GREAVES COTTON LTD. SPARE PARTS CATALOGUE. D SERIES TBD 3 V6 RC 250 KVA Base Engine GREAVES COTTON LTD.
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- Derrick Ryan
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1 GREAVES COTTON LTD. SPARE PARTS CATALOGUE D SERIES TBD 3 V6 RC 250 KVA Base Engine GREAVES COTTON LTD. Diesel Engines Unit, Chinchwad, Pune , India, Tel: (91) Fax: (91) Document number (00) 12/12 Page 1 of 98
2 GREAVES COTTON LTD WATER COOLED DIESEL ENGINE TBD3 V6 RC 250 KVA BASE ENGINE SPARE PARTS CATALOGUE Diesel Engines Unit Chinchwad, Pune INDIA Tel. : ( ) Fax: ( ) Document number (00) 12/12 Page 2 of 98
3 INTRODUCTION This spare parts Catalogue comprises the purchasable and replaceable engine parts shown on diagrams and grouped according to their belongings. On account of continuous technical development the figures and part lists are not binding. Ordering of Spare Parts : To enable us to supply correct spares please furnish following details : 1. Engine - Type (engraved on name-plate). 2. Engine Number (engraved on name-plate and crankcase). 3. Quantity, Description, Part No., and item No. of the Spare Part(s) required. 4, Mode of dispatch you wish. 5. Your address (please specify post or railway station if necessary). Document number (00) 12/12 Page 3 of 98
4 WATER COOLED DIESEL ENGINE TBD3V6 RC BASE ENGINE Document number (00) 12/12 Page 4 of 98
5 Modifications summary Modification No. Document Number / Date Details of Modifications Page No / New Release --- Document number (00) 12/12 Page 5 of 98
6 Contents Sr. no Description Page number 1 Crankcase Front wall Cover Flywheel Housing Crankshaft Assembly Piston and Connecting Rod Camshaft Valve with Actuation Mechanism Cylinder Head assembly Fuel Injector Pump Hand priming pump Fuel Pump Drive assembly Fuel filter Fuel Injector High pressure pipe Lub. Oil Sump assembly Gear Type Lub. Oil Pump with Suction Pipe Lub. Oil Filter Plate type Oil Cooler Assembly Fresh Water Pump Cooling Water Pipes Tension Roller Air Intake Manifold Exhaust Manifold Turbocharger Casing for turbine Cover for exhaust manifold Radiator mounting Fan drive assembly Document number (00) 12/12 Page 6 of 98
7 Sr. No. Description Page No. 29 Circulation Cooling radiator cooled engine Turbocharger attachment RC Air Filter assembly Exhaust out let elbow Engine Foot Flexible pipe Battery charging alternator Turning device Gauges and switches Numerical index Document number (00) 12/12 Page 7 of 98
8 CRANKCASE ASSEMBLY Document number (00) 12/12 Page 8 of 98
9 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK CRANK CASE Crankcase, Assly. consist of fig. No mm Dia X 11Length Plug aluminum mm Dia. Plug aluminum mm Plug aluminium M Taper Plug Brass Sleeve Copper bush Dowel pin for main bearing Dowel pin for main bearing Dowel pin for main bearing M DIN- Hexagon screw m Steel Washer Cam Bearing bush Cam Bearing Bush Brass Cap AM12 X 1.5 DIN Screw Plug A12 X 1.5 DIN7603- Copper Washer 1 Cu Piston Cooling Nozzle M8 45 DIN Hex screw B8 DIN-137 Belevi Washer Thrust Washer (Steel) or Ring half AM6 12 DIN Countersunk Screw for Thrust washer DIN-1481 Clamping sleeve (Spring Dowel) M8 DIN 934m-10 Hex Nut Ring Half or Ring Half - Bronze (Series) 2 * Not illustrated Document number (00) 12/12 Page 9 of 98
