P6170. For Models: L6170A and M6170A PARTS CATALOG. Marine Generators Marine Diesel Engines Land-Based Generators

Transcription

1 P6170 For Models: L6170A and M6170A 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 2010 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 /10

3 PARTS MANUAL P6170 for Models: L6170A & M6170A. Please read thoroughly before attempting to use this manual. TABLE OF CONTENTS Table of Contents... 1 Model Designation & Serial Numbers... 2 Reading a Parts Page... 3 GROUP 1 - ENGINE Cylinder Block Assembly Flywheel & Flywheel Housing Crankshaft Assembly...4 Piston & Connecting Rod...5 Camshaft Timing Cover Idler Gears & Gear Case Housing Lubricating Oil Pump & Suction Pump Lubricating Oil Filter Assembly Oil Pan...16 Oil Fill...17 Intake Valve Lub. Pump & Piping Cylinder Head Rocker Arm & Housing Rocker Arm Cover...24 GROUP 2 - INTAKE & EXHAUST SYSTEM Air Filter...1 'Air-Sep' Air Filter/Crankcase Breather Intake Manifold & Aftercooler Exhaust Manifold Intake and Turbocharger Turbocharger Assembly Dry Exhaust Elbow...18 GROUP 3 - COOLING SYSTEM Remote Expansion Tank Expansion Tank & Heat Exchanger Thermostat Housing Coolant Manifold...6 Corrosion Resistor...7 Coolant Pump & Accessory Drive Raw Water Pump Lubricating Oil Cooler Gear Oil Cooler Keel Cooling Outlet...17 GROUP 4 - FUEL SYSTEM Fuel Injection Pump & Lines Injection Pump Application List...2 Fuel Injectors & Return Lines Fuel Filter & Lines Fuel Supply & Return Connections...9 Fuel Feed Pump Assembly...10 Fuel Injection Pump Drive Fuel Injection Pump Coupling...14 Throttle Linkage...15 GROUP 5 - ELECTRICAL SYSTEM Engine Electrical Circuit Breaker & Relay Panel Stop Solenoid...7 Starter Alternators & Mounting...10 Instrument Panels GROUP 6 - GASKET SETS Gasket Kits GROUP 9 - ACCESSORIES & OPTIONAL EQUIPMENT Front Crankshaft Pulley...1 PTO and Electric Clutch Oil Change Pump Oil Filter Assembly...8 Water Level Switch/Gauge...9 Proprietary Information This publication is the property of Northern Lights, Inc. It may not be reproduced in whole or part without the written permission of Norhtern Lights, Inc. All rights reserved. Litho USA Publication number P /10 1

4 INTRODUCTION MODEL DESIGNATION MODEL NUMBERS Model numbers give unit's application, block model, and aspiration: M - L 6170 A M - Northern Lights marine generator set Model number of Komatsu A - Aftercooled (Turbo) L - Northern Lights propulsion engine engine block 6 cylinder, 170 mm bore EXAMPLE: L6170A Lugger tubocharged-aftercooled marine propulsion engine. Komatsu 170 block. SERIAL NUMBERS LUGGER: When ordering Lugger parts, refer to this serial number located on the flywheel housing. Serial numbers for Northern Lights are eight digits. e.g NORTHERN LIGHTS: Every Northern Lights generator set has two data plates and two serial numbers, which may cause some confusion. One serial number is for the generator end, and it is found on the Generator End Data Plate. The other serial number, found with the Generator set Data Plate, should be used when ordering parts. Serial Numbers for Northern Lights are eight digits. e.g Generator Set Serial Number Generator End Serial Number 2

5 INTRODUCTION READING A PARTS PAGE IMPORTANT: Before selecting parts be sure that you are choosing parts from the correct page. Check the application at top of page. (Do not use this illustration for parts purchasing.) 1 ELECTRICAL SYSTEM ALTERNATOR ASSEMBLY 2 Marine Application 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. Major component group. 2. Title and description of assembly or system. 3. Application. 4. Drawing numbers. Correspond to key numbers. 5. Denotes an assembly or kit. 6. Key column. Key numbers correspond to drawing numbers. 7. Part number to order. 8. Quantity of parts used in assembly. 9. Description of each component part. 10. Serial number. Parts used between, up to or after serial numbers noted. 11. Component group number. 12. Page number within component group. 13. Manual identification. 14. Publication date. a Arrows always point toward the front of the engine. 3

6 GROUP 1 - ENGINE CYLINDER BLOCK Fig

7 GROUP 1 - ENGINE CYLINDER BLOCK Cylinder Block Assembly (includes keys 2 21, 27 & 35) Bushing Main Bearing Cap (#'s 1 5, & 7) Main Bearing Cap (# 6) Dowel pin Bolt Washer Dowel Pin Plug Plug Plug Plug Plug Plug Sealing Washer Dowel Pin Dowel Pin Plug Pin Pipe Dowel Pin Cylinder Liner Crevis Seal O-ring O-ring Nozzle, Piston Cooling Plug O-ring Bolt Lock Washer Cover Cover Bolt Gasket Bolt Lock Washer Washer Breather O-ring Bolt Lock Washer Plug Bracket Bolt Washer Plug Oil Fill, left side Gasket Bolt Lock Washer Cap Plate Gasket Bolt Washer - 1-1

