P864 For Models: M864K, M864W, and M864W3 PARTS CATALOG. Marine Generators Marine Diesel Engines Land-Based Generators

Transcription

1 P864 For Models: M864K, M864W, and M864W3 PARTS CATALOG Marine Generators Marine Diesel Engines Land-Based Generators

2 CALIFORNIA Proposition 65 Warning: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Northern Lights th Avenue N.W. Seattle, WA Tel: (206) Fax: (206) Copyright 2011 Northern Lights, Inc. All rights reserved. Northern Lights, and the Northern Lights logo are trademarks of Northern Lights, Inc. Printed in U.S.A. PART NO.:

3 PARTS CATALOG for Models M864K, M864W, AND M864W3 Please read thoroughly before attempting to use this manual: Table of Contents... I Model Designation & Serial Numbers... II Reading a Parts Page... III Table of Contents GROUP 1 - ENGINE Cylinder Block... 0 Flywheel & Housing... 1 Crankshaft, Pistons & Connecting Rods Lubrication System... 4 Timing Cover... 5 Camshaft & Valve Train Cylinder Head & Valve Cover... 8 Oil Drain / Oil Drain Kit... 9 GROUP 2 - INTAKE & EXHAUST SYSTEM Intake Manifold & Air Filter Exhaust Manifold... 2 Wet Exhaust Elbow... 3 Dry Exhaust Elbow... 4 GROUP 3 - COOLING Expansion Tank & Thermostat Housing... 1 Heat Exchanger & Mounting... 2 Heat Exchanger Assembly... 3 Coolant Pump... 4 Keel Cooling Outlet... 5 Raw Water Pump & Mounting... 6 Raw Water Pump Detail... 7 GROUP 5 - ELECTRICAL SYSTEM Engine Stop Solenoid & Mounting... 4 Alternator Mounting Alternator Assembly... 9 Starter Control Panels Belt Guard GROUP 6 - GASKET SETS Gasket Sets...0 GROUP 8 - FRAME & MOUNTING Engine Lifting Brackets... 1 Base Frame... 2 GROUP 9 - ACCESSORIES GROUP 9 - & OPTIONAL EQUIPMENT PTO Adapter... 1 Electric Clutch... 2 Oil Level Switch... 3 Oil Drain Kit... 4 Water Level Switch... 5 GROUP 4 - FUEL SYSTEM Injection Pump & Piping... 0 Fuel Injectors...1-2, 8-9 Double Wall Fuel Lines... 3 Fuel Filter & Lines Fuel Feed Pump Proprietary Information This publication is the sole property of Northern Lights, Inc. It may not be reproduced in whole or part without the expressed written permission of Northern Lights, Inc. Northern Lights, Inc All rights reserved. Litho U.S.A. Publication number:. I

4 Model Designation MODELS INCLUDED This manual covers the operating instructions for: M864K, M864W, and M864W3 Model Numbers Model numbers give the unit's application, block model, aspiration, and RPM: M 864 K W M - Northern Lights Marine generator set Model number of engine block Bore Cylinders 86 mm 4 Additional letters designate a generator series Designates a new winding in generator M864K = Northern Lights Marine diesel generator set with a 864 engine and a PX-325K1 generator. M864W = Northern Lights Marine diesel generator set with a 864 engine and a PX-325K2 generator. Serial Numbers NORTHERN LIGHTS Northern Lights generator sets have two data plates and two serial numbers. One serial number is for the generator end, and it is found on the Generator End Data Plate. Units with PXK generators have just one plate. Serial numbers for Northern Lights marine units are nine digits in length (e.g ). Generator End Serial Number II

5 Reading a Parts Page IMPORTANT: Before selecting parts, be sure that you are choosing parts from the correct page. Check the model designation at the page top. Do not use this illustration for parts purchasing. 1 ELECTRICAL SYSTEM ALTERNATOR ASSEMBLY: M - NL KEY PART NUMBER QTY. DESCRIPTION SERIALNUMBER Alternator Assembly Flywheel, complete Plate, complete Plate Stator, complete Bearing Nut Spring washer Washer Clamp Screw Screw Collar P844 06/ REFERENCES: 1. Grouping section title. 7. Quantity of parts used. 2. Model designation of equipment that uses parts 8. Description of each component part. listed on this page. 9. Serial number of unit the part fits. 3. Title and description of assembly. 10. Assembly or kit designated by Key 0 or /. 4. Drawing numbers that correspond to key 11. Grouping index number. column numbers for parts identification. 12. Page number within the grouping index. 5. Key column for locating parts shown on drawing. 13. Manual title. 6. Part number. 14. Page publication date. NOTE: Arrows always point toward the front of the engine. III

6 GROUP 1 ENGINE Cylinder Block KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N Cylinder Block Assembly (includes keys 2-12) Bolt Pin Expansion Plug ** Plug Ball Expansion Plug Expansion Plug Expansion Plug Pin Pin Expansion Plug Drain Cock Drain Cock Plug Bolt Gasket Plug 1/8 BSPT Dipstick Guide Dipstick - Fig **As required 1-0