10 CRANKCASE ASSEMBLY Document number (00) 12/12 Page 10 of 98
11 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK B 8 DIN-127 Spring washer m 6 24 DIN-7 Straight pin or dowel M8 110 DIN Stud Cover plate Shaped gasket M8 20 DIN Hex screw M8 25 DIN Stud 'O' ring for Push Rod Sleeve Bracket M20 40 DIN Hexagon Screw DIN 125V 2A Washer Main Bearing Pair Balancing Shaft Bearing bush Balancing Shaft Bearing bush Consisting of sr. no. 42A & Balancing Shaft 1 42A Balancing Shaft Front gear wheel Counter weight mm Dia X 11 Length Plug aluminum M8 30 DIN Allen screw M8 20 DIN Hexagon screw B 8 DIN-127 Spring ring DIN-1481 Clamping sleeve Counter weight M8 25 DIN Hexagon screw Segment M8 X1.25 X CL Hex Screw Cylinder Liner ,5 DIN-3770 'O' ring 12 * Not illustrated 1 1 Document number (00) 12/12 Page 11 of 98
12 FRONT WALL COVER ASSEMBLY Document number (00) 12/12 Page 12 of 98
13 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK FRONT COVER Front wall cover, consisting of fig. No. 1A & 2 1A Front Wall Cover Oil seal Shaped gasket M8 60 DIN M8 70 DIN Hexagon screw 3 Hexagon screw M8 85 DIN Hexagon screw M8 130 DIN Hexagon screw M DIN-931 Hexagon screw M8 20 DIN Hexagon screw B8 DIN-137 Spring washer Spring washer M8 X 110 Stud M8 Hex. Nut Angle plate M8 95 DIN Hexagon screw Cover ( Air starting ) O Ring 1 30 * Cover instd. of hyd pump consisting of r. no.31 & NBR 100 x 3 O Ring End cover instead hyd 1 pump Countersunk screw 1 1 * Not illustrated Document number (00) 12/12 Page 13 of 98
14 Spare part catalogue D Series TBD3V6 RC BASE Engine FRONT WALL COVER ASSEMBLY Document number (00) 12/12 Page 14 of 98
15 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK FRONT COVER 1 34 * Venting Valve Assembly consisting Fig No Vent pipe 'O' Ring Pipe clip M6x25 DIN Hexagon Screw for pipe clip Spring washer for pipe clip M6 DIN-934m - 10 Hexagon Nut for pipe clip 1 *Not illustrated Document number (00) 12/12 Page 15 of 98
16 FLYWHEEL HOUSING ASSEMBLY Document number (00) 12/12 Page 16 of 98
17 FIG, NO PART SPECIAL DATA DESCRIPTION QTY REMARK NUMBER FLYWHEEL HOUSING Flywheel Housing 1 SAE Oil Seal Flywheel side Shaped Gasket M8 85 DIN Hex. Screw 5 8.8CL B8 DIN-137 Spring Washer M DIN M-8G M8 45 DIN-931 8G Hex. Screw 1 Hex. Screw B16 DIN-137 Spring Washer B12 DIN-127 Spring Washer M12 60 DIN-913m - Hex. Screw 8 8G M12 60 DIN Allen Screw 2 10K Nut (Starter Mounting) Spring Washer (Starter Mounting) M10X1.5X25 8.8CL Stud (Starter Mounting) Oval flange 1 Not illustrated M8 x 16 CSK Screw 2 Not illustrated Gasket 1 Not illustrated * Not illustrated Document number (00) 12/12 Page 17 of 98
18 CRANKSHAFT ASSEMBLY Document number (00) 12/12 Page 18 of 98
19 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK CRANK SHAFT 1 ASSEMBLY Crankshaft, compl. consist 1 of Fig No. 1A -7 1A Crankshaft, Front gear wheel(lub oil Pump Driving) Crank Gear Pipe CR Shaft Balance weight M16 90 DIN Hexagon Screw DIN-1481 Spring dowel Crankshaft ring Front Gear Wheel Flywheel 1 10A Flywheel with ring gear consist of Fig No Ring start gear BM Hex screw 6 DIN Grooves V-belt Pulley BM DIN- 96 Allen screw Washer 6 * Not illustrated Document number (00) 12/12 Page 19 of 98
20 PISTON AND CONROD ASSEMBLY Document number (00) 12/12 Page 20 of 98
