P65C-3 For Models: M50C13, M50T13, M55C13, M65C13 and M65T13 PARTS CATALOG. Marine Generators Marine Diesel Engines Land-Based Generators

Transcription

1 P65C-3 For Models: M50C13, M50T13, M55C13, M65C13 and M65T13 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 2015 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 /15

3 PARTS CATALOG For Models: M50C13, M50T13, M55C13, M65C13 and M65T13 Please read thoroughly before attempting to use this manual: Table of Content...I Model Designation & Serial Numbers... II Table of Contents GROUP 1 - ENGINE Cylinder Block Flywheel Housing & Flywheel Crankshaft & Main Bearings & Pulley Connecting Rods and Pistons Balancer Shaft & Front Plate Timing Gear Cover Auxiliary Drive Oil Filter Dipsticks Oil Filter Neck Oil Pump, Drain & Pan Cylinder Head with Valves Rocker Cover, Rocker Shaft, Rocker Arm Valve Cover GROUP 2 - INTAKE & EXHAUST Crankcase Breather Filter Ventilating System...4 Air Intake... 5 Exhaust Manifold Turbocharger Exhaust Elbow GROUP 3 - COOLING SYSTEM Heat Exchanger...0 Thermostat & Thermostat Cover Water Pump & Water Pump Inlet Raw Water Pump & Assembly Oil Cooler... 8 GROUP 4 - FUEL SYSTEM Fuel Injection Pump & Fuel Lines Water Separator...4 Low Pressure Fuel Lines...5 Fuel Filter & Lines Fuel Transfer Pump GROUP 5 - ELECTRICAL SYSTEM 12 & 24 Volt, Standard & Isolated Ground Engine Wiring Harness Oil Pressure Manifold...14 Pre-Alarm Switches...15 Starter Alternator & Mounting DC Electrical Enclosure & Relay Panel Relay Logic Board Control Panels Alternator Diode Belt Tensioner Belt Guard & Kit Engine Sensors Immersion Block Heater Starter Relay GROUP 6 - GASKETS Engine Overhaul...0 GROUP 8 - FRAMES & MOUNTING Base Frames GROUP 9 - ACCESSORIES & OPTIONAL EQUIPMENT PTO Electric Clutch PTO Adapter Electric Clutch Low Oil Level Switch Low Coolant Level Switch Raw Water Flow Switch 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 P /15 I

4 INTRODUCTION MODEL DESIGNATION M 50 C13 = Northern Lights Tier III turbocharged marine diesel generator set with a John Deere 4045 engine, 50 kw. M 50 T13 M 55 C13 M 65 C13 M 65 T13 = = = = Northern Lights Tier III turbocharged marine diesel generator set with a John Deere 4045 engine, 50 kw. Northern Lights Tier III turbocharged marine diesel generator set with a John Deere 4045 engine, 55 kw. Northern Lights Tier III turbocharged marine diesel generator set with a John Deere 4045 engine, 65 kw. Northern Lights Tier III turbocharged marine diesel generator set with a John Deere 4045 engine, 65 kw. All model numbers in parentheses will indicate a John Deere base engine. All variations requiring serial numbers for proper identification will be noted as Northern Lights or John Deere. 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 one of the drawings below. Lugger Serial Number Generator Set Serial Number Generator Set 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 P673 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: aarrows always point toward the front of the engine.

6 GROUP 1 ENGINE Cylinder Block 1-0

7 GROUP 1 ENGINE Cylinder Block KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER 1 R Pipe Plug H584 1 Pipe Plug 1/2" - 3 R Pipe Plug - 4 R Cap Screw - 5 R Bearing Cap - 6 R Bearing Cap H695 1 Pipe Plug 3/8" - 8 RE Short Block Assembly - 9 RE Fitting - 10 U O-Ring - 11 R O-Ring - 12 RE Bleed Valve - 13 R Compression Spring - 14 R Valve - 15 R Spring - 16 R Orifice - 17 R Bushing - 18 T Plug - 19 B153R 2 Dowel Pin - 20 R Bushing - 21 R Plug - 22 A120R 4 Dowel Pin - 23 RE Camshaft - SE Camshaft Reman REMAN FOR RE R Shaft Key - 25 R Plate M Screw M8 X

8 GROUP 1 ENGINE revised Flywheel Housing KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER 1 R Housing SAE #4-2 AR Plug - 3 R Plug - 4 R O-Ring - 5 RE Seal M Screw M12 X M Screw M12 X 50-8 R Bolt - 1-2

9 revised GROUP 1 ENGINE Flywheel KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER 1 RE Flywheel SAE #10 ( MARKED R Includes key 2) - 2 R Ring Gear (142 teeth) - 1-3

10 GROUP 1 ENGINE Crankshaft and Bearings KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER 1 RE Crankshaft (A) - SE Crankshaft Reman (B) REMAN FOR RE R Gear - 3 R Shaft Key - 4 R Dowel Pin - 5 RE Bearing Kit STD; KIT R AND R RE Bearing Kit STD; KIT R AND R R Bolt - (A) Grinding Guidelines : See CTM104 (B) With Bearings 1-4

11 GROUP 1 ENGINE Crankshaft Pulley KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER 1 R Pulley - 2 R Bushing - 3 R Cap Screw - 1-5

12 GROUP 1 ENGINE Connecting Rods and Pistons 1-6

13 GROUP 1 ENGINE Connecting Rods and Pistons KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER 1 RE Piston-Liner Kit Cylinder Liner 1 (ORDER RE536083)NSEP - 3 AR O-Ring Kit - 4 RE Piston Ring Kit (PKG 3) Piston (MARKED RE527039) (ORDER RE536083)NSEP - 6 R Piston Pin OD= 41MM LGTH= 77MM - 7 R Snap Ring - 8 RE Connecting Rod (MARKED R500335) - SE Connecting Rod Reman (MARKED R500335) (REMAN FOR RE500608) 9 R Bushing - 10 R Screw A= 61MM M12-11 RE Bearing (KIT (2) R113698)STD - RE65909 AR Bearing AR (A) ID MM, (KIT (2) R130578) - 1-7

14 GROUP 1 ENGINE Balancer Shaft Key Part No. Part Name Qty. Engine Serial No. Remarks 1... Balancer Shaft 1 NSEP; MARKED RE500449; ORDER RE502446; LH 2 R Shaft Key 1 3 R Plate 1 4 R Gear 1 Z = 15, LH 5 19M8998 Screw 4 M8 X 12 6 R Weight M8882 Screw 8 M8 X 40 8 R Gear 1 Z =15, RH 9... Balancer Shaft 1 NSEP; MARKED RE500448; ORDER RE502447; RH 10 R Bushing 1 11 RE Balancer Shaft 2 LH 12 RE Balancer Shaft 1 RH 1-8

15 GROUP 1 ENGINE Front Plate Key Part No. Part Name Qty. 1-9 Engine Serial No. Remarks 1 R Plate 1 2 R Stud 7 3 R Stud 2 4 R Screw 5 5 R Thrust Washer 2 6 R Shaft 1 7 RE Gear 1 (MARKED R504614) 8... Bushing 1 9 R Dowel Pin M8844 Screw 1 M10 X M8966 Screw 1 M10 X50 12 R Thrust Washer 1 13 RE56369 Gear 1 14 R Bushing 1 15 R Shaft 1 16 R Thrust Washer 1

