Parts Ordering Guidelines :

Transcription

1

2 Parts Ordering Guidelines : Genuine Cummins Parts and service facilities are available all over India. There are more than 100 Cummins sales and service locations giving service support to the engines owned by you. Each distribution outlet is thoroughly equipped with technical data, factory trained mechanics, modern equipments and a full adequate stock of Genuine Cummins Parts. For quicker and better service, your parts requirements should be ordered from your nearest Cummins Distributer or Dealer. At any of the locations prompt, intelligent, courteous service is a basic trade-mark. Each is ready and eager to help in every possible way through personal contact or through the mail-at your convenience. The satisfactory ordering and receiving of parts by the purchase is greatly dependent upon the proper use of available information. In order that all avoidable errors may be eliminated, the following instructions are offered as the purchaser's guide: 1. Write your order clearly, using a typewriter if possible. 2. Be sure to list the correct part number. If in doubt as to the correct part number, state the model and serial number of the engine on which the part is to be used. Part numbers are usually located in various places on the part itself. 3. When possible, arrange your purchase order in part number numerical sequence. 4. Please specify shipping instructions, if any, preferable to you. 5. State your company name and shipping address clearly. Genuine Cummins Parts mean QUALITY : They're designed and engineered to fit best in your Cummins Diesel. Each part is made of the highest quality and accuracy-by the top craftsman of the trade. You can be sure a Genuine Cummins Part will fit better-do the job better-lessen the chances of costly breakdown. When you buy replacement parts, buy quality. Buy Genuine Cummins Parts. YOU OWN BEST... REPAIR WITH THE BEST No part of this manual may be copied, photocopied, reproduced, translated or stored in a retrieval system by any means electronic, mechanical or otherwise without prior permission in writing of Cummins India Limited, Kothrud, Pune Visit us at : 1

3 CUSTOMER SERVICE INFORMATION This parts catalog contains parts information. Engine Model Engine Serial No. OEM Model Genset Serial No. Fuel Pump Assembly No. Injector No. Belt, Fan, Drive Element, Fuel Filter Full Flow Lub. Filter Air Cleaner Since improvements are made from time to time, contents in the parts catalog are subject to change without notice PB PB

4 Table of Contents B-Series Powergen (82.5 KVA To 125 KVA) Description Ref. Page Number A Aftercooler Plumbing - 6BTA 5.9 G1 5 Aftercooler 6 BTA 5.9 G1 6 Air Cleaner Assembly 7 Alternator Charging 8 AVM & Alternator Mounting Single Bearing 9 C Camshaft Assembly 10 Connecting Rod Assembly 11 Connection, Water 12 Cover, Cam Follower 13 Cover, Front Gear 14 Cover, Valve 15 Cylinder Block Cylinder Head Cylinder Head - Mounting 20 D Damper, Vibration 21 Dipstick Arrangement 22 Drive, GEAR 23 E Engine Maintenance - Parts List 52 Exhaust Assembly 24 Exhaust Manifold 25 F Fan, Drive 26 Fuel Drain Tube 27 Flywheel 28 Fuel Filter 29 Fuel Filter - Plumbing 30 Fuel Injection Pump 31 Fuel Injection Pump - Plumbing - 6 BT 5.9G / G1 32 Fuel Injection Pump - Plumbing - 6 BTA 5.9 G1 / G2 33 Fuel Lines Connections 34 Fuel Lift Pump 35 Fuel Pump Coupling 36 PB

5 Table of Contents Description Ref. Page Number G Genset Control Panel Electrical Parts 37 H Housing, Flywheel 38 I Injector Assembly 39 L Lever, Rocker 40 Lube, Oil Cooler 41 Lubricating, Pump 42 O Oil Filler Tube & Cap 43 Oil, Pan 44 P Piston Assembly 45 R Radiator (6BTA5.9G1/G2-1) 46 Radiator 6BT5.9 G1 47 S Starting Motor 48 T Thermostat Arrangement 49 Turbocharger 50 W Water Pump 51 Parts Catalog pages are arranged in alphabetical order 4