21 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK E PISTON EMISSION COMP. 1A E Piston assembly consisting of sr. no. 1,5 & 6 1 E Piston B Ring Set for Piston consisting of sr. no. 2,3 & T Faced ring T - Ring DSF Ring Gudgeon pin x 1.75 DIN 472 Circlip Consists of fig. no. 7A,8,9 &10 Connecting rod, compl. 6 7A Consists of fig. no. Connecting rod +cap 6 7B &10 7B Connecting rod Connecting rod bush (small end) Connecting rod bolt x20 DIN 1481 Spring dowel mm Connecting rod bearing complete (standard) 6 * Not illustrated Document number (00) 12/12 Page 21 of 98
22 CAMSHAFT ASSEMBLY Document number (00) 12/12 Page 22 of 98
23 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK CAMSHAFT ASSEMBLY Cam shaft Cam gear assly. 1 Consisting Fig. No. 3-5, M8 25DIN Allen screw Spring washer Dowel Cam Bush Cam Bush Gear Driving FIP gear Cam Gear Segment M8 20 DIN Hex. screw 2 * Not illustrated Document number (00) 12/12 Page 23 of 98
24 VALVE WITH ACTUATING MACHANISM ASSEMBLY Document number (00) 12/12 Page 24 of 98
25 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK VALVE ACTUATION 1 ASSEMBLY Rocker Arm Assembly 6 complete consisting of Fig. No Washer ,2 DIN-471 Extl. circlip Rocker arm, complete 6 consisting of fig. No. 5,6 4A Rocker arm lever M10 Adjusting Screw M10 DIN-934m - 10 Hexagon nut Push rod tube A22 27 DIN Cu M10 65DIN Copper washer 12 Hexagon screw Washer Push rod assly Mushroom-shaped tappet Actuation of Valve consisting of fig. no.15 & 16 6 * Not illustrated Document number (00) 12/12 Page 25 of 98
26 CYLINDER HEAD ASSEMBLY Document number (00) 12/12 Page 26 of 98
27 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK E CYLINDER HEAD ASSEMBLY 1 E Cylinder Head Complete consist of Fig No. 2 to 13 & Cylinder Head Bare consisting of 2A,21 & A Cylinder Head + V Seat insert 4 E Injector Stud Valve (Inlet) 6 6 P Valve ( Exhaust) Spacer in place of roto cap Spring Cap Valve Collets Valve Spring (Outer) Valve Spring (Inner) EM Sleeve 6 21A Rubber seal mm Dia X 11mm in L Aluminum Plug O' ring Viton (Valve Guide) Valve Seat Insert (inlet) Valve Seat Insert (Exhaust) Valve Guide with out 'O' ring 12 26A Valve guide with '0' ring Cylinder Head Cover 6 31 P Cyl. Head cover Gasket M8X1.25X55 8.8CL Hexagon Screw A8X 14 DIN Cu Copper Washer 6 * Not illustrated Document number (00) 12/12 Page 27 of 98
28 CYLINDER HEAD ASSEMBLY Document number (00) 12/12 Page 28 of 98
29 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK Cylinder Head Gasket X4.5 MM O' Ring Viton X5.0 MM O' Ring Viton M18X 180L CL Cylinder Head Bolt Dia Disc Washer Dia Disc Washer Copper Sleeve or Bush Copper Sleeve or Bush 12 * Not illustrated Document number (00) 12/12 Page 29 of 98
30 FUEL INJECTION PUMP Document number (00) 12/12 Page 30 of 98
31 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK FUEL INJECTION PUMP 1 1/1 P PP6M10P9i+GOV Fuel Injection Pump Complete 1 2 P PP6M10P9i Fuel Injection Pump Lubricating oil supply pipe M10 DIN Cu Banjo Screw A10X14 DIN Copper Washer 2 Cu Flexible Pipe Lub oil Return pipe form FIP A6 DIN Banjo Screw A8 DIN-7623 Banjo Screw A12 18 DIN-7603 Copper Washer A14 20DIN-7603 Copper Washer M8 X 75 DIN931 Hexagon Screw CL Ball Washer M6 30 DIN Hexagon Screw M6 DIN-934M-10 Hexagon nut B6 DIN-127 Spring Washer M8 16 DIN-933- Hexagon Screw Mounting bracket FIP * Flanged FIP side 1 * Not illustrated Document number (00) 12/12 Page 31 of 98
