090 in]

4.4. Draft

4.4.1. Draft shall be applied such that it adds material to the casting from nominal dimensions.

4.4.2. Draft on sand castings shall be in accordance with Table 5: Draft On Sand Castings on
page 8. Larger draft angles are permitted only when necessary to match surfaces from different
mold halves at the parting plane.

Table 5: Draft On Sand Castings

Length of Draw Maximum Allowable Draft

0 - 25 mm [0 - 1 in] 2º
Over 25 mm [1 in] 1º

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4.4.3. Draft On Permanent Mold Castings

The maximum allowable draft on permanent mold castings shall be 3º. Larger draft angles are
permitted only when necessary to match surfaces from different mold segments at the
parting plane.

4.5. Machining Stock

Machining stock requirements in this section shall apply to castings which do not have machining
stock specified in Section 4.11. NH and Derivative Cylinder Blocks on page 11 through Section
4.14. B & C Series Cylinder Block/Cylinder Head/Exhaust Manifold Castings on page 13 of this
standard. Machining stock shall be in accordance with Table 6: Machining Stock for Aluminum
and Iron Castings on page 9 or Table 7: Machining Stock for Steel Castings on page 9 as applicable
and is based on the largest overall cast dimension. It is constant for all parts of the casting,
independent of the individual feature dimensions.

Table 6: Machining Stock for Aluminum and Iron Castings

Machining Stock Machining Stock

Largest Overall Cast Dimension
Sand Cast Permanent Mold
0 - 152 mm [0 - 6 in] 1.8 mm [0.070 in] 1.27 mm [0.050 in]
Over 152 - 305 mm [6 - 12 in] 2.3 mm [0.090 in] 1.8 mm [0.070 in]
Over 305 - 457 mm [12 - 18 in] 3.05 mm [0.120 in] 2.03 mm [0.080 in]
Over 457 - 762 mm [18 - 30 in] 3.81 mm [0.150 in] 2.54 mm [0.100 in]
Over 762 mm [30 in] 5.08 mm [0.200 in] 3.81 mm [0.150 in]
Any disk ground surfaces 0.76 mm [0.030 in] 0.76 mm [0.030 in]

Table 7: Machining Stock for Steel Castings

Largest Overall Cast Dimension Machining Stock

0 - 305 mm [0 - 12 in] 4.57 mm [0.180 in]

Over 305 mm [12 in] 6.35 mm [0.250 in]

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INSPECTION SPECIFICATION 16040

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4.6. Smooth and Flat

Surfaces specified to be cast smooth and flat shall be free of parting line fins, shall have an
out-of-flat condition of not greater than 0.56 mm/25.4 mm [0.022 inch/inch], and shall have a
surface roughness not greater than Alloy Casting Institute (ACI) surface indicator scale SIS-3, in
accordance with SAE J435.

4.7. Chaplet Usage

Except for cylinder head castings, chaplet usage is generally acceptable subject to approval by
Cummins Supplier Quality Improvement (SQI) and Plant Product Engineering.

4.8. Chaplet Usage on Cylinder Head Castings

Chaplets shall not be used on the fire deck of cylinder head castings unless the machining process
removes them. Cummins Supplier Quality Improvement and Product Engineering shall approve
any use of chaplets on cylinder head castings.

4.9. Flywheel Finish Stock

Flywheel finish stock shall be in accordance with Table 8: Flywheel Finish Stock on page 10,
except see, Figure B1: “O” Flywheel on page 16 and Figure B2: “OO” Flywheel on page 17 for
finish stock on KV12 and KV16 SAE Type “0” and “00” flywheels.

Table 8: Flywheel Finish Stock

Clutch Side and Crankshaft

Material Engine Face Side (1) Other
Mounting Face

Gray Iron 2.3 mm [0.090 in] 3.05 mm [0.120 in] 3.05 mm [0.120 in]
Ductile Iron 3.05 mm [0.120 in] 4.57 mm [0.180 in] 3.05 mm [0.120 in]
Note (1): Applies from casting outer diameter (OD) to crankshaft mounting face

4.10. Flywheel Housings

Flywheel housings shall have finish stock in accordance with Table 9: Flywheel Housing Finish
Stock on page 11.

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Table 9: Flywheel Housing Finish Stock

Starter Bore Finish Stock

Cast iron housing 3.81 mm [0.150 in]

Sand cast aluminum 6.35 mm [0.250 in]
Permanent mold aluminum 3.05 mm [0.120 in]
Other areas 3.81 mm [0.150 in]

4.11. NH and Derivative Cylinder Blocks

Requirements of this section apply to the following engine families: D08, D09, D25, D28
(NH and derivatives).

4.11.1. The cam follower opening side walls shall be in nominal location ± 1.52 mm
[0.060 in].

4.11.2. The push tube openings at the head face shall be in nominal location within ± 2.3 mm
[0.090 in].

4.11.3. The camshaft cored holes shall be in nominal location ± 2.3 mm [0.090 in].

4.11.4. The inside wall around the compression release shaft area shall be in nominal location
within ± 1.52 mm [0.060 in].

