Parts Manual Generation Ga eu eig CCC Rom ca i Sn Generator Set with Engine 6CTA8.3 G2 & 6CTAA8.3 G2 with PowerCommand® 1.1 & 1.2 Control C175 DS C200 D5 C220 D5 English - Original instructions 52012 AOASARS6 (Issue 1)Publication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 622005 Table of Contents Description Page Safety Precautions 4 About This Manual 5 Quick Serve Online (QSOL) . 6 Related Literature . 6 Model Identification .....ssssseectseerseerens Ee 7 Abbreviations . 8 Labels = OPEN os esceeeserieeeens : See ad 9 Consumables . 14 Service Consumables "1 Paint and Thread Sealant "1 Engine Accessories 14 Exhaust System - C175 & C200 16 Exhaust System - C220 17 Coolant Heater (Option) 18 Radiator - C175 D5 & C200 DS 20 Skid - C175 D5, C200 D5 & C2205 ...... : cts 2B Control - POG 1302 30 Starting System 82 Wiring Hames - PCC 1902 33 "22012 Copyright Ouninins Power Goneraion PagetParts Manual Publication A0a3A256 Model: C178 DS - 6220 DS Issue 1 - 5.2012 Safety Precautions The following symbols are used in Cummins Power Generation manuals to alert users to the potentially dangerous conditions relating to maintenance of equipment and replacement of parts. Please read and observe, | AWARNING ACAUTION This symbol warns of immediate hazards which will result in severe personal injury or death. This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. Thie symbol refers to a hazard or unsate practice which can result in severe personal in- jury or product or property damage. Product Safety Precautions 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. CEP Note: _AWARNING | AWARNING _ AWARNING. AXWARNING AXWARNING Itis 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. 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, Service and repair of Cummins Power Generation equipment must be performed by trained, experienced personnel only. Improper service, repair or replacement of parts ‘may result in damage to equipment & property, severe personal injury or death. Do not use this catalog as a guide to servicing your equipment. Read and follow the IMPOR- TANT SAFETY INSTRUCTIONS in the Service Manual appropriate for the equipment you are working on. Contact with USED ENGINE OILS has been identified by a United States federal agency and some USA state agencies as causing CANCER or REPRODUCTIVE TOXICITY. When checking or changing engine olls take all necessary precautions not to ingest, breathe the fumes or contact the used oil Contact with ASBESTOS has been Identified by a United States federal agency and some USA state agencies as causing CANCER or REPRODUCTIVE TOXICITY. When handling engine gaskets take all necessary precautions not to ingest, breathe or contact the dust from the gaskets! Use adequate ventilation and wear protective gloves, masks and clothing! Contact with BENZINE and LEAD, found in gasoline, fuel additives and solvents has been identified by a United States federal agency and some USA state agencies as caus- ing CANCER or REPRODUCTIVE TOXICITY. When checking, draining or adding gaso- line and fuel additives or using solvents take all necessary precautions not to ingest, breathe the fumes or contact the liquids. Use adequate ventilation and wear protective gloves, masks and protective clothing! Page? 2012 Conmight Cummins Power GenerationPublication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 622005 About This Manual This manual applies to the generator models C175 D5 - C220 DS. 