32 HAND PRIMING PUMP Document number (00) 12/12 Page 32 of 98
33 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK HAND PRIMING PUMP 1 1 * Hand priming pump 1 2 * M6x25 Hex. screw 2 3 * M6 Hex. nut 2 4 * B6 Spring washer 2 5 * Washer 2 * Not illustrated Document number (00) 12/12 Page 33 of 98
34 FUEL PUMP DRIVE ASSEMBLY Document number (00) 12/12 Page 34 of 98
35 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK FUEL PUMP DRIVE Injection pumps drive 1 compl. Consist of fig. No Housing Shaft DIN-625 Ball bearing DIN-625 Ball bearing DIN-472 Circlip B DIN- Oil seal B1 Fg DIN-6888 Key Gear wheel DIN-1481 Spring dowel M10 30DIN-912- Allen screw O-ring Coupling Assembly 1 consisting of Fig No. 25, 27 for MOTOR PAL FIP Shaft 1 * Not illustrated Document number (00) 12/12 Page 35 of 98
36 FUEL FILTER Document number (00) 12/12 Page 36 of 98
37 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK FUEL FILTER Fuel multi step filter 1 compl., consist of fig. No Filter cartridge (Felt type) Filter cartridge (Paper 1 flocks) star type M8 95 DIN Hexagon Screw 2 8, M10 40 DIN Hexagon Screw 2 8, AM 14 1,5DIN- Screw plug DIN Over flow valve A DIN Copper washer 5 Cu A 8 DIN-7623 Banjo screw Bracket for fuel filter Plain washer Spring washer Nut M M8 20 DIN Hexagon Screw 3 8, Spring washer 3 *Not illustrated Document number (00) 12/12 Page 37 of 98
38 FUEL INJECTOR Document number (00) 12/12 Page 38 of 98
39 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK E FUEL INJECTOR 6 ASSEMBLY 1 E F002C7Z121 Injector Complete Bracket M8 DIN-934m - 10 Hexagon nut A-8-4 DIN St Washer Sealing ring "O" Ring 6 * Not illustrated Document number (00) 12/12 Page 39 of 98
40 HIGH PRESSURE, FUEL INJECTOR PIPE Document number (00) 12/12 Page 40 of 98
41 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK HIGH PRESSURE FUEL 1 INJECTOR PIPE High pressure pipe set 1 2 * Pipe for injector over flow 2 * Not illustrated Document number (00) 12/12 Page 41 of 98
42 LUB. OIL SUMP ASSEMBLY Document number (00) 12/12 Page 42 of 98
43 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK J LUB OIL SUMP ASSLY. 1 1 J Oil sump consisting of fig 1 no.1a,to 14 1A Oil sump M8x20 Hex. screw B8 Spring washer Segmented Gasket Drain Plug Cu. Washer Lub. oil filler neck Dipstick Cap filler with LO name plate M8x25 Stud NutM8 Hex. nut 'O' Ring-dipstick 1 14 * Gasket oil filler neck 1 1 *Not illustrated Document number (00) 12/12 Page 43 of 98
44 GEAR TYPE LUB. OIL PUMP WITH SUCTION PIPE Document number (00) 12/12 Page 44 of 98
45 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK J GEAR TYPE LUB. OIL PUMP ASSLY. 1 1 J Gear oil pump assly O-ring M 8x50 DIN Hexagon screw M 8x35 DIN Hexagon screw B 8 DIN 137 Spring washer Oil pipe A 10 DIN 7623 Banjo screw A 16x22 DIN Copper washer 6 Cu Lubricating oil pipe- 1 consisting of fig. no. 17A to 24 17A Lubricating oil pipe O-ring M8x25 DIN Hexagon screw Fish plate M8x20 DIN Hexagon screw M8x15 DIN Hexagon screw B8 DIN 127 Spring washer 5 25 * Pipe lub oil supply 1 * Not illustrated Document number (00) 12/12 Page 45 of 98