16 GROUP 1 ENGINE revised Timing Gear Cover & Coolant Pump 1-10

17 revised GROUP 1 ENGINE Timing Gear Cover & Coolant Pump Key Part No. Part Name Qty. Engine Serial No. Remarks 1 R Gasket 1 2 R Support M7096 Washer X18X1.600 mm 4 19M8488 Cap Screw 4 M10 X45 5 RE Cover 1 6 RE Cover 1 7 R O-Ring 1 8 RE Insert 1 9 R Gasket 1 10 RE Coolant Pump* 1 11 A364R Snap Ring 1 12 R71228 Ring 1 13 RE46685 Fitting Plug O-Ring X2.200 mm 15 19M7797 Screw 3 M6 X M7796 Screw 5 M6 X M7801 Screw 3 M8 X M8317 Screw 1 M8 X40 19 RE Seal 1 20 RE Hex Plug M20 x 1.5 ** 21 51M7044 O-Ring X2.200 mm 22 RE46687 Drain Pl M22 x 1.5ug O-Ring X2.200 mm 24 14M7296 Flange Nut 9 M M7800 Screw 8 M8 X50 ** As Required *ALSO ORDER S/S Insert Kit RE AND Gasket R

18 GROUP 1 ENGINE Auxiliary Drive 1-12

19 GROUP 1 ENGINE Auxiliary Drive Key Part No. Part Name Qty. Engine Serial No. Remarks 1 RE Adapter Fitting M7785 Screw 2 M10 X25 3 R85145 Cover 1 4 R96935 Gasket 1 5 T77814 O-Ring H5015 Elbow Fitting 1 M12 X1.5 X9/16"-18 UNF, ALSO ORDER T M7040 O-Ring X2.200 mm 8 19M7753 Cap Screw 2 M12 X M7047 Washer 2 13X24X2.500 mm 10 R Gasket 1 11 RE Oil Line* 1 12 R51936 Sealing Washer* 1 13 R Coupling* 1 1/4"-18 NPT X1/2"-24 UNS 14 15H700 Pipe Bushing* 1 1/4", 3/8"-18 NPT X1/4"-18 NPT * Note: Keys #11-14 ysed only on M65C13 keel cooled models on standard base frame. See auxiliary drive oil supply for all M50T13 - M65C13 heat exchanger cooled models equipped with PTO/Electric clutch option. 1-13

20 GROUP 1 ENGINE 930 Auxiliary Drive Oil Supply Conversion Parts * M65T13 INCLUDING M65C13 HE MODELS WITH PTO / ELECTRIC CLUTCH KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER Hose Assembly 1/4"ID x 15" O-Ring - 3 N Restriction Orifice Male Connector 3/8 NPT x 3/8-37T * M. Elbow 90, Stl. M12 x 1.5 x 3/8 O-Ring Face Seal Swivel Elbow 45 o 3/8 NPT - 37T * - * Connector and Swivel Elbow replace Male 45 o Elbow (new parts ease installation) 1-14

21 GROUP 1 ENGINE Auxiliary Drive Cover Key Part No. Part Name Qty. Serial No. HF475 Remarks 1 19M7790 Screw 2 M12 X35 2 R Cover O-Ring X2.616 mm(4.237" X0.103") 1-15

22 GROUP 1 ENGINE Oil Filter 1-16

23 GROUP 1 ENGINE Oil Filter Key Part No. Part Name Qty. Engine Serial No. 1 RE Filter Head 1 2 RE Filter Head 1 3 RE Fitting Plug O-Ring 1 5 R Seal 1 6 RE Valve 1 7 RE52242 Drain Plug O-Ring 1 9 R Gasket 1 10 RE67238 Screw M7802 Screw 5 M8 X Oil Filter 1 Remarks 1-17

24 GROUP 1 ENGINE Engine Oil Dipstick Key Part No. Part Name Qty. 1 RE69243 Dipstick 1 2 R Dipstick Tube 1 3 R Plug 1 Engine Serial No. Remarks 1-18

25 GROUP 1 ENGINE Engine Oil Dipstick Key Part No. Part Name Qty. Engine Serial No. 1 RE Dipstick 1 LH 2 R Dipstick Tube 1 LH 3 R Plug 1 RH Remarks 1-19

26 GROUP 1 ENGINE Engine Oil Dipstick Key Part No. Part Name Qty. Engine Serial No. DFM50 TFM50 Remarks 1 RE66178 Dipstick 1 XX LH 2 R Dipstick Tube 1 X X LH 3 14M7296 Flange Nut 1 XX M10 4 R Bracket 1 XX 5 T28862 Clamp 1 XX 6 19M7784 Screw 1 XX M10 X20 7 R Plug 1 XX RH 1-20

27 GROUP 1 ENGINE Oil Filter Neck Key Part No. Part Name Qty. Engine Serial No. 1 2 R RE67238 Cover Screw 2 4 (A) 3 R Gasket 2 (A) Threads With Pre-Applied Sealant Filetages avec produit d'étanchéité préappliqué Gewinde mit voraufgetragenem Dichtmittel Filetti con sigillante preapplicato Roscas con pasta selladora preaplicada Gängor med redan applicerat tätningsmedel Remarks 1-21

28 GROUP 1 ENGINE Oil Pump Key Part No. Part Name Qty. Engine Serial No. 1 19M7802 Screw 2 M8 X 65 2 R Gear 1 Z= M7066 Nut 1 M12 4 RE Oil Pump 1 5 R97185 O-Ring 1 6 R Tube 1 Remarks 1-22

29 GROUP 1 ENGINE Oil Drain M65T13 KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER Street Elbow, 90, Stl 3/4NPT x 1/2NPT Bushing, Brass 1/2NPT x 3/8NPT Shut-Off Valve, Brass 3/8NPT x 1/2-45T F. Swivel, Brass 1/2HB x 1/2-45T Push-On (Universal Seat) Hose 1/2"ID Push-On M. Connector Brass 1/2NPT x 1/2-45T

30 GROUP 1 ENGINE Oil Pan 1-24

31 GROUP 1 ENGINE Oil Pan Key Part No. Part Name Qty. Engine Serial No. Remarks 1 19M10075 Screw 2 M8 X RE Oil Pump Intake 1 3 R61871 O-Ring 1 4 R Gasket 1 5 RE65978 Clamp 2 6 R Hose 1 7 RE Elbow Fitting O-Ring X mm 9 RE Adapter Fitting 2 10 R Seal 2 11 RE Oil Pan M8062 Screw 6 M8 X RE46685 Fitting Plug O-Ring X mm 15 19M8163 Bolt 22 M8 X RE46687 Drain Plug O-Ring X mm 1-25

