P844L3MS For Models: NL844L3.1MS1 and NL844L3.1MS2 PARTS CATALOG. Marine Generators Marine Diesel Engines Land-Based Generators

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1 P844L3MS For Models: NL844L3.1MS1 and NL844L3.1MS2 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 2012 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.:

3 PARTS CATALOG for Models NL844L3.1MS1 and NL844L3.1MS2 Please read thoroughly before attempting to use this manual: Table of Contents... 1 Model Designation & Serial Numbers... 2 Reading a Parts Page... 3 Table of Contents GROUP 1 - ENGINE Cylinder Block Assembly Crankshaft Assembly Camshaft & Oil Pump... 4 Cylinder Head... 5 Rocker Arm Cover & Assembly GROUP 2 - INTAKE & EXHAUST SYSTEM Air Filter & Mounting... 0 Air Filter Pre-cleaner... 1 Exhaust Manifold... 2 GROUP 3 - COOLING Coolant Pump GROUP 4 - FUEL SYSTEM General Arrangement Governor & Timing Gear Case Fuel Filter & Piping Fuel Injector... 6 Fuel Feed Pump... 7 GROUP 5 - ELECTRICAL SYSTEM 24 Volt Standard Ground Starter & Flywheel Housing... 4 Alternator & Mounting... 5 Relay Board Control Panel... 8 Starter Motor Fan... 9 GROUP 6 - GASKET SETS Gasket Sets...1 GROUP 8 - FRAME & MOUNTING Engine Mounts GROUP 9 - ACCESSORIES GROUP 9 - & OPTIONAL EQUIPMENT Oil Drain Kit... 1 Proprietary Information This publication is the sole property of Northern Lights, Inc. It may not be reproduced in whole or part without the expressed written permission of Northern Lights, Inc. Northern Lights, Inc All rights reserved. Litho U.S.A. Publication number:. 1

4 MODEL DESIGNATION MODELS INCLUDED This manual covers the operating instructions for: NL844L3.1MS1 and NL844L3.1MS2 Model Numbers Model numbers give the unit's application, block model, aspiration, and RPM: NL 844 L 3 NL - Northern Lights Industrial generator set Model number of engine block Bore Cylinders 84 mm 4 Designates a Long Stroke engine. Designates Tier III NL 844L3 = Northern Lights industrial diesel generator set with an 844 engine, radiator, and a Stamford Newage generator, Tier III. Serial Numbers Your set has three serial numbers: 1 an engine number stamped on the block, 2 a generator plate and, 3 a generator set plate. Use the serial number on the generator set plate when ordering parts or in correspondence. The generator set plate is found on the service side of the generator and resembles the drawings below. 2

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 P844 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: Arrows always point toward the front of the engine. 3

6 GROUP 1 ENGINE Cylinder Block Assembly ISMcylblock 1-0

7 GROUP 1 ENGINE Cylinder Block Assembly Cylinder Block Assembly - (includes keys #3-22) Expansion Plug 25 mm Expansion Plug 40 mm Plug Plug Plug Idle Gear Shaft Assembly Plug Bushing; Standard Bushing; Undersize 0.25 mm Bushing; Undersize 0.50 mm Bearing Expansion Plug Needle Bearing Needle Bearing Dowel Pin Dowel Pin Dowel Pin Spring Pin Stud M8 x 1.25 x 20 mm Stud M6 x 1.0 x 35 mm Stud M6 x 1.0 x 60 mm Gasket Oil Seal Drain Cock Filter Joint Oil Filter Tappet Push Rod Relief Valve Assembly O-ring Tube Bushing Oil Pan Bolt Bolt Seal Washer Dipstick O-ring Bolt Dipstick Holder Suction Filter Oil Pipe O-ring Bolt - 1-1

8 GROUP 1 ENGINE Crankshaft Assembly ISMcrankshaft 1-2

9 GROUP 1 ENGINE Crankshaft Assembly Crankshaft Assembly (includes keys #2-4) Gear Key Dowel Pin Bearing Holder Assembly (includes keys #7-8) Bolt Dowel Pin Bearing Holder Assembly (includes keys #7-8) Bearing Holder Assembly (includes keys #7-8) Bearing Holder Assembly (includes keys #7-8) Bearing; Standard, Upper Bearing; Undersize 0.25 mm, Upper Bearing; Undersize 0.50 mm Bearing; Standard, Lower Bearing; Undersize 0.25 mm, Lower Bearing; Undersize 0.50 mm, Lower Thrust Washer Bolt Bolt Ring Kit; Standard Piston Kit; Standard Piston Pin Snap Ring Connecting Rod Assembly (includes keys #22-24) Bushing Connecting Rod Bolt Nut Bearing; Standard Bearing; Undersize 0.25 mm Bearing; Undersize 0.50 mm Thrust Washer Pulley Nut Flywheel Assembly (includes key #30) SAE #7-1/ Ring Gear (109 Teeth) Bolt (not shown) Drive Belt - 1-3

