PARTS MANUAL P For Models: M843NW3 and NL843NW3.

Transcription

1 PARTS MANUAL P843-3 For Models: M843NW3 and NL843NW3

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 2016=7 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.: P /18

3 PARTS CATALOG for Models M843NW3 and NL843NW3 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 Assembly Crankshaft and Flywheel Assembly Camshaft and Oil Pump Cylinder Head Rocker Arm Assembly GROUP 2 - INTAKE & EXHAUST SYSTEM Air Filter and Housing... 1 Air Filter and Mounting... 2 Exhaust Manifold and Muffler... 3 GROUP 3 - COOLING SYSTEM Exhaust Manifold and Heat Exchanger Coolant Pump... 2 Coolant Pump, Fan, & Thermostat Housing... 3 Raw Water Pump and Mounting Radiator and Guard GROUP 4 - FUEL SYSTEM Injection Pump and Lines Governor and Timing Gear Case Fuel Filter and Piping Fuel Line Connection... 6 Fuel Injector... 7 Fuel Feed Pump... 8 GROUP 5 - ELECTRICAL SYSTEM 12 & 24 Volt Engine Alternator, Starter, and Flywheel Housing Alternator Starter Assembly Alternator Assembly Control Panels Belt Guard Assembly GROUP 6 - GASKET SETS Gasket Kit...0 GROUP 7 - GEAR AND ADAPTER SETS Not available at this time. GROUP 8 - FRAME & MOUNTING Base Frame Assembly GROUP 9 - ACCESSORIES GROUP 9 - & OPTIONAL EQUIPMENT PTO Adapter... 1 Electric Clutch... 2 Oil Drain Kit... 3 Keel Cooling Conversion... 4 Coolant Recovery Tank... 5 Remote Expansion Tank... 6 Low Coolant Level Switch/Gauge... 7 Proprietary Information This publication is the property of Northern Lights, Inc. It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc. Northern Lights, Inc. All rights reserved. Litho U.S.A. Publication number I

4 INTRODUCTION Model Designation MODELS INCLUDED This manual covers the operating instructions for: M843nw3 and NL843nw3, which both use the 843 engine. Model Numbers Model numbers give the unit's application, block model, aspiration, and RPM: M - NL 843 N, W, 3 M - Northern Lights marine generator set NL - Northern Lights industrial generator set Model number of engine block Bore Cylinders 84 mm 3 N - series designation W - winding in gen. end 3 - Tier III compliant M843nw3 = Northern Lights marine diesel generator set with an 843 engine and a PX-312K2 NL843nw3 = generator, Tier II compliant. Northern Lights industrial diesel generator set with an 843 engine and a PX-312K2 generator, Tier III compliant. Serial Numbers NORTHERN LIGHTS Your set has three serial numbers: 1 an engine number stamped on the block, 2 a generator plate, and 3 a generator set plate. Use the serial number on the generator set plate when ordering parts or in correspondence. The generator set plate is found on the service side of the generator and resembles the drawing below. Generator Set Serial Number II

5 INTRODUCTION 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 P / 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: a Arrows always point toward the front of the engine. III

6 GROUP 1 ENGINE Cylinder Block Assembly 843NW3cylblock 1-0

7 revised 2/2/15 GROUP 1 ENGINE Cylinder Block Assembly KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER Cylinder Block Assembly (Marine, includes keys #3-18, 28) Cylinder Block Assembly (Industrial, includes keys #3-18, 28) Expansion Plug 25 mm Expansion Plug 40 mm Plug Plug Plug Idle Gear Shaft Assembly Bushing, Standard Bushing, Undersized 0.25 mm Bushing, Undersized 0.50 mm Bearing Expansion Plug Dowel Pin Dowel Pin Dowel Pin Spring Pin Stud Stud Stud Gasket Oil Seal Bushing Filter Joint Oil Filter Assembly (former # ) Tappet Push Rod Relief Valve Assembly O-ring Needle Bearing Drain Cock Tube O-ring Dipstick Tube Bolt Dipstick Oil Pan (Marine) up to s/n xxxx-46623c Oil Pan (Marine) from s/n xxxx-46624c Oil Pan (Industrial) Bolt (Marine & Industrial) Plug, Hex Head M12 x 1 (Industrial) Seal Washer (Industrial) Oil Drain Hose } Cap Bracket up to s/n xxxx-46623c Capscrew, Hex Head 3/8-16 x 3/4 S/S Lock Washer 3/8 S/S - 1-1