4.11.5. Tolerances on cap screw and pipe thread bosses diameter shall be ± 0.76 mm [0.030 in].

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Table 10: General Cylinder Block Casting Tolerances

Characteristic Tolerance
Total casting ± 3.05 mm [0.120 in]
Cored hole ± 1.52 mm [0.060 in]
Wall thickness ± 20% nominal thickness
Maximum allowable mold shift ± 1.02 mm [0.040 in]
Maximum allowable core shift ± 1.52 mm [0.060 in]
Core assembly dimensions ± 1.52 mm [0.060 in]
Finish stock 5.08 mm [0.200 in]

4.12. L10, M11 and Derivative Cylinder Blocks

4.12.1. Requirements of this section apply to the following engine families: D34, D35, D60
(L10, M11 and derivatives).

4.12.2. L10 cylinder block casting tolerances shall be in accordance with Table 11: Cylinder
Block Castings on page 12.

Table 11: Cylinder Block Castings

Characteristic Tolerance
Total casting ± 1.5 mm [0.060 in]
Cored hole (up to 250 mm [9.84 in] size) ± 0.75 mm [0.030 in]
Wall thickness ± 1.00 mm [0.040 in]
Mold shift ± 0.75 mm [0.030 in]
Core shift ± 0.75 mm [0.030 in]
Maximum allowable draft 3º and as noted on drawing
Finish stock (increased by draft when applicable) 4.00 mm [0.160 in]

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4.13. K, KV and Derivative Cylinder Blocks

4.13.1. Requirements of this section apply to the following engine families: D19, D23, D28,
D36, D48, D58, D59, D77, D84, D86 (K, KV and derivatives).

4.13.2. Unless otherwise specified on the drawing, tolerances shall be in accordance with Table
12: KV38/KV50 Cylinder Block Castings on page 13.

Table 12: KV38/KV50 Cylinder Block Castings

Characteristic Tolerances (1)

Total casting ± 3.05 mm [0.120 in]
Cored hole (up to 250 mm [9.84 in] size) ± 1.52 mm [0.060 in]
Wall thickness ± 20% of specified thickness
Mold shift ± 1.02 mm [0.040 in]
Core shift ± 1.52 mm [0.060 in]
Core assembly dimensions ± 1.52 mm [0.060 in]
Finish stock (increased by draft when applicable) 5.08 mm [0.200 in]
Note (1): The tolerances specified are not additive

4.14. B & C Series Cylinder Block/Cylinder Head/Exhaust Manifold Castings

4.14.1. Requirements of this section apply to the following engine families: D31, D32, D38,
D40, D41, D49, D55, D75, D78, D82, D83, D85 (B, C and derivatives).

4.14.2. Unless otherwise specified on the drawing, the progressive tolerances shall apply to
linear dimensions, in reference to datum base lines in accordance with Table 13: B & C Series
Cylinder Block, Cylinder Head on page 14.

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Table 13: B & C Series Cylinder Block, Cylinder Head

and Exhaust Manifold Castings

Specified Dimension Tolerance

0 - 152 mm [0 - 6 in] ± 1.0 mm [0.040 in]
Over 152 - 305 mm [6 - 12 in] ± 1.3 mm [0.051 in]
Over 305 - 457 mm [12 - 18 in] ± 1.5 mm [0.060 in]
Over 457 - 610 mm [18 - 24 in] ± 1.8 mm [0.070 in]
Over 610 mm [24 in] ± 2.0 mm [0.079 in]
Dimension to all intake ports ± 0.8 mm [0.031 in]
Dimension to all exhaust ports ± 1.0 mm [0.040 in]

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Appendix A: Recommended Practices for Casting Date Codes

A1. Option 1
The first digit(s) to specify the actual days date on which the castings were poured. Secondly a
letter (A to M) indicating the month of the year in accordance with Table A1: Month Code on page
15, and finally a digit (0 to 9) indicating the year.

Example: 8H7 is 8th August 1977

Table A1: Month Code

A - January G - July
B - February H - August
C - March J - September
D - April K - October
E - May L - November
F - June M - December

A2. Option 2
A four digit number where the first three digits indicate the day of the year and the fourth digit
indicates the year.

Example: 0068 = Jan. 6, 1978; 2898 = Oct. 16, 1978

A3. Identification
A3.1. All cast identification is to be cast in bold letters 6.4 mm [0.25 in] high raised or indented
1.5 mm [0.06 in] from the cast surface unless smaller letters are essential for appearance or space
limitations, in which cast 3.0 mm [0.12 in] or 4.8 mm [0.19 in] high letter may be used.

A3.2. Flywheel part numbers and cast dates may utilize up to 25.4 mm [1.00 in] high
letters option.

A3.3. Cylinder block and cylinder head part numbers and cast dates may utilize letters up to
15 mm [0.59 in] high.

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Appendix B: Figures

Optional Fillet
“O” Flywheel

Conversion Chart
1. Finish stock 0.19" unless mm. in.
otherwise specified
3.0 0.12
2. Fillet Radii 0.25" 4.8 0.19
6.4 0.25
3. Edge Radii 0.12" 9.7 0.38
25.4 1.00
66.8 2.63

Figure B1: “O” Flywheel

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Appendix B: Figures (Continued)

00 Flywheel
Conversion Chart
1. Finish stock 0.19" unless mm. in.
otherwise specified
3.0 0.12
2. Fillet Radii 0.25" 4.8 0.19
6.4 0.25

3. Edge Radii 0.12" 9.7 0.38

19.0 0.75
25.4 1.00
73.2 2.88
82.6 3.25

Figure B2: “OO” Flywheel

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