8 GROUP 1 - ENGINE FLYWHEEL AND FLYWHEEL HOUSING Fig

9 GROUP 1 - ENGINE FLYWHEEL AND FLYWHEEL HOUSING Flywheel Housing - SAE # Gasket Bolt Bolt Bolt Washer Rear Seal (Standard) Rear Seal (Repair Type) Bolt Washer Manual Rotation Assembly (includes keys 10 15) Case Shaft Gear Spring Seal Pin Gasket Bolt Spring Washer Plug Flywheel Assembly - SAE #18 (includes key 21) Ring Gear (138 teeth) Bolt Washer Bracket, Right hand Bracket, Left hand Pin Bolt Washer - 1-3

10 GROUP 1 - ENGINE CRANKSHAFT Crankshaft Assembly (includes keys 2-4) Key Gear Dowel Pin Damper Pulley Bolt Washer - 9 MAIN BEARING ASSEMBLIES Main bearing set. Standard Main bearing assembly. Standard Main bearing assembly. Undersize, 0.25 mm Main bearing assembly. Undersize, 0.50 mm Main bearing assembly. Undersize, 0.75 mm Main bearing assembly. Undersize, 1.00 mm - 10 THRUST BEARING ASSEMBLIES (Set of 4 Bearings) Thrust bearing assembly. Standard Thrust bearing assembly. Oversize, 0.25 mm Thrust bearing assembly. Oversize, 0.50 mm Thrust bearing assembly. Oversize, 0.75 mm Thrust bearing assembly. Oversize, 1.00 mm - Fig

11 GROUP 1 - ENGINE PISTON AND CONNECTING ROD Fig Piston (formerly # ) Pin Snap ring Piston ring set Connecting rod assembly (includes keys 6 9) Bushing Dowel pin Bolt Washer - 10 ROD BEARING ASSEMBLIES Bearing assembly. Standard Bearing assembly. Undersize, 0.25 mm Bearing assembly. Undersize, 0.50 mm Bearing assembly. Undersize, 0.75 mm Bearing assembly. Undersize, 1.00 mm - 1-5

12 GROUP 1 - ENGINE CAMSHAFT Fig

13 GROUP 1 - ENGINE CAMSHAFT Camshaft assembly (includes keys 1-4) Camshaft (formerly # ) Key Thrust Plate Camshaft Gear Bolt Shaft Cam follower assembly (includes keys 7 13) Lever assembly (includes keys 8 11) - } 8 12 Socket Roller Not available separately Pin Collar Shaft Assembly (includes key #13) Pin Snap Ring Bolt Washer Ring Push rod - 1-7

14 GROUP 1 - ENGINE TIMING COVER Fig

15 GROUP 1 - ENGINE TIMING COVER Cover Plug Plug Plug Gasket Spring Washer Bolt Bolt Spring Washer Plate Gasket Bracket (see heat exchanger parts detail) Pointer Bolt Bolt Spring Washer Washer Front Seal Repair Sleeve (not shown) O-ring Bolt (H.E.) Bolt (K.C.) Bolt (H.E.) Bolt (K.C.) Cover Bolt Lock Washer Trunnion O-ring Bolt Lock Washer M ** Liquid Gasket Cover (K.C. only - see raw water pump detail) - **As required 1-9

16 GROUP 1 - ENGINE IDLER GEARS AND GEAR CASE HOUSING Fig

17 GROUP 1 - ENGINE IDLER GEARS AND GEAR CASE HOUSING Gear Case Housing (includes keys 2 & 3) Plug Dowel Pin Gasket Bolt Bolt Bolt Washer Bolt Lock Washer Cover O-ring Bolt Bolt Lock Washer Gear Assembly (includes key 17) Bushing Idler Gear Dowel Pin Bolt Lock Washer Idler Gear Assembly (includes key 23) Bushing Idler Gear Assembly (includes key 25) Bushing Bearing Plate Shaft Shaft Bolt Bolt Washer

18 GROUP 1 - ENGINE OIL PUMP AND SUCTION PIPE Fig

19 GROUP 1 - ENGINE OIL PUMP AND SUCTION PIPE Oil Pump Assembly (includes keys 1 20) Housing Assembly (includes keys 2 3) Bushing Drive Shaft Cover Assembly (includes key 5) Bushing Drive Shaft Gear Drive Gear Assembly (includes key 9) Bushing Bolt Bolt Lock Washer Nut Plug Relief Valve Assembly (includes keys 15 20) Plunger Ball Spring Pin Spring Shim Bolt Lock Washer O-ring Pipe Gasket Bolt Lock Washer Bracket Bolt Washer Washer Nut Bolt Washer - 34A Spacer Pipe O-ring Gasket Bolt Lock Washer Dowel Pin