6 B-Series B-Series Powergen (82.5 (100 KVA & To KVA) KVA) AFTERCOOLER PLUMBING - 6BTA 5.9 G1 6 No. Part Number Description4 Qty. Remark Tube, Aftercooler Hose, Plain Clamp, Hose Hose, Elbow Coupling, Elbow Hose Aftercooler Assembly 1 5

7 B-Series B-Series Powergen Powergen (82.5(100 KVA & To KVA) KVA) AFTERCOOLER 6BTA 5.9 G Plug, Pipe 1 1/8 NPT Drain Cock 1 1/8 NPTF Gasket, Int Manifold Gasket, Connection Screw, Hex Flange 4 M8 x 1.25 x Aftercooler Screw, Hex Flange 14 M8 x 1.25 x Connection, Air Crossover Clamp, Hose Hose, Plain Plug, Pipe 2 ½ inch NPTF Hose, Plain Tube Air Connection, Spacer 1 6

8 AIR CLEANER ASSEMBLY Air Cleaner Elbow-Hose Hose-Vacuum Clamp-Hose Clamp-Hose Tube-Air Indicator-Service Wing Nut Bracket-Air Cleaner Screw-Hex Flg Hd Screw-Hex Hd Washer-fl Washer-Sprlk Element, Air Cleaner - Primary Element, Air Cleaner - Safety Nut-hex 4 7

9 ALTERNATOR CHARGING Alternator -12V Screw, Hex Flange 2 M8 x 1.25 x Screw, Hex Flange 3 M8 x 1.25 x Nut, Hex Flange 1 M10 x Brace, Alternator Screw, H.F.H.C. 1 M10 x 1.50 x Clamp Support Alternator 1 8

10 AVM & ALTERNATOR MOUNTING SINGLE BEARING No. Part Number Description 6BT 5.9 G/G1 6BTA 5.9 G1 / G2 Remark Screw-Hex Hd Screw-Hex Hd Washer-Spr Lk Washer, Lock Isolator-Vibration Isolator-Vibration 4 2 For 6BT5.9 G/G1 (75 to 82.5 kva) 4 nos. below engine and alternator For 6BTA5.9 G1/G2 (100 to 12.5 kva) 2 nos. below engine 9

11 CAMSHAFT ASSEMBLY Screw, Hexagon Head 2 M8 x 1.25 x Key, Plain Woodruf 1 Alternate Part No Support, Camshaft Thrust Gear, Camshaft Camshaft Tappet Valve 8 10

12 CONNECTING ROD ASSEMBLY Screw, Connecting Rod Cap 12 MJ11 x 1.25 x Rod, Engine Connecting Bearing, Connecting Rod 12 Not Serviceable Bushing Rod, Engine 6 For Service Screw, Con-Rod Cap Bushing 6 SERVICE PARTS A Set, Connecting Rod Bearing 1 Standard B Set, Connecting Rod Bearing 1 Oversize 1 C Set, Connecting Rod Bearing 1 Oversize 2 D Set, Connecting Rod Bearing 1 Oversize 3 E Set, Connecting Rod Bearing 1 Oversize 4 11

13 CONNECTION, WATER Screw, Hex Flange 3 M10 x 1.50 x Seal, Rectangular Connection, Water Inlet Plug NPTF - 1/2" 2 12

14 B-Series Powergen (82.5 KVA To 125 KVA) COVER, CAM FOLLOWER No. Part Number Description Screw Hex Flange Seal, Grommet Cover, Push Rod Gasket, Push Rod Hose, Plain (Breather) Clamp, Hose Qty Remark M8 x 1.25 x 16

