Northern Lights L6140A, L6140AL, L6140AL2, M6140AL Parts Manual

P6140

For Models: L6140A, L6140AL,

L6140AL2, and M6140AL

PARTS CATALOG

Marine Generators | Marine Diesel Engines | Land-Based Generators

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constitu-

ents are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

Northern Lights

4420 14th Avenue N.W. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455

Printed in U.S.A. PART NO.: P6140 08/08

PARTS CATALOG

for Models L6140a, L6140al, L6140al2, & M6140al

Please read thoroughly before aempting to use this manual:

Table of Contents .................................................................................................................................................. I

Model Designation & Serial Numbers .................................................................................................................... II

Reading a Parts Page ........................................................................................................................................... III

Table of Contents

GROUP 1 - ENGINE

Cylinder Block ..............................................................0 - 2

Crankshaft ......................................................................... 3

Flywheel Housing .........................................................4 - 5

Piston and Connecting Rod ................................................ 6

Camshaft .....................................................................................7

Timing Cover ..................................................................... 8

Idler Gear .................................................................................... 9

Lubricating Oil Filter ............................................... 10 - 11

Lubricating Oil and Suction Pump ............................ 12 - 13

Oil Pan ..............................................................................14 - 15

Oil Dipstick, Oil Drain ............................................. 16 - 17

Cylinder Head .......................................................... 18 - 19

Rocker Arm & Housing ............................................ 20 - 23

GROUP 2 - INTAKE & EXHAUST SYSTEM

Air Intake Manifold & Aftercooler ....................................0 - 9

Aftercooler Pump ............................................................10 - 11

Air Filter and Intake ........................................................12 - 14

Exhaust Manifold ............................................................15 - 19

Turbocharger & Mounting .............................................20 - 33

Turbocharger Assembly ..................................................34 - 39

Dry Exhaust Elbow .........................................................40 - 42

Turbo Outlet Adapter ...............................................................43

Wet Exhaust Elbow ..................................................................44

GROUP 3 - COOLING SYSTEM

Remote Expansion Tank ......................................................1 - 2

Expansion Tank Low Prole ..................................................... 2

Heat Exchanger Return, Coolant Pump Inlet ..........................3

Heat Exchanger & Oil Cooler .............................................4 - 7

Heat Exchanger ................................................................ 8 - 11

Heat Exchanger & Super Cooler ...................................12 - 15

Coolant Pump, Thermostat Housing .............................16 - 19

Thermostat Housing .................................................................20

Corrosion Resistor & Piping ..........................................21 - 23

Raw Water Pump, Mounting ..........................................24 - 31

Lubricating Oil Cooler ....................................................32 - 35

Gear Oil Cooler Assembly .............................................36 - 37

Keel Cool Outlet..............................................................38 - 39

GROUP 4 - FUEL SYSTEM

Fuel Injection Pump & Piping ............................................0 - 3

Double Wall Fuel Lines .......................................................4 - 5

Fuel Return Lines, Injectors ........................................ 6 - 7, 10

Injection Pump Application Chart ......................................8 - 9

Proprietary Information

This publication is the sole property of Alaska Diesel Electric, Inc.

It may not be reproduced in whole or part without the expressed written permission of Alaska Diesel Electric, Inc.

P6140 08/08

Fuel Filter .................................................................................. 11

Fuel Feed Pump Assembly ......................................................12

Fuel Injection Pump Coupling .......................................13 - 14

Throttle Assembly ....................................................................15

GROUP 5 - ELECTRICAL SYSTEM

Engine Electrical ..................................................................0 - 5

Wire Harness, Circuit Breaker, & Relay Assembly ..........6 - 9

Stop Solenoid ...................................................................10 - 12

Alternator Mountings ......................................................14 - 25

Alternator Assemblies .....................................................26 - 28

Starting Motor & Mounting ....................................................29

Starting Motor Assembly ................................................30 - 31

Belt Guard ........................................................................32 - 33

Instrument Panels ............................................................34 - 46

GROUP 6 - GASKET SETS

Gasket Kits ............................................................................0 - 4

GROUP 7 - GEAR AND ADAPTER SETS

Gear Attatching Kit MG-5111A/MG-5111 .............................. 1

GROUP 8 - BASE FRAME & MOUNTING

Engine Mounting ........................................................................ 0

GROUP 9 - ACCESSORIES & OPTIONAL EQUIP.