10 GROUP 1 ENGINE Camshaft & Oil Pump ISMcamshaft Camshaft Assembly (includes keys #2-6) Cam Gear Key Gear Spacer Bearing Slider Plate Bolt Idler Gear Assembly (includes key #12) Thrust Washer Spring Rotor Oil Pump Cover Shim, t= Shim, t= Shim, t= Shim, t= Spring Collar Snap Ring Front Plate Gasket Bolt - 1-4

11 GROUP 1 ENGINE Cylinder Head ISMcylhead Cylinder Head Assembly (includes keys #2-12, & 20) Expansion Plug, 18 mm Expansion Plug, 30 mm Expansion Plug, 25 mm Expansion Plug, 10 mm Intake Valve Exhaust Valve Valve Guide Seal - Intake Spring Retainer Keeper Valve Guide Seal - Exhaust Cap Spacer Head Gasket; t = 1.1 mm Head Gasket; t = 1.2 mm Head Gasket; t = 1.3 mm Head Bolt Head Bolt Hanger Bolt Valve Seat, Intake - 1-5

12 GROUP 1 ENGINE Rocker Arm Assembly ISMrockerarmassembly Rocker Arm Assembly (includes keys 2-7, 16, 17) Rocker Arm - Intake Rocker Arm - Exhaust Screw Nut Rocker Arm Shaft Spring Bolt Stud Bolt Nut Oil Pressure Switch (see Electrical) Oil Pipe Gasket Banjo Bolt Gasket O-ring Shim Banjo Bolt (tapped 1/8 NPT) Plug - 1-6

13 GROUP 1 ENGINE Rocker Arm Cover ISMrockerarmcover Rocker Arm Cover (replaced by ) Rocker Arm Cover Gasket Baffl e Breather Element Screw Gasket Cap Nut Cap O-ring Valve, Breather Bolt Bolt Bolt Gasket Plate, Intake Block-off Capscrew, Hex Head Flanged M6 x 1.0 x 16 mm - 1-7

14 GROUP 2 INTAKE & EXHAUST SYSTEM Air Filter & Mounting Air Cleaner Assembly (includes keys #15-18) Mounting Clamp Capscrew, M8 x Lock Washer, M Nut, M Bracket, Air Filter Mtg Intake Gasket Bolt Hose Clamp Hose Stud Washer Lifting Eye M Capscrew, Hex Head Flanged M8 x 1.25 x 25 mm Element (Outer) Element (Inner) Cover Assembly Valve - 844aircleaner 2-0

15 GROUP 2 INTAKE & EXHAUST SYSTEM Air Filter Pre-Cleaner A-11749/ B Air Pre-cleaner 2 I.D

16 GROUP 2 INTAKE AND EXHAUST Exhaust Manifold ISMexhmanifold Exhaust Manifold Gasket Bolt Nut Stud Bolt Gasket - 2-2

17 GROUP 2 INTAKE & EXHAUST SYSTEM Notes 2-3

18 GROUP 3 COOLING SYSTEM Coolant Pump ISMcoolantpump 3-0

19 GROUP 3 COOLING SYSTEM Coolant Pump Coolant Pump Assembly (includes keys #2-5) Backing Plate Gasket Plug Screw Gasket Bolt Nut Bolt Gasket Thermostat F/ 82 C Thermostat Housing Plug Stud M6 x 1.0 x 45 mm Temperature Switch (see electrical system) Hose Hose Clamp Thermostat Cover Gasket Bolt Pulley Spacer Bolt - 3-1

20 GROUP 4 FUEL SYSTEM General Arrangement ISMinjpump,inj 4-0

21 GROUP 4 FUEL SYSTEM General Arrangement Injection Pump Assembly (see parts detail page) Shim Nut Bolt Gasket Fuel Injector (see parts detail page) Return Line Injection Line # Injection Line # Injection Line # Injection Line # Clamp Bolt Nut Glow Plug 24 Volt* Connector Gasket Feed Pump Assembly (see parts detail page) Bolt Stop Solenoid 24 Volt Screw Seal Washer Seal Washer Wire Harness Spring Washer Nut - *Note: See Electrical System 4-1

22 GROUP 4 FUEL SYSTEM Governor & Timing Gear Case ISMtiminggear,gov 4-2

23 GROUP 4 FUEL SYSTEM Governor & Timing Gear Case Timing Gear Case Complete (includes key #2) Spring Pin Gasket Oil Seal Governor Lever Assembly (includes keys 7-10) Tension Lever Snap Ring Washer Snap Pin Governor Spring Arm O-ring Governor Lever Bolt Nut Shaft O-ring Snap Ring Bracket Bolt Bolt Bolt Bolt Bolt Start Spring Cover Gasket Hex Nut O-ring Spring Bolt - 4-3