46 LUBRICATING OIL FILTER Document number (00) 12/12 Page 46 of 98
47 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK LUBRICATING IOL FILTER ASSLY Disposable filler element Filter head Consists of fig. no. 7,8, A Filter head O-ring M10 65 DIN M DIN Hexagon Screw 3 Hexagon Screw B10 DIN-137 Spring Washer M Banjo Screw A/18-24X1.5 Copper washer Adapter Relief valve body Ǿ14mm Steel ball Spring Copper Washer Cap nut 1 * Not illustrated Document number (00) 12/12 Page 47 of 98
48 PLATE TYPE OIL COOLER Document number (00) 12/12 Page 48 of 98
49 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK PLATE TYPE LUB OIL COOLER ASSEMBLY Consisting of fig. no. Oil cooler assly. 1A to 10 & 15 to 22 1A Housing for oil cooler Cartridge oil cooler Plate for Lub. oil cooler Gasket for oil cooler O' ring Spring Washer M8 X 30 Allen Screw M8 Spring Washer M10X25 Hex. Screw M10 Spring washer M10X 70 Stud M10 Plain Washer M10 Nut 6 15 * Adaptor 1 16 * ¾ BSP Hex. Plug 2 17 * Copper washer 2 18 * M14 x 1.5 Hex. Plug 3 19 * CU Washer 3 20 * Support bracket 1 21 * Support bracket 1 22 * Plate for oil cooler 2 23 * Adaptor 1 * Not illustrated Document number (00) 12/12 Page 49 of 98
50 FRESH WATER PUMP ASSEMBLY Document number (00) 12/12 Page 50 of 98
51 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK WATER PUMP ASSLY Water pump assly M8 45 DIN M8 160 DIN Hexagon screw 2 Hexagon screw B8 DIN-127 Spring Washer 4 * Not illustrated Document number (00) 12/12 Page 51 of 98
52 COOLING WATER PIPE Document number (00) 12/12 Page 52 of 98
53 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK COOLING WATER 1 PIPES Oval Flange Gasket M10 40DIN- Hexagon Screw B10 Believed Washer M10 70DIN- Stud Bolt M10 DIN-934 Hexagon Nut 6 mm Pipe (Oil cooler to C' 1 case) M10 25DIN- Hexagon Screw B10DIN-127 Spring Washer Piece of Tube or hose Hose Clip Pipe FWP crankcase Plain washer Gasket 2 * Not illustrated Document number (00) 12/12 Page 53 of 98
54 TENSION ROLLER Document number (00) 12/12 Page 54 of 98
55 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK For 3 groove pulley TENSION ROLLER ASSEMBLY Ring Disc M12 75 DIN Hexagon screw B12DIN-127 Spring Washer Clamping element B14DIN-127 Spring Washer M14 60 DIN Hexagon screw groove pulley Pulley RS-C3 DIN- Ball bearing Bush Lever Tension roller assly. (3 groove) Bush 1 Not illustrated * Not illustrated Document number (00) 12/12 Page 55 of 98
56 AIR INTAKE MANIFOLD Document number (00) 12/12 Page 56 of 98
57 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK Intake manifold Intake manifold Gasket M10 60 DIN M10 80 DIN Hexagon screw 14 Hexagon screw B10 DIN-137 Believed washer A22 27 DIN-7603 Copper washer 4 - Cu /2" BSP Zinc Anode DIN Gasket M10 40 DIN Hexagon screw B10 DIN-137 Believed washer M10 DIN-934 m-10 Hexagon nut Square gasket Square flange (Blank) Oval flange AMU x 1.5 DIN A14 18 DIN Cu Screw plug 2 Copper washer 2 *Not illustrated Document number (00) 12/12 Page 57 of 98
58 EXHAUST MANIFOLD Document number (00) 12/12 Page 58 of 98
59 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK EXHAUST MANIFOLD Exhaust pipe With fig. No M10 30 DIN-939 Stud M DIN-912 Chese head screw Washer Gasket Exhaust elbow 6 8 P Sleeve Exhaust elbow "B" Bank M10 Cu coated Hex. Nut Intermediate piece M10 40 DIN Cheese head screw M10 40 DIN Cheese head screw Exhaust elbow with fig. no. 1 22, M8 20 DIN Stud M DIN- Hexagon Screw 4 931m Shaped gasket M10 DIN Hexagon Nut 10 A3B Shaped gasket 4 *Not illustrated Document number (00) 12/12 Page 59 of 98