Four Groove Pulley .................................................................... 1

PTO & Electric Clutch Mounting ............................................. 2

PTO Adapter-SAE #4/C110 & SAE #3/SP111 .......................3

Electric Clutch Components ..................................................... 4

84 mm & 110 mm Pulley & Drive Assembly ......................... 5

110 mm & 120 mm Pulley & Drive Assembly ....................... 6

PTO Idler..................................................................................... 7

Idler Gear Assembly ..................................................................8

Accessory Drive .........................................................................9

Hydraulic Pump Adapter .........................................................10

PTO Hydraulic Pump Drive .................................................... 11

Hydraulic Pump Installation, Vickers V10-F ........................12

Oil Drain Pump ...............................................................13 - 14

Airsep Air Filter/Crankcase Breather System ..............16 - 19

Crankcase Vent Filter ......................................................20 - 22

8” Wet Riser-Exhaust Aft ........................................................23

Hydraulic Oil Cooler ......................................................24 - 25

Remote Loud Alarm .................................................................26

Local Start/Stop Panel & Mounting ..............................27 - 28

Remote Start/Stop Panel ..........................................................29

Coolant Level Switch Gauge .........................................30 - 33

I

INTRODUCTION

MODEL DESIGNATION

MODEL NUMBERS

Model numbers give the unit’s application, block model, aspiration and RPM:

L - M 6140 A, AL, AL2

L - Lugger propulsion engine

M - Northern Lights marine generator set

L6140A

M6140A

Lugger propulsion engine turbocharged and aftercoled.

Northern Lights marine diesel generator set.

Base engine model series

A

Indicates turbocharged and aftercooled - standard

prole.

AL

Indicates turbocharged and

aftercooled - Low prole.

AL2

Indicates turbocharged with separate circuit after-

cooling - low prole.

SERIAL NUMBERS

LUGGER: Your Lugger propulsion engine has the serial number plate on the ywheel housing.

Lugger Serial Number

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. 1234-5678.

Generator Set

Serial Number

Generator End Serial

Number

P6140 08/08

II

INTRODUCTION

READING A PARTS PAGE

IMPORTANT:

Before selecting parts, be sure that you are choosing parts from the correct page.

Check the model designation at the page top.

Do not use this illustration for parts purchasing.

1

ELECTRICAL SYSTEM

ALTERNATOR ASSEMBLY: M6140

4

6

5

KEY PART NUMBER QTY. DESCRIPTION SERIALNUMBER

0 185046210 1 Alternator Assembly 1 185446219 1 Flywheel, complete 2 185446217 1 Plate, complete 3 185716200 1 Plate 4 185446218 1 Stator, complete 5 040126210 2 Bearing 6 020210010 1 Nut 7 027100010 1 Spring washer 8 026100010 1 Washer 9 185446220 1 Clamp 10 015140408 1 Screw 11 015140425 2 Screw 12 199236510 1 Collar -

7

3

8

2

9

10

13

11

P844 06/96

5-2

14

12

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 ts.

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 identication. 12. Page number within the grouping index.

5. Key column for locating parts shown on drawing. 13. Manual title.

6. Part number. 14. Page publication date.

NOTE: a Arrows always point toward the front of the engine.

P6140 0808

III

GROUP 1 - ENGINE

CYLINDER BLOCK

P6140 08/08

1 - 0

Figure 2005

GROUP 1 - ENGINE

CYLINDER BLOCK

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 6211-21-1103 1 Cylinder Block Assembly (includes keys 2-27 former #6211-21-1102) - 2 04020-00820 12 Dowel Pin 3 07043-70108 13 Plug 4 07046-42516 2 Expansion Plug 16mm 5 07046-41810 2 Plug 6 07046-11816 2 Plug 7 6210-21-1790 1 Bushing 8 07046-41008 1 Plug 9 6210-21-1910 3 Pin 10 6210-21-1490 7 Camshaft Bushing 11 07046-47020 1 Plug 12 07046-43516 7 Plug 13 6210-81-9210 2 Plug 14 6150-21-4770 2 Dowel Pin 15 6150-21-5910 1 Bushing 16 04020-01024 2 Dowel Pin 17 07043-00211 1 Plug 18 07046-42010 1 Plug 19 07046-42816 2 Plug 20 07043-00415 1 Plug 21 07043-71019 1 Plug 22 6210-21-1210 6 Main Bearing Cap, #1 - 6 23 6210-21-1250 1 Main Bearing Cap, #7 24 04020-00514 2 Dowel Pin 25 6210-21-1390 6 Pin 26 6210-21-1710 14 Bolt 27 01643-31845 14 Washer 28 6211-21-2220 6 Cylinder Liner 29 6210-21-2250 6 Crevice Seal 30 6210-21-2240 6 Center O-Ring 31 6210-21-2230 6 Lower O-Ring 32 6210-21-6410 2 Cover 33 6150-21-6460 2 O-Ring 34 6210-21-6471 6 Bolt 36 6150-21-6390 6 Packing 37 6210-21-6440 1 Cover 6210-25-6440 1 Cover L6140AL2 38 6210-21-6452 1 O-Ring (formerly #6210-21-6451) L-M6140A & AL 39 12-00832 2 Capscrew, Hex Head M10 x 1.5 x 30 mm 40 15-00805 2 Flat Washer M10 41 6210-21-6540 1 Oil Filler Neck 6210-25-6540 1 Oil Filler Neck L6140AL2 42 12-00071 1 Capscrew, Hex Head M10 x 1.5 x 70 mm 43 12-00832 3 Capscrew, Hex Head M10 x 1.5 x 30 mm 44 6210-21-1850 1 Cover (keel cooled units) 45 12-00912 1 Capscrew, Hex Head M12 x 1.75 x 25 mm 46 01580-11210 3 Nut 47 6150-21-5920 1 Collar 48 6150-21-5930 1 Nut 49 6210-21-5410 1 Dipstick Tube - Left Side 27-65001 1 Dipstick Tube - Right Side