8 GROUP 1 ENGINE Crankshaft and Flywheel Assembly 843NW3crankshaft 1-2

9 GROUP 1 ENGINE Crankshaft and Flywheel Assembly Crankshaft Assembly (includes keys 2-5) Crankshaft Gear Key Dowel Pin Spring Pin Bearing Holder Assembly (includes keys 9 &12) Bearing Holder Assembly (includes keys 9 &12) Bearing Holder Assembly (includes keys 9 &12) Dowel Pin Bearing; Standard (Upper) Bearing; Undersized 0.25 mm (Upper) Bearing; Undersized 0.50 mm (Upper) Bearing; Standard (Lower) Bearing; Undersized 0.25 mm (Lower) Bearing; Undersized 0.50 mm (Lower) Bolt Bolt Bolt Thrust Washer Piston Ring Kit, Standard Piston Kit, Standard (formerly # ) Piston Pin Snap Ring Connecting Rod Assembly (includes keys 21-23) Bushing Connecting Rod Bolt Nut Bearing, Standard Bearing, 0.25 mm Bearing, 0.50 mm Crankshaft Pulley (Marine) Crankshaft Pulley (Industrial) Nut Flywheel Assembly (includes key 28) Ring Gear (109 Teeth) Bolt - 1-3

10 added GROUP 1 ENGINE Kit, Oil Drain and Valve M843N From S/N xxxx-46624c KEY PART NUMBER QTY DESCRIPTION S/N Ball valve, Brass 90 Deg 1/4NPT Male X 1/4NPT Female Male Connector Brass 1/4NPT X 3/8HB Push-On Hose 3/8 ID X 7 Push-On Plug, Hex Head, Brass 1/4NPT Male Connector, Stl. 1/4NPT X 3/8-37T Female Swivel, Brass. 3/8HB X 3/8-37T Push-On - b

11 added GROUP 1 ENGINE Notes 1-5

12 GROUP 1 ENGINE Camshaft and Oil Pump 843NW3oilpump 1-6

13 GROUP 1 ENGINE Camshaft and Oil Pump Camshaft Assembly (includes keys 2-6) Cam Gear Key Gear Spacer Bearing Slider Plate Bolt Idle Gear Assembly (includes key #12) Thrust Washer Spring Rotor Oil Pump Cover Shim; t = Shim; t = Shim; t = Shim; t = Spring Collar Snap Ring Front Plate - Marine (white) Front Plate - Industrial (blue) Gasket Bolt O-ring Oil Pipe Suction Filter Assembly Bolt - 1-7

14 GROUP 1 ENGINE Cylinder Head 843NW3cylhead 1-8

15 revised GROUP 1 ENGINE Cylinder Head Cylinder Head Assembly (Marine, includes keys 1-14) Cylinder Head Assembly (Industrial, includes keys 1-14) Expansion Plug, 18 mm Expansion Plug, 30 mm Expansion Plug, 25 mm Expansion Plug, 10 mm Intake Valve (former # ) Exhaust Valve (former # ) Valve Guide Seal - Intake Spring Retainer Cotter Valve Guide Seal - Exhaust Cap Valve Seat - Intake Head Gasket t=1.3 mm Head Gasket t=1.4 mm Head Bolt Head Bolt Lifting Eye (Marine) Lifting Eye (Industrial) Bolt - 1-9

16 GROUP 1 ENGINE Rocker Arm Assembly 843NW3rockerarm Rocker Arm Assembly (Marine, includes keys 2-7, 16-17) Rocker Arm Assembly (Industrial, includes keys 2-7, 16-17) Intake Rocker Arm Exhaust Rocker Arm Screw Nut Rocker Arm Shaft Spring Bolt Stud Nut Oil Pressure Switch (see Electrical System) Oil Pipe Assembly Sealing Washer Banjo Bolt Gasket O-ring Shim Banjo Bolt (Tapped 1/8 NPT)

17 GROUP 1 ENGINE Rocker Arm Cover Marine 843NW3rockercover Rocker Arm Cover Gasket Oil Stopper Steel Wool Screw Gasket Cap Nut Cap O-ring Breather Valve Bolt Bolt Bolt Caution Plate

18 GROUP 1 ENGINE Rocker Arm Cover Industrial 843NW3rockercoverind Rocker Arm Cover Gasket Oil Stopper Steel Wool Screw Gasket Cap Nut Cap O-ring Breather Valve Bolt Bolt Bolt Caution Plate Gasket Air Intake Bolt

19 GROUP 2 INTAKE AND EXHAUST Air Filter and Housing Marine A-10262, A / C Connector, Air Inlet Gasket, Air Intake Mounting Capscrew, Hex Head M6 x 1.0 x 20 mm Wave Washer M6 S/S Hose 1-3/4" ID x 2-1/4" Hose Clamp # Front Cover, Air Filter Housing Plate, Air Filter Baffle Element, Air Filter Screen, Air Filter Retaining Rear Cover, Air Filter Housing Capscrew, Hex Head M6 x 1.0 x 85 mm S/S Wave Washer M6 S/S Bracket, Air Filter Support Capscrew, Hex Head M8 x 1.25 x 16 mm S/S Wave Washer M8 S/S Hose, Air Intake (Molded) Hose Clamp # Cushion Clamp # Capscrew, Hex Head M6 x 1.0 x 16 mm S/S Flat Washer, M6 S/S - 2-1