7 GROUP 1 ENGINE Flywheel and Housing Fig Flywheel Housing SAE # Stud Nut Washer Bolt Flywheel Assembly SAE #7-1/ Ring Gear (108 Teeth) Bolt ** Plug, Socket Head M20 x **As required 1-1

8 GROUP 1 ENGINE Crankshaft, Pistons & Connecting Rods Fig

9 GROUP 1 ENGINE Crankshaft, Pistons & Connecting Rods KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N Connecting Rod Assembly Connecting Rod Bushing Connecting Rod Bolt Nut Piston Assembly, Standard (includes key #21A) Piston Assembly, 0.50 mm O/S (includes key #21A) Snap Ring Connecting Rod Bearing Set, 0.25 mm, Undersize Connecting Rod Bearing Set, 0.50 mm, Undersize Connecting Rod Bearing, Mark 1 - Standard Connecting Rod Bearing, Mark 2 - Standard Connecting Rod Bearing, Mark 3 - Standard Note: Standard size connecting rod bearings must be matched to rods Note: stamped with Mark 1, Mark 2 or Mark Main Bearing Set, 0.25 mm, Undersize Main Bearing Set, 0.50 mm, Undersize Main Bearing Set, 0.75 mm, Undersize Main Bearing Set, 1.00 mm, Undersize Main Bearing, Mark 1 - Standard Main Bearing, Mark 2 - Standard Main Bearing, Mark 3 - Standard Main Bearing, Mark 4 - Standard Main Bearing, Mark 5 - Standard Main Bearing, Mark 6 - Standard Note: Standard size main bearings must be matched to cylinder blocks Note: with bearing caps stamped with Mark 1 through Mark Piston Ring Set, Standard Piston Ring Set, 0.50 mm, Oversize Thrust Washer Set, Standard Only Thrust Washer Set O/S, mm Thrust Washer Set O/S, 0.25 mm Crankshaft Crankshaft Pulley - Standard Key Crankshaft Timing Gear Key Bolt Plate Washer - 1-3

10 updated 1/15/10 GROUP 1 ENGINE Lubrication System Components Oil Pump Assembly Bolt Oil Regulator Oil Strainer Gasket Bolt Oil Filter Union Oil Pan Adapter, Oil Drain Connection Gasket (for Oil Pan drain plug joint) Bolt w/ Washer Stud Nut - Fig. 1501/

11 GROUP 1 ENGINE Timing Cover & Rear Seal Fig Timing Gear Case Timing Gear Cover Oil Seal Gasket, Rear Oil Seal Retainer Rear Oil Seal Retainer Seal, Engine Rear Oil Pump Drive Gear Bearing, Pump Drive Gear, No Bearing, Pump Drive Gear, No Pin Bolt Bolt Bolt Plug, With Head Taper Screw Bolt Bolt Oil Fill Cap Gasket Bolt Washer - 1-5

12 GROUP 1 ENGINE Camshaft & Valve Train Fig

13 GROUP 1 ENGINE Camshaft & Valve Train Shaft Spring Spring (Retainer for Valve Rocker Shaft) Valve Rocker Arm, No Valve Adjusting Screw Spring Nut Camshaft Bearing Set, Standard Camshaft Bearing Set, mm Camshaft Bearing Set, 0.25 mm Camshaft Plug Camshaft Timing Gear Push Rod Intake Valve Seal Exhaust Valve Valve Lifter Valve Spring Valve Spring Retainer Valve Lock Injection Pump Drive Gear Camshaft Thrust Plate #1 Idler Gear Idler Gear Shaft #1 Valve Rocker Support #2 Valve Rocker Support Idler Gear Thrust Plate Bolt #2 Idler Gear Sub-Assembly #2 Idler Gear Thrust Plate Hexagon Bolt #2 Idler Gear Shaft Plate Washer Screw Bolt Cap, Valve Stem Plate Washer Capscrew, Hex Head Flanged M10 x 1.25 x 60 mm Key Bolt with Washer - 1-7

14 GROUP 1 ENGINE Cylinder Head & Valve Cover Fig 1104 KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N Cylinder Head (includes keys #2-5 & 8) Intake Valve Guide (Standard) Intake Valve Guide Intake (O/S 0.05) Plug Tube Expansion Plug Bolt Stud Precombustion Chamber Insert Gasket Bolt with washer Washer Oil Fill Cap Gasket Cylinder Head Cover Gasket Label "864" Plug - 1-8

15 GROUP 1 ENGINE Oil Drain A-9502 / B Gasket F. Adapter, Steel, 3/8 NPT x M25 x M. Elbow, 90 0, Steel, 3/8 NPT X 1/2-37T Hose Assembly, 1/2" ID x 18-1/2" Cap, Hex Head, Brass 1/2 NPT Bracket Capscrew, Hex Head M8 x 1.25 x 25 mm Lock Washer, M Flat Washer Oil Drain Hose Support Bracket Capscrew, Hex Head M8 x 1.25 x 20 mm S/S Lock Washer, M8 S/S Flat Washer, M8 S/S - 1-9