15 COVER, FRONT GEAR Screw, Hex Flange 11 M8 x 1.25 x Screw, Round Head 2 M5 x 0.80 x Seal, Rectangular Gasket, Gear Housing Cover, Gear Screw, Hex Flange 16 M8 x 1.25 x Liquid Gasket 1 Available in 60 gm Tube Housing, Gear 1 Old Part No Seal Oil Housing, Timing Pin 1 Not Serviceable Pin, Timing Ring, Retaining Seal, 'O' Ring Housing, Timing Pin Gasket, Gear Cover 1 Service Part 14

16 COVER, VALVE Screw, Hex Flange 6 M8 x 1.25 x Valve, Cover Isolator, Noise Gasket, Valve Cover 6 5 S 602 Washer, Plain 6 15

17 CYLINDER BLOCK 16

18 CYLINDER BLOCK Crankshaft, Assembly Crankshaft Gear, Crankshaft Dowel, Pin Plug, Expansion Dowel, Ring Dowel, Pin Plug, Expansion Plug, Expansion Plug, Expansion Bushing Dowel, Ring Assy. Cap Main Bearings Screw, Hex Flange Head Cap Bearing, Crankshaft Thrust 1 Not Serviceable Alt Plug, Pipe Plug, Expansion 4 On Cam Follower side Seal, O Ring Block 1 Not Serviceable Bearing, Main 6 Not Serviceable Bearing, Main 7 Not Serviceable Plug Pipe 1 Alternate Part No Nozzle, Piston Cooling 6 Alternate Part No SERVICE PARTS A Set, Main Bearing (Std.) 1 Set of Main Bearing & Thrust Bearing B Set, Main Bearing 1 Oversize # 1 C Set, Main Bearing 1 Oversize # 2 D Set, Main Bearing 1 Oversize # 3 E Set, Main Bearing 1 Oversize # 4 F Sleeve, Salvage 6 Collared Sleeve G Cylinder Block Assembly 1 Complete Cyl. Block Assy. H Cylinder Block Assembly 1 Oversize # 1 I Bushing 6 Oversize J Bushing 1 Oversize K Crankshaft Assembly 1 Pin undersize L Crankshaft Assembly 1 Journal undersize M Crankshaft Assembly 1 Pin & Journal undersize 17

19 CYLINDER HEAD 18

20 CYLINDER HEAD Collet 12 Used 2 Nos. per Valve Spring Plug, Pipe 1 1/8 NPT Spring, Intake Valve Screw, Hex Flange 6 M12 x 1.75 x Screw, Hex Flange 14 M12 x 1.75 x Valve, Intake Valve, Exhaust Seal, Valve System Tube, Aftercooler Spring, Exhaust Valve Retainer, Valve Spring Head, Cylinder 1 Old Part No Plug, Pipe Plug, Pipe 1 SERVICE PARTS A Insert, Valve 6 Exhaust B Insert, Valve 6 Inlet C Guide, Valve Stem 6 Inlet (Length : mm) D Guide, Valve Stem 6 Exhaust (Length : mm) E Head, Cylinder 1 Assembly Part - Serviceable 19

21 CYLINDER HEAD - MOUNTING Gasket, Cylinder Head Plug, Pipe Connector Bracket, Lifting Screw, Hex Flange 2 M12 x 1.75 x 30 20

22 DAMPER, VIBRATION Screw, Hex Flange 4 M12 x 1.25 x Damper, Vibration 1 21

23 DIPSTICK ARRANGEMENT Plug, Expansion Tube Oil Gauge Dip Stick 1 22

24 DRIVE, GEAR Front Side Rear Side Cover, Access Hole Seal, Rectangular Gasket, Hydraulic Plate Cover Screw, Hex Flange 2 M12 x 1.75 x 25 23

25 EXHAUST ASSEMBLY Pipe - Exhaust (Below) Clamp - Exhaust Clamp 'V' Band Screw Hex. Flange HD (4 Nos.) Elbow - Exhaust Brace Exhaust Elbow - exhaust Clamp - Exhaust Pipe - Exhaust Plug - Pipe Bracket - Exhaust Screw Hex Flange Hd Muffler 1 6BT Muffler 1 6BTA Gasket - Exhaust Screw, Twelve Point Cap Flange 3 Added in place of Not in Sos 24

