A030u593 - I2 - 201111 Part Manual

Parts Manual
Generator Set
QSK78G9 Engine with PowerCommand® 3.3 Control
C2750 D5
C3000 D5
English – Original Instructions 11-2011 A030U593 (Issue 2)

Publication A030U593 Parts Manual
Issue 2 – 11-2011 Model: C2750 D5, C3000 D5 (QSK78G9)
Safety
WARNING: INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN
SEVERE PERSONAL INJURY OR DEATH, AND/OR EQUIPMENT
DAMAGE. SERVICE PERSONNEL MUST BE TRAINED AND
EXPERIENCED TO PERFORM ELECTRICAL AND MECHANICAL
SERVICE.
General Information
Note: It is in the Operator’s interest to read and understand all Health and Safety
information together with all Warnings and Cautions contained within the
documentation relevant to the generator set, its operation and daily
maintenance.
Generator Plant Safety Code

Before operating the generator set, read the manuals and become familiar with them and
the equipment. Safe and efficient operation can be achieved only if the equipment is
properly operated and maintained. Many accidents are caused by failure to follow
fundamental rules and precautions.
WARNING: IMPROPER OPERATION AND MAINTENANCE CAN LEAD TO SEVERE
PERSONAL INJURY OR LOSS OF LIFE AND PROPERTY BY FIRE,
ELECTROCUTION, MECHANICAL BREAKDOWN OR EXHAUST GAS
ASPHYXIATION. READ AND FOLLOW ALL SAFETY PRECAUTIONS IN
THE HEALTH AND SAFETY MANUAL 0908-0110.
WARNING: ONLY AUTHORISED AND TRAINED COMPETENT PERSONNEL WHO
ARE FAMILIAR WITH THE EQUIPMENT AND ITS OPERATION SHOULD
CARRY OUT MAINTENANCE/SERVICE TASKS.
© Copyright Cummins Power Generation Page 3

Parts Manual Publication A030U593
Model: C2750 D5, C3000 D5 (QSK78G9) Issue 2 – 11-2011
Schedule of Abbreviations
AC Alternating Current LED Light-Emitting Diode

ACB Air Circuit Breaker LTP Limited Time Power Rating
ACH Anti-Condensation Heaters LTA Low Temperature Aftercooling
ATS Automatic Transfer Switch LV Low Voltage
AVR Automatic Voltage Regulator
MCB Miniature Circuit Breaker
BHP Brake Horsepower MCCB Moulded Case Circuit Breaker
BMS Building Management System MF Mains Failed
BST Busbar Sensing Transformer MFSS Master First Start Sensor
MR Mains Returned
CAN Controlled Area Network MST Mains Sensing Transformer
CB Circuit Breaker MSU Mains Sensing Unit
CCA Cold Cranking Amps MV Medium Voltage
CHP Combined Heat and Power
COP Continuous Power Rating NEC Neutral Earthing Contact
CT Current Transformer
PC PowerCommand®3.3
dB(A) Unit of noise level PF Power Factor
DC Direct Current PFC Power Factor Controller
DIP Dual In-line Package PLC Programmable Logic Controller
DMC Digital Master Control PMG Permanent Magnet Generator
DMSU Demand Load Standby Unit PRP Prime Power Rating
PSU Power Supply Unit
ECM Engine Control Module PT/CT Potential Transformer/Current Transformer
EMCU Engine Monitoring and Control Unit PTC Power Transfer Control
EMF Electromotive Force
EPU Engine Protection Unit QCC Quadrature Current Control
FAE Full Authority Engine RFI Radio Frequency Interference

FSS First Start Sensor RMS Root Mean Square
RPM Revolutions Per Minute
GCP Generator Control Panel RTD Resistance Temperature Detector
Genset Generator set
GKWT Global Kilowatt Transducer V Volts
VAC Volts, Alternating Current
HMI Human/Machine Interface VCB Vacuum Circuit Breaker
HV High Voltage VDC Volts, Direct Current
VF Volt-free
IC Integrated Circuit VT Voltage Transformer
I/O Input / Output
kVA Apparent Power

kVAR Reactive Power
kW Active / Real Power
kWh Unit of electrical energy or work
Page 4 © Copyright Cummins Power Generation

About this manual

This manual applies to the generator models C2750 D5, C3000 D5. Parts illustrations are arranged in
groups relating to their position and function on the generator set. Each part illustrated is identified by
a reference number corresponding to the list of part numbers in the accompanying table.
Engine and alternator parts that have been modified or added by Cummins Power Generation are
identified in this catalogue. All other replacement parts must be ordered from the engine/alternator
manufacturer by referring to the item nameplate and supplying all available information. Contact your
nearest authorised distributor for assistance in ordering parts.
QuickServe Online (QSOL)