20 GROUP 2 INTAKE AND EXHAUST Air Filter and Mounting Industrial Air Filter Assembly (includes keys #13-16) Clamp # Hose Bracket Bracket Lifting Eye Bolt Bolt Bolt Washer Bolt Bolt Housing Element Cover Assembly Valve - 843NW3aircleaner 2-2

21 GROUP 2 INTAKE AND EXHAUST Exhaust Manifold and Muffler Industrial 843NW3muffler Muffler Assembly (includes keys #2-8) Bolt Muffler Element Gasket Exhaust Manifold Gasket Flange Bolt Gasket Bolt Stud Nut Exhaust Elbow (can use # ) Exhaust Elbow 1-1/2 NPT Clamp Washer Spring Washer Nut Bolt - 2-3

22 GROUP 3 COOLING SYSTEM Exhaust Manifold and Heat Exchanger Marine A-4760B/ D-2106C 3-0

23 updated GROUP 3 COOLING SYSTEM Exhaust Manifold and Heat Exchanger Marine Exhaust Manifold / Expansion Tank Heat Exchanger Element Wet Exhaust Elbow S/S Wet Exhaust Elbow (Cast Iron) Heat Exchanger End Cap Thermostat Housing Cover Plate Pressure Cap (formerly # ) Thermostat, 180 F / 82 C Exhaust Manifold Gasket Wet Exhaust Elbow Gasket Spring Northern Lights Decal (145 mm x 41 mm) Formed Hose Hose 3/4" ID x 18-1/2" Overflow Hose 5/16" ID x 25" Union 3/4 HB x 3/4 HB Socket Head Plug 1/2 NPT Connector 1/2 NPT x 3/4 HB Hose Clamp # Hose Clamp # Hose Clamp # Hex Head Plug, Brass 3/8 NPT Capscrew, Hex Head M6 x 1.0 x 105 mm S/S Capscrew, Hex Head M6 x 1.0 x 110 mm S/S Capscrew, Hex Head M8 x 1.25 x 25 mm S/S Flat Washer M6 S/S Flat Washer M8 S/S Thermostat Gasket Hose Clamp # Stud M8 x 1.25 x 20 x 10 S/S (35 mm OAL) Hex Nut, M8 x 1.25 S/S Filler Neck Switch, High Exhaust Temperature (not shown) - 3-1

24 GROUP 3 COOLING SYSTEM Coolant Pump Marine Fig Coolant Pump Assembly (includes keys #2-5) Backing Plate Gasket Plug Screw Gasket Bolt Nut Pulley Spacer Bolt - 3-2

25 GROUP 3 COOLING SYSTEM Coolant Pump, Fan, and Thermostat Housing Industrial 843NW3coolantpumpind Coolant Pump Assembly (includes keys #2-5) Backing Plate Gasket Plug Screw Gasket Bolt Nut Bolt Gasket Spring Thermostat, 180 F / 82 C Thermostat Housing Plug Temperature Switch, F/ C Nut Stud Hose Hose Clamp # Pulley Spacer Fan (Blower) Bolt, M6 x 1.0 x 35 mm - 3-3

26 GROUP 3 COOLING SYSTEM Raw Water Pump and Mounting Marine A-4779/ B O-ring 2-1/2 x 2-3/4 x 1/ Nut M10 x Lock Washer M Fitting 1/2 NPT x 3/4 HB Raw Water Pump (see parts detail) Drive Gear Capscrew, Hex Head M8 x 1.25 x 90 mm Capscrew, Hex Head M8 x 1.25 x 85 mm Lock Washer, Helical M Hex Nut M8 x

27 updated GROUP 3 COOLING SYSTEM Raw Water Pump Detail A-3706/ C Raw Water Pump Assembly (includes keys 1-17) Repair Kit (includes keys 3-9, 11) Raw Water Pump Body Shaft Impeller 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/ Split Lock Washer #

28 GROUP 3 COOLING SYSTEM Radiator and Guard 10 A-6501/ B

29 GROUP 3 COOLING SYSTEM Radiator and Guard Top Panel Side Panel Radiator Support Radiator Assembly, Aluminum (includes keys 23-25) Spacer, Radiator Support Capscrew, Hex Head M6 x 1.0 x 16 mm Capscrew, Hex Head M6 x 1.0 x 20 mm Flat Washer M Lock Washer, Helical M Capscrew, Hex Head M8 x 1.25 x 16 mm Capscrew, Hex Head M8 x 1.25 x 20 mm Flat Washer M Lock Washer, Helical M Hex Nut, Nylock M8 x Capscrew, Hex Head M10 x 1.5 x 16 mm Lock Washer, Helical M Flat Washer M Hose, Radiator Inlet Hose, Radiator Outlet Hose Clamp # Label Northern Lights (not shown) Grille Drain Cock Filler Cap Vent Hose Shroud with Fan Guard O-ring 3-7