32 GROUP 1 ENGINE Cylinder Head with Valves 1-26

33 GROUP 1 ENGINE Cylinder Head with Valves Key Part No. Part Name Qty. Engine Serial No. Remarks 1 RE Cylinder Head 1 SE Cylinder Head Reman 1 REMAN FOR RE CD16284 Plug 4 3 RE31617 Seal 8 4 R26125 Spring 8 5 RE60005 Rotator 8 6 R91889 Retainer 16 7 RE Sleeve 4 8 T58477 Fitting 1 ALSO ORDER R R26906 O-Ring 1 10 R43409 Plug 2 11 R Valve Seat Insert 4 12 R90692 Exhaust Valve 4 13 R Valve Seat Insert 4 14 R98062 Intake Valve 4 15 R Cap Screw 2 16 R85363 Cap Screw R Engine Cylinder Head Gasket

34 GROUP 1 ENGINE Rocker Arm, Rocker Arm Shaft & Cam Follower 1-28

35 GROUP 1 ENGINE Rocker Arm, Rocker Arm Shaft & Cam Follower Key Part No. Part Name Qty. Engine Serial No. 1 RE Rocker Arm Shaft 1 2 R Stud 4 3 R Washer R T20314 Rocker Arm Shaft Spring RE Rocker Arm M7148 Nut 1 M10 8 R Support 4 9 T20316 Washer 2 10 R54565 Plug R R Push Rod Cam Follower 8 8 Remarks 1-29

36 GROUP 1 ENGINE Valve Cover 1-30

37 GROUP 1 ENGINE Valve Cover Key Part No. Part Name Qty. Engine Serial No. Remarks 1 RE Screw 2 (A) M6X12 2 R Heat Shield 1 3 H23125 Plug 4 4 R Nut 4 M8 5 R O-Ring X mm (0.299" X 0.103") 6 R Valve Cover 1 7 R Gasket 1 SUB FOR R M7862 Screw 1 M6 X R Medallion 1 11 RE Filler Cap 1 SUB FOR RE R Packing 1 ID = 44 mm (A) Threads With Pre-Applied Sealant Filetages avec produit d'étanchéité préappliqué Gewinde mit voraufgetragenem Dichtmittel Filetti con sigillante preapplicato Roscas con pasta selladora preaplicada Gängor med redan applicerat tätningsmedel 1-31

38 GROUP 2 INTAKE & EXHAUST SYSTEM Crankcase Breather Filter M65T13 2-0

39 GROUP 2 INTAKE & EXHAUST SYSTEM Crankcase Breather Filter M65T13 KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER 1 RE Crankcase Breather Bracket M Capscrew, Hex Head Flanged M8 x 1.25 x 20mm MSCR, RD HD Phillips M5 x 0.8 x 16 mm S/S with captive lock and flat washers Hose, Crankcase Breather Inlet 1" ID Molded * Reducing Union, PVC 1" HB x 3/4 HB Hose 3/4" ID 1 Ply Hose, Crankcase Breather Inlet 1" ID Molded * Male Union, PVC 1" HB - 12 R Hose, Rocker Cover Vent Male Elbow 90, Stl. 3/4NPT x 1"HB HOose 90 degree 1/2" ID Molded - 15 R Hose Barb Reducer 1/2" x 3/8" Hose 3/8" ID Female Swivel, Brs. 3/8 HB x 3/8-37T One Way Valve, Brs. 1/4 NPT x T Street Elbow 90, Brs. 1/4 NPT Adapter, Stl. 1/4 NPT x M22 x O-Ring Hose Clamp #16 S/S Hose Clame #8 S/S - 2-1

40 GROUP 2 INTAKE & EXHAUST SYSTEM Crankcase Breather Filter M65T13 Westport Special 2-2

41 GROUP 2 INTAKE & EXHAUST SYSTEM Crankcase Breather Filter M65T13 Westport Special KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER 1 RE Crankcase Breather Bracket M Capscrew, Hex Head Flanged M8 x 1.25 x 20mm MSCR, RD HD Phillips M5 x 0.8 x 16 mm S/S with captive lock and flat washers Hose, Crankcase Breather Inlet 1" ID Molded * Hose Clamp #16 S/S Reducing Union, PVC 1" HB x 3/4 HB Hose 3/4" ID 1 Ply - 9 R Hose Male Elbow 90, Stl. 3/4 NPT x 1"HB Hose 90 degree 1/2"ID Molded Hose Clamp #8 S/S - 13 R Hose Barb Reducer 1/2" x 3/8" Hose 3/8" ID Female Swivel, Brs 3/8HB x 3/8-37T One Way Valve, Brs 1/4 NPT x 3/8-37T Street Elbow 90 Brs 1/4 NPT Plate Gasket - 2-3

42 GROUP 2 INTAKE & EXHAUST SYSTEM Ventilating System Key Part No. Part Name Qty. 1 R Elbow Fitting 1 2 R72328 O-Ring 1 Engine Serial No. Remarks 2-4

43 GROUP 2 INTAKE & EXHAUST SYSTEM Air Intake Key Part No. Part Name Qty. Engine Serial No. TFM75 Remarks 1 R Clamp 2 X 2 R Hose 1 X 3 RE Air Intake 1 X 4 19M8412 Screw 2 X M10 X 55, 10.9, SUB FOR 19M8292; APPL 5 24M7096 Washer 2 X X 18 X mm 6 51M7041 O-Ring 1 X X mm 7 RE46684 Fitting Plug 1 X M14 X R81275 Gasket 2 X 9 R Spacer 1 X USE WITH (2) R M7039 O-Ring 1 X X mm 11 RE60071 Fitting 1 X M10 X 1 2-5

44 GROUP 2 INTAKE & EXHAUST SYSTEM Exhaust Manifold 2-6

45 GROUP 2 INTAKE & EXHAUST SYSTEM Exhaust Manifold Key Part No. Part Name Qty. Engine Serial No. 1 RE Manifold Kit 1 2 R Stud H638 Pipe Plug 1 1/8" 4 N Plug M9017 Screw 9 M10 X165 6 RE Pipe Plug 3 7 R43409 Plug 3 8 RE Gasket 1 9 AT13740 Drain Valve 1 11 R Gasket 1 12 R Gasket 1 13 R Gasket 1 14 F2576R O-Ring 2 15 F1430R O-Ring 2 Remarks 2-7

46 GROUP 2 INTAKE & EXHAUST SYSTEM Turbocharger 2-8

47 GROUP 2 INTAKE & EXHAUST SYSTEM Turbocharger Key Part No. Part Name Qty. Engine Serial No. Remarks 1 19M7786 Screw 1 M10 X30 2 R Clip 1 3 R Spacer 1 4 R63548 O-Ring 1 5 M87733 Adapter Fitting 1 6 RE Oil Line 1 7 R67364 Elbow Fitting 1 8 RE Tube 1 9 R51936 Sealing Washer 2 10 RE Fitting 1 11 RE Turbocharger 1 12 R Gasket M7296 Flange Nut 4 M H696 Pipe Plug 1 1/4" 15 R Gasket 1 16 T77613 O-Ring H5154 Elbow Fitting M7042 O-Ring X mm 19 N Screw 2 NLA; ORDER 19M M8063 Screw 2 M8 X 25, SUB FOR N RE Line 1 2-9