Documentation and operator manuals pertaining to the generator set are available on QuickServe
Online.
QuickServe Online: https://quickserve.cummins.com/info/index.html
The information contained within this manual is based on information available at the time of going to
print. In line with Cummins Power Generation policy of continuous development and improvement,
information may change at any time without notice. Ensure that the documentation is the latest
information available. Contact your authorised distributor for assistance.
Supplementary Publications
The Supplementary Publications appropriate to your generator set are:
Title Publication No
Operator Manual (Generator Set) A030T601
Operator Manual (EBU Engine O&M) 3666714
Installation Manual A030U100
Recommended Spares List (RSL) C2750 D5 A030U597
Recommended Spares List (RSL) C3000 D5 A030U598
Controller Service Manual (PC 3.X) 0900-0670
Alternator Manual (MV) 0900-9903
Alternator Manual (HV) 0900-9907
If further, more detailed information is required, contact your authorised distributor.
Model Identification
This manual covers models produced under the Cummins and Cummins Power Generation brand
names.
To avoid errors or delay in filling your parts order, always state the MODEL and SERIAL NUMBER
from the Cummins Power Generation nameplate.
For reference insert your nameplate information in the spaces below.
Model
Generator Set Serial Number
Engine Serial Number
Digital Control Software

CONTENTS
Description Page
Safety ................................................................................................................................................... 3
General Information ............................................................................................................................ 3
Generator Plant Safety Code.............................................................................................................. 3
Schedule of Abbreviations .................................................................................................................. 4
About this manual ............................................................................................................................... 5
QuickServe Online (QSOL) ................................................................................................................ 5
Supplementary Publications ............................................................................................................... 5
Model Identification ............................................................................................................................. 5
CONTENTS.......................................................................................................................................... 6
Index ..................................................................................................................................................... 7
Generator Set Layout ......................................................................................................................... 8
Engine Accessories .......................................................................................................................... 10
Air Cleaner Inst. - Heavy Duty .......................................................................................................... 12
Coolant Heater Inst ........................................................................................................................... 14
Silencers ........................................................................................................................................... 16
Exhaust Adapters ............................................................................................................................. 18
Exhaust Kit ........................................................................................................................................ 20
Exhaust Pyrometer Inst .................................................................................................................... 22
Radiator Inst...................................................................................................................................... 24
Radiator Flatbed (40° C & 50° C) ..................................................................................................... 26
Radiator Fuel Cooler 40ºC & 50ºC Assy .......................................................................................... 28
Alternator Inst.................................................................................................................................... 30
Metering Current Transformers Inst.................................................................................................. 32
Differential Current Transformers Inst. ............................................................................................. 34
Control Box Inst ................................................................................................................................ 36
ECM Installation Harness Inst .......................................................................................................... 38
RTD Inst ............................................................................................................................................ 40
RTD Protection Harness Inst ............................................................................................................ 42
AC Voltage / Current Harness Inst ................................................................................................... 44
AUX 101 Module Inst ........................................................................................................................ 46
Control Heater Inst ............................................................................................................................ 48
Relay Inst .......................................................................................................................................... 50
Alarm Inst .......................................................................................................................................... 52
Heater Box Control Assy .................................................................................................................. 54
Heater Inst ........................................................................................................................................ 56
Alternator & Panel Heater Harness Inst ........................................................................................... 58
Spring Vibration Isolator Inst............................................................................................................. 60
Oil Drain Inst ..................................................................................................................................... 62
Oil Drain Pump Inst ........................................................................................................................... 64
Oil System Pre-Lube Inst .................................................................................................................. 66
Drip Pan Inst ..................................................................................................................................... 68
Centinel Tank Inst ............................................................................................................................. 70
Battery (225 Ah) Inst ......................................................................................................................... 72
Skid Assy .......................................................................................................................................... 74