30 GROUP 4 FUEL SYSTEM Injection Pump and Lines 843injectionlines 4-0

31 GROUP 4 FUEL SYSTEM Injection Pump and Lines Injection Pump Assembly Shim Set Nut Bolt Gasket Injector Assembly Return Line Injection Line # Injection LIne # Injection LIne # Clamp Bolt Nut Glow Plug, 12 Volt Glow Plug, 24 Volt Connector Gasket Feed Pump Assembly (see parts detail) Bolt Solenoid, 12V Standard Ground Solenoid, 12V Isolated Ground Solenoid, 24V Isolated Ground Seal Washer Seal Washer Screw Wire Harness Spring Washer Nut - 4-1

32 GROUP 4 FUEL SYSTEM Governor and Timing Gear Case 843timinggear 4-2

33 revised GROUP 4 FUEL SYSTEM Governor and Timing Gear Case Timing Gear Case - Marine (white) - (includes key #2) Timing Gear Case - Industrial (blue) Spring Pin Gasket Oil Seal Governor Lever Assembly (includes keys 6-8) Tension Lever Snap Ring Washer Snap Pin Spring Arm O-ring Governor Lever Bolt Nut Shaft O-ring Snap Ring Bracket Bolt Bolt Bolt Bolt Bolt ** Bolt (**as required) Cover (Marine only, Keel Cooled) Cover (Industrial only) Gasket (former # ) Nut O-ring Start Spring Spring Bolt Oil Fill O-ring }Marine only Cap Caution Plate - } 4-3

34 GROUP 4 FUEL SYSTEM Fuel Filter and Piping 843NWfuelfilter 4-4

35 GROUP 4 FUEL SYSTEM Fuel Filter and Piping Fuel Filter Assembly (includes keys #2-5) Fuel Filter Gasket Joint Bolt Plug Bracket (Marine) Bracket (Industrial) Bracket (Marine) Bracket (Industrial) Bolt Nut Spring Washer Nut Bracket - Industrial only Bolt - Industrial only ** Bolt Pipe Pipe Connector, Fuel Inlet Bolt Washer Gasket Joint Bolt Joint Bolt Seal Washer Joint Bolt Sealing Washer M ** Washer Spacer (Marine) Lifting Eye - **As required 4-5

36 GROUP 4 FUEL SYSTEM updated USCG SAE J1527 ISO 7840 Fuel Lines M843N up to s/n xxxx-46623c NL 843N All A / B Fuel Manifold 1/4 NPT Capscrew, Hex Head M6 x 1.0 x 16 mm S/S Lock Washer, Helical M6 S/S Plug, Hex Head Brass 1/4 NPT Male Elbow 90, Brass 1/4 NPT x 5/16-45T Male Elbow 90 0, Brass 1/4 NPT x 1/4-45T Hose Assembly 1/4" ID x 14-1/ Hose Assembly 1/4" ID x

37 updated GROUP 4 FUEL SYSTEM USCG SAE J1942 ABS Fuel Lines M843N up to s/n xxxx-46623c A / B Fuel Manifold 1/4 NPT Capscrew, Hex Head M6 x 1.0 x 16 mm S/S Lock Washer, Helical M6 S/S Plug, Hex Head Brass 1/4 NPT Male Elbow 90, Steel 1/4 NPT x 5/16-37T Male Elbow 90 0, Steel 1/4 NPT x 1/4-37T Hose Assembly 1/4" ID x Hose Assembly 3/16" ID x

38 GROUP 4 FUEL SYSTEM updated USG A-1 SAE J1527 ISO 7840 Fuel Lines M843N from s/n xxxx-46624c B-9827 Key Part Number Qty Description Serial Number Plug, Hex Head Brass 1/4 NPT Male Elbow, 45, Brass. 1/4NPT X 5/16-45T Male Elbow, 45, Brass. 1/4NPT X 1/4-45T Hose Assembly 1/4 ID x 14-1/ Hose Assembly 1/4 ID x

39 updated GROUP 4 FUEL SYSTEM USG A-1 SAE J1942 ABS Fuel Lines M843N from s/n xxxx-46624c B-9827 Key Part Number Qty Description Serial Number Plug, Hex Head Brass 1/4 NPT Male Elbow, 45, Steel 1/4NPT X 5/16-37T Male Elbow, 45, Steel 1/4NPT X 1/4-37T Hose Assembly 1/4 ID x Hose Assembly 3/16 ID x

40 GROUP 4 FUEL SYSTEM Fuel Injector injector Injector Assembly (includes keys #1-8) Nut Gasket Shim Spring Spring seat Spacer Nozzle Nut

41 GROUP 4 FUEL SYSTEM Fuel Feed Pump feedpump Feed Pump Assembly (includes keys #1-15) Housing* Spring Piston Spring Diaphragm Pin Lever O-ring Spring Guide* Gasket Cap* Screw Gasket Banjo Bolt - *No longer available separately. 4-11

42 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Standard Ground MARINE UNITS A-6258 / C-2490C 5-0