48 GROUP 2 INTAKE & EXHAUST SYSTEM Exhaust Elbow Key Part No. Part Name Qty. 1 RE47537 Clamp 1 2 R Elbow Fitting 1 3 RE71255 Pipe Plug 1 Engine Serial No. Remarks 2-10

49 GROUP 2 INTAKE & EXHAUST SYSTEM Exhaust Elbow Key Part No. Part Name Qty. Engine Serial No. 1 RE Elbow Fitting H638 Pipe Plug 1 1/8" 3 RE47537 Clamp 1 4 TY22467 Clamp 1 5 R Hose 1 6 TY22470 Clamp 1 Remarks 2-11

50 GROUP 3 COOLING SYSTEM Heat Exchanger 3-0

51 GROUP 3 COOLING SYSTEM Heat Exchanger Key Part No. Part Name Qty. Engine Serial No. DFM50 TFM50 Remarks 1 RE43593 Filler Cap 1 XX 2 19M7775 Screw 4 XX 3 RE46165 Filler Neck 1 XX M6 X16 4 R Gasket 1 XX Hose 5/16 ID PVC ** XX 6 R Strap 1 XX (Solid Per Inch) 7 D2420R Stud 1 XX 8 R Plug 1 XX 9 24M7106 Washer 1 XX 10X18 X2.500 mm 10 N10215 Lock Nut 1 XX mm (3/8") 11 F2576R O-Ring 2 XX X5.334 mm (3.850" X0.210") 12 RE Cover 2 XX INCLUDESH26723 ANDRE54993; SUB FOR R R Cover 2 XX ORDER RE M7835 Screw 4 XX M10 X35 14 RE57836 Pipe Plug 2 XX (A) mm(1/2"), SUB FOR 15H624; APPL H26723 RE54994 Drain Plug Cover 2 2 XX XX mm (1/4") MARKED R (A) Threads With Pre-Applied Sealant Filetages avec produit d'étanchéité préappliqué Gewinde mit voraufgetragenem Dichtmittel Filetti con sigillante preapplicato Roscas con pasta selladora preaplicada Gängor med redan applicerat tätningsmedel ** As Required 3-1

52 GROUP 3 COOLING SYSTEM revised Thermostat Cover Key Part No. Part Name Qty. Engine Serial No. DFM70 TFM75 Remarks 1 19M7810 Screw 4 XX M10 X H695 Plug 1 XX 3/8" NPT 3 RE57836 Plug 1 XX 1/2" NPT (A) 4 R Thermostat Housing 1 XX Thermostat Housing (modified with extra parts) 1 XX RE46684 O-Ring Plug 1 1 XX XX M14 X1.5 7 R Gasket 1 XX (A) Threads With Pre-Applied Sealant Filetages avec produit d'étanchéité préappliqué Gewinde mit voraufgetragenem Dichtmittel Filetti con sigillante preapplicato Roscas con pasta selladora preaplicada Gängormed redan applicerat tätningsmedel 3-2

53 revised GROUP 3 COOLING SYSTEM Thermostat Key Part No. Part Name Qty. Engine Serial No. TFM75 TFM76 Remarks 1 AR48675 Thermostat 2 XX 82 C F 3-3

54 GROUP 3 COOLING SYSTEM revised Coolant Pump Inlet Key Part No. Part Name Qty. Engine Serial No. Remarks 1 R Stud 1 2 R89944 O-Ring 1 3 RE46685 Fitting Plug M7043 O-Ring X mm 5 R Water Pump Connection M7802 Screw 1 M8 X 65 7 AR65294 Clamp 3 8 R Hose 1 9 RE Tube M7867 Screw 1 M8 X RE40436 Clamp 1 12 T27104 Radiator Hose H604 Pipe Plug 1 1/4" 3-4

55 revised GROUP 3 COOLING SYSTEM Coolant Pump Pulley Key Part No. Part Name Qty. 1 R Pulley 94mm OD M7774 Screw M6 x 12mm 3 Engine Serial No. Remarks 3-5

56 GROUP 3 COOLING SYSTEM Raw Water Pump Key Part No. Part Name Qty. 1 RE Raw Water Pump (See Parts Detail) 1 Engine Serial No. Remarks 3-6

57 updated GROUP 3 COOLING SYSTEM Raw Water Pump Assembly KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER RE Raw Water Pump Assembly (Includes all keys) Repair Kit (Includes keys #3-8 & 10-11) - 1 Housing Shaft Cam Screw Bearing Seal, Mechanical/ Carbon Wear Plate Impeller with Gasket Gasket Cover Screw - 3-7

58 GROUP 3 COOLING SYSTEM Oil Cooler Key Part No. Part Name Qty. Engine Serial No. Remarks 1 RE67231 Screw 6 (A) M6X16 2 RE59296 Oil Cooler 1 (B) 3 T O-Ring X2.616 mm(1.174" X0.103") 4 R Gasket 1 5 R Housing 1 6 RE46686 FittingPlug 1 M12 X RE O-Ring Adapter Fitting X2.200 mm 9 R Gasket O-Ring X3.531 mm(1-31/64" X0.139") Intermediate Housing 1 (MARKED R502811) (ORDER RE508599) 12 19M7802 Screw 2 M8 X M7970 Screw 2 M8 X RE67238 Screw 1 (A) M8X20 15 RE46685 FittingPlug 1 M18 X O-Ring X2.200 mm (A) Threads with Pre Applied Sealant Filetages avec produit d'étanchéité préappliqué Gewinde mit voraufgetragenem Dichtmittel Filetti con sigillante preapplicato Roscas con pasta selladora preaplicada Gängor med redan applicerat tätningsmedel (B) 5Plates 5 plaques 5Platten 5 piastre 5 placas 5 plåtar 3-8

59 GROUP 3 COOLING SYSTEM Notes 3-9

60 GROUP 4 FUEL SYSTEM updated Fuel Injection System 4-0

61 updated GROUP 4 FUEL SYSTEM Fuel Injection System Key Part No. Part Name Qty. Engine Serial No. Remarks 1 R91360 Nut 1 2 R Gear 1 3 R55453 O-Ring 1 4 R Adapter Fitting M7298 Flange Nut 3 M8 6 R O-Ring 1 7 RE Fitting M7044 O-Ring X2.200 mm 9 RE Fuel Injection Pump 1 SE Fuel Injection Pump Reman 1 REMAN FOR RE RE RE Control Valve Fuel Temperature Sensor R O-Ring RE M7868 Screen Screw 1 2 M8 X30 15 RE Fuel Line 1 16 RE Fuel Line 1 17 R Bracket M7785 Screw 2 M10 X M8320 Screw 1 M10 X45 20 RE Rail 1 21 RE Pressure Relief Valve 1 22 RE Restrictor 4 23 RE Sensor R Stud Engine Controller 1 1 Serial Number Required when Ordering 26 RE Fuel Line 2 27 RE Fuel Line 2 28 RE Screw With Washer 4 29 R Clamp 4 30 RE SE Nozzle Kit Injection NozzleReman 4 4 INCLUDES R REMAN FOR RE RE Electrical Connector Cap R R Nut O-Ring R Washer 4 35 RE Wiring Harness M8747 Elec. Connector Housing 1 37 R Bracket 1 38 R Seal 1 39 RE Screw 4 40 R Bracket M7233 RE Weld Nut Cap Screw 1 1 M8 43 AH80916 Clip 2 44 R O-Ring 1 4-1