24 GROUP 4 FUEL SYSTEM Fuel Filter & Piping ISMfuel fi lter Fuel Filter Assembly (includes keys #2-5) Fuel Filter Cartridge Gasket Banjo Bolt Plug Bracket Bracket Bolt Nut Spring Washer Nut Bolt, M8 x Pipe Pipe Pipe Bolt Washer Gasket Banjo Bolt Banjo Bolt Gasket Banjo Bolt Gasket Washer Spacer - 4-4

25 Updated GROUP 4 FUEL SYSTEM Fuel Filter A / B Fuel Filter/ Water Separator Bracket Capscrew, Hex Head Flanged M10 x 1.5 x 30 mm Capscrew, Hex Head M14 x 1.5 x 40 mm Lock Washer, Helical M Electric Fuel Pump 24 VDC (includes adelle clamp) Capscrew, Hex Head 3/8-16 x 3/ Lock Washer, Helical 3/ Plug, Hex Head Brass 1/4 NPT Male Elbow, 90 0 Brass 1/4 NPT x 1/4-45T Female Swivel, Brass 1/4 HB x 1/4-45T Hose, 1/4 I.D. Push-on Bracket, Bulkhead Connector Mtg Capscrew, Hex Head Flanged M10 x 1.5 x 45 mm Bulkhead Union, Steel 1/4-37T Nut, Bulkhead Elbow, 90 0 Swivel Steel 1/4-37T Male Connector, Steel 1/4-37T x M8 x Sealing Washer, Bonded M Cap, Hex Head Steel 1/4-37T Adelle Clamp - 22 R24P 1 Element (supercedes , this application only) Hose, 1/4 I.D. Push-0n Hose, 1/4 I.D. Push-0n - 4-5

26 GROUP 4 FUEL SYSTEM Fuel Injector ISMinjector Injector Assembly (includes keys #1-8) Nut Gasket Shim Spring Spring seat Spacer Nozzle Nut - 4-6

27 GROUP 4 FUEL SYSTEM Fuel Feed Pump ISMfuelfeedpump Feed Pump Assembly (includes keys #1-15) Housing Spring Piston Spring Diaphragm Pin Lever O-ring Spring Guide Gasket Cap Screw Gasket Banjo Bolt - 4-7

28 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground Up to S/N XXXX A / C-2490ELAM 5-0

29 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground Up to S/N XXXX Engine Wire Harness, Standard Ground Relay Board/ Side Panel Assembly 24 Volt Male Branch Tee, Steel 1/8 NPT x 1/8 NPT Pressure Sender 0-80 PSI Standard Ground Switch, Pressure 14.2 PSI Standard Ground Temperature Sender F Standard Ground Temperature Switch F/ C Glow Plug 24 Volt Starter 24 V Standard Ground Capscrew, Hex Head M10 x 1.5 x 35 mm Lock Washer, Helical M Flat Washer, M Solenoid 24 VDC 85 Amp Capscrew, Hex Head M6 x 1.0 x 16 mm Flat Washer M Hex Nut, Nylock M6 x Terminal Strip 14 Connection 600 VAC Timer Module 24 VDC 0-20 Sec Switch, Pressure 25 PSI Switch, Temperature F Pigtail Harness 36 S-1A Speed Sensor, Variable Reluctance Alarm Horn 24 V Machine Screw, PH Phillips #8-32 x 3/4 S/S Grommet 1-1/8 I.D. x 1-7/8 O.D Capscrew, Hex Head M6 x 1.0 X 30mm - 5-1

30 Added GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground From S/N XXXX A / C-2490ELAM 5-2

31 Added GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground From S/N XXXX Engine Wire Harness, Standard Ground Relay Board/ Side Panel Assembly 24 Volt (See Parts Detail) Male Branch Tee, Steel 1/8 NPT x 1/8 NPT Pressure Sender 0-80 PSI Standard Ground Switch, Pressure 14.2 PSI Standard Ground Temperature Sender F Standard Ground Temperature Switch F/ C Glow Plug 24 Volt Starter 24 V Standard Ground Capscrew, Hex Head M10 x 1.5 x 35 mm Lock Washer, Helical M Flat Washer, M Solenoid 24 VDC 85 Amp Capscrew, Hex Head M8 x Hex Nut, Nylock M8 x Terminal Strip 10 Connection 600 VAC Front Number Strip Rear Number Strip Switch, Pressure 25 PSI Switch, Temperature F Pigtail Harness 36 S-1A Speed Sensor, Variable Reluctance Alarm Horn 24 V Timer Module 24 VDC 0-20 Sec Capscrew, Hex Head M6 x 1.0 x 30mm Flat Washer M Hex Nut, Nylock M6 x Machine Screw, Truss Head Philips #8-32 3/4 S/S Thin Hex Nut, Nylock #8-32 S/S - 30 NG-79-R 2 Grommet - ** As Required 5-3