43 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Standard Ground MARINE UNITS Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/8 NPT Bushing, Brass 3/8NPT x 1/8 NPT (for sender ) Temperature Switch 95 C M16 X Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 12 Volt SPDT Terminal Retainer Relay Base Circuit Breaker, DC 15 Amp - Snap-In Type Circuit Breaker DC 15 Amp - Screw mount type Control Panel, S1-B (see detail) Engine Wire Harness - Round, Merc Plug Connector Diode, 6 Amp 50 Volt PIV Wire Harness Extension 20 (not shown) Grommet Machine Screw #10-32 x 3/8 s/s Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 12 Volt (see also Fuel System) Alternator 12 Volt 40 AMP Banjo Bolt M8 x 1.25 x 18mm (Tapped 1/8 NPT) Oil Line Starter 12 Volt (see mounting detail) Street 90 o Steel 1/8 NPT x 1/8 NPT (not shown) - 5-1

44 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Standard Ground B+ SYSTEM MARINE UNITS A-6258 / C-2490D 5-2

45 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Standard Ground B+ SYSTEM MARINE UNITS Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/8 NPT Bushing, Brass 3/8NPT x 1/8 NPT (for sender ) Temperature Switch 95 C M16 X Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 12 Volt SPDT Terminal Retainer Relay Base Circuit Breaker DC 10 Amp - Screw mount type Control Panel, S1-B (see detail) Engine Wire Harness - Square, Deutsch Plug Connector Diode, 1 Amp 200 Volt PIV Wire Harness Extension 20 (not shown) Grommet Machine Screw #10-32 x 3/8 s/s Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 12 Volt (see also Fuel System) Alternator 12 Volt 40 AMP Banjo Bolt M8 x 1.25 x 18mm (Tapped 1/8 NPT) Oil Line Starter 12 Volt (see mounting detail) Street 90 o Steel 1/8 NPT x 1/8 NPT - 5-3

46 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Isolated Ground MARINE UNITS A-6398, A-6402 / C-2490C 5-4

47 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Isolated Ground MARINE UNITS Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F (former # ) * Temperature Switch 95 C M16 X Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 12 Volt SPDT Relay Base Terminal Retainer Circuit Breaker, 15 Amp - Snap-In Type Circuit Breaker 15 Amp - Screw Mount type Control Panel, S1-B (see detail) Engine Wire Harness - Round Merc Plug Connector Ground Harness Addition Diode, 6 Amp 50 Volt PIV Wire Harness Extension 20 (not shown) Grommet Machine Screw #10-32 x 3/8 S/S Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 12 Volt (see also Fuel System) Alternator 12 Volt 40 AMP (See mounting detail) Banjo Bolt M8 x 1.25 x18mm (Tapped 1/8 NPT) Oil Line Starter 12 Volt (see mounting detail) Branch Tee Steel 1/8 NPT x 1/8 NPT Plug 1/8BSPT Bushing 3/8 NPT x 1/4 NPT * - * Bushing required with replacement sender

48 revised GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Isolated Ground B+ SYSTEM MARINE UNITS A-6398, A-6402 / C-2490F 5-6

49 revised GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Isolated Ground B+ SYSTEM MARINE UNITS Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/4 NPT Temperature Switch 95 C M16 X Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 12 Volt SPDT Relay Base Terminal Retainer Circuit Breaker 10 Amp - Screw Mount type Control Panel, S1-B (see detail) Engine Wire Harness - Square Deutsch Plug Connector Ground Harness Addition Diode, 1 Amp 200 Volt PIV Wire Harness Extension 20 (not shown) Grommet Machine Screw #10-32 x 3/8 S/S Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 12 Volt (see also Fuel System) Alternator 12 Volt 40 AMP (see mounting detail) Banjo Bolt M8 x 1.25 x18mm (Tapped 1/8 NPT) Oil Line Starter 12 Volt (see mounting detail) Branch Tee Steel 1/8 NPT x 1/8 NPT Plug 1/8BSPT Bushing 3/8 NPT x 1/4 NPT * - * Bushing required with sender

50 revised GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground MARINE UNITS A-6258 / C-2490C 5-8

51 revised GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground MARINE UNITS Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F (former # ) Bushing, Brass 3/8NPT x 1/8 NPT (for sender ) Temperature Switch 95 C M16 x Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 24 Volt SPDT Relay Base Terminal Retainer Circuit Breaker, 15 Amp - Snap-In Type Circuit Breaker 15 Amp - Screw Mount Type Control Panel, S1-B (see detail) Engine Wire Harness - Round Merc Plug Connector Diode, 6 Amp 50 Volt PIV Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" s/s Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 24 Volt (see also Fuel System) Alternator 24 Volt 40 AMP up to S/N xxxx-46623c Alternator 24 Volt 25 AMP from S/N xxxx-46624c Banjo Bolt M8 x 1.25 x 18mm (Tapped 1/8 NPT) Oil Line Starter 24 Volt (see mounting detail) (former # ) Street 90 o Steel 1/8 NPT x 1/8 NPT - 5-9