(with standard oil pan - see assembly detail) -

— Continued Next Page —

P6140 0808

1 - 1

GROUP 1 - ENGINE

CYLINDER BLOCK (CONTINUED)

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

50 6210-21-5310 1 Dipstick - Left & Right Side 0-5° (with standard oil pan) 36-75011 1 Dipstick - Right Side 0-5° 36-75009 1 Dipstick - Right Side 0-7° 36-75007 1 Dipstick - Left Side 6-7° 51 6210-21-1860 1 Cover 52 07025-00100 1 Cap 53 12-00912 1 Capscrew, Hex Head M12 x 1.75 x 25 mm 54 01640-21223 2 Washer 55 07040-11409 2 Plug 56 07005-01412 2 Gasket 57 6210-21-1781 1 Bushing 61 6210-21-1950 1 Flange 62 6696-61-9920 1 Gasket 63 12-00912 2 Capscrew, Hex Head M12 x 1.75 x 25 mm 64 07040-11007 1 Plug 65 07005-01012 1 Gasket 66 6211-21-1800 6 Piston Cooling Nozzle Assembly 6211-21-1900 6 Piston Cooling Nozzle Assembly 67 02720-40104 1 Plug 68 01437-01025 6 Capscrew, 12 Point M10 x 1.5 x 25mm 69 01641-21016 6 Washer -

70 6212-25-1111 1 Cover (formerly #6212-25-1110, standard prole only) -

71 07043-00415 3 Plug, Socket Head 1/2BSPT 72 6210-21-1971 1 Gasket 73 12-00071 4 Capscrew, Hex Head M10 x 1.5 x 70 mm 75 287-35-11470 1 Plug 76 6210-21-1820 1 Plate 77 6210-61-6550 1 Gasket 78 12-00831 2 Capscrew, Hex Head M10 x 1.5 x 25 mm 79 09605-01440 1 Name Plate 80 04418-02550 4 Screw -

(with modied oil pan 36-75001) -

(with standard oil pan) -

(includes key #67) L-M6140A&AL -

(includes key #67) L6140AL2 -

P6140 08/08

1 - 2

GROUP 1 - ENGINE

CRANKSHAFT

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

Figure 2303

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 6211-31-1010 1 Crankshaft Assembly (includes keys #2 - #4) 2 6210-31-1120 1 Gear 3 6150-31-1130 1 Key 4 6211-31-1420 1 Pin 5 6211-31-8200 1 Damper Assembly (no separate spacer) Early Production 6211-32-8200 1 Damper Assembly (uses separate spacer #6) Late Production

(formerly 6211-31-8201) -

6 31-65002 1 Damper Spacer up to S/N xxxx-0583 6210-31-1420 1 Damper Spacer from S/N xxxx-0584 7 04020-01024 1 Dowel Pin 8 01010-51225 6 Capscrew, Hex Head M12 x 1.75 x 25 mm up to S/N xxxx-0583 01010-51230 6 Bolt from S/N xxxx-0584 9 6210-81-8710 6 Bolt 10 01643-31232 6 Washer from S/N xxxx-0584 11 MAIN BEARING ASSEMBLIES

•• 6210-21-8000 1 Main Bearing Set - Standard -

•• 6210-21-8010 7 Main Bearing Assembly - Standard -

•• 6210-29-8010 7 Main Bearing Assembly - Undersize, 0.25 mm -

•• 6210-28-8010 7 Main Bearing Assembly - Undersize, 0.50 mm -

•• 6210-27-8010 7 Main Bearing Assembly - Undersize, 0.75 mm -

•• 6210-26-8010 7 Main Bearing Assembly - Undersize, 1.00 mm 12 MAIN THRUST BEARING ASSEMBLIES (set of 3 bearings)

•• 6210-21-8050 1 Thrust Bearing Assembly - Standard -

•• 6210-29-8050 1 Thrust Bearing Assembly - Oversize, 0.25 mm -

•• 6210-28-8050 1 Thrust Bearing Assembly - Oversize, 0.50 mm -

•• 6210-27-8050 1 Thrust Bearing Assembly - Oversize, 0.75 mm -

•• 6210-26-8050 1 Thrust Bearing Assembly - Oversize, 1.00 mm -

P6140 0808

1 - 3

GROUP 1 - ENGINE

FLYWHEEL AND FLYWHEEL HOUSING - EARLY PRODUCTION

Propulsion Applications

SAE #0

SAE #1

221B02

Figure 2201 / 221A02

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 6210-21-4130 1 Flywheel Housing - SAE #0 6210-21-4120 1 Flywheel Housing - SAE #1 2 01010-31645 2 Bolt -

3 01010-31660 8 Bolt for SAE #1 Housing 01010-31655 8 Bolt for SAE #0 Housing 4 6150-31-1810 10 Washer 5 6150-21-4230 1 Rear Main Seal - Standard* 6150-29-4230 1 Rear Main Seal - Repair* -