20 GROUP 1 - ENGINE OIL FILTER ASSEMBLY Fig

21 GROUP 1 - ENGINE OIL FILTER ASSEMBLY Oil Filter and Bracket Assembly (includes keys 2 9) Cap* Packing Spring Valve* Cartridge Sensor Sealing Washer Plug Adapter Assembly (includes keys 10 16) Adapter Cap Packing Spring Plunger Plug Plug Bolt Bolt Bolt Bolt Lock Washer Washer O-ring O-ring Bolt Bolt Bolt Washer Washer - *Note: Original Cap key #2 and Packing key #5 have been replaced by numbers now listed (formerly and ) 1-15

22 GROUP 1 - ENGINE OIL PAN Fig Oil Pan Plug Elbow, 1/2 BSPT x 15 mm Hose Stub (Plain - no barb) Capscrew, Hex Head M10 x 1.5 x 30 mm Plug Plate Gasket Capscrew, Hex Head M10 x 1.5 x 16 mm Plug, M36 x O-ring Bushing Collar Nut Dipstick Tube Dipstick } Left or right side Cover Cover Capscrew, Hex Head Flanged M10 x 1.5 x 20 mm ** Liquid Gasket - **As required 1-16

23 GROUP 1 - ENGINE OIL FILL DRAWING NOT AVAILABLE AT THIS TIME A Tube Cap Gasket Capscrew, Hex Head M10 x 1.5 x 25 mm Lock washer, Helical 3/ U-bolt Clamp Cushion

24 GROUP 1 - ENGINE INTAKE VALVE LUBRICATION PUMP AND PIPING Fig

25 GROUP 1 - ENGINE INTAKE VALVE LUBRICATION PUMP AND PIPING Lubrication pump up to S/N Bolt Washer Tube Tube Tube Tube Bolt Gasket Clip Plate Clamp Clamp Bolt Lock Washer 15A Spacer Elbow Plate Bolt Lock Washer Spacer 21 MK-2M-36E O-ring Bolt Bolt Bolt 24A Washer Lock Washer Spacer Spacer 1-19

26 GROUP 1 - ENGINE CYLINDER HEAD Fig

27 GROUP 1 - ENGINE CYLINDER HEAD Cylinder head assembly (includes keys 2 14) Injector sleeve O-ring Intake seat insert, Standard Intake seat insert, Oversize 0.25 mm Intake seat insert, Oversize 0.50 mm Intake seat insert, Oversize 0.75 mm Intake seat insert, Oversize 1.00 mm Exhaust seat insert, Standard Exhaust seat insert, Oversize 0.25 mm Exhaust seat insert, Oversize 0.50 mm Exhaust seat insert, Oversize 0.75 mm Exhaust seat insert, Oversize 1.00 mm Valve guide Push rod tube O-ring Guide Plug Plug Plug Expansion plug Pin Intake valve (replaces ) Exhaust valve Valve spring, outer (formerly ) Valve spring, inner Retainer Keeper Spring seat Crosshead Screw Nut Head bolt (formerly # ) Washer Head Gasket Standard Head Gasket Repair (.4 mm thicker than standard)* - *Refer to service manual for application and specifications. Note: Quantities for keys 2 14 are per each cylinder head. 1-21

28 GROUP 1 - ENGINE ROCKER ARM AND HOUSING Fig

29 GROUP 1 - ENGINE ROCKER ARM AND HOUSING Housing (No. 1 & 5) Housing (No 2, 3, 4 & 6) Intake Rocker Arm Assembly (includes keys 4 & 5) Bushing Rivet Exhaust Rocker Arm Assembly (includes keys 6 & 8) Bushing Rivet Rocker Arm Shaft Assembly (includes key 10) Pin Adjusting Screw Nut Collar Bolt Bolt Washer - 16A Spacer Gasket Packing Bolt Washer

30 GROUP 1 - ENGINE ROCKER ARM COVER Fig Cover Gasket Bolt Spring washer Washer Packing

31 GROUP 2 - INTAKE AND EXHAUST AIR FILTER Standard A-6007/ B Air Filter Base Air Filter Sleeve T-Bolt Clamp 6-1/4" S/S - 2-1

32 GROUP 2 - INTAKE AND EXHAUST 'AIR-SEP' AIR FILTER/CRANKCASE BREATHER Arrangement with Vacuum Limiter, Early Production A-6039 / D

33 GROUP 2 - INTAKE AND EXHAUST 'AIR-SEP' AIR FILTER/CRANKCASE BREATHER Arrangement with Vacuum Limiter, Early Production 'Air-Sep' Filter Assembly* (includes keys & 30) Vacuum Limiter One Way Valve Bracket Adapter Hose Clamp # Hose 1-1/4" ID x 3-1/2" Hose Clamp # Hose, 2" x 3-1/2" Tube Tube Rubber Connector 6" ID x 3" Hose Clamp # Male Elbow 90 0, 3/8" NPT x 3/8" Hose Clamp # Hose 3/8" x 32" Male Elbow 90 0, 1/4 NPT x 3/8 HB Gasket Adelle Clamp 1-1/8" ID x 1/2" Stud Spacer Element 12" OD x 10" Cover Capscrew, Hex Head M10 x 1.25 x 30 mm Lock Washer, Helical M Flat Washer M Rubber Bushing 5-1/2" ID x 6" OD Flat Washer M Nylock Nut M8 x Capscrew, Hex Head M8 x 1.25 x 25 mm Cover, Retaining Spring - *Replaces earlier filter assemblies: (9" OD x 12" Tapered Element) (Same element as shown in parts list) 2-3