Index
AIR CLEANER 12, 13 FUEL – PIPE 70, 71

AIR CLEANER REPLACEMENT 12, 13 FUEL – VALVE 70, 71
ALARM MODULE (AUDIO) 52, 53 GASKET – EXHAUST 20, 21
ALTERNATOR 30, 31 GASKET – RADIATOR 24, 25
BATTERY – CHARGER (240V) 73 GAUGE – FUEL 70, 71
BATTERY - LEAD ACID 72, 73 GAUGE – DRIP PAN 68, 69
BATTERY - TRAY 72, 73 GAUZE – VENT 68, 69
BRACKET - AIR CLEANER 12, 13 HARNESS – AC VOLTAGE 44, 45
BRACKET – ALTERNATOR HEATER 58, 59 HARNESS – AUX 101 MODULE 46, 47
BRACKET – CONTROL BOX 36, 37 HARNESS – CURRENT METERING 32, 33
BRACKET – COOLANT HEATER 14, 15 HARNESS – DIFFERENTIAL 34, 36
BRACKET – CURRENT METERING 32, 33 HARNESS – HEATER 56, 57
BRACKET – ECM HARNESS 38, 39 HARNESS – PANEL 58, 59
BRACKET – OIL PUMP 64, 65 HARNESS – RELAY 50, 51
BRACKET – RTD 40, 41 HARNESS – RTD PROTECTION 42, 43
CABLE – ELECTRICAL 10, 11 HEATER – COVER 54, 55
CABLE – STARTER 10, 11 HEATER – CIRCUIT BREAKERS 54, 55
CAP – CENTINAL TANK 70, 71 HEATER – RELAY 54, 55
CAP – OIL FILL 62, 63 HEATER – STRAP 54, 55
CLAMP – AIR CLEANER 12, 13 HEATER - SWITCH 54, 55
CLAMP – ALTERNATOR 58, 59 HOUSING - AIR FILTER 12, 13
CLAMP – COOLANT HEATER 14, 15 ISOLATOR VIBRATION 60, 61
CLAMP – CURRENT HARNESS 44, 45 LUBE – OIL PRE-LUBE SYSTEM 66, 67
CLAMP – CURRENT TRANSFOMER 32, 33 METERING – CURRENT 32, 33
CLAMP – EXHAUST PYROMETER 22, 23 PANEL – CONTROL BOX 36, 37
CLAMP - HEATER 56, 57 PANEL - ELECTRICAL STRAP 36, 37
CLAMP – RADIATOR HOSE 24, 25 PUMP – OIL DRAIN 64, 65
DIFFERENTIAL CURRENT 34, 35 RELAY INST 50, 51
ENGINE ACCESSORIES 10, 11 SENDER – TEMPERATURE RTD 40, 41
ENGINE LAYOUT 8, 9 SENSOR – HARNESS PROTECTION 42, 43
EXHAUST ADAPTERS 18, 19 SENSOR – PRESSURE 12, 13
EXHAUST KIT 20, 21 SKID BASE ASSEMBLY 74, 75
EXHAUST PYROMETER 22, 23 SILENCER 16, 17
FUEL – TANK 70, 71 THERMOSTAT – COOLANT 14, 15

Generator Set Layout

Table 1 Generator Set Layout
Item Part No. Description Qty

1 - Air Cleaner (Heavy Duty) 4
2 - Engine QSK78G9 1
3 - Control Unit 1
4 - Batteries 6
5 - Alternator terminal Box 1
6 - Skid Assembly 1

Engine Accessories

Table 2 Engine Accessories

1 0416-0680 CABLE, ELECTRIC 1
2 0416-0446 KIT, JUMPER CABLE 3
3 0416-0639 KIT, BATTERY CABLE 6
4 0416-1019 BOOT, BATTER RED 3
5 0416-1020 BOOT, BATTER BLACK 9
6 0800-2111 SCREW, HEX HEAD 2
7 0850-2012 WASHER, LOCK 2
8 0526-2140 WASHER, FLAT 2
9 0856-0013 WASHER, LOCK 2
10 0332-4269 TIE, CABLE 2
11 0416-1167 CABLE, STARTER 2
12 0501-0812 LINE, FUEL 1
13 0501-0813 LINE, FUEL 1
14 011284 LEAD, EARTH 2
15 0416-1235 CABLE, ELECTRICAL 1
16 0331-0585-04 CONDUIT 0
17 0518-0391 SEALANT, THREAD 0

Air Cleaner Inst. - Heavy Duty

Table 3 Air Cleaner - Heavy Duty

1 A029R106 SUPPORT, AIR FILTER 1
2 A029P985 SCREW, HEX HEAD 4
3 A029P83 SCREW, HEX HEAD 4
4 A029G975 STRAP, AIR FILTER 12
5 0821-6004-02 SCREW, HEX HEAD 24
6 A029G993 FILTER, AIR 4
7 A029T132 BRACKET, SUPPORT 1
9 A029K624 DUCT, INLET 4
10 A029K623 SENSOR, PRESSURE 4
11 A030D864 DUCT, INLET 1
16 0503-2478 HOSE 4
17 A029M834 HOSE, HUMP 4
18 A026L078 CLAMP, TEE BOLT 8
19 A026L077 CLAMP, TEE BOLT 8
20 0503-1870-15 CLAMP, HOSE 8
21 0821-6004-04 SCREW, HEX HEAD 8
22 0526-0399-63 WASHER, FLAT 24

Coolant Heater Inst

Table 4 Coolant Heater Inst

1 0130-4546-01 BRACKET, HEATER 2
2 0502-1369 ELBOW, MALE FEMALE 1
3 0231-0402-02 ADAPTER, PIPE 1
4 A028Y974 FITTING, PIPE NIPPLE 1
5 0505-1574 ELBOW, PIPE 1
6 0504-0239 VALVE, BALL 1
7 0505-2086 FITTING, PIPE NIPPLE 1
8 0133-0233 HEATER, MANIFOLD 1
9 0502-1475 ADAPTER, HOSE 2
10 0518-0548-05 CLAMP, HOSE 6
11 0155-3451 CLAMP 2
12 0821-6003-02 SCREW, HEX HEAD 10
13 0526-0399-63 WASHER, FLAT 4
14 0850-0114-55 WASHER, LOCK 4
15 0862-0026-56 NUT, HEX 4
16 A029D273 BRACKET SUPPORT 1
17 0309-0649 THERMOSTAT 1
18 0505-2128-02 BUSHING REDUCER 1
19 A030A081 HOSE ASSEMBLY 1
20 A030A274 HOSE ASSEMBLY 1
21 A030C086 HOSE ASSEMBLY 1
22 A030D937 HOSE ASSEMBLY 1
23 A030D939 HOSE ASSEMBLY 1
24 0821-6002-03 SCREW, HEX HEAD 4
26 0333-0634-02 HEATER, WATER 2