6 6211-31-1502 1 Flywheel Assembly - SAE #18 6211-31-1401 1 Flywheel Assembly - SAE #14 7 6211-31-1350 1 Ring Gear 6150-31-1351 1 Ring Gear

(for SAE #18 Flywheel) - (for SAE #14 Flywheel) -

(includes key #7) - (includes key #7) -

8 6210-31-1360 6 Bolt - SAE #14 Flywheel 6210-31-1350 6 Bolt - SAE #18 Flywheel 9 6120-21-3750 1 Lifting Eye - SAE #1 Flywheel Housing -

10 12-00831 4 Capscrew, Hex Head M10 x 1.5 x 25 mm -

11 6210-21-3820 1 Plate -

12 12-00953 4 Capscrew, Hex Head M12 x 1.75 x 30 mm -

*

Can use repair sleeve #6610-29-2370 with either rear main seal.

P6140 08/08

1 - 4

GROUP 1 - ENGINE

FLYWHEEL AND FLYWHEEL HOUSING - LATE PRODUCTION

SAE #0

SAE #1

Figure 2202

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 6210-21-4232 1 Flywheel Housing SAE #0 (formerly #6210-21-4230) from S/N xxxx-0548 6210-21-4740 1 Flywheel Housing SAE #1 “ 2 07042-00617 1 Plug SAE #1 Housing “ 3 01010-31660 2 Capscrew, Hex Head M16 x 2.0 x 60mm “ 4 01010-31655 6 Capscrew, Hex Head M16 x 2.0 x 55mm 01010-31645 8 Capscrew, Hex Head M16 x 2.0 x 45mm 5 6151-21-4150 1 Rear Main Seal - Standard *

(formerly #6150-21-4230) “

(SAE #0 Housing) “ (SAE #1 Housing) “

6150-29-4230 1 Rear Main Seal - Repair * “ 6 6211-31-1502 1 Flywheel Assembly SAE #18 6210-31-1800 1 Flywheel Assembly SAE #14 7 6211-31-1350 1 Ring Gear - SAE#18 Flywheel 6150-31-1351 1 Ring Gear - SAE#14 Flywheel

(includes key #7) “ (includes key #7) “

(179 teeth) “ (148 teeth) “

8 6210-31-1350 6 Bolt “ 9 6210-21-4770 1 Lifting Eye - SAE#1 Flywheel Housing 00-75021 1 Lifting Eye - SAE#1 Flywheel H

(Standard) “

(low prole) formerly #00-75015 “

10 01435-01025 4 Bolt “ *

Can use Repair Sleeve #6610-29-1370 with either Rear Main Seal.

P6140 0808

1 - 5

GROUP 1 - ENGINE

PISTON AND CONNECTING ROD

Figure 2351

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 6212-31-2170 6 Piston 2 6211-31-2410 6 Piston Pin -

3 04065-05220 12 Snap Ring -

4 6211-31-2031 6 Piston Ring Set -

5 6211-31-3100 6 Connecting Rod Assembly

(includes keys #6 - #8) -

6 6211-31-3130 6 Bushing 7 02400-10413 12 Dowel Pin -

8 6210-31-3310 12 Connecting Rod Bolt -

9 ROD BEARING ASSEMBLIES -

•• 6210-32-3040 6 Bearing Assembly - Standard

•• 6210-39-3042 6 Bearing Assembly - Undersize, 0.25 mm

6210-39-3040) -

•• 6210-38-3040 6 Bearing Assembly - Undersize, 0.50 mm

6210-38-3040) -

•• 6210-37-3040 6 Bearing Assembly - Undersize, 0.75 mm

6210-37-3040) -

•• 6210-36-3040 6 Bearing Assembly - Undersize, 1.00 mm

6210-36-3040) -

(formerly 6210-31-3041 & 6210-31-3040) -

(formerly 6210-39-3041 &

(formerly 6210-38-3041 &

(formerly 6210-37-3041 &

(formerly 6210-36-3041 &

P6140 08/08

1 - 6

GROUP 1 - ENGINE

CAMSHAFT

Figure 2401

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

•• 6210-41-1011 1 Camshaft Assembly (includes keys #1 - #4) 1 6210-41-1111 1 Camshaft 2 6210-41-1130 1 Thrust Plate 3 6210-41-1120 1 Camshaft Gear 4 04010-00725 1 Key 5 6210-81-3510 1 Shaft 6 6210-81-8340 2 Bolt -

•• 6210-41-2010 6 Cam Follower Assembly 7 6210-41-2300 12 Lever Assembly 8 1 Socket 9 12 Cam Follower Roller 10 12 Pin 11 6210-41-2400 6 Shaft Assembly 12 6150-81-8420 6 Ball Bearing 13 04064-02212 24 Snap Ring 14 6210-41-2430 12 Dowel Ring 15 6210-41-2450 12 Bolt 16 6210-41-3120 12 Push Rod

(includes keys #8 - #10) -

(includes key #12) -

(formerly #6210-41-3110) -

(includes keys #7 - #13) -

Not available separately

}

P6140 0808

1 - 7

GROUP 1 - ENGINE

TIMING COVER

Figure 2021

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 6210-21-3121 1 Timing Cover -