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, Contact your nearest authorized distributor for assistance in ordering replacement parts. All other replacement parts must be ordered from the engine/altemmator manufacturer by referring to the item nameplate and supplying all available information Standby Ratings Prime Ratings Model Frequency | Engine Battery Name ran re ita, rh Hz Model Voltage 17505 175 140 160 128 50 ectassG2 | 24voc 200 Ds 200 100 182 145 50 ectassG2 | 2avoc 220 Ds 220 176 200 160 50 ectaassG2| 24vDc Replacement parts not identified in this manual can be ordered by contacting: Engine Parts: Alternator Parts: Cummins Engine Company, Ltd Cummins Generator Technologies +1 (800) 343-7357 Within the US: 1-763-528-7301 Web: http://www.quickserve.cummins.com Outside the US: +44 (0) 1760-48474 ‘Web; http://www.cumminsgeneratortechnolo- gies.com "22012 Copyright Ouninins Power Goneraion PagesParts Manual Publication A0a3A256 Model: C178 DS - 6220 DS Issue 1 - 5.2012 Quick Serve Online (@SOL) Documentation and operator manuals pertaining to the generator set are available on QuickServe Online. QuickServe Online: https://quickserve.cummins.com/info/index.htm! The information contained within this manual is based on information available at the time of going to print, In line with Gummins Power Generation policy of continuous development and improvement, information may change at any time without notice. Obtain the most up to date version available on QuickServe Online or con- tact your authorized distributor for assistance. Related Literature The related literature that is appropriate to your generator set includes: ‘+ Operator Manual for 6CTA8.3 and 6CTAAS.3 with PowerCommand 1.1 Control (A043A274) + Operator Manual for 6CTA8.3 and 6CTAAB.3 with PowerCommand 1.2 Control (A043A275) + Installation Manual for 6CTA8.3 and 6CTAA8.3 with PowerGommand 1301, 1.1 and 1.2 Control (aos2ws42) ‘+ Recommended Spares List for G175 D5 (A042M526) ‘+ Recommended Spares List for C200 D5 (A042M529) ‘+ Recommended Spares List for C220 D5 (A042M530) ‘= Warranty Manual (1117) If further information is required, contact your authorized distributor. Pages ‘E2012 Cony Cummins Power GenerationPublication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 622005 Model Identification This manual covers generator set models produced under the Cummins Power Generation and Cummins ‘Onan brand names. To avoid errors or delay in filing your parts order, always state the MODEL and SERIAL NUMBER from the Cummins Power Generation nameplate, R Power Generation tsa atone ease, Ova Roeder Taito eco Tenaga 1] Tee Tepe] Teormatennne] The engine serial number is located on a data tag on the engine or is stamped on the engine block. The control software number is located on the electronic control module (EGM) or can be obtained via the igital interface if one is available. For reference document your genset information in the spaces below. Generator Model Number: Generator Set Serial Number: Generator Spec Letter: Engine Serial Number: Digital Control Software’ "22012 Copyright Ouninins Power Goneraion PagesParts Manual