16 GROUP 2 INTAKE & EXHAUST SYSTEM Intake Manifold & Air Filter A-9503 / C

17 GROUP 2 INTAKE & EXHAUST SYSTEM Intake Manifold & Air Filter Intake Manifold Gasket Stud Nut Capscrew, Hex Head Flanged M8 x 1.25 x 25 mm Air Filter Housing Gasket Capscrew, Hex Head M8 x 1.25 x 25 mm Wave Washer M Bracket, Air Filter Housing Support Capscrew, Hex Head M8 x 1.25 x 20 mm Flat Washer Lock Washer Male Connector, Brass, 1/4 NPT x 3/8 HB Hose, 3/8" ID Push-On Screen Air Filter Element Plate, Intake Cover Hose, Air Inlet Hose Clamp # Cushion Clamp # Capscrew, Hex Head M6 x 1.0 x 10 mm S/S Lock Washer M6 S/S Flat Washer M6 S/S Clamp - 2-1

18 GROUP 2 INTAKE & EXHAUST SYSTEM updated 1/26/11 Exhaust Manifold A-9505 / B Exhaust Manifold (includes key #9) Exhaust Manifold Gasket Capscrew, Hex Head M10 x 1.25 x 100 mm S/S Flat Washer M10 S/S ** Plug, Hex Head Brass 3/8 NPT ** Plug, Hex Head Brass 1/2 NPT Drain Cock 1/4 NPT Street Elbow 90 0 Brass 1/4 NPT Expansion Plug - **As required 2-2

19 GROUP 2 INTAKE & EXHAUST SYSTEM Wet Exhaust Elbow A-9506 / B Wet Exhaust Elbow Gasket Capscrew, Hex Head M8 x 1.25 x 30 mm S/S Flat Washer, M8 S/S Male Elbow 90, 1/2 NPT x 3/4 Hose Barb Hose Clamp, # Hose, 3/4" ID x 43" Wire Reinforced Adelle Clamp Capscrew, Hex Head M10 x 1.25 x 20 mm S/S Capscrew, Hex Head M8 x 1.25 x 20 mm S/S Lock Washer M8 S/S Flat Washer S/S Switch, High Exhaust Temperature 205 F up to xxxx Switch, High Exhaust Temperature 205 F from xxxx Flat Washer M10 S/S Lock Washer M8 S/S Harness, High Exhaust Temperature Connection (not shown) from xxxx

20 GROUP 2 INTAKE & EXHAUST SYSTEM Dry Exhaust A-4267 / B-3632A Dry Exhaust Elbow, 2" NPT Female Dry Exhaust Adapter 2" NPT Female Exhaust Elbow Gasket Lock Washer, Helical M Capscrew, Hex Head M8 x 1.25 x 20 mm Heat Shield - 2-4

21 updated 1/26/11 GROUP 3 COOLING SYSTEM Expansion Tank & Thermostat Housing Expansion Tank Capscrew, Hex Head M10 x 1.5 x 75 mm S/S Flat Washer, M Thermostat Seal Ring Thermostat F/ 82 0 C Thermostat Housing Gasket, Thermostat Housing Capscrew, Hex Head M10 x 1.5 x 105 mm S/S Capscrew, Hex Head M10 x 1.5 x 85 mm S/S Flat Washer, M10 S/S Capscrew, Hex Head M8 x 1.25 x 100 mm S/S Capscrew, Hex Head M8 x 1.25 x 80 mm S/S Flat Washer M8 S/S Hose, 1" ID x 6", 3 Ply Silicone Hose Clamp #16 Extended Band S/S Filler Cap Hose, 5/16" ID X 30" Polyvinyl Hex Head Plug, Brass 1/2 NPT Nameplate, "Northern Lights" Cap Clamp A-9507 / C-4881

22 GROUP 3 COOLING SYSTEM updated 1/26/11 Heat Exchanger & Mounting A-4221A / C-2341z Heat Exchanger Assembly (see parts detail) Capscrew, Hex Head 5/16-18 x 1" S/S Flat Washer, 5/16" S/S Hose Hose Clamp # Gasket - 3-2

23 GROUP 3 COOLING SYSTEM Heat Exchanger Assembly A-4219 / C Heat Exchanger Assembly (includes all keys) Heat Exchanger Zinc Electrode Brass Plug, 1/4 NPT x 5/ Brass Plug, 1/4 NPT Heat Exchanger Gasket, 3" Heat Exchanger End Plates, 3" Capscrew, Hex Head Stainless Steel 3/8-16 x 3/4" Label Zinc - 3-3

24 GROUP 3 COOLING SYSTEM Coolant Pump Coolant Pump Assembly (formerly # ) Pulley O-ring Elbow Fitting with 3/8 BSPT Heater Outlet Bolt with Washer Capscrew, Hex Head Flanged M8 x 1.25 x 16 mm Cap Clip - 3-4

25 updated 2/8/11 GROUP 3 COOLING SYSTEM Keel Cooling Outlet A-4400 / B Keel Cooling Adapter Gasket Lock Washer, 5/16" USS S/S Capscrew, 5/16-18 x 1" S/S - 3-5