62 GROUP 4 FUEL SYSTEM Low Pressure Fuel Lines 4-2

63 updated GROUP 4 FUEL SYSTEM Low Pressure Fuel Lines Key Part No. Part Name Qty. Engine Serial No. Remarks M7009 R Hollow Screw Sealing Washer RE Fuel Line 1 4 R51936 Sealing Washer 5 5 RE Fitting M7039 O-Ring X1.600 mm 7 8 RE R97061 Fuel Line TeeFitting RE Fuel Line 1 10 RE Fitting 1 11 AR85519 Plug 1 12 RE Elbow Fitting O-Ring X2.200 mm RE R74012 Fuel Line Sealing Washer RE60029 Adapter Fitting O-Ring X2.200 mm 18 RE Fuel Line 1 19 R Fitting 2 20 R O-Ring 2 21 RE46686 Fitting Plug 4 22 RE Fitting RE R Fuel Line Clamp M7783 Screw 1 M10 X16 4-3

64 GROUP 4 FUEL SYSTEM updated Fuel Filter / Water Separator Assembly Key Part No. Part Name Qty. Engine Serial No. Remarks 1 19M7785 Screw 3 M10 X25 2 R Bracket H2522 Spacer " X0.675" X13/16" 4 19M7805 Screw 1 M10 X45 5 RE Filter 1 6 RE Fuel Filter 1 7 RE54723 Drain Valve 1 8 RE Wire Harness, 12 Volt ** * RE Wire Harness, 24 Volt ** * 9 RE60854 Valve Kit 1 * Used on units with Standard Ground Electrical Systems 4-4

65 GROUP 4 FUEL SYSTEM Low Pressure Fuel Lines Key Part No. Part Name Qty. Engine Serial No. Remarks 1 19M7784 Screw 2 M10 X20 2 RE Fuel Filter 1 3 RE60854 Valve Kit 1 4 RE Fuel Filter 1 5 RE54723 Drain Valve 1 6 RE Wiring Harness, 24 Volt 1 24 V 7 19M7805 Screw 1 M10 X M7785 Screw 1 M10 X25 9 R Bracket H2522 Spacer " X0.675" X13/16" 4-5

66 GROUP 4 FUEL SYSTEM updated Fuel Filter Assembly

67 updated GROUP 4 FUEL SYSTEM Fuel Filter Key Part No. Part Name Qty. Engine Serial No. TFM76 Remarks 1 RE Fuel Filter Assembly 1 X 2 19M7784 Screw 4 X M10 X20 3 R Bracket 1 X 4 RE Seal Kit ** X 5 RE Repair Kit ** X 7 RE60854 Valve Kit ** X 9... Retainer 1 * RE Retainer O-Ring Kit 1 1 X X * PKG Retainer 1 X * O-Ring ** X 14 RE46686 FittingPlug ** X M12 X Drain Plug 1 X ORDER RE60854 OR RE * 16 R O-Ring 1 X RE Filter Element Retainer 1 1 X X (Includes #19) ORDER RE526834; NSEP * Valve 1 X 20 RE51648 Heat Exchanger ** X 21 RE Heater ** X 12 VOLT, 100W 22 RE50467 Hand Primer ** X 23 RE O-ring Kit ** X PKG 10 ** As Required * Note: Items not sold separately Order repair Kit RE

68 GROUP 4 FUEL SYSTEM USCG A-1 SAE J1942 ABS Fuel Lines (Plumbed to Base Pan) M65T13 KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER M. Elbow 45 Stl. 3\8NPT x 3\8-37T Hose Assembly 5\16"ID x 29" 3/8FMS x 3/8FMS Elbow, 90, Swivel 3/8-37T M. Connector, Stl. 3/8-37T x M12 x M. ELbow 45, Stl. 3/8 NPT x 1/4-37T Hose Assembly 3/16"ID x 35" 1/4FMS x 1/4FMS Elbow 45, Swivel, Stl. 1/4-37T Banjo Ftg, Stl. 10mmID x 1/4-37T Male Banjo Bolt M10 x 1.0 x 30mm Double Length Sealing Washer, Bonded M Plug, Hex Head, Brs. 3/8NPT - 4-8

69 updated GROUP 4 FUEL SYSTEM USCG A-1 SAE J1942 ABS Fuel Lines (Plumbed to Base Frame) M50T13-M65T13 KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER Manifold Capscrew, Hex Head M6 x 1.0 x 20mm Hex Nut, Nylock M6 x 1.0 Class Male Elbow 90 Stl. 3/8 NPT x 3/8-37T Hose Assy 5/16"ID x 29" 3/8FMS x 3/8FMS USCG A-1 SAE J1942 ABS Elbow 90 Swivel, Stl. 3/8-37T Male Connector, Stl. 3/8-37T x M12 x Male Elbow 90 Stl. 3/8NPT x 1/4-37T Hose Assy 3/16"ID x 35" 1/4FMS x 1/4FMSUSCG A-1 SAE J1942 ABS Elbow, 45 Swivel, Stl. 1/4-37T Banjo Ftg. Stl. 10mmID x 1/4-37T Male Banjo Bolt M10 x 1.0 x30mm Double Length Sealing Washer, Copper M Plug Hex Head, Brs. 3/8NPT - 4-9

70 GROUP 4 FUEL SYSTEM updated USCG A-1 SAE J1942 ABS Fuel Lines (Plumbed to Base Frsame with Centerbonded Mounts) M50T13-M65T13 KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER Manifold Capscrew, Hex Head M6 x 1.0 x 20mm Hex Nut, Nylock M6 x 1.0 Class Male Elbow 90 Stl. 3/8 NPT x 3/8-37T Hose Assy 5/16"ID x 27" 3/8FMS x 3/8FMS USCG A-1 SAE J1942 ABS Elbow 90 Swivel, Stl. 3/8-37T Male Connector, Stl. 3/8-37T x M12 x Male Elbow 90 Stl. 3/8NPT x 1/4-37T Hose Assy 3/16"ID x 35" 1/4FMS x 1/4FMSUSCG A-1 SAE J1942 ABS Elbow, 45 Swivel, Stl. 1/4-37T Banjo Ftg. Stl. 10mmID x 1/4-37T Male Banjo Bolt M10 x 1.0 x30mm Double Length Sealing Washer, Copper M Plug Hex Head, Brs. 3/8NPT

71 GROUP 4 FUEL SYSTEM Fuel Transfer Pump Key Part No. Part Name Qty. Engine Serial No. Remarks 1 RE Fuel Pump 1 INCLUDES R R Pin 1 3 RE Cap Screw 2.. R O-Ring