Model: C178 DS - 6220 DS Publication A0a3A256 Issue 1 - 5.2012 Abbreviations ‘Some of the following abbreviations may be used throughout this Parts Manual: AC ACB ‘ACH ATS. Amp AR AVR AWG. BHP. BMS BsT CAN cB cca CHP CoP cr dB(A) oc Deg OP DMG DMSU ECM EFC er EMCU EMF EPROM PU eT FAE FSS Gor Genset GFI GkwT HMI HV Ic ID IEC wo IT kvA kVAR kW kWh LPs u Alternating Current Air Circuit Breaker ‘Anti-Condensations Heaters Automatic Transfer Switch Ampere As Required ‘Automatic Voltage Regulator ‘American Wire Gauge Brake Horsepower Building Measurement System Busnar Sensing Transformer Controlled Area Network Circuit Breaker Cold Cranking Amps Combined Heat and Power Continuous Power Rating Current Transformer Unit of noise level Direct Current Degree Dual In-line Package Digital Master Control Demand Load Standby Unit Engine Control Module Electronic Fuel Control External/Internal Tooth Engine Monitoring and Control Unit Electromotive Force Erasable Programmable Read ‘Only Memory Engine Protection Unit External Tooth Full Authority Engine First Start Sensor Generator Control Pane! Generator set Ground Fault interrupter Global Kilowatt Transducer Human/Machine Interface High Voltage Integrated Circuit Inside Diameter International Electrotechnical ‘Commission Input / Output Internal Tooth Apparent Power Reactive Power Active / Real Power (Kilowatt) Unit of electrical energy or work Liquid Petroleum Gas Left LED uP TA WwW M Mee: Moca Me MFSs mm MOH MR. MST Msu Mv NEC NFS NPT op oz Po PC PF Ph PFO PLO PMG PRP PSU PT/CT PTC ace RFI RMS: RPM AT RTD Spec Thk UL UNC UNF v VAC veB voc VE vt Light-Emitting Diode Limited Time Power Rating Low Temperature Aftercooling Low Voltage’ Meter Miniature Circuit Breaker Moulded Case Circuit Breaker Mains Failed Master First Start Sensor Millimeter Mobile Off Highway Mains Returned Mains Sensing Transformer Mains Sensing Unit Medium Voltage Neutral Earthing Contact Not For Sale National Pipe Thread Outside Diameter Ounce PowerCommand 3.3 Printed Circuit Power Factor Phase Power Factor Controller Programmable Logic Controller Permanent Magnet Generator Prime Power Rating Power Supply Unit Potential Transformer/Current Transformer Power Transfer Control Quadrature Current Control Radio Frequency Interference Root Mean Square Revolutions Per Minute Right Resistance Temperature Detector Specification Thick Underwriters Laboratories Inc. Union National Coarse Union National Fine Volts: Volts, Alternating Current ‘Vacuum Circuit Breaker Volts, Direct Current Volt-free Voltage Transformer WAET, IT, EIT) With Pages "E2012 Copyright Canwnins Power GanerationPublication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 220 D5 Labels - Open A / 6 7 2 10 ‘SAE r5W-40 AA " a i < > www.cumminspower.com "2012 Copyright Cummins Power Page?Parts Manual Publication A0a3A256 Modol: C178 DS - C220 D8 Issue t - 62012 Labels - Open Item Part No. Description aty 10088-6130 Label - Caution (Rotating Parts) 5 2 | 0086-6005 Label - Warning (Hot Surface) 7 30086-8084 LLabal = Warning (Press Liquic) 1 4 | 0086-8101 Label — information (uiting Eye) 4 5 | 0088-6008 Label - Danger (Auto Start 1 6 A0s0F080 Label - Warning ‘ 7__| 0088-8007 Labo — Information (Earth / Ground) 2 8 | 0088-8219 Label - Warning 2 @ | 0086-6105 Label — information (Tag - il Fil) 