26 GROUP 3 COOLING SYSTEM updated 2/4/11 Raw Water Pump & Mounting A-9509 / C Raw Water Pump (see parts detail) Mounting Clip O-ring Capscrew, Hex Head M10 x 1.5 x 130 mm S/S Brass Male Connection, 1/2 NPT x 3/4 HB Wire Reinforced Hose, 3/4" ID Hose Clamp # Lock Washer M10 S/S Hex Nut M10 x 1.5 S/S - 3-6

27 GROUP 3 COOLING SYSTEM Raw Water Pump Detail Raw Water Pump Assembly (includes all keys) Repair Kit (includes keys #3 - #9, #11) Pump Housing Shaft Impeller (includes key #11) Cam Wear Plate End Cover Bearing Lip Seal Mechanical Seal Spline Seal O-Ring Retaining Ring Retaining Ring Washer Pan Head Screw #10-32 x 3/ Hex Head Screw #10-32 x 3/ Lock Washer #10 - A-4761 / C

28 GROUP 4 FUEL SYSTEM Injection Pump & Piping P864Injpump Injection Pump Assembly (formerly # ) Injection Line # Injection Line # Injection Line # Injection Line # Capscrew, Hex Head M6 x 1.0 x 25 mm Lock Washer M Clamp Injection Pump Support Bolt Bolt O-ring Flat Washer M

29 Changed GROUP 4 FUEL SYSTEM Fuel Injectors Standard Fuel Return P864Injectors Fuel Injector Injection Nozzle Seat Gasket Tube, Fuel Return* Fuel Return Hose* Hose Clamp* Pipe Assembly, Fuel Return* - *See also USCG Fuel System 4-1

30 GROUP 4 FUEL SYSTEM Changed Fuel Injectors USCG & ISO 7840 Fuel Return P864Injectors Fuel Injector Injection Nozzle Seat Gasket Tube, Fuel Return* Fuel Return Hose* Hose Clamp* Pipe Assembly, Fuel Return* - *See also USCG & ISO 7840 Fuel Lines 4-2

31 GROUP 4 FUEL SYSTEM Double Wall Fuel Lines A-10059/ B Injection Line #1 Double Wall Injection Line #2 Double Wall Injection Line #3 Double Wall Injection Line #4 Double Wall Fuel Alarm Manifold Banjo Bolt Banjo Washer O-ring Male Elbow, 90 0 Steel 1/4 BSP x 1/4-37T Hose Assembly 1/4 ID x Union, Steel 8 mm Alarm Tank Assembly Bracket, Alarm Tank Mtg Capscrew, Hex Head M12 x 1.25 x 25 mm Lock Washer, Helical M Capscrew, Hex Head M8 x 1.25 x 20 mm Wave Washer M Spacer, Tube Clamp Support Capscrew, Hex Head M6 x 1.0 x 30 mm - 4-3

32 GROUP 4 FUEL SYSTEM Fuel Filter and Lines Fuel Filter Base Assembly (includes key #2) Fuel Filter Capscrew, Hex Head M10 x 1.5 x 40 mm Wave Washer M Tube, Fuel Filter Inlet Tube, Fuel Filter Outlet Oil Supply Line Vent Plug Washer Banjo Bolt Banjo Bolt Sealing Washer M Banjo Bolt Banjo Bolt Adelle Clamp Capscrew, Hex Head M6 x 1.0 x Flat Washer Hex Nut Nylock M6 x A-9654/ A-9883A 4-4

33 GROUP 4 FUEL SYSTEM Fuel Lines (Push-On Type) Fuel Manifold, 1/4 NPT Capscrew, Hex Head M6 x 1.0 x 16 mm S/S Lock Washer, Helical M6 S/S Male Elbow, 90 0 Brass 1/4 NPT x 5/16-45T Male Elbow, 90 0 Brass 1/4 NPT x 1/4-45T Female Swivel, Brass 5/16 HB x 5/16-45T Female Swivel, Brass 1/4 HB x 1/4-45T " Hose, 5/16" ID " Hose, 1/4" ID Hose Clamp Hose Clamp Plug (for shipping) - A-9510 / C

34 GROUP 4 FUEL SYSTEM Fuel Lines USCG A-1 & ISO Fuel Manifold, 1/4 NPT Capscrew, Hex Head M6 x 1.0 x 16 mm S/S Lock Washer, Helical M6 S/S Male Elbow, 90 0 Brass 1/4 NPT x 5/16-45T Male Elbow, 90 0 Brass 1/4 NPT x 1/4-45T Hose Assembly 5/16 I.D. x 12-1/ Hose Clamp #12 Extended Band Hose Assembly 1/4 I.D. x 18-1/ Hose Clamp #8 Extended Band Plug (for shipping) - A / C