Silencers

Table 5 Silencer

1 A029D674 SILENCER, RESIDENTIAL 1
2 A029D670 SILENCER, INDUSTRIAL 1

Exhaust Adapters

Table 6 Exhaust Adapters

1 A029D666 ADAPTER, EXHAUST 1
2 0155-4073 ADAPTER, EXHAUST (FLEXIBLE) 1

Exhaust Kit

Table 7 Exhaust Kit

1 0155-4080 FLANGE, EXHAUST 2
2 0155-4081 GASKET, EXHAUST 2
3 0800-3017-95 SCREW, HHC, STL 24
4 0862-0026-59 NUT, HEX 24
5 0526-0399-70 WASHER, FLAT 48
6 0850-0114-58 WASHER, SPRING 24

Exhaust Pyrometer Inst

Table 8 Exhaust Pyrometer Inst

1 A030E630 LABEL, INSTRUCTION 1
2 A030E633 LABEL, INSTRUCTION 1
3 0300-5796 PYROMETER, EXHAUST 2
4 A030G350 HARNESS, METER 1
5 A030G352 HARNESS, METER 1
6 0098-8157 LABEL, INSTRUCTION 4
7 0098-8184 LABEL, INSTRUCTION 1
8 0518-0548-15 CLAMP 2
9 0526-0399-63 WASHER, FLAT 2
10 0800-3017-35 SCREW, HEX HEAD 2
11 A030S866 SENDER, TEMERATURE 2
12 0332-0941 TIE, CABLE 0

Radiator Inst

Table 9 Radiator Inst

A028U440 TUBE, WATER (IS 0 FLANGES) 1
1
A028U441 TUBE, WATER (ANSI FLANGES) 1
2 0505-2294-02 ADAPTER, PIPE 1
3 0130-6522 GASKET 2
4 0130-5900 GASKET, RADIATOR OUTLET 2
5 0130-5899 GASKET, RADIATOR OUTLET 1
A028U442 ADAPTER, PIPE (IS 0 FLANGES) 2
6
A028U443 ADAPTER, PIPE (ANSI FLANGES) 2
A028U505 ADAPTER, PIPE (IS 0 FLANGES) 1
7
A028U506 ADAPTER PIPE (ANSI FLANGES) 1
8 0503-1726 HOSE, RADIATOR 1
9 0503-1872 CLAMP, HOSE 2
10 0502-1326 ADAPTER, PIPE 1
11 0505-0102 ADAPTER, CLOSE NIPPLE 2
12 0231-0402-02 ADAPTER, PIPE 1
13 0505-1574 ELBOW, PIPE 1
14 0504-0239 VALVE, BALL 2
15 A028V731 ADAPTER, HOSE 2
16 0526-0399-62 WASHER, FLAT 17
17 0800-3017-41 SCREW, HEX HEAD 4
18 0850-0114-55 WASHER, LOCK 13
19 0862-0026-56 NUT, HEX 4
20 0800-3017-38 SCREW, HEX HEAD 9
22
23 0503-1708 HOSE, RADIATOR 1
24 0503-1872-04 CLAMP, HOSE 2
25 A028U096 PLATE, SUPPORT 1
26 0821-6003-02 SCREW, HEX HEAD 4
27 A028U121 CLAMP 1
28 0148-1373-02 FUEL SYSTEM 1
29 0526-0399-64 WASHER, FLAT 4
30 A028W700 BOLT, HEX 2
31 0509-0548 SEAL, 0 RING 1
32 0850-0114-56 WASHER, LOCK 2
33 0862-0026-57 NUT, HEX 2

Radiator Flatbed (40° C & 50° C)

Table 10 Radiator Flatbed (40° C & 50° C)

0130-5738 RADIATOR (40° C 50Hz 380V – 440V) 1
1
0130-5739 RADIATOR (50° C 50Hz 380V – 440V) 1
2 0098-8094 LABEL – WARNING (Pressurised Liquid) 4
3 0098-8095 LABEL – WARNING (Hot Surface) 4
4 0098-8104-3 LABEL – WARNING 1
5 0098-8106 LABEL – INFORMATION (Tag Water Fill) 2
6 0098-8130 LABEL – CAUTION (Rotating Parts) 12