72 GROUP 5 ELECTRICAL SYSTEMS updated Engine Electrical, 12Volt Standard Ground CAN-BUS M50T13 - M65T13 KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER Harness Assembly Wire Harness Addition, Isolated Ground Dual Station Relay Panel Assembly (See Parts Detail) Relay, SPDT 50 Amp MSCR, Ph Phillips #10-32 x 3/4" S/S Hex Nut, Nylock #10-32 S/S Sender, Pressure 0-80 PSI, Isolated Ground 1/8 NPT Switch, Pressure 15 PSI N.O./N.C. 1/8NPT Sender, Temperature 250F Isolated Ground 1/2 NPT Switch, Temperature 215F N.O./N.C. Isolated Ground 3/8NPT - 11 RE Starter 2.5 kw StandardGround R.H. 2-Bolt SAE Type #4 Mount Capscrew, Hex Head Flanged M10 x 1.5 x 30 mm Grade Stud M10 x 1.5 x 30mm (42mm LOA) Grade Hex Nut, Flanged M10 x 1.5 Property Class Soleniod 85 Amp Isolated Ground Bracket Lock Nut, Serrated Flange 1/ Hose Clamp #60 S/S Capscrew, Hex head M8 x 1.26 x 50mm Flat Washer M Hex Nut, Nylock M8 x 1.25 Class 8-22 RE Harness Assy Filter / Separator Connection Grommet - * Note: Items #19-21 used to mount engine controller 5-0

73 updated GROUP 5 ELECTRICAL SYSTEMS Basic Engine Electrical, 12 Volt Standard Ground CAN-BUS M65C13 KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER Label "Genset Control - Run / Stop / Crank" Toggle Switch, SPST On-Off 10A 250VAC Toggle Switch (On) - Off 10A 250VAC Harness Assembly Grommet - 7 RE Starter 2.5 kw Standard Ground R.H. 2-Bolt SAE Type 4 Mount - 8 RE Alternator 75 Amp Standard Ground Capscrew, Hex Head Flanged M10 x 1.5 x 30mm STUD M10 x 1.5 x 25mm (37mm LOA) Hex Nut, Flanged M10 x AT Transient Voltage Protector Solenoid 85 Amp Isolated Ground Bracket, Solenoid Mounting Lock Nut, Serrated Flange 1/ Hose Clamp #60 S/S Capscrew, Hex Head M8 x 1.25 x 50mm Flat Washer M Hex Nut, Nylock M8 x 1.25 Class 8 - * Note: items #17-19 used to mount engine controller 5-1

74 GROUP 5 ELECTRICAL SYSTEMS updated Expanded Engine Electrical System, 12 Vol Standard Ground M65C13 NO SEPARATE TEMPERATURE SWITCH - HIGH TEMPERATURE SHUTDOWN BY ECU KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER Harness Assembly Wire Harness Addition, Isolated Ground Dual Station Relay Board Sub-Assembly Manual Start (See Parts Detail) Relay, SPDT 50 Amp MSCR, Ph Phillips #10-32 x 3/4" S/S Hex Nut, Nylock #10-32 S/S Sender, Pressure 0-80 PSI, Isolated Ground 1/8 NPT Switch, Pressure 15 PSI N.O./N.C. 1/8NPT Sender, Temperature 250F Isolated Ground 1/2 NPT - 11 RE Starter 2.5 kw Standard Ground R.H. 2-Bolt SAE Type #4 Mount Capscrew, Hex Head Flanged M10 x 1.5 x 30 mm Grade Stud M10 x 1.5 x 30mm (42mm LOA) Grade Hex Nut, Flanged M10 x 1.5 Property Class Soleniod 85 Amp Isolated Ground Bracket, Solenoid Mtg Lock Nut, Serrated Flange 1/ Hose Clamp #60 S/S Capscrew, Hex head M8 x 1.26 x 50mm Flat Washer M Hex Nut, Nylock M8 x 1.25 Class 8-22 RE Harness Assy Filter / Separator Connection Grommet - * Note: Items #19-21 used to mount engine controller 5-2

75 updated GROUP 5 ELECTRICAL SYSTEMS Engine Electrical, 12 Volt Isolated Ground CAN-BUS M50T13 - M65T13 KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER Harness Assembly Wire Harness Addition, Isolated Ground Dual Station Relay Panel Assembly (See Parts Detail) Relay, SPDT 50 Amp MSCR, Ph Phillips #10-32 x 3/4" S/S Hex Nut, Nylock #10-32 S/S Sender, Pressure 0-80 PSI, Isolated Ground 1/8 NPT Switch, Pressure 15 PSI N.O./N.C. 1/8NPT Sender, Temperature 250F ISO Ground 1/2 NPT Switch, Temperature 215F N.O./N.C. Isolated Ground 3/8NPT Starter 12 Volt Isolated Ground R.H. 2-Bolt SAE Type #4 Mount Capscrew, Hex Head Flanged M10 x 1.5 x 30 mm Grade Stud M10 x 1.5 x 30mm (42mm LOA) Grade Hex Nut, Flanged M10 x 1.5 Property Class Soleniod 85 Amp Isolated Ground Bracket Lock Nut, Serrated Flange 1/ Hose Clamp #60 S/S Insulator Insulator M Capscrew, Hex Head Flanged M8 x 1.25 x 55mm Grade Snubbing Washer S/S Hex Nut, Nylock M8 x 1.25 S/S (316) Grommet - * Note: Items #19-23 used to mount engine controller 5-3

76 GROUP 5 ELECTRICAL SYSTEMS updated Basic Engine Electrical System, 12 Volt Isolated Ground M65C13 Key Part Number Qty Description Serial Number Label "Genset Control - Run / Stop / Crank" Toggle Switch Toggle Switch Harness Assy Grommet Starter 2.5 kw Isolated Ground R.H. 2-Bolt SAE Type 4 Mount Alternator 72 Amp Isolated Ground (See Parts & Mounting Detail) Capscrew, Hex Head Flanged M10x1.5 X 30mm Grade Stud M10x1.5 X 30mm (42mm Loa) Grade Hex Nut,Flanged M10x1.5 Property Class Solenoid 85 Amp Isolated Ground Bracket Lock Nut,Serrated Flange 1/ Hose Clamp #60 S/S Insulator Insulator M Capscrew,Hex Head Flanged M8x1.25 X 55mm Grade Snubbing Washer S/S Hex Nut,Nylock M8x1.25 S/S (316) - * Note: Items #17-21 used to mount engine controller 5-4

77 updated GROUP 5 ELECTRICAL SYSTEMS Expanded Engine Electrical System, 12 Volt Isolated Ground M65C13 Key Part Number Qty Description Serial Number Harness Assembly Wire Harness Addition Isolated Ground Dual Station Relay Board Sub-Assy,Manual Start (See Parts Detail) Relay,SPDT 50 Amp MSCR,Ph Phillips #10-32 X 3/4" S/S Hex Nut, Nylock #10-32 S/S Sender,Pressure 0-80 PSI, Isolated Ground 1/8Npt Switch,Pressure 15PSI N.O./N.C. 1/8NPT Sender,Temperature 250F Isolated Ground 1/2NPT Starter 2.5 kw Isolated Ground R.H. 2-Bolt SAE Type 4 Mount Capscrew,Hex Head Flanged M10x1.5 X 30Mm Grade Stud M10x1.5 X 30mm (42mm Loa) Grade Hex Nut M10x1.5 (17mm Hex) Solenoid 85 Amp Isolated Ground Bracket Lock Nut,Serrated Flange 1/ Hose Clamp #60 S/S Insulator Insulator M Capscrew,Hex Head Flanged M8x1.25 X 55mm Grade Snubbing Washer S/S Hex Nut,Nylock M8x1.25 S/S (316) Grommet - * Note: Items #17-23 used to mount engine controller 5-5