1 40 | 0086-8512 Label = Instruction 3 11 | 0088-8102 Label — information (Tag ~ Fust ny 1 12 | 0068-6103 Label — information (Tag - Fuel Out) 1 13 | 0088-8220 Labol- Information 2 i4 0006-7805 Label — Warning (Bo Not Li) 5 Pages "E2012 Copyright Cunmnins Power GoneraonPublication AOASA256 Issue 1 - 8.2012 Parts Manual Model: 6178 DS - 622005 Consumables The following is a list of consumables associated with the generator models covered in this manual: Service Consumables. Ref. Page No. Part No. Description ty 300848063 Battery 2 27 | ADdOES46 Hose, Fusl (inet) 1 27__|Ao4ave47 Hose, Fucl (Out!) 1 30 0528-0368-62 Washer, Fat 2 ‘Air Fiter ‘AS10835 Dy140 8 DY160 1 AOS1C857 Dyi7e 1 LF8008 Oil Fiter 1 Fsi260 Fuol Wator Separator 1 FF5052 Fu Filter 1 3911620 Fan Balt 1 WF2073 Water Fiter 1 Paint and Thread Sealant Item Part No. Description ty T_OMS1-0016 Material Spac-Paint (reon) na 2 (0526-0826 Sealant, Thread nia PagesParts Manual Model: C178 DS - 6220 DS Publication A0a3A256 Issue 1 - 5.2012 Main Components ~ Generator Set for PCC 1302 0387-1617-01 tem Part No, Description aty 7 Engine CTAR 3 G2 C75 (60H2) 1 6CTAR3 G2 ‘€200 (50H2) i ‘ECTAASS G2 (©220 (50Hz) 1 2 Alternator 18720014804 (UCI274F 14) C175 i ‘A041 A633 (UCIZ74HT4) ‘200 1 ‘AD41A633 (UCI274H14) 220 1 3 Radiator A0356514 C175 (60°C Ambient) i A055814 {©200 (50°C Ambion’) ‘A0356822 (©220 (50°C Ambient) PowerCommand Control POC 1302 2012 Conmight Cummins Power GenerationPublication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 622005 This page is Intentionally blank, "E2012 Copyright Cummins Power Gonaration PageParts Manual Model: C178 DS - 6220 DS Engine Accessories Page 12 Publication A0a3A256 Issue 1 - 5.2012 "E2012 Copyright Canwnins Power GanerationPublication AOASA256 Issue 1 - 8.2012 Parts Manual Model: 6178 DS - 622005 Engine Accessories Item Part No. Description aty 7 53837021 Oil Drain Assombiy 7 2 301630200 Switch, Magnetic 1 3 | Baea7002 ‘Connector 1 4 | 301848600 Fuel Adaptor, Inet 1 5 |0103-0430-01 ‘Sender, Oil Pressure 1 6 |caseeip Raduoer Bushing 1 7 |0103-0520-01 Sensor, Temperature 1 8 59837081 Fuel Adaptor, Outlot 1 Page 13Parts Manual Publication A0a3A256 Model: C178 DS - 6220 DS Issue 1 - 5.2012 Exhaust System - C175 & C200 6 5 5 | - - 4 WX 1} 2 1 ftom Part No. Description aty 7 Ss6sT07 Giamp, TooTm— Teo 7 2 | 89035001 exible 1 a |Aodorsss Gasket 2 49085002 bow 7 5 | AOMOE5oS Gasket 2 89035003 Muster 1 Page 14 "E2012 Copyright Cunmnins Power GoneraonPublication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 622005 Exhaust System - C220 Item Part No. Description aty 7 B3851017 Clamp, 10mm — 120mm 7 2 83036057 Flexible 1 3 A0#1D573 Gasket 2 4 | 83035058 ‘Adaptor Pipe 1 5 Aosoaies Gasket 3 6 | 83086059 Elbow 1 7 |Ba0asoeo Muflor 1 39035061 Bracket Assombly 3 * bracket 8 * bracket 10 * bracket "22012 Copyright Ouninins Power Goneraion Page 15Parts Manual Publication A0a3A256 Model: C178 DS - 6220 DS Issue 1 - 5.2012 Coolant Heater (Option) Page 16 ‘E2012 Cony Cummins Power GenerationPublication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 622005 Coolant Heater (Option) Item Part No. Description aty 7 Bsea71se Nipple (G12) 7 283637135 ‘Connoctor (G12 - G1/2 - 3/4) 1 3 |easeaiD Reducer Bushing 1 4 | caat@ses7-20 Draincock 1 583837066 Connector (63/4) 1 8 83851000 