34 GROUP 2 - INTAKE AND EXHAUST 'AIR-SEP' AIR FILTER/CRANKCASE BREATHER Arrangement with Vacuum Regulator A-7692 / D

35 GROUP 2 - INTAKE AND EXHAUST 'AIR-SEP' AIR FILTER/CRANKCASE BREATHER Arrangement with Vacuum Regulator 'Air-Sep' Filter Assembly (includes keys 21-22, & 26) Vacuum Regulator (includes key #30) One Way Valve Bracket Adapter Hose Clamp # Hose 1-1/4" ID x 3-1/2" Hose Clamp # Hose, 2" x 3-1/2" Tube Tube Rubber Connector 6" ID x 3" Hose Clamp # Male Elbow 90 0, 3/8" NPT x 3/8" Hose Clamp # Hose 3/8" x 32" Male Elbow 90 0, 1/4 NPT x 3/8 HB Gasket Adelle Clamp 1-1/8" ID x 1/2" Stud Spacer Element 12" OD x 10" Cover Capscrew, Hex Head M10 x 1.25 x 30 mm Lock Washer, Helical M Flat Washer M Cover Retaining Spring Flat Washer M Nylock Nut M8 x Capscrew, Hex Head M8 x 1.25 x 25 mm Element, Vacuum Regulator - 2-5

36 GROUP 2 - INTAKE AND EXHAUST IINTAKE MANIFOLD AND AFTERCOOLER Fig

37 GROUP 2 - INTAKE AND EXHAUST IINTAKE MANIFOLD AND AFTERCOOLER Air Intake Manifold Aftercooler Element Cooler Gasket Bolt Connector O-ring Gasket Plug Plug Gasket Bolt Bolt Bolt Bolt Spacer Bolt Lock Washer Washer Washer Connector Plug Plug Gasket Bolt Spacer Gasket Bolt Lock Washer Pipe O-ring Bolt Lock Washer Cover Gasket Bolt Lock Washer Washer - 2-7

38 GROUP 2 - INTAKE AND EXHAUST EXHAUST MANIFOLD Fig

39 Updated GROUP 2 - INTAKE AND EXHAUST EXHAUST MANIFOLD Exhaust manifold assembly (includes keys 1-9, - formerly # ) See keys 18 & Exhaust manifold assembly (includes keys 1-9, - formerly # ) See keys 18 & Plate Gasket Bolt Flange Gasket Bolt Plug Plug Gasket Bolt Stud Washer Washer Nut Gasket Connector (2 bolt flange - use with ) Connector (4 bolt flange - use with ) Connector (2 bolt flange - use with ) ** Gasket (2 bolt flange - use with ) ** Gasket (4 bolt flange - use with ) ** Bolt Hose, 1-5/16 ID x 6" Silicone (former # ) Hose Clamp #28 Extended Band Elbow Nipple Tube Stay Clip Bolt Nut - **As required. 2-9

40 GROUP 2 - INTAKE AND EXHAUST INTAKE AND TURBOCHARGER Early Production Fig. A-6013/ D

41 GROUP 2 - INTAKE AND EXHAUST INTAKE AND TURBOCHARGER Early Production Turbocharger O-ring Connector Gasket Capscrew, Hex Head M8 x 1.25 x 150 mm Capscrew, Hex Head M8 x 1.25 x 35 mm Flat Washer M Gasket Adapter, Turbo Mounting * Gasket Stud 3/8-16 x 3/8-24 x 2" * Flat Washer 3/8 SAE * Hex Nut 3/8-24 * ** Capscrew, Hex Head M12 x 1.75 x 65 mm (**As required) Capscrew, Hex Head M12 x 1.75 x 30 mm Lock Washer, Helical M Adapter, Turbo Oil Inlet Gasket Capscrew, Hex Head 3/8-16 x 1-3/4" Lock Washer, Helical 3/ Male Connector 3/8 NPT x 3/8-37T Tube Assembly, Turbo Oil Supply Adelle Clamp 3/8" ID x 3/8" Stud Male Connector, Brass 1/4 NPT x 3/8-37T Adapter, Turbo Oil Return Gasket Capscrew, Socket Head 3/8-16 x 1" Male Connector 1/2 NPT x 3/4-37T Tube Assembly, Turbo Oil Return Hose 3/4" ID x 4-1/2" Hose Clamp # Male Connector 1/2 NPT x 3/4 HB Elbow /2 NPT x 1/2 NPT Adapter, Turbo Oil Return Gasket Capscrew, Hex Head M10 x 1.5 x 25 mm Lock Washer, Helical M Adapter, Turbo Coolant Supply Gasket Elbow /4 NPT x 3/4-37T Tube Assembly, Turbo Coolant Supply Elbow /4 NPT x 3/4-37T Elbow /4 NPT x 3/4-37T, tapped 1/8 NPT Drain Cock, Brass 1/8 NPT Tube Assembly, Turbo Coolant Return Male Elbow, 90 0 Steel 3/4 NPT x 3/4-37T up to s/n xxxx Female Elbow, 90 0 Steel 5/8 O-ring port x 1/2 NPT from s/n xxxx Manifold up to s/n xxxx Connector from s/n xxxx Stud 3/8-16 x 3/8-24 x 1-1/4" Wave Washer M Hex Nut 3/8-24 Stainless Steel - 50 R O-ring Connector 1/2 NPT O-ring Tube O-ring - *For Turbo Mtg. upgrade use , , (for Hp), (for 900 Hp), and