2 07046-11816 2 Plug -

3 07046-11516 2 Plug -

4 01010-81290 3 Bolt -

5 01011-81200 1 Bolt -

6 01010-81280 1 Bolt -

7 01017-51220 1 Bolt -

8 01640-21223 6 Washer -

9 01011-81000 3 Capscrew, Hex Head M10 x 1.5 x 100 mm -

10 01640-21016 3 Flat Washer M10 -

11 01010-81050 2 Capscrew, Hex Head M10 x 1.5 x 50 mm -

12 00-75019 1 Ling Eye -

13 01010-E1035 4 Capscrew, Hex Head M10 x1.5 x 35 mm -

14 6210-21-8711 1 Breather

(formerly #6210-21-8710) -

(see Crankcase Vent Filter detail in Accessories)

15 01010-81020 2 Capscrew, Hex Head M10 x 1.5 x 20 mm -

16 01640-21016 2 Flat Washer M10 -

17 6210-81-4110 1 Tachometer Drive -

18 07000-03050 1 O-ring -

19 01010-50616 2 Bolt -

20 6136-81-5291 1 Cap -

21 6130-82-5270 1 Gasket -

22 6210-21-1880 1 Cover -

23 07000-12060 1 O-ring -

24 01010-81020 3 Capscrew, Hex Head M10 x 1.5 x 20 mm -

25 6210-21-3350 1 Pointer -

26 01010-50610 2 Bolt -

27 01640-20610 2 Washer -

28 6150-21-3230 1 Front Seal -

00-04803 1 Wear Sleeve (repair type) -

29 07000-62060 1 O-ring -

30 6210-21-3250 1 Gasket -

P6140 08/08

1 - 8

GROUP 1 - ENGINE

IDLER GEAR

Figure 2031

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 6210-31-6311 1 Idler Gear 2 6210-31-6201 1 Idler Gear Assembly

(includes key #3) -

3 6210-31-6131 1 Bushing 4 6127-21-1260 1 Dowel Pin 5 01010-30830 6 Bolt 6 6210-21-2421 1 Thrust Plate 7 6210-21-2412 1 Idler Gear Shaft 8 6210-21-2440 1 Bolt 10 6210-31-6101 1 Idler Gear Assembly

(includes key #11) -

11 6210-31-6121 1 Bushing 12 6210-21-2421 1 Thrust Plate 13 6210-21-2512 1 Idler Gear Shaft 14 01050-31880 1 Bolt 15 01643-31845 1 Washer -

P6140 0808

1 - 9

GROUP 1 - ENGINE

LUBRICATING OIL FILTER

P6140 08/08

1 - 10

Figure 3101

GROUP 1 - ENGINE

LUBRICATING OIL FILTER

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

•• 6211-51-5500 1 Adapter Assembly (includes keys #1 - #12) up to S/N xxxx-0742

•• 6212-55-5500 1 Adapter Assembly 1 6211-51-5510 1 Body 2 07043-00211 1 Plug 3 6210-51-5570 2 Plug 4 07000-62018 2 O-ring - 5 6210-51-5590 1 Seat 6 6210-51-5560 1 Spring, Pressure Relief 6212-55-5560 1 Spring, Pressure Relief 7 6210-51-5550 1 Valve 8 6211-51-5520 1 Cover 9 6210-51-5580 1 O-ring 10 07000-63032 1 O-ring 11 01010-30816 3 Bolt 12 01640-20816 3 Washer 13 6210-21-6462 1 O-ring

(formerly #6210-21-6460) -

14 07000-63028 2 O-ring 15 07000-63032 1 O-ring 16 12-00832 2 Capscrew, Hex Head M10 x 1.5 x 30 mm 17 12-00048 5 Capscrew, Hex Head M10 x 1.5 x 60 mm 18 15-00805 7 Flat Washer M10 -

•• 6211-51-5400 1 Oil Filter Assembly 19 6211-51-5410 1 Bracket 20 6162-53-5450 1 Packing 21 600-211-1870 1 Spring 22 6162-53-5420 1 Cap 23 6162-53-5430 1 Packing 24 24-04801 1 Oil Filter 25 07000-73048 1 O-ring 26 07000-63032 1 O-ring 27 12-00832 1 Capscrew, Hex Head M10 x 1.5 x 30 mm 28 12-00819 3 Capscrew, Hex Head M10 x 1.5 x 75 mm 29 01010-51085 1 Bolt 30 15-00805 5 Flat Washer M10 31 21-00050 ** Plug, Square Head 1/8 BSPT -