60 TURBOCHARGER Document number (00) 12/12 Page 60 of 98
61 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK TURBOCHARGER V (Holset) Turbocharger Assembly 1 * Not illustrated Document number (00) 12/12 Page 61 of 98
62 CASING FOR TURBINE Document number (00) 12/12 Page 62 of 98
63 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK TURBOCHARGER GUARD T/c Guard M6 30 DIN Stud Bush M6 16DIN Hexagon screw M6DIN-934m- 10 Hexagon nut M6 20 DIN Hexagon screw A6, 4DIN-125-St Washer Plate 2 10 * Spring Washer 4 * Not illustrated Document number (00) 12/12 Page 63 of 98
64 COVER FOR EXHAUST MANIFOLD Document number (00) 12/12 Page 64 of 98
65 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK GUARD FOR EXHAUST 1 MANIFOLD Exh. Manifold cover Exh. Manifold cover Bracket M8X15 DIN Hexagon screw B 8 DIN 127 Spring washer A 6,4 DIN St Washer M6X25 DIN Hexagon screw M6X8 DIN Hexagon screw 4 10 * Bush 8 11 * B 6 DIN 127 Spring washer 4 12 * A 8,4 DIN St Washer 4 13 * M8X65 DIN Hexagon screw 4 * Not illustrated Document number (00) 12/12 Page 65 of 98
66 RADIATOR MOUNTING Document number (00) 12/12 Page 66 of 98
67 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK RADIATOR MOUNTING BRACKET ASSLY Radiator A.V. Mounting M8 X 40 Hexagon Bolt Hexagon Nut B-10 Plain Washer Radiator Bracket M8X1.25X40 8.8/CL Hexagon Screw M10X1.5X35 8.8CL Hexagon Screw M10 DIN 934M-10 Hexagon Nut A10.5 (M10) Plain washer B-8 Spring Washer M-10 Spring Washer Bushing M8 x 17 x 1.6 Washer 6 15 * M8X15, 8.8/CL Hexagon Screw 4 * Not illustrated Document number (00) 12/12 Page 67 of 98
68 FAN DRIVE ASSEMBLY Document number (00) 12/12 Page 68 of 98
69 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK FAN DRIVE ASSLY Fan drive, Compl. Consisting of Fig. No Plate Bearing shaft Z-C3 DIN-625 Grooved ball bearing Round flange Baring Bush fan drive M DIN Hexagon screw M20 25 DIN Hexagon nur M6 25 DIN Hexagon screw Washer Ring DIN-471 Circlip B6 DIN-127 Spring washer Fan pulley Bush M DIN Hexagon screw M10 DIN-934 M-10 Hexagon nut B10 DIN-137 Spring washer Fan 34 pusher type Intermediate flange M8 35 DIN M8 25 DIN Hexagon screw 6 Hexagon screw B8 DIN-127 Spring washer DIN Cap 1 * Not illustrated Document number (00) 12/12 Page 69 of 98
70 CIRCULATION COOLING RADIATOR COOLED ENGINE Document number (00) 12/12 Page 70 of 98
71 FIG, PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK NO CIRCULATION COOLING 1 RADIATOR COOLED ENGINE Thermostat Hose piece Hose clip 8 4 * Rubber Band Pipe clip B8 DIN-127 Spring washer M8 DIN-934 Hexagon nut Dia X 55 L Hose pipe By Pass Pipe Pipe Between thermostat Pipe FWP to Radiator Hose Piece Hose clip Pipe clip Hose clip M8 20 DIN * M10 40 DIN Hexagon screw 1 Hexagon screw 4 19 * Elbow 1 20 * Plain washer 8 21 * M10 30 Stud 2 22 * M10 Hex. nut AX 65 V- Belt 3 24 * Pipe elbow to thermostat 2 25 * Dia X 70 L Hose pipe M8 15 DIN Hexagon screw 1 * Not illustrated Document number (00) 12/12 Page 71 of 98
72 TURBOCHARGER ATTACHMENT RC Document number (00) 12/12 Page 72 of 98