Clamp (16-22 mm) 4 7__|0603-2203-02 Hose (Diameter 16mm) 2M 8 B2510102 Cablo (8x25 square mn) 1M @ 88600087 Terminal JUTI—10 1 jo | Baea7i16 ‘Connector 1 11 B3282105 Heater 1 42 [62010120 Braoket, Coolant Heater 1 1383210086 Broaker (OSMC32N1C10) 1 Page 17Parts Manual Publication A0a3A256 Model: C178 DS - 6220 DS Issue 1 - 5.2012 Radiator ~ C175 D5 & C200 D5 Page 18 "E2012 Copyright Cunmnins Power GoneraonPublication AOASA256 Issue 1 - 8.2012 Parts Manual Model: 6178 DS - 622005 Radiator - C175 D5 & C200 D5 Item Part No. Description aty 1 ADHOSSS Cor, Radiaior 1 2 | aosozE6s Tank, Radiator 1 3 Ansics4e ‘Tank, Radiator 1 4 | A040z680 Member, Side 1 5 Aosozeat Member, Side 1 8 | ADsiAs60 Panel, Fan Shroud 1 7 |Aosic564 Guard, Fan 1 | AOSTADS Guard 1 2 | AOSTAOSS Tube, Bypass: 1 40 | AO#1A081 Tube, Coolant 1 11 | A041a082 Tube, Coolant 1 32 | AosiBa66 Hose, Coolant 2 13 | A0#1A080 Hose, Coolant 2 14 | A0416367, Hose, Coolant 2 35 Aosovo23 Clamp, Hose 4 16 | AOsiC569 lamp, Hose 4 17 AO#1B368 ‘Clamp, Hose 4 18 | AOsOYOSS Plug, Threaded 1 12 AO#1B365 ‘Cap, Faciator 1 20 | Ao4ovo36 Plug, Threaded 3 21 A0416373 Joint 1 22 | a0siB972 Hose, Vent 1 23. A02E333 Bushing, Reducer 1 24 A032E364 Valve, Draincook 1 Page 18Parts Manual Publication A0a3A256 Model: C178 DS - 6220 DS Issue 1 - 5.2012 Radiator ~ C220 D5 | hp \ LL ESET TL IAA \\ 19 25 15 25 26 19 22 26.25 2414 26 22 26 28 Page 20 "E2012 Copyright Cunmnins Power GoneraonPublication AOASA256 Issue 1 - 8.2012 Parts Manual Model: 6178 DS - 622005 Radiator - C220 D5 Item Part No. Description aty 1 ADs0z685 Cor, Radiaior 1 2 | Aostaoge Core, Radiator 1 3 | Aosozess ‘Tank, Radiator 1 4 | A040z670 Tank, Radiator 1 5 AD#1A083 Member, Side 1 8 ADs A084 Member, Side 1 7 |Aosoz723 Panel, Shroud Side 1 | AOSIAS6 Panel, Shroud Sido 1 8 ADsiAssa Panel, Fan Shroud 1 40 | AOs0z7s4 (Guard, Fan 1 11 |Ao41A046 Guara 1 32 | AOs1A056 Tube, Bypass 1 13 | A0s1Ae0 Tube, Coolant 1 14 | A041A470 Tube, Coolant 1 35 | AOSIAS71 Tube, Air 1 18 | AOSIAST2 Tube, Al 1 17__|AOsIAS76 Clamp, Tube 4 18 | AOMASTS Shield, Plato 2 19 | AOSIAST7 Hose, Air 4 20 A4iB386 Hose, Coolant 2 21 A016367 Hose, Coolant 2 22 | A041A089 Hose, Coolant 2 23. AOSIB388 lamp, Hose 4 24 | Ao4ovo23 Clamp, Hose 4 25_/ADSTA87B Clamp, Hose @ 28 ADSIC589 Clamp, Hose 4 27 | A0si6972 Hose, Vent 1 28 AOS1B365 (Cap, Radiator 1 29 Ao4ovosa Pug, Threaded 3 30 Ao4ovo35 Plug, Threaded 1 31 AO418373 Joint 1 32 | A0a2E333 Bushing, Reducer 1 33 ANS2E364 ‘Valve, Drainoook 1 Page2iIssue 1 - 52012 Publication A0a3A256 Model: C178 DS - 6220 DS Parts Manual Alternator - 6C "E2012 Copyright Cunmnins Power GoneraonPublication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 622005 Alternator - 6C Item Part No. Description ty 145-0075 Complote PMG Upiit Kit 7 2480-14360 PMG Cover (Gover included in above kit) 1 450-1450 Non PMG Cover 1 345-1080 (Current PMG Rotor / Stator Repair Kit 1 45-1080 Current PMG Rotor / Stator Repair Kit 1 5380-10386 Main Stator Bottom Gover C-D 1 390-10887 Main Stator Bottom Cover E-F 1 '390-10386 Main Stator Bottom Cover @ 1 '390-10088 ‘Main Stator Bottom Cover H 1 8 | 330-1020 Air inlet Cover 1 7380-10381 Main Stator Top Gaver ¢-D 1 380-10382 ‘Main Stator Top Gover E-F 1 380-10383 Main Stator Top Cover @ 1 390-10384 Main Stator Top Cover H 1 "390-10002 NDE