52 revised GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground B+ SYSTEM MARINE UNITS A-6258 / C-2490C 5-10

53 revised GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground B+ SYSTEM MARINE UNITS Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/4 NPT Bushing, Brass 3/8NPT x 1/8 NPT (for sender ) Temperature Switch 95 C M16 x Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 24 Volt SPDT Relay Base Terminal Retainer Circuit Breaker 10 Amp - Screw Mount Type Control Panel, S1-B (see detail) Engine Wire Harness -Square Deutsch Plug Connector Diode, 1 Amp 200 Volt PIV Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" s/s Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 24 Volt (see also Fuel System) Alternator 24 Volt 25 Amp (See mounting detail) Banjo Bolt M8 x 1.25 x 18mm (Tapped 1/8 NPT) Oil Line Starter 24 Volt (see mounting detail) Street 90 o Steel 1/8 NPT x 1/8 NPT

54 revised GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Isolated Ground MARINE UNITS A-6398, A-6402 / C-2490C 5-12

55 added GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Isolated Ground MARINE UNITS Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/4 NPT (former # ) Temperature Switch 95 C M16 x Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 24 Volt SPDT Relay Base Terminal Retainer Circuit Breaker, DC 15 Amp - Snap-In Type Circuit Breaker 15 Amp - Screw Mount Type Control Panel, S1-B (see detail) Engine Wire Harness - Round Merc Plug Connector Ground Harness Addition Diode, 6 Amp 50 Volt PIV Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" S/S Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 24 Volt (see also Fuel System) Alternator 24 Volt 35 AMP up to S/N xxxx-46623c Alternator 24 Volt 25 AMP from S/N xxxx-46622c Banjo Bolt M8 x 1.25 x 18mm (Tapped 1/8NPT) Oil Line Starter 24 Volt (see mounting detail) (former # ) Branch Tee Steel 1/8 NPT x 1/8 NPT (not shown) Plug 1/8BSPT - * Bushing required with replacement sender

56 revised GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Isolated Ground B+ SYSTEM MARINE UNITS A-6398, A-6402 / C-2490C 5-14

57 revised GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Isolated Ground B+ SYSTEM MARINE UNITS Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/4 NPT * Temperature Switch 95 C M16 x Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 24 Volt SPDT Relay Base Terminal Retainer Circuit Breaker 15 Amp - Screw Mount Type Control Panel, S1-B (see detail) Engine Wire Harness - Square Deutsch Plug Connector Ground Harness Addition Diode, 1 Amp 200 Volt PIV Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" S/S Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 24 Volt (see also Fuel System) Alternator 24 Volt 25 AMP (see mounting detail) Banjo Bolt M8 x 1.25 x 18mm (Tapped 1/8NPT) Oil Line Starter 24 Volt (see mounting detail) Branch Tee Steel 1/8 NPT x 1/8 NPT Plug 1/8BSPT - * Bushing required with replacement sender

58 GROUP 5 ELECTRICAL SYSTEM Engine Electrical - 12 Volt Standard Ground Industrial 5-16 A-4786/ C-2490Bnl Temperature Sender, F Single Station 3/8 NPT Temperature Switch 221 F/ 105 C Oil Pressure Sender 0-80 PSI, Single Station 1/8 NPT Oil Pressure Switch Relay, 12 Volt SPDT Relay Base Circuit Breaker Terminal Retainer Engine Wire Harness (includes key #10) Diode, 6 Amp 50 Volt Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" Stainless Steel Flat Washer # Hex Nut, # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Street Elbow 90 0, 1/8 NPT Steel Alternator 12 Volt (see parts detail) Oil Line Banjo Bolt (Tapped 1/8 NPT Female) Starter 12 Volt (see parts detail) Fuel Solenoid -

59 revised GROUP 5 ELECTRICAL SYSTEM Alternator, Starter, and Flywheel Housing 843NWalternator Tensioning Arm Alternator, 12 Volt 40 Amp Standard Ground Alternator, 12 Volt 40 Amp Isolated Ground Bolt Washer Bracket Bolt Bolt Nut Spring Washer Drive Belt Bolt Flywheel Housing (Marine) Flywheel Housing (Industrial) Bolt Starter, 12 Volt Standard Ground Starter, 12 Volt Isolated Ground Starter, 24 Volt Standard Ground Starter, 24 Volt Isolated Ground Capscrew, Flange Head M10 x 1.5 x 25 mm (12 volt starters) Capscrew, Flange Head M10 x 1.5 x 30 mm (24 volt starters) Bracket, Drain Hose Support Spring Washer Bolt