35 GROUP 4 FUEL SYSTEM US Coast Guard Approved Fuel Lines A-9941 / B Fuel Line Connection Manifold Capscrew, Hex Head M6 x 1.0 x 16 mm S/S Lock Washer M6 S/S Male Elbow 90 0 Steel, 1/4 NPT x 5/16-37T Male Run Tee, Steel, 1/4 NPT x 1/4-37T Elbow 90 0 Swivel, Steel 1/4-37T Hose Assembly 1/4 ID x 11-1/2 1/4 NPT Banjo Fitting 14 mm ID x 1/4 NPT Sealing Washer Hose Assembly 1/4 ID x 22 M12 Banjo Sealing Washer Hose Assembly 3/16 ID x 26 1/4 FMS Tube Assembly, Fuel Return Banjo Bolt - 4-7

36 GROUP 4 FUEL SYSTEM Fuel Injector P864injector 4-8

37 GROUP 4 FUEL SYSTEM Fuel Injector Injector, Complete Nozzle Retaining Nut Nozzle (formerly # ) Spacer Pin Spring, Nozzle Holder Pressure ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= ** Shim, T= Sealing Washer Nut, Return Line Retaining - **As required 4-9

38 GROUP 4 FUEL SYSTEM Fuel Feed Pump Assembly PLO

39 GROUP 4 FUEL SYSTEM Fuel Feed Pump Assembly Feed Pump Assembly Housing Sub-Assembly (includes keys 2-3) Rod Seal (not shown) Valve Spring Gasket Support Piston Tappet Roller Pin Block Spring Plug Filter Screw Primer Pump Washer Washer Snap Ring Hollow Screw Plug Washer

40 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt & 24 Volt Standard Ground Generator Set Applications A-9511, A-9589 / C

41 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt & 24 Volt Standard Ground Generator Set Applications Oil Pressure Switch Oil Pressure Sender - Single Station PSI Oil Pressure Sender - Dual Station PSI Temperature Switch Temperature Sender - Single Station Temperature Sender - Dual Station 250 F ** Bushing, Brass 3/8 NPT x 1/4 NPT - } (use with dual station) sender ** Bushing, Brass 1/2 NPT x 1/4 NPT as required Relay Base Terminal Retainer Relay, SPDT 12 VDC 50 Amp Relay, SPDT 24 VDC 20 Amp Circuit Breaker, 15 Amp Female Connector, Steel 1/8 NPT x 1/8 BSPT Grommet Machine Screw, BH Slotted #10-32 x 3/8" S/S Flat Washer # Hex Nut, # Diode, 6 Amp 50 Volt ' Wire Harness Extension (not shown) Wire Harness Assembly (includes key #14) Starter, 12 Volt - } (see mounting detail) Starter, 24 Volt Alternator, 12 Volt 40 Amp (see mounting & parts detail) Alternator, 24 Volt 40 Amp (see mounting detail) Stop Solenoid 12 Volt - } (see mounting detail) Stop Solenoid 24 Volt Switch, High Exhaust Temperature F (see wet exhaust detail) Glow Plug 12 Volt Glow Plug 24 Volt Buss Bar Retaining Cap - **As required 5-1

42 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt & 24 Volt Isolated Ground Generator Set Applications A-9588, A9590/ C

43 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt & 24 Volt Isolated Ground Generator Set Applications Oil Pressure Switch Oil Pressure Sender PSI, Single Station Temperature Switch Temperature Sender F, Single Station Relay Base (without Retainer) Terminal Retainer Relay, SPDT 12 Volt DC 50 Amp Relay, SPDT 24 Volt DC 20 Amp Circuit Breaker Female Connector, Steel 1/8 NPT x 1/8 BSPT Grommet Machine Screw, BH Slotted #10-32 x 3/8" S/S Flat Washer Hex Nut, # Diode, 6 Amp 50 Volt ' Wire Harness Extension (not shown) Wire Harness Assembly - } Starter, 12 Volt Starter, 24 Volt (see mounting detail) Alternator, 12 Volt 90 Amp Alternator, 24 Volt 35 Amp } Stop Solenoid 12 Volt (see mounting detail) Stop Solenoid 24 Volt Switch, High Exhaust Temperature F (see wet exhaust detail) Glow Plug, 24 Volt Glow Plug, 12 Volt Buss Bar Retaining Cap - 5-3

44 GROUP 5 ELECTRICAL SYSTEM Stop Solenoid & Mounting A-9566, A-9567 / B Synchro-Start Products, Inc Stop Solenoid 12 Volt (with brackets) Stop Solenoid 24 Volt (with brackets) Capscrew, Hex Head M6 x 1.0 x 25 mm Lock Washer, Helical M Flat Washer, M Capscrew, Hex Head M6 x 1.0 x 50 mm Hex Nut, M6 x Spring Cover - 5-4

45 GROUP 5 ELECTRICAL SYSTEM Small Frame Alternators 12 Volt/ 40 Amp Standard or Isolated Ground Without PTO A-9512/ C Alternator, 12 Volt 40 Amp Standard Ground (see parts detail) Alternator, 12 Volt 40 Amp Isolated Ground Bracket, Small Frame Alternator Mtg Capscrew, Hex Head M10 x 1.25 x 30 mm Lock Washer, M Hex Nut, M10 x Capscrew, Hex Head M8 x 1.25 x 45 mm Capscrew, Hex Head M8 x 1.25 x 40 mm Flat Washer, M Hex Nut, Nylock M8 x Tensioning Arm Capscrew, Hex Head M8 x 1.25 x 75 mm Lock Washer, M Capscrew, Hex Head M8 x 1.25 x 30 mm Stud Washer Drive Belt (formerly # ) - 5-5