Bracket 1 @ | 45-0868 NDE Bearing Kit 1 10 a8ws088 Exciter Stator C -D (40mm) 1 45WS085 Excitor Stator E — H (60mm) 1 11 | QMSN Main Stator Bar Assembly 1 12330-10137 Foot 1 13 |OMSN Main Rotor Assombiy 1 74 4SwS134 Exciter Rotor G — D (40mm) 1 45WS135 Exciter Rotor € - H (60mm) 1 15 | 48-0828 Rotating Recife Assembly 1 18 RSK-2001 Diode Fwd/Rev & Varistor Kit 1 17 |480-18817 Main Terminal Board 1 18 | 00-02276 ‘Terminal Box End Panol NDE (Access) 1 ‘900-02275 “Torminal Box End Panol NDE (Plain) 1 39 | e00-o2074 Terminal Box End Panal DE 1 20800-02277 ‘Terminal Box Side Panel (Right Hand) 1 21 | @00-02278 ‘Terminal Box Side Panel (Loft Hand) 1 ‘200-02278 ‘Torminal Box Side Panel (Access) 1 22 | 900-00202 Terminal Box Lid 1 23. | 450-14310 AVR Cover Plato to (28/11/04) 1 410-10536 ‘AVR Gover Piate from (28/11/04) 1 24 | 45-0742 AVR Mounting Bracket 1 25 £000-23812/1P ‘AVR MX341 (Standard Series 3) 1 000-23212/1P AVR MX321 (Saries 3) 1 000-24403 AVR AS440 (Standard Series 4) 1 000-24602/1F AVR SX460 (Standard Series 6) 1 28003-14027 Auxiliary Totminal Board 1 27 (45-0118 Heater 170-125 Vor 1 45-0117 Heater 220-260 Volt 1 2845-0004 Terminal Box for Heaters 1 "22012 Copyright Ouninins Power Goneraion Page 23Parts Manual Publication A0a3A256 Model: C178 DS - 6220 DS Issue 1 - 5.2012 item Part No. Description aty 28330-10007 DE Adaptor Ring 7 3045-0600 DE Adaptor Kit (SAE 1) 1 45-0520 DE Adaptor Kit (SAE2) i 45-0521 DE Adaptor Kit (SAE3) i 3H __| 310-1040 DE Screen (included in Adaptor Kits) i 3245-0698 DE Louvre i 3345-0764 ‘Coupling Kit SAE 10 1 45-0765, Coupling Kit SAE 11.5 1 45-0768 ‘Coupling Kit SAE 14 1 45-0768 ‘Coupling Kit SAE 11.5 (For SAE 1 New) 1 Page 2 2012 Conmight Cummins Power GenerationPublication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 622005 This page is Intentionally blank, "E2012 Copyright Cummins Power Gonaration Page 25Skid - C175 D5, C200 D5 & C220 DS LS Page 23 UL LLY LoPublication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 622005 Skid - C220 D5 Item Part No. Description aty T__AOHGS50 Chassis, Tank 7 2 | Bi0#0008 Isolator 4 3 ADs Aas1 Bracket, Alternator 1 4 | AS10552 Bracket, Engine 1 5 A03s0375 Gauge, Level 1 8 AnssEdes. (Cap, Fuel Tank 1 7 |AodoEes6 Hose, Ful (ini) 1 | Aosouea7 Hose, Fusl (Outlot) 1 Skid - C175 D5 & C200 DS Item Part No. Description aty 1 |AO#ASSS (Chassis, Tank i 2 | B10#0006 Isolator 4 3 ADsIAaSi Bracket, Aiternator 1 4 | AOSTA2® Bracket, Engine 1 5 | AOSs0375 Gauge, Level 1 6 AUssEse8, (Cap, Fuel Tank 1 7 A0doE6s6 Hose, Fu! (inet) 1 | Aosouea7 Hoso, fuel (Outlet) 1 Page 27Parts Manual Publication A0a3A256 Model: C178 DS - 6220 DS Issue 1 - 5.2012 Control - PCC 1302 Co Page 28 ‘E2012 Cony Cummins Power GenerationPublication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 622005 Control - PCC 1302 Item Part No. Description aty 10887-1507 Card, Governor 1 2 /087-1617-01 PCB, Base 1 30300-6014 Module, Digital Display 1 4 | Bazesoc2 ‘Switoh, Emergency Stop 1 5 Broker, Circuit (includes Mounting Screws) B3210112-01 3°, 400A 1 6 83236018 Bus Bar 1 753236028 Ground Copper Plate 1 3 | Ba236028 ‘Connecting Capper Plata 1 @ | AosiD558 Control Housing 1 Page 23Parts Manual Modal: C178 DS - 022005 Publication A0a3A256 Issue 1 - 5.2012 Starting System Item Part No. Description aty 7 50888005 Battery 2 