Radiator Fuel Cooler 40ºC & 50ºC Assy

Table 11 Radiator Fuel Cooler 40ºC & 50ºC Assy

40ºC FUEL COOLER
1 0130-6047 RADIATOR (40º C FUEL COOLER) 50Hz 380V - 440V 1
2 0130-6049-01 RADIATOR (40º C FUEL COOLER) 60Hz 380V -
3 0130-6049-02 RADIATOR (40º C FUEL COOLER) 60Hz 415V - 480V -
4 0130-6049-03 RADIATOR (40º C FUEL COOLER) 60Hz 380V UL NEMA -
5 0130-6049-04 RADIATOR (40º C FUEL COOLER) 60Hz 415V - 480V UL NEMA -
6 0098-8094 LABEL, WARNING (PRESS LIQUID) 2
7 0098-8095 LABEL, WARNING (HOT SURFACE) 2
8 0098-8104-01 LABEL, WARNING (380V AC) 1
11 0098-8130 LABEL, CAUTION (ROTATING PARTS) 2
50ºC FUEL COOLER
1 0130-6048 RADIATOR (50º C FUEL COOLER) 50Hz 380V - 440V 1
2 0130-6050-01 RADIATOR (50º C FUEL COOLER) 60Hz 380V -
3 0130-6050-02 RADIATOR (50º C FUEL COOLER) 60Hz 415V - 480V -
4 0130-6050-03 RADIATOR (50º C FUEL COOLER) 60Hz 380V UL NEMA -
5 0130-6050-04 RADIATOR (50º C FUEL COOLER) 60Hz 415V - 480V UL NEMA -
6 0098-8094 LABEL, WARNING (PRESS LIQUID) 2
7 0098-8095 LABEL, WARNING (HOT SURFACE) 2
11 0098-8130 LABEL, CAUTION (ROTATING PARTS) 2

Alternator Inst

Table 12 Alternator Inst

1 0526-2250 WASHER, FLAT 8
2 0800-6351 SCREW, HEX HEAD 4
3 0526-0399-64 WASHER, FLAT 20
4 0850-0114-56 WASHER, LOCK 19
5 0800-3017-59 SCREW, HEX HEAD 16
6 0725-1167 SCREW, SOCKET HEAD 12
7 0337-0090 STRAP, ELECTRICAL 1
8 0860-2072 NUT, HEX 4
9 0856-0013 WASHER, LOCK 2
10 0800-6288-16 SCREW, HEX HEAD 1
11 0862-0026-57 NUT, HEX 2
12 0800-6288-08 SCREW, HEX HEAD 1
14 0512-0259 COUPLING, FLEXIBLE 1
15 A030S368 NUT, HEX FLANGE 4
16 0800-3017-75 SCREW, HEX HEAD 4
17 0232-4227-01 SHIM, GENERATOR As Req
22 0518-0206 SEALANT, THREAD As Req

Metering Current Transformers Inst

Table 13 Metering Current Transformers Inst

0315-1687-02 TRANSFORMER, CURRENT (P80_MV/HV 800:1) 3
1 0315-1687-05 TRANSFORMER, CURRENT (P80_MV/HV 250:1) 3
0315-1687-03 TRANSFORMER, CURRENT (P80_MV/HV 400:1) 3
2 0526-2100 WASHER, FLAT 16
3 0815-0829-04 SCREW, HEX FLANGE HEAD 12
4 0319-5970 BRACKET 1
5 0319-6586 MEMBER, MOUNTING 1
6 0332-4152 CLAMP 3
7 0851-0048-01 WASHER, BELLEVILLE 4
12 0338-5072 HARNESS, TRANSFORMER 1
13 03323-1794 TIE, CABLE 0
14 0520-2651-05 STUD 4
15 0870-2065-03 NUT, FLANGE 4
17 0518-0548-58 CLAMP 2
18 0821-6003-02 SCREW, HEX HEAD 2

Differential Current Transformers Inst.

Table 14 Differential Current Transformers Inst.

0315-1692-01 TRANSFORMER, CURRENT (Turn ratio 200:5) 3
1 0315-1692-09 TRANSFORMER, CURRENT (Turn ratio 600:5) 3
0315-1692-03 TRANSFORMER, CURRENT (Turn ratio 300:5) 3
2 0526-2100 WASHER, FLAT 16
4 0319-5970 BRACKET 1
5 0319-6586 MEMBER, MOUNTING 1
6 0332-4152 CLAMP 3
7 0851-0048-01 WASHER, BELLEVILLE 4
8 0520-2651-05 STUD 4
9 0870-2065-03 NUT, HEX FLANGE 4
14 0332-3388 TIE, CABLE 0
16 0332-3102 TIE, CABLE 3
17 0518-0548-58 CLAMP 2
18 0821-6003-02 SCREW, HEX HEAD 2
19 0338-4818 HARNESS, ALTERNATING CURRENT 1
20 0332-4044 JUMPER, TERMINAL 3

Control Box Inst

Table 15 Control Box Inst

1 A030T874 BRACKET 1
2 A030T715 BRACKET 1
3 A030U732 BRACKET 1
5 0402-0666-03 ISOLATOR, VIBRATION 4
6 A029K729 WASHER, FLAT 4
7 A030D422 CONTROL 1
8 0853-0040-55 WASHER, LOCK 4
11 0800-6374-03 SCERW, HEX FLANGE HEAD 4
12 A029K723 WASHER, FLAT 2
15 0870-2065-03 NUT, HEX FLANGE 5
16 0818-0231-02 RIVET, POP 8
17 A030U757 CHANNEL, RUBBER 1
18 A030V284 SCREW 4
19 0337-0049 STRAP, ELECTRICAL 2