46 GROUP 5 ELECTRICAL SYSTEM Medium Frame Alternators 12 & 24 Volt Standard or Isolated Ground Without PTO A-9592, A-9593, A-9594/ C Alternator, 12 Volt 90 Amp, Isolated Ground Alternator, 24 Volt 40 Amp, Standard Ground Alternator, 24 Volt 35 Amp, Isolated Ground Pulley Bracket Capscrew, Hex Head M10 x 1.25 x 30 mm Lock Washer, M Hex Nut, M10 x Capscrew, Hex Head 1/2-13 x 2-1/2" Flat Washer Hex Nut, Nylock 1/ Tensioning Arm Capscrew, Hex Head M8 x 1.25 x 75 mm Lock Washer, M Capscrew, Hex Head 5/16-18 x 1-1/4" Lock Washer, 5/ Washer, SAE 5/ Drive Belt, 31/64" x 43-3/8" - 5-6

47 GROUP 5 ELECTRICAL SYSTEM Small Frame Alternator 12 Volt 40 Amp Standard or Isolated Ground With PTO A-9657, A-9658 / C Alternator, 12 Volt 40 Amp Standard Ground Alternator, 12 Volt 40 Amp Isolated Ground Bracket, Small Frame Alternator Mtg Capscrew, Hex Head M10 x 1.25 x 25 mm Lock Washer, M Capscrew, Hex Head M8 x 1.25 x 45 mm Capscrew, Hex Head M8 x 1.25 x 40 mm Flat Washer M Hex Nut, Nylock M8 x Tensioning Arm Capscrew, Hex Head M8 x 1.25 x 75 mm Lock Washer, M Capscrew, Hex Head M8 x 1.25 x 30 mm Stud Washer Drive Belt - 5-7

48 GROUP 5 ELECTRICAL SYSTEM Medium Frame Alternators 12 & 24 Volt Standard or Isolated Ground With PTO A-9661, A-9662 / C Alternator, 12 Volt 90 Amp Isolated Ground Alternator, 24 Volt 40 Amp Standard Ground Alternator, 24 Volt 35 Amp Isolated Ground Pulley Bracket Capscrew, Hex Head M10 x 1.5 x 30 mm Lock Washer, M Capscrew, Hex Head 1/2-13 x 2-1/2" Flat Washer Hex Nut, Nylock 1/ Tensioning Arm Capscrew, Hex Head M8 x 1.25 x 75 mm Lock Washer, M Capscrew, Hex Head 5/16-18 x 1-1/4" Lock Washer, 5/ Washer, SAE 5/ Drive Belt - 5-8

49 GROUP 5 ELECTRICAL SYSTEM Alternator - 12 Volt / 40 Amp Standard Ground Fig Alternator Assembly with Regulator (includes all keys) Alternator Rotor Assembly - 2A Bearing Alternator Brush Holder Assembly Drive End Frame Assembly - 12A Bearing - 12C Stud Bolt Alternator Pulley Rear End Cover Alternator Brush Brush Spring Holder with Rectifi er - AE Bearing Retainer Plate - AF Bushing - AG Rectifi er End Frame - AJ Hexagon Bolt - AK Plate Washer - AL Pulley Lock Nut - AP Insulator - AR Nut - AS Spring Washer - AY Nut - BS Regulator Assembly - CF Bearing Cover - CH Nut - 5-9

50 GROUP 5 ELECTRICAL SYSTEM Starter - 12 & 24 Volt Standard Ground B-7546ver Starter Assembly 12 Volt Starter Assembly 24 Volt Stud Lock Washer M Hex Nut M12 x

51 GROUP 5 ELECTRICAL SYSTEM Starter - 12 Volt Isolated Ground B-7546ver Starter Assembly 12 Volt Adapter Stud Lock Washer M Hex Nut M12 x R Capscrew, Flange Head M12 x 1.75 x 40* - *Note: Replaces Socket Head Screw and Lock Washer to ease assembly. 5-11

52 GROUP 5 ELECTRICAL SYSTEM Starter - 24 Volt Isolated Ground B-7546ver Starter Assembly 24 Volt Adapter Capscrew, M12 x 1.25 x 60 mm Lock Washer M Flat Washer

53 GROUP 5 - ELECTRICAL SYSTEM S-1 Control Panel 12 & 24 Volt A-8551, A-8552/ B S-1 Start/Stop Control Panel, 12 Volt (includes all keys) S-1 Start/Stop Control Panel, 24 Volt (includes all keys) Plate, S-1 Control Panel Rocker Switch Rocker Switch Wire Harness, 12 Volt Wire Harness, 24 Volt Label "12 Volt" * Label "24 Volt" * Resistor, 200 Ohm, 3 Watt (24 Volt Panel only) * - *Not shown 5-13