(includes keys #1 - #12) from S/N xxxx-0743

(83mm LOA) up to S/N xxxx-0742 (93mm LOA) from S/N xxxx-0743

(includes keys #19 - #24) -

**As required.

P6140 0808

1 - 11

GROUP 1 - ENGINE

LUBRICATING OIL PUMP AND PICK-UP

P6140 08/08

1 - 12

Figure 3001

GROUP 1 - ENGINE

LUBRICATING OIL PUMP AND PICK-UP

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

•• 6212-51-1001 1 Oil Pump Assembly (includes keys #1 - #17 - formerly #6212-51-1000) - 1 6212-51-1200 1 Body Assembly 2 6151-51-1420 1 Bushing 3 6136-52-1620 1 Pin 4 6212-51-1300 1 Pump Shaft & Gear Assembly 5 6212-51-1310 1 Shaft 6 6212-51-1510 1 Pump Drive Gear 7 6212-51-1250 1 Pump Gear Assembly 8 6151-51-1421 2 Bushing 9 6212-51-1100 1 Cover Assembly 10 6151-51-1420 1 Bushing 11 6212-51-1320 1 Drive Shaft 12 6136-52-1640 1 Valve 13 6136-52-1650 1 Spring 14 6150-51-1650 1 Retainer 15 04050-14035 1 Cotter Pin 16 01010-30825 4 Bolt 17 01602-00825 4 Spring Washer 18 07000-63038 1 O-ring 19 01010-31230 1 Bolt 20 01010-31240 2 Bolt 21 01643-31232 1 Washer 22 6210-51-6210 1 Pick-Up w/Screen up to S/N xxxx-0547 6210-51-6311 1 Pick-Up w/Screen from S/N xxxx-0548 23 07000-63040 1 O-ring 24 12-00831 1 Capscrew, Hex Head M10 x 1.5 x 25 mm 25 6210-51-6220 1 Bracket up to S/N xxxx-0547 6210-51-6321 1 Bracket from S/N xxxx-0548 26 01010-31225 1 Bolt up to S/N xxxx 0547 01010-31230 1 Bolt from S/N xxxx-0548 27 01640-21223 1 Washer up to S/N xxxx-0547 01643-51032 1 Washer from S/N xxxx-0548 28 01010-31020 1 Bolt 29 01580-01008 1 Nut 30 15-00805 2 Flat Washer M10 -

(includes keys #2 - #3) -

(includes key #5) -

(includes key #8) -

(includes keys #10 - #11) -

P6140 0808

1 - 13

GROUP 1 - ENGINE

OIL PAN - EARLY PRODUCTION

Lugger Application

Figure 2105

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 6210-21-5210 1 Frame up to S/N xxxx-0547 2 6210-21-5280 1 Gasket “

3 6210-81-9410 32 Bolt “

4 6210-81-9440 2 Bolt “

5 6210-81-9450 4 Bolt “

6 15-00805 74 Flat Washer M10 “

7 6210-21-5120 1 Oil Pan - Standard “

10-75000 1 Oil Pan - with right side dipstick

(not shown) “

8 6150-21-5630 1 Drain Fitting M36 x 1.5 x 1/2 BSPT “ 9 07002-23634 1 O-ring “

10 6210-21-5812 1 Gasket “

11 12-00832 36 Capscrew, Hex Head M10 x 1.5 x 30 mm “

12 07043-00211 3 Plug “

13 07042-00415 1 Plug, Socket Head 1/2 BSPT “

P6140 08/08

1 - 14

GROUP 1 - ENGINE

OIL PAN - LATE PRODUCTION

Figure 2106

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 6211-21-5240 1 Oil pan (standard) from S/N xxxx-0548 10-75001 1 Oil pan with right side dipstick

(not shown) “

2 6136-21-5770 1 Cover Plate “ 3 6136-21-5870 1 Gasket “ 4 01010-30610 3 Bolt “ 5 01641-00608 3 Washer “ 6 07002-23634 1 O-ring “ 7 6150-21-5630 1 Drain Fitting M36 x 1.5 x 1/2 BSPT “ 8 21-51905 1 Plug, Socket Head 1” NPT “ 9 6210-21-5820 1 Gasket “ 10 12-00831 38 Capscrew, Hex Head M10 x 1.5 x 25 mm “ 11 02720-21616 1 Plug, Square Head 1/2 BSPT “ 12 15-00805 38 Flat Washer M10 “

P6140 0808

1 - 15

GROUP 1 - ENGINE

RIGHT SIDE DIPSTICK

A-7228 / C-3241

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 27-65001 1 Dipstick Tube, Right Hand 2 36-75018 1 Dipstick 3 23-71105 1 Bracket 4 21-62512 1 Elbow, Male 90° 3/4NPT x 1/2-37T 5 21-73202 1 Bushing 1”NPT x 3/4NPT 6 19-43201 1 Adelle Clamp 1/2”ID x 3/8” 7 12-00805 1 Capscrew, Hex Head M10 x 1.5 x 20mm 8 12-00831 1 Capscrew, Hex Head M10 x 1.5 x 25mm 9 15-00802 1 Lock Washer, Helical M10 10 15-00805 1 Flat Washer M10 11 14-00812 1 Hex Nut, Nylock M10 x 1.5 -

P6140 08/08

1 - 16

GROUP 1 - ENGINE

OIL DRAIN

Marine Generator Set

A-6590 / B-7866

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 21-00037 1 Elbow 90° 1/2 NPT x 1/2 NPT 2 36-70006 1 Ball Valve, Brass 1/2 NPT 3 21-71040 1 Male Connector 1/2 NPT x 1/2-45T 4 21-71042 2 Female Swivel, 1/2 HB x 1/2-45T 5 18-05002 1 Hose 1/2”ID x 21” 6 21-01016 1 Male Elbow, 90° 1/2 NPT x 1/2-45T 7 21-00530 1 Plug, Hex Head 1/2 NPT 8 6150-21-5630 1 Drain Fitting -