42 GROUP 2 - INTAKE AND EXHAUST INTAKE AND TURBOCHARGER Late Production Fig. A-6013/ D

43 GROUP 2 - INTAKE AND EXHAUST INTAKE AND TURBOCHARGER Late Production Turbocharger O-ring Connector Gasket Capscrew, Hex Head M8 x 1.25 x 150 mm Capscrew, Hex Head M8 x 1.25 x 35 mm Flat Washer M Gasket Adapter, Turbo Mounting Gasket Stud 1/2-13 x 1/2-20 x 1.855" Lock Nut, 12 Pt Flanged Capscrew, Hex Head M12 x 1.75 x 65 mm Capscrew, Hex Head M12 x 1.75 x 30 mm Lock Washer, Helical M Adapter, Turbo Oil Inlet Gasket Capscrew, Hex Head 3/8-16 x 1-3/4" Lock Washer, Helical 3/ Male Connector 3/8 NPT x 3/8-37T Tube Assembly, Turbo Oil Supply Adelle Clamp 3/8" ID x 3/8" Stud Male Connector, Brass 1/4 NPT x 3/8-37T Adapter, Turbo Oil Return Gasket Capscrew, Socket Head 3/8-16 x 1" Male Connector 1/2 NPT x 3/4-37T Tube Assembly, Turbo Oil Return Hose 3/4" ID x 4-1/2" Hose Clamp # Male Connector 1/2 NPT x 3/4 HB Elbow 45 0, 1/2 NPT x 1/2 NPT Adapter, Turbo Oil Return Gasket Capscrew, Hex Head M10 x 1.5 x 25 mm Lock Washer, Helical M Adapter, Turbo Coolant Supply Gasket Male Elbow 90 0, Steel 3/4 NPT x 3/4-37T Tube Assembly, Turbo Coolant Supply Male Elbow 45 0, Steel 3/4 NPT x 3/4-37T Male Elbow 90 0, Steel 3/4 NPT x 3/4-37T, tapped 1/8 NPT Drain Cock, Brass 1/8 NPT Tube Assembly, Turbo Coolant Return Female Elbow 90 0, Steel 5/8 O-ring port x 1/2 NPT from s/n xxxx Connector from s/n xxxx Stud 3/8-16 x 3/8-24 x 1" Wave Washer M Hex Nut 3/8-24 Stainless Steel - 50 R O-ring Adapter 1/2 NPT O-ring Tube, Air Inlet O-ring

44 GROUP 2 - INTAKE AND EXHAUST ITURBOCHARGER ASSEMBLY L6170 up to 800 Hp 2-14

45 GROUP 2 - INTAKE AND EXHAUST ITURBOCHARGER ASSEMBLY L6170 up to 800 Hp Turbocharger (includes all keys) Cartridge Assembly (includes keys 2 9, 12 16, 18, 20, 21, 26 & 27) Compressor Cover Lock Nut (formerly # ) Compressor Wheel Flinger Sleeve Piston Ring Oil Deflector Snap Ring Compressor Insert O-ring V-Clamp Thrust Bearing Assembly Spacer Sleeve Pin Bearing Snap Ring V-Clamp Bearing Housing Assembly Turbine Housing Assembly Shaft and Turbine Wheel Assembly (formerly # ) Thrust Ring Self Tapping Screw* Name Plate* Clamp Nut Turbine Backplate Piston Ring Plug* Plug* Expansion Plug 1-1/4"* - *Not shown Note: Repair kit

46 GROUP 2 - INTAKE AND EXHAUST ITURBOCHARGER ASSEMBLY L6170 up to 900 Hp 2-16

47 GROUP 2 - INTAKE AND EXHAUST ITURBOCHARGER ASSEMBLY L6170 up to 900 Hp Turbocharger (includes all keys) Cartridge Assembly (includes keys 2 9, 12 16, 18, 20, 21, 26 & 27) Repair Kit (includes keys 2,5, 9, 10, 12, 15, 16, 21, 24, 25, & 27) Compressor Cover Lock Nut Compressor Wheel Flinger Sleeve* Piston Ring Oil Deflector* Snap Ring* Compressor Insert* O-ring Speed Control Washer (not shown) V-Clamp* Thrust Bearing Assembly Spacer Sleeve* Pin* Bearing Snap Ring V-Clamp* Bearing Housing Assembly Turbine Housing Assembly Shaft and Turbine Wheel Assembly (formerly # ) Thrust Ring Self Tapping Screw (not shown)* Name Plate (not shown)* Clamp Nut O-ring (not shown) Turbine Backplate* Piston Ring - *Not currently available Note: Repair kit