60 GROUP 5 ELECTRICAL SYSTEM Alternator Isolated and Standard Ground A-7631, A-7632, A-7633/ D Alternator (12V/51A ISO Ground) Alternator (24V/40A Standard Ground) Alternator (24V/35A ISO Ground) Pulley, 1-A x 2-1/2" x 5/8" ID Alternator Mounting Bracket Capscrew, Hex Head M8 x 1.25 x 20 mm Lock Washer, Helical M Capscrew, Hex Head 1/2-13 x 2-3/4" Spacer Flat Washer 1/2 SAE Hex Nut, Nylock 1/ Tensioning Arm Tensioning Arm (24 Volt 35 Amp Alternator only) Capscrew, Hex Head 5/16-18 x 1" Stud Washer 5/ Lock Washer, Helical 5/ Diode Harness Addition Drive Belt D.C. Voltage Regulator 12 Volt Wire Harness, 36" Machine Screw, BH Slotted #10-32 x 3/4" S/S Flat Washer #10 S/S Hex Nut, Nylock #10-32 S/S

61 GROUP 5 - ELECTRICAL SYSTEMS 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 5-19

62 GROUP 5 ELECTRICAL SYSTEM S-1 Control Panel 12 & 24 Volt B+ ELECTRICAL SYSTEMS S-1 Start/Stop Control Panel (includes all keys) Plate, S-1 Control Panel Rocker Switch, Momentary (On)-Off Rocker Switch, Momentary (On)-Off-(On) Green Lamp Wire Harness Label "12-24 Volt" (Not Shown)

63 GROUP 5 ELECTRICAL SYSTEM Series 1-B Start-Stop Control Panel 12 AND 24 VOLTS A-8553/ B S 1-B Start/ Stop Control Panel - 12 Volt (includes all keys) S 1-B Start/ Stop Control Panel - 24 Volt (includes all keys) Plate Rocker Switch Rocker Switch Hour Meter Machine Screw, Round Head Philips #6-32 x 1/2" Star Washer, Internal #6, Stainless Steel Hex Nut #6-32, Stainless Steel Wire Harness - 12 Volt Panels Wire Harness - 24 Volt Panels

64 GROUP 5 ELECTRICAL SYSTEM Series 1-B Start/Stop Control Panel B+ ELECTRICAL SYSTEMS Complete Series 1-B Start/Stop Control Panel (includes all keys) Plate Rocker Switch, Momentary (On)-Off Rocker Switch, Green LED (On)-Off-(On) Green Lamp Hour Meter Machine Screw, Round Head Phillips #6-32 x 1/2" Star Washer, Internal #6, Stainless Steel Hex Nut #6-32, Stainless Steel Wire harness Label Volts (Not shown)

65 revised GROUP 5 ELECTRICAL SYSTEM Flush Mount Dual Station Control Panel 12 & 24 Volt VDO OCEAN LINE GAUGES A-11322, A-11323/ C-2441 KEY PART NUMBER QTY DESCRIPTION A-4732, A-4597/ SERIAL C-2441 NUMBER S-3C Control Panel, 12 Volt (includes all keys) S-3C Control Panel, 24 Volt (includes all keys) Panel Plate Oil Pressure Gauge, 0-80 PSI 12 Volt Oil Pressure Gauge, 0-80 PSI 24 Volt Temperature Gauge, F 12 Volt Temperature Gauge, F 24 Volt DC Voltmeter, 8-16 VDC DC Voltmeter, VDC Hourmeter 12/ 24 Volt Panel Wire Harness Self Tapping Screw, Oval Head Phillips #6 x 3/ Toggle Switch Label 12 Volt (not shown) Label 24 Volt (not shown) ** 12 Volt Bulb (not shown) ** 24 Volt Bulb (not shown) - **As required 5-23

66 added GROUP 5 ELECTRICAL SYSTEM S-3C Control Panel 12 Volt VDO Viewline Black Bezel Gauges C S-3C Control Panel, 12 Volt (includes all keys) S-3C Control Panel, 24 Volt (includes all keys) Panel Plate Oil Pressure Gauge, 0-80 PSI 12/24 Volt * Temperature Gauge, F 12/24 Volt * DC Voltmeter, 8-16 VDC * Voltmeter VDC * Hourmeter 12/ 24 Volt Panel Wire Harness Self Tapping Screw, Oval Head Phillips #6 x 3/ Toggle Switch Label 12 Volt (not shown) Bezel - * Note Bezel supplied separately 5-24

67 GROUP 5 ELECTRICAL SYSTEM S-3B Control Panel 12 & 24 Volt VDO OCEAN LINE BLACK BEZEL GAUGES A-11320, A C S-3C Control Panel, 12 Volt (includes all keys) S-3C Control Panel, 24 Volt (includes all keys) Enclosure Oil Pressure Gauge, 0-80 PSI 12 Volt Oil Pressure Gauge, 0-80 PSI 24 Volt Temperature Gauge, F 12 Volt Temperature Gauge, F 24 Volt DC Voltmeter, 8-16 VDC DC Voltmeter, VDC Hourmeter 12/ 24 Volt Panel Decal Terminal Strip Toggle Switch Number Strip Wire Harness (not shown) Grommet Connection Harness Label 12 Volt (not shown) Label 24 Volt (not shown) ** 12 Volt Bulb (not shown) ** 24 Volt Bulb (not shown) **As required 5-25