P6140 0808

1 - 17

GROUP 1 - ENGINE

CYLINDER HEAD

P6140 08/08

1 - 18

Figure 01 18

Updated 7-8-08

GROUP 1 - ENGINE

CYLINDER HEAD

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 6211-11-1103 6 Cylinder Head Assembly, w/o valves (includes keys #2-#11 & #23-#24) from S/N 17628 6211-11-1101 6 Cylinder Head Assembly, w/o valves former #6211-11-1100) S/N 10420-17223 2 6212-16-1440 4 Valve Guide from S/N 17628 6210-16-1340 4 Valve Guide S/N 10420-17627 3 6210-11-1140 2 Crosshead Guide from S/N 10420 4 04020-00820 2 Dowel Pin from S/N 10420 5 07046-41810 1 Expansion Plug from S/N 10420 6 6162-13-1150 12 Expansion Plug from S/N 10420 7 6210-11-1330 2 Intake Seat Insert - Standard from S/N 10420 6210-19-1330 2 Intake Seat Insert - Oversize 0.25 mm from S/N 10420 6210-18-1330 2 Intake Seat Insert - Oversize 0.50 mm from S/N 10420 6210-17-1330 2 Intake Seat Insert - Oversize 0.75 mm from S/N 10420 6210-16-1330 2 Intake Seat Insert - Oversize 1.00 mm from S/N 10420 8 6210-11-1321 2 Exhaust Seat Insert - Standard 6210-19-1321 2 Exhaust Seat Insert - Oversize 0.25 mm 6210-18-1321 2 Exhaust Seat Insert - Oversize 0.50 mm 6210-17-1321 2 Exhaust Seat Insert - Oversize 0.75 mm 6210-16-1321 2 Exhaust Seat Insert - Oversize 1.00 mm 9 6210-11-1150 1 Pipe from S/N 10420 10 07000-63025 1 O-Ring from S/N 10420 11 07043-50108 1 Plug from S/N 10420 12 6215-41-4110 2 Intake Valve from S/N 13924 6210-41-4110 2 Intake Valve 13 6215-41-4212 2 Exhaust Valve 6210-41-4210 2 Ex Valve 14 6210-41-4440 4 Valve Spring, Inner 15 6210-41-4430 4 Valve Spring, Inner

(replaced by 2 ea. #6215-41-4110 & 1 ea. #6210-41-5620) S/N 10420-13923

(formerly #6215-41-4210) from S/N 17224

(replaced by 2 ea. #6215-41-4210 & 1 ea. #6210-41-5620) S/N 10420-13923

(formerly #6210-41-4410) from S/N 14189 (formerly #6210-41-4420) from S/N 14189

16 6210-41-4530 4 Spring Seat from S/N 10420 17 6210-41-4510 4 Retainer from S/N 10420 18 6136-41-4520 8 Cotter 19 6210-41-5610 2 Crosshead S/N 10420-13923 6210-41-5620 2 Crosshead from S/N 13924 20 6210-41-5640 1 Screw S/N 10420-13923 6210-41-5640 2 Screw from S/N 13924 21 6162-43-5630 2 Nut from S/N 17628 6127-41-5630 2 Nut S/N 13924-17627 22 6212-41-4540 2 Valve Seal 6210-41-4541 2 Valve Seal

(use with Guide #6212-16-1440) from S/N 17628 (use with Guide #6120-16-1340 - formerly #6210-41-4540) up to S/N 17627

23 01010-51016 1 Bolt S/N 17224-17627 24 07003-01015 1 Gasket S/N 17224-17627 25 6210-17-1814 6 Head Gasket

(formerly #6210-17-1812, #6210-17-1811, & #6210-17-1813) -

26 6210-11-1820 1 Grommet from S/N 11874 27 6210-11-1830 1 Grommet from S/N 11874 28 6210-11-1840 1 Grommet from S/N 11874 29 6210-11-1962 1 Grommet 30 6210-11-1952 4 Grommet

(formerly #6210-11-1961 & #6210-11-1850) from S/N 11874 (formerly #6210-11-1951 & #6210-11-1860) from S/N 16848

31 6210-11-1610 36 Head Bolt from S/N 10420 32 6150-81-9160 6 Head Bolt from S/N 10420 33 02720-40104 6 Plug from S/N 17224

(includes keys #2-#11 & #23-#24) S/N 17224-17627

(formerly #6210-11-1320) from S/N 16092

(formerly #6210-19-1320) from S/N 16092 (formerly #6210-18-1320) from S/N 16092 (formerly #6210-17-1320) from S/N 16092 (formerly #6210-16-1320) from S/N 16092

NOTE: Quantities for items #2 - #24 & #26 - #30 are for each Cylinder Head.