54 GROUP 5 - ELECTRICAL SYSTEM S-1B Control Panel 12 & 24 Volt A / B S-1B Control Panel Assembly, 12 Volt (includes all keys) S-1B Control Panel Assembly, 24 Volt (includes all keys) Plate, S-1B Control Panel Rocker Switch Rocker Switch Hourmeter Machine Screw, Round Head #6-32 x 1/2" S/S * Star Washer * Hex Nut * Wire Harness without Resistor 12V Wire Harness with Resistor 24V Label "12 Volt" * Label "24 Volt" * Resistor, 200 OHM ** - *Not shown **Note: Shown for spare parts reference, included in Harness Assembly. 5-14

55 GROUP 5 - ELECTRICAL SYSTEM Flush Mount S-3C Control Panel 12 & 24 Volt A-9329, A-9330 / C S-3C Control Panel 12 Volt (includes all keys) S-3C Control Panel 24 Volt (includes all keys) Panel Plate Oil Pressure Gauge, PSI Engine Temperature Gauge, F DC Voltmeter, 12 Volt DC Voltmeter, 24 Volt Hourmeter Panel Wire Harness ** Self Tapping Screw, Oval Head Phillips #6 x 3/4" Toggle Switch Resistor Kit (24 volt panel only) ** 12 Volt Bulb (not shown) ** 24 Volt Bulb (not shown) - **As required 5-15

56 GROUP 5 - ELECTRICAL SYSTEM S-3B Control Panel 12 Volt & 24 Volt A-4721, A-4695, A-4722, A-4723 / C S-3B Control Panel, 12 Volt S-3B Control Panel, 24 Volt Enclosure Oil Pressure Gauge 0-80 PSI Engine Temperature Gauge F DC Voltmeter, 12 Volt DC Voltmeter, 24 Volt Hourmeter, Standard Line Series 3 Control Panel Decal Terminal Board Switch Number Strip Wire Harness (not shown) O-ring ** 12 Volt Bulb ** 24 Volt Bulb Resistor Kit (24 Volt only) Connection Harness Hex Nut, XL #6-32 x 1/2" Grommet - **As required 5-16

57 GROUP 5 ELECTRICAL SYSTEM Belt Guard & Mounting Small & Medium Frame Alternators, Units without PTO A-9655, A-9656, A-9659, A-9660 / C Belt Guard, Small Frame Alternator, Heat Exchanged units Belt Guard, Small Frame Alternator, Keel Cooled units Belt Guard, Medium Frame Alternator, Heat Exchanged units Belt Guard, Medium Frame Alternator, Keel Cooled units Stud, Belt Guard Mtg. (Special) Stud, Belt Guard Mtg. (Special) Bracket, Lower Belt Guard Mtg Capscrew, Hex Head, M8 x 1.25 x 45 mm Wave Washer M Capscrew, Hex Head, M8 x 1.25 x 20 mm S/S Lock Washer, M Hex Nut, M8 x 1.25 S/S Lock Washer, M8 S/S Snubbing Washer S/S

58 GROUP 5 ELECTRICAL SYSTEM Belt Guard & Mounting Small & Medium Frame Alternators, Keel Cooled Units with PTO A-9657, A-9662 / C Belt Guard, Small Frame Alternator (Right 1/2) Belt Guard, Medium Frame Alternator (Right 1/2) Stud, Belt Guard Mtg. (Special) Stud, Belt Guard Mtg. (Special) Bracket, Lower Belt Guard Mtg Capscrew, Hex Head, M8 x 1.25 x 45 mm Wave Washer M Capscrew, Hex Head, M8 x 1.25 x 20 mm S/S Lock Washer, M Hex Nut, M8 x 1.25 S/S Lock Washer, M8 S/S Snubbing Washer S/S Stud, Belt Guard Mtg. (Special) Belt Guard, Small & Medium Frame Alternator (Left 1/2)

59 GROUP 5 ELECTRICAL SYSTEM Belt Guard & Mounting Small & Medium Frame Alternators, Heat Exchanged Units with PTO A-9658, A-9661 / C Belt Guard, Small Frame Alternator (Right 1/2) Belt Guard, Medium Frame Alternator (Right 1/2) Stud, Belt Guard Mtg. (Special) Stud, Belt Guard Mtg. (Special) Bracket, Lower Belt Guard Mtg Capscrew, Hex Head, M8 x 1.25 x 45 mm Wave Washer M Capscrew, Hex Head, M8 x 1.25 x 20 mm S/S Lock Washer, M Hex Nut, M8 x 1.25 S/S Lock Washer, M8 S/S Snubbing Washer S/S Stud, Belt Guard Mtg. (Special) Belt Guard, Small & Medium Frame Alternator (Left 1/2)