68 GROUP 5 ELECTRICAL SYSTEM S-3B Control Panel Volt B+ Systems VDO Viewline Black Bezel Gauges 5-26

69 GROUP 5 ELECTRICAL SYSTEM S-3B Control Panel Volt B+ Systems VDO Viewline Black Bezel Gauges S-3C Control Panel, 12 Volt (includes all keys) S-3C Control Panel, 24 Volt (includes all keys) Enclosure Decal Oil Pressure Gauge, PSI 12/24 Volt * Temperature Gauge, F 12/24 Volt * Voltmeter, 8-16 VDC * Voltmeter VDC * Hourmeter 12/ 24 Volt Bezel Terminal Strip Number Strip Jam Nut, Nylock #8-32 S/S Toggle Switch Toggle Switch Bracket, Relay Mounting Wire Harness (not shown) (Includes keys 22-23) Machine Screw, Phillips #8-32 x 1/2 S/S Star Washer #8 S/S ** Relay 12 Volt ** Relay 24 Volt Connection Harness Label 12 Volt (not shown) Grommet Machine Screw, Pan Head, Phillips #8-32 x 5/8 S/S Relay Base Retainer - * Note Bezel supplied separately 5-27

70 GROUP 5 ELECTRICAL SYSTEM updated 4/25/14 Belt Guard Assembly Marine A-5004, A-5020/ B Belt Guard, Small Frame Alternators (without PTO) Belt Guard, Small Frame Alternators (with PTO) Belt Guard, Medium Frame Alternators (without PTO) Belt Guard, Medium Frame Alternators (with PTO) Stud, All Thread M8 x 1.25 x 110 mm S/S Stud, All Thread M6 x 1.0 x 140 mm S/S Hex Nut M8 x 1.25 S/S Lock Washer M8 S/S Flat Washer M8 S/S Hex Nut M6 x 1.0 S/S Lock Washer M6 S/S Flat Washer M6 S/S Stud, All Thread M6 x 1.0 x 70 mm S/S Hex Nut, X-L M6 x 1.0 x 19 mm ** Bracket (used with only not shown) ** Bracket (used with and only not shown) PTO Guard (not shown) - **As required 5-28

71 GROUP 5 ELECTRICAL SYSTEM Notes 5-29

72 GROUP 6 GASKET SETS Gasket Kit Gasket Kit (Marine, includes all keys) Gasket Kit (Industrial, includes keys #1-39) Oil Seal, Rear O-ring, Oil Line Gasket, Oil Pan Seal Washer, Oil Pan Drain Gasket, Front Plate O-ring, Governor Shaft O-ring Gasket, Timing Gear Case Oil Seal, Front Gasket, Gear Case Cover Adjusting Shim Set, Injection Pump Seal Washer, Air Bleed Screw Gasket, Banjo Bolt Head Gasket, t= Valve Guide Seal, Exhaust Valve Guide Seal, Intake Gasket, Lower side Injector Gasket, Upper side injector O-ring, Rocker Arm Shaft Gasket, Rocker Arm Bracket Gasket, Rocker Arm Cover Gasket, Rocker Arm Cover O-ring, Oil Fill Cap Gasket, Air Intake Gasket, Coolant Pump Set Plate Gasket, Coolant Pump Gasket, Thermostat Housing Gasket, Fuel Pump Joint Bolt Gasket, Fuel Feed Pump O-ring, Dipstick Tube Seal Washer, Solenoid O-ring, Relief Valve Gasket, Fuel Feed Pump Joint Bolt Gasket Gasket Gasket, Exhaust Manifold Gasket, Elbow O-ring, Gear Case Cover Gasket, Exhaust Manifold/ Expansion Tank Gasket, Thermostat Cover O-ring, Raw Water Pump - 6-0

73 updated GROUP 8 FRAME AND MOUNTING Base Frame Assembly M843N up to s/n xxxx-46623c A-7843 & A-7893 / D Base Frame, Steel Base Frame, Aluminum Bracket Capscrew, Hex Head M14 x 1.5 x 30 mm Lock Washer, Helical M Plateform Mount, 220 lb. (with PTO) Plateform Mount, 250 lb. (with PTO) Plateform Mount, 220 lb Capscrew, Hex Head M8 x 1.25 x 20 mm, S/S Lock Washer, Helical M8, S/S ** Snubbing Washer Capscrew, Hex Head M12 x 1.75 x 80mm S/S (w/o PTO) Capscrew, Hex Head M12 x 1.75 x 90 mm S/S (with PTO) Capscrew, Hex Head M12 x 1.75 x 75 mm S/S Flat Washer M12 S/S Hex Nut, Nylock M12 x 1.75 S/S Capscrew, Hex Head 3/8-16 x 1-1/4" Lock Washer, Helical 3/ Capscrew, Hex Head 5/16-18 x 1-1/ Lock Washer, Helical 5/16 (**As required) - 8-1