TATA CUMMINS ENGINE
6BT5.9TC
6-No. of cylinders
B-Series
T-Turbocharger
5.9-Displacement in liters
TATA CUMMINS Pvt. Ltd is a 50:50 joint venture between TATA Motors and
Cummins Inc. USA.
In 1998 ,12 V Cummins phased out in favor of a redesign 24 valve version
of engine.
5.9 L CUMMINS was altogether retired in 2007 model year ,being replaced
by the more emission friendly 6.7 L CUMMINS.
Working Principle
Suction
Isentropic Compression
Constant pressure cycle (Heat addition take place)
Isentropic expansion
Constant volume heat rejection
Exhaust stroke
*No adiabatic or isentropic
*Valve timing does not occur at TDC and BDC.
SPECIFICATION
Model CUMMINS 6 BT 5.9 TC
Type 6 CYLINDER INLINE
Bore/Stoke 102MM/120MM
Capacity 5883CC
Maximum Engine Output 190 HP @2500 RPM
Maximum Torque 400 NM @1400-1700 RPM
Compression Ratio 17.6:1
Firing Order 1-5-3-6-2-4
Measurement in engine
Cylinder bores
Pistons
Crank shaft main and big end journals
Cam shaft journals
Cam Bushes
Valve Timing
Fuel injection Pump timing
Valve Clearance Adjustment
Cylinder Compression Test
Timing Marks:
CAM Timing Pump timing
Valve Clearance Adjustment.
CYLINDER 1 TDC METHOD
• Locate the timing pin on the back of the front cover, below the
injection pump.
Rotate the engine until the timing pin can be inserted into the
camshaft gear. Do NOT attempt to rotate the engine while the timing
pin is engaged - it WILL break off in the front cover.
Once the timing pin is in place, cylinder 1 is at top dead center (TDC)
of compression stroke.
•Adjust valve clearance of valve number 1,2,3,6,7,10 from front end.
Turn crank shaft 360 degree so as to bring position No. 6 at TDC
compression stroke.
Adjust valve clearance of valve numbers 4,5,8,9,11,12.
FIP TIMING
Plunger lift method
Bring Cylinder 1 at top dead center (TDC) of compression stroke.
Now insert timing tool adjuster with dial gauge at the rear end of FIP.
Rotate the crank anti clockwise viewing from front until the dial gauge
pointer stops rotating. Now rotate the scale of dial gauge to read zero.
Rotate the crank in clockwise direction and bring back the TDC
position of cylinder 1 once again . At this point read the dial gauge .It
should be 0.24 mm .
If plunger lift is not correct ,loosen the 3 bolts used for mounting
FIP .Rock the FIP towards engine or outwards till you get desired FIP
plunger lift.
Piston Projection:
Used to determine the gaskets thickness.
Clean the deck of the cylinder completely.
Set a dial gauge on the cylinder block surface in illustration
to zero
For every Cylinder measure the piston projection and record
length
Determine the maximum length of piston projection and
select the suitable head gasket .
Piston Projection(mm) Identification notches
0.975-1.074 mm 3 notches,1.7 mm thick
0.875-0.974 mm 2 notches,1.6 mm thick
0.774-0.874 mm 1 notche,1.5 mm thick
Faults Causes:
Incorrect piston projection And Valve
Incorrect FIP timing Clearance
Engine Cranks but does not start. Abnormal Engine Noise
Engine run rough or misfire. High fuel consumption
Engine does not attain rated Poor Pickup
speed. Engine run rough or misfire.
Poor pickup.
Black smoke
Cylinder head gasket blown.
High Fuel Consumption
Engine overheat
Thank you
Name :Nav Raj Shahi
Service Engineer
Trainee