26 EXHAUST MANIFOLD Manifold, Exhaust Gasket, Exhaust Manifold Screw, Flat Head Capscrew 12 M10 x 1.50 x 65 25

27 FAN, DRIVE Pulley, Fan Screw, Hex Flange 4 M8 x 1.25 x Support, Fan Spacer, Fan Pilot 1 For 6 BTA Screw, Hex Flange Head Cap 4 M10 x 1.50 x 70 For 6 BTA Tensioner Belt Bracket, Tensioner Belt Belt, 'V' Ribbed 1 Not in above Picture Fan Assy. 1 For 6 BTA Fan Assy. 1 For 6 BT Spacer - Fan 1 For 6 BT Screw - Hex Flg. Hd. 4 For 6 BT 26

28 FUEL DRAIN TUBE Washer, Sealing Seal, Grommet Clamp Clamp, Hose Banjo Connector Hose, Straight 1 27

29 FLYWHEEL Washer, Plain 8 M Screw, Hex Head 8 M12 x 1.25 x Flywheel with Ring Gear - SAE Alternate Part No Ring Gear -159 Teeth 1 28

30 FUEL FILTER } Head, Fuel Filter Nut, Regular Hexagonal 1 M16 x 1.50 Hex Seal, O Ring Fuel Filter with Rectangular Gasket 1 Serviceable by Fleetguard Seal, O Ring Screw, Banjo Connector Screw, Hex Flange Washer, Sealing Adaptor, Filter Head 1 M16 x 1.50 (Both Ends) Head, Fuel Filter Head Fuel Filter Gasket Rectangular Separator, Fuel Water 1 Serviceable by Fleetguard Drain Valve 1 Serviceable by Fleetguard Gasket Rectangular Fuel Filter (without Rectangular Gasket) 1 29

31 FUEL FILTER - PLUMBING Tube Fuel Supply Tube, Fuel Supply Washer, Sealing Screw, Banjo Connector 1 M14 x 1.50 x 26 30

32 FUEL INJECTION PUMP Pump, Fuel Injection (75/82.5 KVA) 1 6 BT 5.9 G/G Pump, Fuel Injection (100 KVA) 1 6 BTA 5.9 G Pump, Fuel Injection (125 KVA) 1 6 BTA 5.9 G2-I Feed Pump, Fuel (MICO) 31

33 B-Series B-Series Powergen Powergen (82.5 KVA (82.5 To KVA) 125 KVA) FUEL INJECTION PUMP - PLUMBING - 6 BT 5.9G Seal, Banjo Connector 6 6.2mm Screw, Banjo Connector 6 M6 x 1.00 x Washer, Sealing 2 8mm Valve, Check 1 M8 x 1.25 x Screw, Hex Flange 1 M8 x 1.25 x Fuel, Manifold Tube, Inj Fuel Supply Tube, Inj Fuel Supply 1 32

34 B-Series B-Series Powergen (82.5 (100 KVA & 125 To 125 KVA) KVA) FUEL INJECTION PUMP - PLUMBING - 6 BTA 5.9 G1/G Manifold, Fuel Seal, Banjo Connector mm Screw, Banjo Connector 6 M6 x 1.00 x Washer, Sealing 2 8mm Valve, Check 1 M8 x 1.25 x Tube, Inj Fuel Supply Tube, Inj Fuel Supply 1 33

35 FUEL LINES CONNECTIONS Hose, Plain Washer, Sealing Screw, Banjo Connector 1 M14 x 1.50 x Tube Fuel Supply Clamp, Hose Strainer, Fuel Banjo Connector 1 34

36 FUEL LIFT PUMP Screw, Hex Flange 2 M8 x 1.25 x Plate, Cover Screw, Banjo Connection 1 M12 x 1.50 x Washer Sealing 2 12mm Washer Sealing Gasket, Cover Plate Screw, Banjo Connector 1 M14 x 1.50 x Tube, Fuel Supply (Feed Pump to Filter) 1 6BT Tube, Fuel Supply (Feed Pump to Filter) 1 6BTA 35