2 aosavoes ‘Tray, Battery i 3 Aos#yoss Rod, Battery Holddown 2 4 AossD254 ‘Clamp, Battary 1 5 0526-0390-62 Washer, Fiat 2 6 0850-0114-85 Waster, Look 2 7 Aozewess Nat, Wing 2 @_62510304-09 ‘Cable, Battery =ve i 8 5251033401 Cable, Battery 1 to 5251033402 Cable, Battery ve. 1 Page 30 "E2012 Copyright Canwnins Power GanerationPublication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 622005 Wiring Harness - PCC 1302 3 Item Part No, Description aty 7 AOsHTST amass Assembly ~ POC 1302 7 ASTHTaS Engine Hamess 1 (0338-4708-02 Harness Accessory 1 ‘2012 Copyright Cum ne Power Gonaration Page 3Parts Manual Publication A0a3A256 Model: C178 DS - 6220 DS Issue 1 - 5.2012 Current Transformer 1 f ——S=Sj \ tem Part No. Description ty 7 Transformor Curont 32400082 ecTAa.3 G2 (6005) 3 2400020 eCTAAE.S G2 (750:5) 3 Page "E2012 Copyright Cunmnins Power GoneraonPublication AOASA256 Issue 1 - 8.2012 Parts Manual Model: 6178 DS - 622005 Topical Index A Adaptor Pipe, 15 Air Inlet Cover, 23 Alternator - 60, 22 Auxiliary Terminal Board, 23 AVR Mounting Bracket, 23 Battery, 30 Bracket, Alternator, 27 Bracket, Coolant Heater, 17 Bracket, Engine, 27 Bus Bar, 20 Bushing, Reducer, 19, 21 c Cable, Battery +ve, 30 Cable, Battery -ve, 30 Cap, Fuel Tank, 27 Cap, Radiator, 19, 21 Card, Governor, 29 Chassis, Tank, 27 Clamp, 1oomm - 120mm, 14, 15 Clamp, Battery, 30 Clamp, Hose, 19, 21 Clamp, Tube, 21 Complete PMG Upfit Kit, 23 Connecting Copper Plate, 29 Connector, 13, 17 Control - POC 1302, 28 Control Housing, 29 Core, Radiator, 19, 24 (Current Transformer, 32 D DE Adaptor Ring, 24 DE Louvre, 24 Draincock, 17 E Elbow, 15 Engine Accessories, 12 Engine Harness, 31 Exhaust System — C175 & C200, 14 Exhaust System - C220, 15 F Fuel Adaptor, Inlet, 13 Fuel Adaptor, Outlet, 13 G Gasket, 15 Gauge, Level, 27 Ground Copper Plate, 29 Guard, 19, 21 Guard, Fan, 19, 21 H Hames Accessory, 31 Hamess Assembly - PCC 1902, 31 Heater, 17 Heater, Coolant, 16 Hose, Air, 21 Hose, Coolant, 19, 24 Hose, Fuel (inlet), 27 Hose, Fuel (Outlet), 27 Hose, Vent, 19, 21 Isolator, 27 ‘22012 Copynant Our ne Power Gonaration Page 3Parts Manual Model: C178 DS - 6220 DS Publication A0a3A256 Issue 1 - 5.2012 Index (Continued) J Joint, 19, 24 Main Components ~ Generator Set for PCC 1802, 10 Main Rotor Assembly, 23 Main Stator Bar Assembly, 23 Main Terminal Board, 23, Member, Side, 19, 21 Module, Digital Display, 29 Mutter, 15 NDE Bearing Kit, 23, NDE Bracket, 23, oO Ol Drain Assembly, 13, P Paint and Thread Sealant, 9 Panel, Fan Shroud, 19, 21 Panel, Shroud Side, 21 PCB, Base, 29 Plug, Threaded, 19, 21 R Radiator - C175 DS & C200 DS, 18 Radiator - 0220 D5, 20 Reducer Bushing, 13, 17 Rod, Battery Holddown, 30 Rotating Rectifier Assembly, 23 s Sender, Oil Pressure, 13 Sensor, Temperature, 13 Service Consumables, 9 Shield, Plate, 21 Skid ~ C175 DS, C200 DS & C220 D5, 26 Starting System, 30 ‘Switch, Emergency Stop, 29 Switch, Magnetic, 13, T Tank, Radiator, 19, 21 Terminal Box for Heaters, 23, Terminal Box Lid, 23 Tube, Air, 24 Tube, Bypass, 19, 21 Tube, Coolant, 19, 24 Vv Valve, Draincock, 19, 21 WwW Wiring Harness - PCC 1302, 31 Pages 2012 Conmight Cummins Power GenerationPublication AOASA256 Parts Manual Issue 1 - 8.2012 Model: 6178 DS - 622005 Numerical Index Part No. _Page Part No. _ Page Part No. _Page Part No. _ Page 