78 GROUP 5 ELECTRICAL SYSTEMS updated Engine Electrical 24 Volt Standard Ground M50T13 - M65T13 Key Part Number Qty Description Serial Number Harness Assembly Wire Harness Addition, Isolated Ground Dual Station Relay Panel Assembly (See Parts Detail) Relay, SPDT 20 Amp MSCR, PH Phillips #10-32 x 3/4" S/S Hex Nut, Nylock #10-32 S/S (18-8) Pressure Sender 0-80 PSI Standard Ground 1/8 NPT Switch, Pressure 15 PSI N.O./N.C. 1/8 NPT 10 A Contacts Sender, Temperature 250F Isolated ground 1/2 NPT Switch, Temperature 215F N.O./N.C. Isolated Ground 3/8 NPT Starter 4.5 kw Standard Ground R.H. 2-Bolt SAE Type #4 Mount Capscrew, Hex Head Flanged M10 x 1.5 x 30 mm Grade Stud M10 x 1.5 x 30 mm (42mm LOA) Grade Hex Nut, Flanged M10 x 1.5 Property Class Solenoid 85 Amp Isolated Ground Bracket Lock Nut, Serrated Flange 1/ Hose Clamp Capscrew, Hex Head M8 x 1.25 x 50mm Flat Washer M Hex Nut, Nylock M8 x 1.25 Class 8-22 RE Harness Assembly Filter / Separator Connection Grommet - * Note: Item # used to mount engine controller 5-6

79 updated GROUP 5 ELECTRICAL SYSTEMS Engine Electrical System, 24 Volt Standard Ground - M65C13 Key Part Number Qty Description Serial Number Label, "Genset Control - Run / Stop / Crank" Toggle Switch Toggle Switch Harness Assembly Grommet Starter 12V 4.5kW Isolated Ground R.H. 2-Bolt SAE Type #4 Mount Alternator 50 Amp Standard Ground (See Parts & Mounting Details) Capscrew, Hex Head Flanged M10 x 135 x 30mm Grade Stud M10 x 1.5 x 30mm (42mm LOA) Grade Hex Nut, Flanged M10 x 1.5 Property Class Solenoid 85 Amp Isolated Ground Bracket Lock Nut, Serrated Flange 1/ Hose Clamp #60 S/S Capscrew, Hex Head M8 x 1.25 x 50 mm Flat Washer M Hex Nut, Nylock M8 x 1.25 Class 8 - * Note: Item # used to mount engine controller 5-7

80 GROUP 5 ELECTRICAL SYSTEMS updated Expanded Engine Electrical System, 24 Volt Standard Ground M65C13 Key Part Number Qty Description Serial Number Harness Assembly Wire Harness Addition, Isolated Ground Dual Station Relay Board Sub-Assembly, Manual Start (See Parts Detail) Relay, SPDT 20 Amp MSCR, PH Phillips #10-32 x 3/4" S/S Hex Nut, Nylock #10-32 S/S (18-8) S/S Sender, Pressure 0-80 PSI, Isolated Ground 1/2 NPT Switch, Pressure 15 PSI N.O./N.C. 1/8 NPT 10A Sender, Temperature 250 o F Isolated Ground 1/2 NPT Starter, 4.5kW Standard Ground, R.H. 2-Bolt SAE Type #4 Mount Capscrew, Hex Head Flanged M10 x 1.5 x 30mm Grade Stud M10 x 1.5 x 30mm (42mm LOA) Grade Hex Nut, Flanged M10 x 1.5 Property Class Solenoid 85 Amp Isolated Ground Bracket Lock Nut, Serrated Flange 1/ Hose Clamp #60 S/S Capscrew, Hex Head M8 x 1.25 x 50mm Flat Washer M Hex Nut, Nylock M8 x 1.25 Class 8-22 RE Harness Assembly Filter / Separator Connection Grommet - 5-8

81 updated GROUP 5 ELECTRICAL SYSTEMS Engine Electrical System, 24 Volt Isolated Ground M50T13-M65T13 Key Part Number Qty Description Serial Number Harness Assembly Wire Harness Addition, Isolated Ground Dual Station Relay Panel Assembly (See Parts Detail) Relay, SPDT 20 Amp MSCR, PH Phillips #10-32 x 3/4" S/S Hex Nut, Nylock #10-32 S/S (18-8) S/S Sender, Pressure 0-80 PSI, Isolated Ground 1/2 NPT Switch, Pressure 15 PSI N.O./N.C. 1/8 NPT 10A Sender, Temperature 250 o F Isolated Ground 1/2 NPT Switch, Temperature 215F N.O./N.C. 1/8NPT Starter, 4.5kW Standard Ground, R.H. 2-Bolt SAE Type #4 Mount Capscrew, Hex Head Flanged M10 x 1.5 x 30mm Grade Stud M10 x 1.5 x 30mm (42mm LOA) Grade Hex Nut, Flanged M10 x 1.5 Property Class Solenoid 85 Amp Isolated Ground Bracket Lock Nut, Serrated Flange 1/ Hose Clamp #60 S/S Insulator Insulator Hex Nut, Nylock M8 x 1.25 Class M Capscrew, Hex Head Flanged M8 x 1.25 x 55mm Grade Grommet - 5-9

82 GROUP 5 ELECTRICAL SYSTEMS updated Basic Engine Electrical System Conversion, 24 Volt Isolated Ground - M65C13 Key Part Number Qty Description Serial Number Label, "Genset Control - Run / Stop / Crank" Toggle Switch Toggle Switch Harness Assembly Grommet Starter 4.5kW Isolated Ground R.H. 2-Bolt SAE Type #4 Mount Alternator 50 Amp Isolated Ground (See Parts & Mounting Details) Capscrew, Hex Head Flanged M10 x 135 x 30mm Grade Stud M10 x 1.5 x 30mm (42mm LOA) Grade Hex Nut, Flanged M10 x 1.5 Property Class Solenoid 85 Amp Isolated Ground Bracket Hex Nut, Nylock 1/ Hose Clamp #60 S/S Insulator Insulator M Capscrew, Hex Head Flanged M8 x 1.25 x 55mm Grade Snubbing Washer S/S Hex ut, Nylock M8 x 1.25 S/S (316) - * Note: Item # used to mount engine controller 5-10