48 GROUP 2 - INTAKE AND EXHAUST DRY EXHAUST ELBOW A-6008/ C Dry Exhaust Elbow 8" Clip Lock Washer, Helical 3/ Hex Nut 3/ Plug, Brass 1/4 NPT Gasket Capscrew, Hex Head M8 x 1.25 x 25 mm Gasket Capscrew, Hex Head 3/4-10 x 2" Lock Washer, Helical 3/ Hex Nut 3/ Bracket Capscrew, Hex Head M12 x 1.75 x 180 mm Flat Washer M Hex Nut, Nylock M8 x 1.25 mm

49 GROUP 2 - INTAKE AND EXHAUST NOTES 2-19

50 GROUP 3 - COOLING SYSTEM REMOTE EXPANSION TANK A-7671/ B Remote Expansion Tank Assembly (see assembly detail, next page) Male Elbow 90 0 Brass, 1/2 NPT x 3/4 HB Male Connector Steel, 1/4 NPT x 1/4-37T Male Elbow 90 0 Steel, 1/8 NPT x 1/4-37T Female Swivel Steel 1/4 HB x 1/4-37T - 3-0

51 GROUP 3 - COOLING SYSTEM REMOTE EXPANSION TANK A-3521E & A-3841 / B-3365C Remote Expansion Tank Assembly (includes all keys) Plug, Hex Head Brass 1/4 NPT Filler Cap 7 lb Sight Glass (w/ Banjo Bolts and O-rings) Thermometer Sight Glass (w/ Banjo Bolts and O-rings) Hose 1/4" ID x 30" Connector 1/2 NPT x 3/4 HB Male Elbow 900 1/4 NPT x 1/4-45T Female Swivel 1/4 HB x 1/4-45T - 3-1

52 GROUP 3 - COOLING SYSTEM EXPANSION TANK AND HEAT EXCHANGER A-6090/ D

53 GROUP 3 - COOLING SYSTEM EXPANSION TANK AND HEAT EXCHANGER Expansion tank Plug, Hex Head, Brass M36 x O-ring Filler Cap 7 lbs PSI Filler Neck O-ring Capscrew, Hex Head M8 x 1.25 x 20 mm Lock Washer, Helical M Plug, Hex Head, Brass 1/2 NPT Plug, Hex Head, Brass 1/4 NPT Capscrew, Socket Head M10 x 1.5 x 30 mm Flat Washer (special) Locking Bar Capscrew, Hex Head M12 x 1.75 x 20 mm Lock washer, Helical M Elbow O-ring Capscrew, Hex Head M10 x 1.5 x 185 mm Capscrew, Hex Head M10 x 1.5 x 30 mm Lock Washer, Helical M Sight Glass 5" (includes key 22) O-ring O-ring O-ring Heat Exchanger Housing O-ring End Cover Elbow O-ring Capscrew, Hex Head M16 x 2.0 x 60 mm Stainless Steel Flat Washer M Zinc Electrode Zinc Plug, Brass 1/2 NPT x 7/ Connector Element Gasket Connector Flat Washer M Capscrew, Socket Head M12 x 1.75 x 30 mm Bracket Capscrew, Hex Head M10 x 1.5 x 35 mm Capscrew, Hex Head M14 x 2.0 x 145 mm Capscrew, Hex Head M14 x 2.0 x 45 mm Lock Washer, Helical M Hose 5/16" ID x 25" (not shown) Adapter Drain Cock, Brass 1/4 NPT Capscrew, Hex Head M10 x 1.5 x 110 mm Coolant Level Switch (formerly # )* - *Optional 3-3

54 GROUP 3 - COOLING SYSTEM THERMOSTAT HOUSING Fig

55 GROUP 3 - COOLING SYSTEM THERMOSTAT HOUSING Thermostat Housing Cover Plug Plug Thermostat F/ C, 700 & 800 Hp Thermostat F/ 65 0 C, 900 Hp Seal Gasket Plug Elbow, Coolant Outlet (see Expansion Tank & Heat Exchanger detail) Tube, Coolant Outlet (see Keel Cooling Outlet detail) Gasket Lifting Eye (Heat Exchanged) Capscrew, Hex Head M10 x 1.5 x 200 mm Capscrew, Hex Head M10 x 1.5 x 110 mm Lock Washer M Lifting Eye (Keel Cooled) ** Bolt Bolt Bolt Bolt Bolt Bolt Washer Bypass elbow Gasket Bolt Washer Tube O-ring Bolt Lock Washer Connector Bolt Washer Tube (see Engine Oil Cooler detail) O-ring Plate Bolt Washer Bolt Washer - **As required 3-5