37 FUEL PUMP COUPLING Nipple, Plain Hexagon 1 1/8 NPTF Stud 4 M10 x 1.5 Both Ends Screw, Hex Flange 3 M8 x 1.25 x Nut, Hex Flange 4 M10 x Screw, Hex Flange 2 M10 x 1.50 x Screw, Banjo Connector 1 M10 x 1.00 x Washer, Sealing Cap, Tube Tee, Female Branch Gear, Fuel Pump Brace Fuel Pump Brace, Fuel Pump Hose, Flexible 1 Old Part No

38 GENSET CONTROL PANEL ELECTRICAL PARTS PCC 0301 Multi Function Meter (MFM) Control (PCC0301 Control Assy.) Meter-Multi 1 Temp in o C/Press. in kg/cm Meter-Multi 1 Temp in o F/Press. in psi Harness-Control Panel Sensor-Temperature Transformer-Current Relay-Control Coil Switch-Temperature 1 Replaced for Switch-Pressure 1 Note : 1] This Configuration is for New Products, using PCC 0301 & MFM 2] Refer SPT for Cut-off Date & FESN, for changeover to New Configuration with PCC 0301 & MFM. 37

39 HOUSING, FLYWHEEL Housing, Flywheel Screw, Hexagon Head 2 M8 x 1.25 x Plug, Threaded Plug, 'O' Ring Seal 'O' Ring Seal, Rectangular Screw, Hex Flange 6 M6 x 1.00 x Gasket, Rear Cover Screw, Hex Flange 8 M12 x 1.75 x Cover, Rear Plate, Cover Seal, Oil Clip 1 38

40 INJECTOR ASSEMBLY Injector Assembly Seal, Rectrangular 6 39

41 LEVER, ROCKER Rocker Assy Screw, Hex Head 6 M8 x 1.25 x Screw, Hex Flange Rod, Push Ring, Retaining 12 (Service Part) Washer, Plain 12 (Service Part) M Insert, Rocker Lever 12 (Service Part) Screw, RKR LVR Adjust 12 (Service Part) Lever, Rocker 6 (Service Part) Lever, Rocker 6 (Service Part) Support, Rocker Lever 6 (Service Part) Shaft, Rocker Lever 6 (Service Part) Nut, Heavy Hexagon 12 (Service Part) 3/8-24 THD. 40

42 LUBE, OIL COOLER Screw, Hex Flange 12 M8 x 1.25 x Plug, Pipe Plug, Threaded Gasket, Oil Cooler 1 Old Part No Gasket, Filter Head 1 Old Part No / Plunger, Pressure Head, Lube Oil Filter Core, Cooler Spring, Compression Seal, O Ring Valve Bypass 1 Old Part No Cartridge, Lub Oil Filter 1 41

43 LUBRICATING, PUMP Screw, Hex Head 4 M8 x 1.25 x Pump Lubricating 1 Old Part No

44 OIL FILLER TUBE & CAP Cap Filler Tube Oil Tube - Oil Cap - Filler 1 43

45 OIL, PAN Oil, Pan Liquid Gasket 1 Available as 60gms. tube Washer, Sealing 1 22mm Gasket, Flange Plug, Threaded Washer, Sealing 1 18mm Plug, Threaded 1 M18 x 1.50 Thd Screw, Hex Flange 2 M8 x 1.25 x Connection, Oil Sump Valve - Ball Plug - 1/8 NPTF A Plug - 1/2 NPTF 1 44

46 PISTON ASSEMBLY Ring, Compression 6 Not Serviceable Ring, Compression 6 Not Serviceable Ring, Retaining Ring, Oil Piston 6 Not Serviceable Piston, Engine 6 Not Serviceable Pin, Piston 6 Not Serviceable SERVICE PARTS A Kit, Piston 1 Complete Engine Set (Std.) Piston Ring, Retaining Pin, Piston 6 B Set, Ring Piston 6 Note : Kit Piston consists of Piston, Pin Piston & Ring Retaining for one Engine. 45