83 updated GROUP 5 ELECTRICAL SYSTEMS Expanded Engine Electrical System, 24 Volt Isolated Ground - M65C13 Key Part Number Qty Description Serial Number Harness Assembly Wire Harness Addition, Isolated Ground Dual Station Relay Board Sub-Assy, Manual Start (See Parts Detail) Relay, SPDT 24 VDC 20A MSCR, PH Phillips #10-32 x 3/4" S/S Hex Nut, Nylock #10-32 S/S (18-8) Pressure Sender 0-80 PSI Isolated Ground 1/8 NPT Switch, Pressure 15 PSI N.O./N.C. 1/8 NPT Sender, Temperature 250F Isolated ground 1/2 NPT Starter 4.5 kw Isolated Ground R.H. 2-Bolt SAE Type #4 Mount Capscrew, Hex Head Flanged M10 x 1.5 x 30 mm Grade Stud M10 x 1.5 x 30 mm (45mm LOA) Grade Hex Nut, Flanged M10 x 1.5 Property Class Solenoid 85 Amp Isolated Ground Bracket Lock Nut, Serrated Flange 1/ Hose Clamp Insulator Insulator M Capscrew, Hex Head M8 x 1.25 x 55mm Grade Snubbing Washer S/S Hex Nut, Nylock M8 x 1.25 S/S (316) Grommet

84 GROUP 5 ELECTRICAL SYSTEMS Engine Wiring Harness 5-12

85 GROUP 5 ELECTRICAL SYSTEMS Engine Wiring Harness Key Part No. Part Name Qty. Engine Serial No. Remarks 1 RE Wiring Harness M10604 Elec. Connector Housing M10605 Elec. Connector Housing M7280 Elec. Connector Housing M8601 Elec. Connector Housing M7305 Elec. Connector Housing M9246 Clip M8746 Elec. Connector Housing M9267 TeeFitting 1 10 R78052 Electrical Connector Assy 1 11 RE12362 Electrical Connector Assy M9327 Sleeve M8407 Elec. Connector Housing M8403 Elec. Connector Housing M8400 Elec. Connector Housing M9005 Elec. Connector Housing M M7296 Half Clamp Flange Nut 2 3 M RE M7749 Harness Kit Electrical Connector Assy M8112 Elec. Connector Housing M7919 Elec. Connector Housing M M8131 Elec. Connector Housing Electronic Terminator M7304 Elec. Connector Housing M8637 R44302 Elec. Connector Housing Tie Band M10613 Elec. Connector Housing M10615 RE Elec. Connector Housing Tie Band M8487 R78053 Electrical Connector Cap Electrical Connector Assy M8600 Elec. Connector Housing 1 34 R Electrical Connector Assy 1 35 RE12363 Electrical Connector Assy M7547 Elec. Connector Terminal M7298 Flange Nut 1 M R M7476 Stud Washer X21X4mm 40 19M7861 Screw 2 M6 X10 41 R Bracket M8242 Screw 1 M12 X M7783 Screw 1 M10 X16 44 R Bracket M7867 Screw 2 M8 X25 46 R Bracket 1 47 R Bracket M7298 Flange Nut 2 M8 5-13

86 GROUP 5 ELECTRICAL SYSTEMS Oil Pressure Manifold KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER Manifold, Oil Pressure 6ea 1/8 NPT & 1ea 1/4 NPT Ports Spacer, BP. 1/2 SCHD 80 x 21/32" Capscrew, Hex Head M12 x 1.75 x 40 mm Lock Washer, Helical M12 Din Code 127-B Flat Washer M12 Din Code 125A Male Connector Steel, 18/8 NPT x 1/4-37 T Hose Assembly 1/4" ID x 9" Male Elbow 90 Steel, 1/8 NPT x 1/4-37T Plug, Hex Head, Brass 1/8 NPT Bushing, Brass 1/4 NPT x 1/8 NPT

87 updated GROUP 5 ELECTRICAL SYSTEMS Pre-Alarm Switches, High Coolant Temperature / Low Oil Pressure M65T13 KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER Switch, Pressure 25PSI N.O./N.C. 1/8NPT Switch, Temperature 205F N.O./N.C. 3/8NPT Isolated Ground * Terminal Strip 10 Connection 20A 600VAC #12-22 AWG MSCR, PH Phillips #8-32 x 3/4" S/S Hex Nut, Nylock #8-32 S/S Oil Temperature Switch 240F Cooling System Pressure Switch 9PSI - * Pre-Alarm temperature rating was 195 o F. See also Engine Electrical For Revised shut-down rating. (Was 205 o F now 215 o F) 5-15

88 GROUP 5 ELECTRICAL SYSTEMS Starter Key Part No. Part Name Qty. Engine Serial No. Remarks 1 RE Starter 12 Volt Standard Ground 1 (Includes T146102) Starter 12 Volt Isolated Ground Starter 24 Volt Standard Ground Starter 24 Volt Isolated Ground M M7786 Stud Screw 1 1 M10 X M7296 Flange Nut 1 M

89 updated GROUP 5 ELECTRICAL SYSTEMS Alternator 14 Volt / 75 Amps Standard Ground Key Part No. Part Name Qty. Engine Serial No. Remarks 1 RE Alternator 14 Volt 75 Amp 1 Standard Ground (includes keys 2-3) 2 R Fan 1 3 RE Pulley M8291 Screw 1 5 R Washer 1 M8 X 35mm M7812 R64525 Screw Thrust Washer 1 1 M10 X100mm Flange Nut 1 M M7011 Lock Washer 1 5 mm 10 14M7297 Nut 1 11 RE Wiring Harness 1.. RE Capacitor 1 Not Shown.. RE Regulator 1 Not Shown 5-17

90 GROUP 5 ELECTRICAL SYSTEMS Alternator 14 Volt / 75 Amps Key Part No. Part Name Qty. Engine Serial No. Remarks 1 RE Wiring Harness M7868 R Screw Washer 1 1 M8 X 30 mm 4 14M7297 Nut 2 M5 5 12M7064 Lock Washer 2 5 mm 6 14M7296 Flange Nut 1 M Alternator 14 Volt / 75 Amp 1 Isolated Ground (includes keys #8-9) 8 R Fan 1 9 RE Pulley M7812 R64525 Screw Thrust Washer 1 1 M10 X100 mm 5-18

91 updated GROUP 5 ELECTRICAL SYSTEMS Alternator 14 Volt / 95 Amps Key Part No. Part Name Qty. Engine Serial No. Remarks 1 AH Alternator 1 (BOSCH 95AMP) SE Alternator Reman 1 (REMAN FOR AH137883) RE Alternator 1 (ISKRA 95 AMP) (INCLUDES R505711, RE516489) 2 T Fan 1 (USE WITH AH137883) R Fan 1 (USE WITH RE533653) 3 R Pulley 1 (USE WITH AH137883) RE Pulley 1 (USE WITH RE533653) M7812 R64525 Screw Thrust Washer 1 1 M10 X100mm 6 14M7296 Flange Nut 1 M10 7 RE Wiring Harness M7297 Nut 1 M5 9 12M7064 Lock Washer 1 5 mm 10 19M8291 Screw 1 M8 X 35mm 11 R Washer 1.. H Capacitor 1 (USE WITH AH137883).. RE Capacitor 1 (USE WITH RE533653).. H Voltage Regulator 1 (USE WITH AH137883).. RE Regulator 1 (USE WITH RE533653) 5-19