73 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK TURBOCHARGER ATTACHMENT RC L.O. Supply Pipe to T/c Elbow M15 x 1.5 Hollow screw B 10 DIN 127 Spring washer Lubricating oil Drain pipe "O" Ring Spring washer Gasket turbo. drain M10 35 DIN Hex. Screw Pipe clip Hex. nut Washer Elbow Fastening plate Humped Hose /4 Hose clip Pipe Turbocharger to 1 After Cooler Pipe After Cooler to 1 manifold Housing with fig.no.37, M10 30 DIN CL M8 x 25 DIN CL Stud bolt 12 Stud Bolt B10 DIN-137 Belvaled Washer M10 DIN-934 M - 10 Hexagon nut A10, 5 DIN St Washer M10 35 DIN Hexagon screw Trestle Complete L.O. Supply Pipe Hose Hose Clip Adaptor for TC Gasket exhaust for TC 1 * Not illustrated Document number (00) 12/12 Page 73 of 98 1
74 AIR FILTER ASSEMBLY Document number (00) 12/12 Page 74 of 98
75 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK Air filter Pre Cleaner Holder Clamp Hex. Screw M10 x Air Filter / Cleaner Hose Clip 170 mm Hose-Piece Pipe - Air filter to Turbocharger Hex. Screw - M8 x 1.25 x25cl Spring Washer B Hex. Nut DIN 934 M Hex. Screw M8 x 1.25 x15cl A B10 Spring Washer Hose Clip Hose Piece Air Filter Element - Outer Air Filter Element - Inner AV Mounting Pads M10 DIN 934M-10 Hex. Nut DIN 934 M B10 Spring Washer 8 21 * Vacuum Indicator 1 22 * M8 x 17 x 1.6 Washer 4 23 * Plain washer * Bracket A/F support 2 25 * Plate air pipe holding 1 26 * Clamp air pipe holding 1 * Not illustrated Document number (00) 12/12 Page 75 of 98
76 EXHAUST OUT LET ELBOW Document number (00) 12/12 Page 76 of 98
77 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK FLEX. EXHAUST PIPE Exhaust elbow Gasket M10 Stud M10 Hexagon nut NW x 220 mm Bellow exh. 1 lg Round flange Gasket M16 X 2.0 X Hex Screw 16 CL M16 Hexagon nut Clamp for exh. bend. 2 * Not illustrated Document number (00) 12/12 Page 77 of 98
78 ENGINE FOOT Document number (00) 12/12 Page 78 of 98
79 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK ENGINE FOOT Engine foot M12 35 DIN 933 Hexagon screw B12 DIN-127 Spring washer Engine Bearer 1 * Not illustrated Document number (00) 12/12 Page 79 of 98
80 FLEXIBLE PIPE Document number (00) 12/12 Page 80 of 98
81 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK SET OF FLEX. FUEL PIPE M14 x 31lg. Banjo screw 8 Not illustrated Cu washer 16 Not illustrated M14x18 Cu washer 20 Not illustrated mm lg Flexible pipe fuel pump, FIP over flow mm lg Flexible hose assly. filter inlet, filter out let 1 1 Not illustrated 1 Not illustrated Banjo bolt 1 Not illustrated FLEXIBLE PIPE Flexible fuel pipe 2 Not illustrated M14 x 31lg. Banjo screw 1 Not illustrated Cu washer 2 Not illustrated * Not illustrated Document number (00) 12/12 Page 81 of 98
82 BATTERY CHARGING ALTERNATOR & SARTER Document number (00) 12/12 Page 82 of 98
83 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK BATTERY CHARGING 1 ALTERNATOR & STARTER Battery charging alternator 1 24V 30AMP Lever M12 DIN-934 Hexagon Nut B12 DIN-127 Spring Washer A13 DIN St. Plain washer M10 25 DIN-933- Hexagon screw B10 DIN-127 Spring washer M DIN Hexagon screw Bracket Bracket M10 30 DIN-933- Hexagon screw Bush M10 DIN-934 Hexagon nut M12 40 DIN Hexagon screw V-belt pulley M10 45 DIN Hexagon screw DIN-125- St Plain washer V belt guard A X 45 V belt GSL/5A STARTER GSL/5A/24V LUCAS 1 * Not illustrated Document number (00) 12/12 Page 83 of 98