ECM Installation Harness Inst

Table 16 ECM Installation Harness Inst

1 A029D841 BRACKET 1
2 A029J490 HARNESS, INTERFACE 1
8 0821-6001-01 SCREW, HEX HEAD 3
9 0337-3582-06 CONDUCTOR, ELECTRICAL 2
10 A030E192 MODULE, CONTROL 1
11 A030E756 MODULE, CONTROL 1

RTD Inst

Table 17 RTD Inst

1 0193-0554 SENSOR, TEMPERATURE 1
2 0898-1370 SLEEVE, BRAIDED 5
3 0898-1369 SLEEVE, HEAT SHRINK 0
4 0332-3973 TIE, CABLE 25
5 0332-3974 TIE, CABLE 25
6 0822-3074 SCREW, PAN HEAD 25
7 0800-3017-03 SCREW, HEAD HEX 2
8 0850-0014-53 WASHER, LOCK 2
9 0526-0399-58 WASHER, FLAT 2
10 0898-1368 SLEEVE, BRAIDED 0
11 0191-2345-02 BRACKET, ALTERNATOR ADJUST 2
12 0331-0612 CONNECTOR, CONDUIT 1
13 A030W002 SENDER, TEMPERATURE 1

RTD Protection Harness Inst

Table 18 RTD Protection Harness Inst

1 A029J493 HARNESS, SENSOR 1
2 0332-3838-02 TIE, CABLE 12
3 0327-1536 CARD, INPUT / OUTPUT 1
4 0526-0399-57 WASHER, FLAT 7
5 0850-0114—52 WASHER, LOCK 7
6 0800-0309-91 SCREW, HEX HEAD 4
7 0800-0309-87 SCREW, HEX HEAD 3

AC Voltage / Current Harness Inst

Table 19 AC Voltage / Current Harness Inst

1 A029E094 HARNESS, ALTERNATING CURRENT 1
2 0332-3838-02 TIE, CABLE 12
3 0518-0548-05 CLAMP, HOSE 1
4 0821-6003-03 SCREW, HEX HEAD 1

AUX 101 Module Inst

Table 20 AUX 101 Module Inst

1 0327-1536 CARD INPUT / OUTPUT 1
2 0821-6001-06 SCREW, HEX HEAD 4
3 0338-4885 HARNESS WIRING 1

Control Heater Inst

Table 21 Control Heater Inst

1 REF CONTROL ASSEMBLY 1
2 033-0645-01 HEATER, THERMOSTAT (CONT) 120V 1
3 033-0645-02 HEATER, THERMOSTAT (CONT) 240V 1
4 0332-4320 BLOCK, TERMINAL 2
5 0332-3125-01 BLOCK, TERMINAL 2
6 0332-4002 BLOCK TERMINAL (GROUND) 1
7 0818-1150-02 RIVET, DRIVE 2
8 0332-2420 MOUNT, CABLE TIE 1

Relay Inst

Table 22 Relay Inst

1 REF CONTROL ASSEMBLY 1
2 0332-2878 BLOCK TERMINAL 2
3 0307-2873 RELAY, CONTROL (12V DC) 1
4 0307-2874 RELAY, CONTROL (24V DC) 1
5 0305-1009 SUPPRESS0R, VOLTAGE 1
6 0338-5261 HARNESS, RELAY 1

Alarm Inst

Table 23 Alarm Inst

1 0300-3998-01 MODULE, ALARM 1
2 0526-0399-58 WASHER, FLAT 2
3 0850-0114-53 WASHER, LOCK 2
4 0725-1028 SCREW, SOCKET 2
5 0226-4696 LEADE, ELECTRICAL 1
6 0332-3388 TIE, CABLE 4