56 GROUP 3 - COOLING SYSTEM COOLANT MANIFOLD Fig Tube up to S/N xxxx Connector from S/N xxxx Coolant Manifold up to S/N xxxx Coolant Manifold from S/N xxxx Coolant Manifold O-ring ** Snap Ring Plug 1/2 BSPT Plug Connector Gasket Bolt Washer Connector O-ring Bolt Washer Washer Tube O-ring ** Plug M16 x Gasket - **As required 3-6

57 GROUP 3 - COOLING SYSTEM CORROSION RESISTOR Fig Corrosion Resistor Assembly (includes keys 1-11) Head Assembly (includes keys 1-9) Head Valve O-ring O-ring Cover Handle Plate Nut Washer O-ring Element Bracket Bolt Washer Gasket Bolt Bolt Washer - 3-7

58 GROUP 3 - COOLING SYSTEM COOLANT PUMP AND ACCESSORY DRIVE Fig

59 GROUP 3 - COOLING SYSTEM COOLANT PUMP AND ACCESSORY DRIVE Coolant Pump Assembly (includes keys 1-17) Housing * Shaft assembly Pulley Bearing Snap ring Snap ring Bearing Oil seal Coolant seal Impeller Inlet housing O-ring O-ring Bolt Bolt Washer Washer Bracket Bolt Bolt Washer Housing Plug O-ring - 24A O-ring Bushing Shaft Spring pin Thrust bearing Oil seal Plug Gear Shaft Gasket Bolt Washer Bolt Bolt Washer Elbow O-ring Bolt Washer Connector O-ring Gasket Bolt Bolt Washer Bolt Washer - *Not available separately 3-9

60 GROUP 3 - COOLING SYSTEM RAW WATER PUMP Note: Torque Nut #14 to 30 lbs./ft. A-6091/ D Raw Water Pump Assembly (includes keys #1, 6-9, & 11-15) Raw Water Pump (see parts detail, not available separately) Gasket V-Clamp Adapter ** Adapter, 2" BSPP Female ** Elbow Gear Adapter Capscrew, Hex Head M8 x 1.25 x 25 mm Lock Washer, Helical M O-ring O-ring Key Tab Washer Lock Nut, M20 x Shim Washer - **As required 3-10

61 Corrected page GROUP 3 - COOLING SYSTEM RAW WATER PUMP Raw Water Pump Assembly (includes keys 1 20 & 22 33) Spares Kit (includes keys 2, 6, 23, 24 & 30 32) Outer Housing Cotter Pin Castle Nut 5/ Flat Washer Key O-ring Inner Housing Capscrew, Hex Head 3/8-24 x 7/8" Lock Washer 3/8 Stainless Steel Spacer Gasket Shaft Bearing Housing Bearing Tab Washer Lock Nut Snap Ring Bearing Wear Sleeve Lip Seal Adapter, Pump Outlet V-clamp Mechanical Seal Spacer Port Plate Spacer Impeller (replaces Impeller # ) Data Plate (not shown) Plug, Hex Head, Stainless 1/4 BSPT ** Shim 0.25 mm ** Shim 0.38 mm Snap Ring, Beveled V-clamp Port Plate (**As required) A-7484A/ A-9720

62 GROUP 3 - COOLING SYSTEM LUBRICATING OIL COOLER Fig

63 GROUP 3 - COOLING SYSTEM LUBRICATING OIL COOLER Lubricating Oil Cooler Assembly (includes keys 1-11) Cover Element Gasket - 3A O-ring Nut Lock Washer Washer Drain Cock Cover Gasket Bolt Lock Washer Housing Plug Baffle Plate Bolt Lock Washer Washer Gasket Gasket Bolt Bolt Bolt Bolt Bolt Bolt Lock Washer Washer Bypass Valve Assembly (includes keys 28-35) Housing Plunger Spring Shim Plug O-ring Bolt Lock Washer Gasket Bolt Lock Washer Washer Connector Tube O-ring Gasket Bolt Lock Washer Plate Gasket Bolt Lock Washer

64 GROUP 3 - COOLING SYSTEM GEAR OIL COOLER Heat Exchanged Units A-6811/ D

65 GROUP 3 - COOLING SYSTEM GEAR OIL COOLER Heat Exchanged Units Gear Oil Cooler (includes keys 1, & 27) Housing End Cap End Cap Gasket Bracket Capscrew, Socket Head M10 x 1.5 x 30 mm Lock Washer M Capscrew, Hex Head M10 x 1.5 x 35 mm (formerly # ) Lock Washer, Helical M O-ring 5-3/4" ID x 1/4" Male Connector 1-1/2 BSPP x 1" NPSM Sealing Washer 1-1/2 BSP Drain Cock, Brass 1/4 NPT Plug, Hex Head, Brass 1/4 NPT Plug, Hex Head, Brass 1/2 NPT Capscrew, Hex Head M12 x 1.75 x 20 mm Flat Washer M Lock Washer, Helical M Capscrew, Hex Head M10 x 1.5 x 20 mm Flat Washer M Tube Hose 3-1/2" ID x 4" Hose Clamp # Bracket Hose Clamp # Capscrew, Hex Head M10 x 1.5 x 140 mm Element