84 TURNING DEVICE Document number (00) 12/12 Page 84 of 98
85 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK TURNING GEAR Rod Intermediate flange M 12x45 DIN Allen screw B 12 DIN 127 Spring washer 6 * Not illustrated Document number (00) 12/12 Page 85 of 98
86 GAUGES AND SWITCHES Document number (00) 12/12 Page 86 of 98
87 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK GAUGES & SWITCH V Relay box assly Cable harness for V engine A Fuse link Rad. Water level sensor LOP Sensor Temp. sensor Cu. Washer M10 x 1.5 Screwed plug Adaptor for pressure 1 sensor Copper washer Angle plate 2 1 *Not illustrated Document number (00) 12/12 Page 87 of 98
88 SET OF HOSES, SET OF HOSE CLIPS, SET OF O RING, & SET OF GASKET Document number (00) 12/12 Page 88 of 98
89 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK SET OF HOSE DIA.X60L. Hose Humped hose T/C ELBOW-PIPE D.X70L SILICON Hose RBR 65 ID,5THK,50L Hose DIA.X 55L Hose Hose piece DIA.X60L Hose DIA. Hose bend DIA.X70 L. Hose DIA.X55L Hose DIA.X 65L. Hose 2 2 SET OF HOSE CLIP /2A Hose clip /4 Hose clip /4X Hose clip MM Hose clip /6 Hose clip /2A Hose clip /3X Hose clip (2X)9THK. Hose clip 8 SET OF 0 RING VITON 9X4.5MM O Ring X3 D/234 O Ring RUBR VITON- 18MMX5.0MM O Ring VIT-142X4.5 O Ring NBR 80X3 O Ring VITON 20X4 O Ring NBR 124X3 O Ring X4MM O Ring 2 *Not illustrated Document number (00) 12/12 Page 89 of 98
90 SET OF HOSES, SET OF HOSE CLIPS, SET OF O RING, & SET OF GASKET Document number (00) 12/12 Page 90 of 98
91 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK SET OF 0 RING X4MM O Ring VITON 20X4 O Ring NBR 100X3 O Ring O Ring DIPSTICK SILICON 35X3 O Ring SILICON 24X3.5 O Ring 4 SET OF GASKET Gasket-gear end plate Gasket cyl head(128dia) Gasket-gear end cover 1 4 P Gasket-cover cyl. head Oval gasket Gasket for oil cooler hsg Gasket air intake mani Gasket intake manifold Gasket water manifold Gasket- oil filler neck Segmented gasket-v6 sump 12 P Sump gasket intermediate 2 13 P Sump gasket g/e side 1 14 P Sump gasket f/w side Gasket-t/c outlet Shaped gasket-ss aisi Shaped gasket Sect. gasket-elbow to t/c Gasket-exhaust manifold Gasket intake manifold Gasket turbo oil drain Gasket exhaust for holset t/c Gasket - caf/g Gasket l o drain on hsg Gasket - Exh. silencer 1 *Not illustrated 1 Document number (00) 12/12 Page 91 of 98
92 NUMERICAL INDEX PART No. TO PAGE No. AND FIG CODE NO FIG NO PAGE NO A A A A CODE NO FIG NO PAGE NO A A Document number (00) 12/12 Page 92 of 98
93 NUMERICAL INDEX PART No. TO PAGE No. AND FIG CODE NO FIG NO PAGE NO A B A A A CODE NO FIG NO PAGE NO B Document number (00) 12/12 Page 93 of 98
94 NUMERICAL INDEX PART No. TO PAGE No. AND FIG CODE NO FIG NO PAGE NO CODE NO FIG NO PAGE NO Document number (00) 12/12 Page 94 of 98
95 NUMERICAL INDEX PART No. TO PAGE No. AND FIG CODE NO FIG NO PAGE NO CODE NO FIG NO PAGE NO Document number (00) 12/12 Page 95 of 98
96 NUMERICAL INDEX PART No. TO PAGE No. AND FIG CODE NO FIG NO PAGE NO A CODE NO FIG NO PAGE NO Document number (00) 12/12 Page 96 of 98
97 NUMERICAL INDEX PART No. TO PAGE No. AND FIG CODE NO FIG NO PAGE NO A CODE NO FIG NO PAGE NO Document number (00) 12/12 Page 97 of 98
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