47 B-Series Powergen (( KVA To 125 KVA) Radiator (6BTA5.9G1/G2-1) Hose Fuel Bracket - Radiator Elbow - Hose Tube Water Tube Fill Radiator (Including Shroud, Fan Guard & Stone Guard) Hose Radiator Radiator Bracket - Radiator Screw - Hex Flg Hd Washer - Fl Spacer - Contact Tube - Water Hose - Water Clamp - Hose Tube - Water Hose - Water Clamp - Hose Clamp - Hose Coupling - Tube Hose - Fuel Screw - Hex Hd Washer - Fl Washer - Spr Lk Nut - Hex Bracket - Engine Bracket - Engine Bracket - Engine Screw - Hex Flg Hd Fan Assy. (26" ø) 1 Plastic Tank Radiator 1 Service only Cap Coolant Fill 1 Service only 10 psi Elbow - Hose 1 Service only Hose Radiator 1 Service only Tube Fill 1 Service only 46

48 B-Series B-Series Powergen Powergen (82.5 KVA ( 82.5 To KVA 125 ) KVA) RADIATOR 6BT5.9 G Tube Water Hose - Water Clamp - Hose Radiator Tube Water Clamp Hose Radiator Bracket - Engine (L) Bracket - Engine (R) Bracket - Engine Screw - Hex Flg Hd Screw - Hex Hd Washer - Fl Washer - Spr Lk Nut - Hex Tube - Water Tube - Water Hose - Water Hose - Water Clamp - Hose Clamp - Hose Hose - Fuel Coupling - Tube Bushing - Reducer Bracket - Radiator Spacer - Contact Screw - Hex Hd Washer - Fl Nut - Hex Fan Assy - 24" Dia 1 6 Blades - Steel Cap Coolant Fill 1 Service Only 7 psi 47

49 STARTING MOTOR Starter Motor 12V Screw, Twelve Point 3 M10x1.5 x 35 48

50 THERMOSTAT ARRANGEMENT Bracket, Lifting Screw, Hex Flange Plug, Expansion Seal, Rectangular Screw, Hex Flange 2 M8 x 1.25 x Housing, Thermostat Plug, Pipe Thermostat Gasket, Thermostat 1 49

51 TURBOCHARGER Turbocharger - HX35 1 6BT 5.9 G/G Turbocharger - HX35 1 6BTA 5.9 G1/G Stud 4 M10 x 1.50 (both Ends) x Nut, Hexagon Flange 4 M10 x Gasket, Turbocharger Repair Kit, Turbo 1 50

52 WATER PUMP Pump, Water Screw, Hex Head 2 M8 x 1.25 x Seal, 'O' Ring 1 51

53 Engine Maintenance - Parts List Cartridge, Lube Oil Filter Seperator, Fuel Water Fuel Filter (with Rectangular Gasket) Belt, Fan Drive 1 Poly 'V' Element, Air Cleaner - Outer Element, Air Cleaner - Inner 1 Engine 'Minor Repairings - Parts List Switch, Water Temp. ( HWT Safety) 1 Electronic Switch, Oil Pr. (LLOP Safety) Sensor, Water Temp / Oil Temp Sensor, Oil Pressure (Transducer) Shut Off Coil (Solenoid) - 12 V Instrument Cluster Overspeed Safety Card Magnetic Pickup Feed Pump, Fuel (MICO) Thermostat Seal, Oil - Front End Crankshaft Seal, Oil - Rear End Crankshaft Core, Oil Cooler Expansion Bellow (Connection, Exh Outlet) Oil Drain Valve 1 On Oil Pan Set, Upper Engine Gasket Set, Lower Engine Gasket Kit, Gast - O.H. 1 52