P6140 0808

1 - 19

GROUP 1 - ENGINE

ROCKER ARM AND HOUSING

P6140 08/08

1 - 20

Figure 01 20

GROUP 1 - ENGINE

ROCKER ARM AND HOUSING

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 6210-11-7100 6 Rocker Arm Housing up to S/N 17627 2 07046-41008 18 Expansion Plug 3 6210-11-7131 6 O-ring 4 6210-11-7813 6 Gasket 5 01437-11080 17 Capscrew, 12 Point M10 x 1.5 x 80 mm 6 01643-51032 18 Washer 7 6150-81-9250 1 Capscrew, 12 Point M10 x 1.5 x 90 mm 01437-11080 1 Capscrew, 12 Point M10 x 1.5 x 80 mm 8 6210-81-8330 1 Capscrew, 12 Point M12 x 1.75 x 80 mm 9 01643-51232 6 Washer 10 6215-41-5041 1 Intake Rocker Arm Assembly

(includes key #11) -

11 6210-41-5420 1 Arm Bushing 12 6215-41-5050 6 Exhaust Rocker Arm Assembly

(includes keys #13 & #14) -

13 6162-43-5340 1 Rivet 14 6210-41-5420 1 Bushing 15 6150-41-5540 12 Screw 16 01582-01008 12 Adjusting Nut 17 6210-41-5300 6 Rocker Arm Shaft Assembly

(includes key #18) -

18 6150-81-8420 6 Ball Bearing 19 6210-81-8310 12 Rocker Arm Shaft Bolt 20 6210-11-6540 1 Water Tube 21 07206-30710 6 Banjo Bolt 22 07005-01012 12 Gasket 23 6210-11-8110 6 Rocker Arm Cover 24 6210-11-8810 6 Gasket 25 01010-50865 18 Bolt 26 6210-11-8120 18 Washer 27 6210-11-8140 18 Seal Washer -

(high prole) (low prole) -

P6140 0808

1 - 21

GROUP 1 - ENGINE

ROCKER ARM AND HOUSING

P6140 08/08

1 - 22

Figure 01 22

GROUP 1 - ENGINE

ROCKER ARM AND HOUSING

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 6210-11-7121 6 Rocker Arm Housing from S/N 17628 2 07046-41008 18 Expansion Plug from S/N 10420 3 6210-11-7830 6 Gasket from S/N 17628 4 01437-11080 17 Capscrew, 12 Point M10 x 1.5 x 80 mm from S/N 17628 5 6150-81-9250 1 Capscrew, 12 Point M10 x 1.5 x 90 mm 01437-11080 1 Capscrew, 12 Point M10 x 1.5 x 80 mm 6 01643-51032 18 Washer from S/N 10600 7 01437-01280 5 Capscrew, 12 Point M12 x 1.75 x 80 mm from S/N 17628 8 01643-51232 6 Washer from S/N 11600 9 6210-41-5041 6 Intake Rocker Arm Assembly

(includes key #10 & #11) from S/N 17628

10 6210-41-5421 1 Bushing from S/N 17628 11 6162-43-5340 1 Rivet from S/N 17628 12 6210-41-5501 6 Exhaust Rocker Arm Assembly

(includes key #13) from S/N 17628

13 6210-41-5520 1 Bushing from S/N 17628 14 6150-41-5540 12 Screw from S/N 10420 15 01582-01008 12 Adjusting Nut from S/N 10420 16 6210-41-5303 6 Rocker Arm Shaft Assembly

(includes key #17) from S/N 17628

17 6162-43-5340 1 Rivet from S/N 17628 18 6210-81-8310 6 Bolt from S/N 17628 19 6210-81-5530 6 Rocker Arm Shaft Support from S/N 17628 20 04020-00514 6 Dowel Pin from S/N 17628 21 6210-41-5440 6 Collar from S/N 17628 22 01438-01220 12 Capscrew, 12 Point M12 x 1.75 x 120 mm from S/N 17628 23 6210-11-6521 1 Tube, Coolant Vent from S/N 17628 24 6210-11-6621 1 Tube, Coolant Vent from S/N 17628 25 07206-30710 5 Banjo Bolt, M10 x 1.25 x 20 mm from S/N 17224 26 6215-11-6560 1 Banjo Bolt, M10 x 1.25 x 35 mm from S/N 17224 27 07003-01015 18 Sealing Washer from S/N 17628 28 01050-31020 1 Bolt from S/N 17224 29 01640-21016 1 Washer from S/N 17224 30 6210-11-6570 6 Adapter, Coolant Vent Connection 1/8 BSPP x M10 x 1.25 from S/N 17628 31 6210-11-8111 6 Cover, Rocker Arm Housing from S/N 17628 32 6210-11-8820 6 Gasket from S/N 17628 33 01435-00855 18 Capscrew, Hex Head Flanged M8 x 1.25 x 55 mm from S/N 17628

(high prole) from S/N 10420 (low prole) from S/N 10420

P6140 0808

1 - 23

GROUP 2 - INTAKE AND EXHAUST SYSTEM

INTAKE MANIFOLD & AFTERCOOLER

P6140 08/08

2 - 0

Figure 1301