60 GROUP 6 GASKET SETS Overhaul Gasket Set Gasket Kit - Engine Overhaul (components not listed) Gasket, Hydraulic Pump Drive Cover Gasket, Air Filter Housing Mtg Gasket, Exhaust Elbow Mtg Thermostat Seal Ring Gasket, Thermostat Housing Mtg O-ring Gasket, KC Adapter & HE Mtg Gasket, Rubber 3" Seat, Fuel Injector Gasket, Fuel Injector O-ring, Injection Pump Mtg Sealing Washer, Return Line Sealing Washer, Bonded - 6-0

61 GROUP 8 - FRAME & MOUNTING Engine Lifting Brackets P864Liftingbrackets Front Lifting Bracket Rear Lifting Bracket Capscrew, Hex Head Flanged M10 x 1.25 x 18 mm - 8-1

62 GROUP 8 FRAME & MOUNTING Base Frame A-9514 / D Base Frame, Steel Base Frame, Aluminum Front Engine Mounting Bracket, Left Hand Front Engine Mounting Bracket, Right Hand Capscrew, Hex Head M10 x 1.25 x 25 mm Lock Washer Hex Nut, Nylock M12 x 1.75 S/S Flat Washer, M12 S/S Snubbing Washer Plateform Mount, 310 lb Plateform Mount, 250 lb Capscrew, Hex Head M8 x 1.25 x 20 mm S/S Lock Washer, M8 S/S Capscrew, Hex Head M12 x 1.75 x 100 mm S/S Capscrew, Hex Head M12 x 1.75 x 90 mm S/S Capscrew, Hex Head M10 x 1.5 x 25 mm Lock Washer, M Capscrew, Hex Head 3/8-16 x 1-1/4" Lock Washer, 3/

63 GROUP 9 ACCESSORIES & OPTIONAL EQUIPMENT P.T.O. Adapter PTO Clutch Housing Engine/PTO Support Bracket (Right Hand) Engine/PTO Support Bracket (Left Hand) Capscrew, Hex Head M10 x 1.5 x 25 mm Wave Washer, M Capscrew (Special) PTO Drive Adapter Capscrew, Hex Head Flanged M8 x 1.25 x 20 mm Coupling Assembly Hub Capscrew, Socket Head M12 x 1.75 x 40 mm Capscrew, Socket HD M12 x 1.75 x 35 mm Taper Pin #4 x 1" Plateform Mount, 400 lbs Plateform Mount, 220 lbs Capscrew, Hex Head M12 x 1.75 x 110 mm S/S Capscrew, Hex Head M12 x 1.75 x 80 mm S/S Hex Nut, Nylock M12 x 1.75 S/S - A-9569 / D

64 GROUP 9 ACCESSORIES & OPTIONAL EQUIPMENT Electric Clutch 12 Volt and 24 Volt H-28 B-Spline A A-6346 / C Electric Clutch Assembly (12 volt) Electric Clutch Assembly (24 volt) Capscrew, Hex Head 1/2-13 x 1-1/ Flat Washer M Grommet Capscrew, Socket Head 3/8-24 x 3/

65 GROUP 9 ACCESSORIES & OPTIONAL EQUIPMENT Oil Level Switch/Gauge A-9957 / C Oil Level Switch Gauge, Isolated Ground Bracket Capscrew, Hex Head M12 x 1.75 x 25 mm Lock Washer, Helical M Capscrew, Hex Head 1/4-20 x 3/4" Lock Washer, Helical 1/4" Flat Washer, 1/4" SAE Male Elbow 90 0, Steel 1/2 NPT x 1/2-37T Tube Assembly Male Branch Tee, Steel 3/8 NPT x 1/2-37T Male Comp. Fitting, Brass 1/4" Tube x 1/4 HB " Hose 1/4" ID Push-on Female Swivel Steel 1/4 HB x 1/4-37T Push-on Male Elbow 90 0 Steel 1/8 NPT x 1/4-37T Strain Relief Connection 1/2 NPT - 9-3

66 GROUP 9 ACCESSORIES & OPTIONAL EQUIPMENT Oil Drain Kit A-5024 / B Oil Drain Kit Complete (includes all keys) Hand Pump Adapter, Oil Drain O-ring - 9-4

67 GROUP 9 ACCESSORIES & OPTIONAL EQUIPMENT Water Level Switch/Gauge Tank Mounted A-4888 / C-2515A Coolant Level Switch Gauge, Isolated Ground Male Elbow, 90 Brass 1/4 NPT x 1/4-45T Female Swivel, Brass 1/4-45T x 1/4 HB Hose, 1/4" ID x 8" Push-On Male Elbow, 90 Brass 1/8 NPT x 1/4-45T Capscrew, Hex Head 3/8-16 x 3/4" Lock Washer, Helical 3/ Flat Washer 3/ Capscrew, Hex Head 1/4-20 x 1 1/4" Bracket, Switch Gauge Mounting Snubbing Washer Nylock Hex Nut, 1/ Bushing, Brass 1/2 NPT x 1/4 NPT Hose Assembly 1/4" ID x 15" Male Elbow, 45 Steel 1/4 NPT x 1/4-37T Strain Relief Connection Grommet Sleeve Adelle Clamp Capscrew, Hex Head M6 x 1.0 x 20 mm Flat Washer M Hex Nut, Nylock M6 x

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