Heater Box Control Assy

Table 24 Heater Box Control Assy

1 0319-5484-02 BOX, CONTROL HEATER 1
2 0319-5485-02 COVER, HEATER BOX 1
3 0332-4050-01 RAIL, TERMINAL BLOCK 1
4 0332-3926 TERMINAL BLOCK (END STOP) 2
5 0308-1151 SWITCH, ROTARY (20A 2P 2POS) 1
6 0332-3927-01 TERMINAL, BLOCK (END PLATE) 1
7 0332-3923-01 TERMINAL BLOCK (WAGO) 4
8 0332-3923-03 TERMINAL BLOCK (WAGO) 5
9 0332-3927-03 TERMINAL BLOCK (END PLATE) 1
10 0249-0814 RELAY, 2 POLE BASE 2
11 0249-0813 RELAY, 2P 24V 5A W/DIODE 2
12 0306-4954 CONTACTOR (LC1 – 18BD) 1
13 0320-2257-01 CIRCUIT BREAKER (2 POLE 2A) 1
16 0332-3928 TERMINAL BLOCK (END PLATE) 1
17 0332-3924 TERMINAL BLOCK (WAGO) 2
18 0332-3932 TERMINAL BLOCK (END PLATE) 1
19 0332-3931 TERMINAL BLOCK (WAGO) 2
20 0308-1160 SWITCH, ROTARY (63A 2P 2POS) 1
21 0098-8107 LABEL, INFORMATION (EARTH POINT) 1
22 0098-8271 LABEL, INFORMATION (AC SUPPLY) 1
23 0098-8270 LABEL, INFORMATION (AC SUPPLY) 1
24 0334-2278-01 WIRE, STRANDED (BS6231, GREY, 1mm) AR
25 0334-2278-02 WIRE, STRANDED (BS6231, GREY, 2.5mm) AR
27 0334-2280-01 WIRE, STRANDED (BS6231, GRN/YLW, 1mm) AR
28 0334-2280-01 WIRE, STRANDED (BS6231, GRN/YLW, 2.5mm) AR
29 0334-2280-01 WIRE, STRANDED (BS6231, GRN/YLW, 4mm) AR
30 0800-0309-76 SCREW, HHM (STL, M4 x 16) 2
31 0850-0114-51 WASHER, LK (STL, M4) 6
32 0526-0339-54 WASHER, FL (STL, M4) 6
33 0800-0309-89 SCREW, HHM (STL, M5 x 16) 6
34 0850-0114-52 WASHER, LK (STL, M5) 6
35 0526-0339-56 WASHER, FL (STL, M5) 6
36 0862-0026-54 NUT, HEX (STL, M6) 2
37 0850-0114-53 WASHER, LK (STL, M6) 2
38 0526-0339-58 WASHER, FL (STL, M6) 3
39 0800-3017-06 SCREW, HHM (STL, M6 x 30) 1
40 0856-0023 WASHER, ET LOCK (STL, M6 2
41 0337-3582-07 STRAP, GROUND (200mm, M6 / M8) 1
42 0337-3582-06 STRAP, GROUND (240mm, M6 / M6) 1
43 0332-2774 TIE, CABLE AR
44 0306-4945 CONTACTOR (LC1 – D09BD) 1
45 0098-8314 LABEL, UNIT ID (ISO ‘A’) 1
46 0098-8315 LABEL, UNIT ID (ISO ‘B’) 1
47 0822-3075 SCREW, PAN HD SLTD (M4 x 0.7 x16CL 4.8) 4
48 0862-0026-52 NUT, HEX (M4) 4

Heater Inst

Table 25 Heater Inst

1 A030A739 HARNESS, HEATER 1
2 A030A741 HARNESS, WIRING 1
4 0130-5391-02 COVER, HEATER 2
5 0815-0646 SCREW, RECESSED HEAD 4
6 0332-3196 CLAMP, J 13
7 0821-6002-03 SCREW, HEAD HEX HEAD 11
8 0870-2065-01 NUT, HEX 6
9 0332-1389 TIE, CABLE 17

Alternator & Panel Heater Harness Inst

Table 26 Alternator & Panel Heater Harness Inst

2 A030F062 HARNESS, WIRING 1
3 0332-3196 CLAMP, J 6
4 0821-6003-03 SCREW, HEX HEAD 6

Spring Vibration Isolator Inst

Table 27 Spring Vibration Isolator Inst

1 A028T523 ISOLATOR, VIBRATION 2

Oil Drain Inst

Table 28 Oil Drain Inst

1 A028V778 ADAPTER 1
2 A028V913 SEAL, OIL 1
3 0504-0239 VALVE, BALL 1
4 0505-1574 ELBOW, PIPE 1
5 0502-1623-02 ADAPTER, TUBE 1
6 A028Y124 HOSE, OIL 1
7 0505-2291 ADAPTER, PIPE 1
8 0123-2277 CAP, OIL FILL 1
9 0526-0399-63 WASHER, FLAT 1
10 0850-0114-55 WASHER, LOCK 1
11 0800-3017-38 SCREW, HEX HEAD 1

Oil Drain Pump Inst

Table 29 Oil Drain Pump Inst

1 0149-2687 PUMP, FUEL 1
2 0120-1345-02 BRACKET, OIL PUMP 1
3 0505-1574 ELBOW, PIPE 3
4 0502-1623-02 ADAPTER, TUBE 2
5 A028V731 ADAPTER, HOSE 1
6 0504-0239 VALVE, BALL 1
7 A028V778 ADAPTER 1
8 A028V913 SEAL, OIL 1
11 0870-2225-03 NUT, LOCK 2
12 0526-0399-62 WASHER, FLAT 2
13 A028V907 HOSE, OIL 1

Oil System Pre-Lube Inst

Table 30 Oil System Pre-Lube Inst

1 A029J270 BRACKET 1
2 A029H985 RELAY, SOLENOID 1
3 A030V799 LEAD, BATTERY 1
4 0416-1019 BOOT, BATTERY RED 4
5 0416-1020 BOOT, BATTERY BLACK 2
6 A030W621 LEAD, BATTERY 1
7 0402-0830 ISOLATOR, VIBRATION 4
8 0332-3919-07 TERMINAL RING 4
9 0334-2278-02 WIRE STRANDED 0
10 0898-1195-02 SLEEVE, CONVOLUTED 0
11 0862-0026-54 NUT, HEX 8
12 0526-0399-58 WASHER, FLAT 8
13 0850-0114-53 WASHER, LOCK 8
14 A030V801 LEAD, BATTERY 1
15 0332-3985 BOOT, INSULATION 4