66 GROUP 3 - COOLING SYSTEM GEAR OIL COOLER Keel Cooled Units A-5882/ D Gear Oil Cooler (includes keys 1, & 22) Housing End Cap End Cap Gasket Bracket Capscrew, Socket Head M10 x 1.5 x 30 mm Lock Washer M Capscrew, Hex Head M10 x 1.5 x 35 mm (formerly # ) Lock Washer, Helical M O-ring 5-3/4" ID x 1/4" Male Connector 1-1/2 BSPP x 1" NPSM Sealing Washer 1-1/2 BSP Drain Cock, Brass 1/4 NPT Plug, Hex Head, Brass 1/4 NPT Plug, Hex Head, Brass 1/2 NPT Capscrew, Hex Head M12 x 1.75 x 20 mm Flat Washer M Lock Washer, Helical M Capscrew, Hex Head M10 x 1.5 x 20 mm Flat Washer M Male Elbow, Brass 1/2 NPT x 3/4 HB Element

67 GROUP 3 - COOLING SYSTEM KEEL COOLING OUTLET A-6677/ C Tube, Coolant Discharge Gasket Bracket (Early Production) Bracket (Late Production) U-Bolt Clamp 3-1/2" ID Capscrew, Hex Head M10 x 1.5 x 25 mm Lock Washer, Helical M Flat Washer M Bracket (Late Production) Nylock Nut M10 x Lock Nut, Flanged 3/

68 GROUP 4 - FUEL SYSTEM FUEL INJECTION PUMP AND FUEL LINES Fig

69 GROUP 4 - FUEL SYSTEM FUEL INJECTION PUMP AND FUEL LINES 1 1 Injection Pump Assembly (see authorized pump repair station for parts, see application table) Bracket Dowel Pin Capscrew, Hex Head, M12 x 1.75 x 40 mm Capscrew, Hex Head, M12 x 1.75 x 45 mm Lock Washer Washer Capscrew, Hex Head M10 x 1.5 x 100 mm Washer Washer Injection line # Injection line # Injection line # Injection line # Injection line # Injection line # Clamp Rubber Clamp Bolt Bolt Lock Washer Clamp Clamp Bolt Bolt Lock Washer Bracket Capscrew, Hex Head M8 x 1.25 x 20 mm Lock Washer Oil Supply Tube (formerly # ) Bolt Sealing Washer Clamp Oil Return Tube (units with injection pump # ) Oil Return Tube (units with injection pump # ) Banjo Bolt Gasket Coupling Guard Adapter Capscrew, Hex Head M10 x 1.5 x 16 mm Plug - 42 DK Banjo Bolt Capscrew, Hex Head M10 x 1.5 x 35 mm Lock Washer M Spacer - 46 DK Banjo Bolt - 47 DK Sealing Washer - 48 DK Coupling Assembly (see parts detail) - 49 DK Fuel Feed Pump Assembly (see parts detail) - 4-1

70 GROUP 4 - FUEL SYSTEM INJECTION PUMP APPLICATION LIST Part # Engine Model Application Notes Propulsion Engines, Pre-Emissions Compliant through December * L6170A High-Output RPM L6170A Medium Duty RPM L6170A Continuous RPM *Specify rating when ordering. Propulsion Engines, Emissions Compliant from January L6170A RPM A L6170A RPM B L6170A RPM 4-2

71 GROUP 4 - FUEL SYSTEM NOTES 4-3

72 GROUP 4 - FUEL SYSTEM FUEL INJECTORS AND RETURN LINES Fig

73 Updated GROUP 4 - FUEL SYSTEM FUEL INJECTORS AND RETURN LINES Fuel Injector (includes keys 1-8, replaces # & , - units with series injection pump)* Fuel Injector (includes keys 1-8, units with series - injection pump)* Holder Nozzle (for injector ) - DK Nozzle (for injector ) - 3 DK Push Rod - 4 DK Spring - 5 DK ** Shim 0.50 mm - DK ** Shim 0.54 mm - DK ** Shim 0.58 mm - DK ** Shim 0.62 mm - DK ** Shim 0.66 mm - DK ** Shim 0.70 mm - DK ** Shim 0.74 mm - DK ** Shim 0.78 mm - DK ** Shim 0.82 mm - DK ** Shim 0.86 mm - DK ** Shim 0.90 mm - DK ** Shim 0.94 mm - DK ** Shim 0.98 mm - DK ** Shim 1.00 mm - 6 DK Spacer - 7 DK Retaining Nut - 8 DK Flange Bolt Fuel Return Tube Fuel Return Tube Banjo Fitting Fuel Return Tube Nipple Clip Capscrew, Hex Head M10 x 1.5 x 60 mm - * See Cylinder Head parts detail for Injector Sealing Sleeve and related parts. ** As required 4-5