0908-14027, 28 45-0075, 23 80380284, 30 0818969, 19, 21 0088-7895, 8 45-0117,23 0950375, 27 0413967, 19, 21 0088-6004, 8 45-0118,29 ‘40356488, 27 0413368, 19, 21 0088-6005, 8 45-0428, 23 AOAOESO4, 14 0818872, 19,21 0088-6097, 8 45-0520, 24 AOAOE64S, 0, 27 oe 0086-6090, 8 45-0521, 24 A0sorsaa, 14 snoaice4s 19 0088-8101, 8 45-0689, 24 0400168, 15 ncaiessa 19 088-0102, 8 45-0860, 24 ‘80400047, 9,27 nostesto 27 cose-£103,8 45-0742, 23 040028, 19, 21 snoneass oy 0088-0105, 8 45-0764, 24 040095, 19,21 nonenes ae 08-6120, 8 45-0765, 24 ‘040036, 19, 21 0098-6219, 8 45-0766, 24 A040Z665, 21 ae 0098-6220, 8 45-0768, 24 A040Z666, 19, 21 prone 0096-6312, 8 45-0868, 23 ‘A040Z679, 21 BoE DS/SM5) 0183-0430-01, 13 45-1080, 23. A040Z680, 19 AOAIHIBE, 31 0193-0529-01. 13 4450-14310, 23 0402681, 19 AOSIHIG1, 31 0300-8014, 20 450-4960, 28 aodoz723, 21 0207-1507, 28 450-4480 23 ‘AO40Z764, 21 B 0207-1617-01, 10,28 450-18617, 28 A0s1A048, 19, 21 0398-4708-02, 91 45015085, 23 ADs1A056, 19,21 0849003, 9, 90, 803-2203-02, 17 45w/S088, 23, AOs1A081, 19| 31040008, 27 024-0928, 9 45W/8134, 23, 0814062, 19 2010120, 17 0s20-0999-€2, 9,90 4518135, 23, 0414060, 19, 21 2400020, 92 0860-0114-55, 0 800-00202, 28 AO41A002, 21 2400002, 92 310-10400, 24 900-0227, 28 041089, 21 ERT 330-10001, 24 900-02275, 23 A041A094, 21 B2510334-01, 30 3920-10002, 28 800-02276, 28 AO41AG80, 19 32510994-02, 30 330-1020, 23 900-02277, 23 AOSIAKG4, 21 182510334-03, 30 330-10137, 23 900-02278, 23 A041 AgG6, 21 83035001, 14 320-10991, 28 800-02278, 28 ADHASO®, 21 sesssone 4 320-10982, 23 AOSASTO, 21 32026000, 14 320-10993, 23 A A0siaa7s, 21 eee 320-10994, 28 AOMAST2, 21 330-10386, 23 AQZBWE83, 30, AO41A475, 21 B9036088, 15 330-10387, 23 ‘AO3OFO80, 8 A041A476, 21 153036080, 15 330-10388, 23 AQ32E333, 19 21 (A041 A877, 21 183035060, 15 1330-10389, 23 A032E364, 19, 21 AOSIAA7B, 21 83035081, 15 301548600, 13 ‘A034Y083, 30 A041A529, 27 83210086, 17 aere2c200, 13 Ac34vo8s, 20 AOS1ABS1, 27 82010112-01,20 410-10536, 23 0968814, 10 AO41A899,27 8225002, 28 45-0024,28 Ac36B822, 10 AOS1E905, 19,21 33036015, 20 "E2012 Copyright Cummins Power Gonaration Page 5Parts Manual Model: C178 DS - 6220 DS Publication A0a3A256 Issue 1 - 5.2012 Numerical Index (Continued) PartNo, Page PartNo, Page PartNo, Page PartNo, Page saee0028, 20 189851009, 17 E Q 'B9z98020, 29 83851011, 14,15, 33242105, 17 £000-29212/1P, 23 sasa7002, 13 Be000087. 17 £000-25412/1P, 23 cusny 23 9897021, 13 000-24403, 23 9897061, 13 000-24802/1P, 23 30807000, 17 c 53807116, 17 oO R aettn cas1es007-20,17 89897195, 17 caseei0, 13,17 omsi-0018, 9 ASK-2001, 23 Pages 2012 Conmight Cummins Power GenerationCummine Power Generation 1400 72a Ava, NE Minneapolis, MN $5422 usa Tok +1 (769) $74-s000 Tol Free: <1 (600) aa 0020 Fac +1 (763) 574 5208, Cummins Power Generation S5A/12 Erandawana Pune 411 026 India Te (01 020) 2004 8600 Fee (81 020) bone 6080 Cummins Power Generation (Latin Ameriea Support) $250 Sout 14m Ave, Suite 205 Miramar FL 9027 Usa Te (@1 020) 9028 2000 Fax (91 020) 6602 6090 Web: www.cumminspower.com Cummins Power Generation Columoas Avenue Marston Pavk Marston, Ramsgate Kent cti2 sar United Kanadom Te +44 (9 1040 255000, Fac 44 (0) 1649 250002 CCummine Power Generation Guanunos - $ ua Jai, 210 ~ Cumbica Braz! 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