Drip Pan Inst

Table 31 Drip Pan Inst

1 A029T246 PAN, DRIP 1
2 0505-2069 ELBOW, MALE 2
3 A029S639 GAUGE, SIGHT 1
4 0123-2204 GAUZE, VENT 1
5 0502-1369 ELBOW, FEMALE 1
6 0505-2098 FITTING, PIPE NIPPLE 1
7 0504-0247 VALVE, BALL 1
8 0502-1475 ADAPTER, HOSE 1
9 0821-6003-03 SCREW, HEX HEAD 2
10 0503-1870-02 CLAMP, HOSE 2

Centinel Tank Inst

Table 32 Centinel Tank Inst

1 A029S003 TANK 1
2 0509-0516 WASHER, SEALING 2
3 0502-1623-02 ADAPTER, TUBE 2
4 0504-0239 VALVE, BALL 1
5 0526-0399-63 WASHER, FLAT 1
6 0850-0114-55 WASHER, LOCK 1
7 0800-3017-38 SCREW, HEX HEAD 1
8 A029M018 PIPE 1
9 A029M020 CAP 1
10 A029M022 PIPE 1
11 A029M016 SOCKET 1
12 A029M024 PIPE 1
13 A029M028 PIPE 1
14 A029M026 PIPE 1
15 0505-2069 ELBOW, MALE 2
16 A029M030 GAUGE, SIGHT 1
17 A029M036 BRACKET, SUPPORT 4
18 0821-6003-02 SCREW, HEX HEAD 16
19 A029M776 SWITCH, LEVEL 1
20 A029P442 HOSE, OIL 1
21 A029R507 ADAPTER, BREATHER 1
22 A029P551 UNION, MALE 1
23 0123-2277 CAP, OIL FILL 1
24 A029W015 BOLT, EYE 1

Battery (225 Ah) Inst

Table 33 Battery (225 Ah) Inst

1 A029A996 TRAY, BATTERY 1
2 A029K034 BATTERY, LEAD ACID 6
3 A029B000 FRAME, BATTERY 1
4 A029A998 PLATE, COVER 1
5 A029B042 ROD, BATTERY RETAINING 4
6 0526-0399-58 WASHER, FLAT 4
7 0850-0114-53 WASHER, LOCK 4
8 0865-0030 NUT, WING 4
Battery Charger

1 A008P944 CHARGER, BATTERY 5A 12v 240V 1
2 A008P940 CHARGER, BATTERY 10A 24V 240v 1

Skid Assy

Table 34 Base Skid Assy

1 A026J631 BASE SKID ASSEMBLY 1

Cummins Power Generation Cummins Power Generation Cummins Power Generation

1400 73rd Avenue NE Columbus Avenue 10 Toh Guan Road #07-01
Minneapolis Manston Park TT International Tradepark
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Web: www.cumminspower.com Web: www.cumminspower.com Web: www.cumminspower.com
Cummins Power Generation Cummins Power Generation

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®
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are trademarks of Cummins Inc.
©2011 Cummins Power Generation, Inc. All rights reserved

A030u593 - I2 - 201111 Part Manual

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Parts Manual

English – Original Instructions 11-2011 A030U593 (Issue 2)

Generator Plant Safety Code

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AC Alternating Current LED Light-Emitting Diode

FAE Full Authority Engine RFI Radio Frequency Interference

kVA Apparent Power

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About this manual

QuickServe Online (QSOL)

If further, more detailed information is required, contact your authorised distributor.

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AIR CLEANER 12, 13 FUEL – PIPE 70, 71

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Generator Set Layout

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Table 1 Generator Set Layout

Item Part No. Description Qty

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Table 2 Engine Accessories

Item Part No. Description Qty

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Air Cleaner Inst. - Heavy Duty

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Table 3 Air Cleaner - Heavy Duty

Item Part No. Description Qty

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Coolant Heater Inst

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Table 4 Coolant Heater Inst

Item Part No. Description Qty

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Page 16 © Copyright Cummins Power Generation

Item Part No. Description Qty

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Page 18 © Copyright Cummins Power Generation

Table 6 Exhaust Adapters

Item Part No. Description Qty

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Page 20 © Copyright Cummins Power Generation

Table 7 Exhaust Kit

Item Part No. Description Qty

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Exhaust Pyrometer Inst

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Table 8 Exhaust Pyrometer Inst

Item Part No. Description Qty

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Table 9 Radiator Inst

Item Part No. Description Qty

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Radiator Flatbed (40° C & 50° C)

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Table 10 Radiator Flatbed (40° C & 50° C)

Item Part No. Description Qty

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Radiator Fuel Cooler 40ºC & 50ºC Assy

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Table 11 Radiator Fuel Cooler 40ºC & 50ºC Assy

Item Part No. Description Qty