32 GROUP 5 ELECTRICAL SYSTEM Starter & Flywheel Housing ISMfl ywheelhsg Flywheel Housing Back Plate Starter - 24 Volt - Standard Ground Bolt Bolt Bolt Bolt Nut Lock Washer Bolt Bolt - 5-4

33 GROUP 5 ELECTRICAL SYSTEM Alternator and Mounting A-11748/ B-9146A Alternator 24V/ 40 Amp Standard Ground Pulley, 1-A x 2-1/2 x 5/8 I.D Alternator Mounting Bracket M Capscrew, Hex Head Flanged M8 x 1.25 x 20 mm Grade Bolt, M8 x 1.25 x 20 mm Capscrew, Hex Head 1/2-13 x 2-1/4" Drive Belt Flat Washer 1/2 SAE Hex Nut, Nylock 1/ Bracket, Tensioning Arm Capscrew, Hex Head 5/16-18 x 1" Stud Washer 5/ Lock Washer, Helical 5/

34 Revised GROUP 5 ELECTRICAL SYSTEM Relay Board/ J-Box Side Cover Up to S/N A-6476/ B Relay Board/ J-Box Cover Assembly (includes all keys) Wiring Set Relay, 24 Volt Relay Base Retainer Terminal Strip 12 Connection 600 VAC Circuit Breaker 10 Amp Mounting Plate Number Strip Machine Screw, Binding Head Phillips #8-32 x 3/ Machine Screw, Binding Head Phillips #8-32 x 3/ Hex Nut, Nylock # Hex Nut # Flat Washer # Lock Washer # Pigtail Harness - 5-6

35 Added GROUP 5 ELECTRICAL SYSTEM Relay Board/ J-Box Side Cover From S/N XXXX A-6476/ B-4619b Relay Board/ J-Box Cover Assembly (includes all keys) Mounting Plate Relay Base Retainer Circuit Breaker 10 Amp Terminal Strip 10 Connection Machine Screw, Binding Head Phillips #8-32 x 3/ Machine Screw, Binding Head Phillips #8-32 x 3/ Flat Washer #8 S/S Thin Hex Nut, Nylock # Number Strip Relay, 24 Volt - 5-7

36 GROUP 5 ELECTRICAL SYSTEM S-1A Control Panel revised A-11743/ B S-1A Autostart Panel (includes all keys) Autostart Module Hourmeter Toggle Switch, SPST On-off 10 Amp 250 Volt Plate Wire Harness Machine Screw, Round Head Phillips #6-32 x 1/2 S/S Hex Nut, Nylock #6-32 S/S Machine Screw, PH Phillips #8-32 x 1-1/2 S/S Hex Nut, Nylock #8-32 S/S Machine Screw, OH Phillips #6-32 x 1/

37 GROUP 5 ELECTRICAL SYSTEM Starter Motor Fan, 1/3 Hp 208 VAC Picture not available A-10035C Fan, Motor Starter Assembly (includes all keys) Enclosure, NEMA x 8 x Back Plane 8-3/4 x 6-7/ Din Rail 35 mm x 7.5 mm x 3-4 LP1K06110BD 1 Contactor, 3 Hp 575 VAC 3 Pole (24 VDC Coil) - 5 LR2K Overload Module End Clamp, 35 x 7.5 Rail Fuse Holder, 1 Pole 13/32 x 1-1/2 with Indicator Fuse, 5A 600 VAC 13/32 x 1-1/

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

39 Revised GROUP 8 FRAME AND MOUNTING Engine Mounting Assembly Up to S/N XXXX A-11968/ B Bracket, Front Engine Mounting Capscrew, Hex Head M14 x 1.5 x 30 mm Lock Washer, Helical M Capscrew, Hex Head 3/8-16 x 1-1/ Lock Washer, Helical 3/ Capscrew, Hex Head 5/16-18 x 3/ Flat Washer 5/16 SAE Spacer - 8-0

40 GROUP 8 FRAME AND MOUNTING Engine Mounting Assembly From S/N XXXX Updated A-11968/ B Bracket, Front Engine Mounting Capscrew, Hex Head M14 x 1.5 x 30 mm Lock Washer, Helical M Capscrew, Hex Head 3/8-16 x 1-1/ Lock Washer, Helical 3/ Capscrew, Hex Head 5/16-18 x 1-1/ Lock Washer, Helical 5/16-8-1

41 GROUP 9 ACCESSORIES AND OPTIONAL EQUIPMENT Oil Drain Kit A-6480, A-11767/ A Drain Valve - 9-1

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