P773-2 For Model: M773LW2 PARTS MANUAL. Marine Generators Marine Diesel Engines Land-Based Generators

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1 P773-2 For Model: M773LW2 PARTS MANUAL 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 th Ave. NW., Seattle WA Tel: (206) Fax: (206)

3 PARTS CATALOG for Model M773LW2 Please read thoroughly before attempting 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 Assembly Crankshaft Assembly Oil Pump... 4 Camshaft... 5 Cylinder Head... 6 Rocker Arm... 7 Rocker Arm Cover... 8 GROUP 2 - INTAKE & EXHAUST SYSTEM Air Intake and Filter... 1 GROUP 3 - COOLING SYSTEM Exhaust Manifold and Heat Exchanger Coolant Pump... 2 Raw Water Pump and Mounting... 3 Raw Water Pump... 4 Coolant Recovery Tank... 5 GROUP 5 - ELECTRICAL SYSTEM 12 Volt Engine... 1 Alternator and Starter Alternator Starter Assembly... 6 Control Panels Belt Guard Assembly GROUP 6 - GASKET SETS Gasket Kit...0 GROUP 8 - FRAME & MOUNTING Base Frame Assembly... 1 GROUP 9 - ACCESSORIES GROUP 9 - & OPTIONAL EQUIPMENT Oil Drain Kit... 0 Keel Cooling Conversion... 1 GROUP 4 - FUEL SYSTEM General Arrangement Governor and Timing Gear Case Fuel Filter and Piping Fuel Line Connection... 6 Fuel Injector... 7 Fuel Feed Pump... 8 Proprietary Information This publication is the property of Northern Lights, Inc. It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc. Northern Lights, Inc. All rights reserved. Litho U.S.A. Publication number I

4 INTRODUCTION MODEL DESIGNATION MODELS INCLUDED This manual covers the operating instructions for: M773LW2 which uses the 773LW2 engine MODEL NUMBERS Model numbers give the unit's application, block model, aspiration, and RPM: M 773 LW2 M - Northern Lights marine generator set Model number of engine block Bore Cylinders 77 mm 3 L - Long Stroke W - New winding 2 - Tier II compliant M773LW2 = Northern Lights marine diesel generator set with an 773 engine and a PX309K2 generator, with a new winding, Tier II compliant. SERIAL NUMBERS NORTHERN LIGHTS Your set has three serial numbers: 1 an engine number stamped on the block, 2 a generator plate, and 3 a generator set plate. Use the serial number on the generator set plate when ordering parts or in correspondence. The generator set plate is found on the service side of the generator and resembles the drawing below. Generator Set Serial Number for units with PXK generators II

5 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: 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. III

6 GROUP 1 ENGINE Cylinder Block Assembly Fig

7 GROUP 1 ENGINE Cylinder Block Assembly KEY PART NUMBER QTY DESCRIPTION S/N Cylinder Block Assembly (Includes keys #2 - #21) Plug Expansion Plug, 25 mm Expansion Plug, 35 mm Expansion Plug, 15 mm Plug Expansion Plug, 40 mm Plug Idle Gear Shaft Assembly Oil Pan Bushing; S.T.D. (formerly # ) Bushing; U.S (formerly # ) Bushing; U.S (formerly # ) Bearing Expansion Plug, 45 mm Bearing Dowel Pin Dowel Pin Dowel Pin Spring Pin Stud Stud Stud Capscrew, Hex Head M6 x 1.0 x 14 mm (with Lock Washer) Gasket Oil Seal Drain Cock Joint Oil Filter Tappet Push Rod Relief Valve Assembly O-ring Bushing Snap Ring Plug Dipstick Tube Bolt Dipstick O-ring Cap Bracket Lock Washer 3/ Capscrew, Hex Head 3/8-16 x 3/4" Oil Drain Hose Tube - 1-1

8 GROUP 1 ENGINE Crankshaft Assembly Fig

9 GROUP 1 ENGINE Crankshaft Assembly Crankshaft Assembly (includes keys #2-4 & 24) Crankshaft Gear Key Dowel Pin Bearing Holder Assembly (includes keys #6 & 7) Bolt Dowel Pin Bearing Holder Assembly (includes keys #6 & 7) Bearing Holder Assembly (includes keys #7 & 12) Bearing; Upper S.T.D. (formerly # ) Bearing; Upper Undersized 0.25 mm (formerly # ) Bearing; Upper Undersized 0.50 mm (formerly # ) Bearing; Lower S.T.D. (formerly # ) Bearing; Lower U.S mm (formerly # ) Bearing; Lower U.S mm (formerly # ) Bolt Bolt Bolt Ring Kit; S.T.D Ring Kit; Oversized 0.50 mm Piston Kit; S.T.D Piston Kit; Oversized 0.50 mm Piston Pin Snap Ring Connecting Rod Assembly (includes keys #20-22) Bushing Connecting Rod Bolt Nut Bearing; S.T.D. (formerly # ) Bearing; Undersized 0.25 (formerly # ) Bearing; Undersized 0.50 (formerly # ) Spring Pin Crankshaft Pulley Nut Flywheel Assembly (includes key #28) Ring Gear Bolt - 1-3

10 GROUP 1 ENGINE Oil Pump & Pick-up Fig Idle Gear Assembly Thrust Washer Spring Rotor Oil Pump Cover ** Shim, 0.1 mm ** Shim, 0.15 mm ** Shim, 0.2 mm ** Shim, 0.5 mm Spring Collar Snap Ring Front Plate Gasket Bolt O-ring Oil Pipe Pick-up Bolt - **As required 1-4

11 GROUP 1 ENGINE Camshaft Cam Shaft Assembly (includes keys #2-6) Cam Gear Assembly Key Gear Spacer Bearing Slider Plate Bolt Bolt - Fig

12 GROUP 1 ENGINE Cylinder Head Fig Cylinder Head Assembly - (Includes keys #1-14) Valve Seat Expansion Plug, 30 mm Expansion Plug, 18 mm Intake Valve Exhaust Valve Intake Valve Guide Seal Exhaust Valve Guide Seal Spring Retainer Cotter Cap Head Gasket; t = Head Gasket; t = Head Bolt Head Bolt Lifting Eye Bolt - 1-6

13 GROUP 1 ENGINE Rocker Arm Assembly 773LW2rockercover Rocker Arm Assembly (includes keys #2-7, 16,17,19, & 20) Intake Rocker Arm Exhaust Rocker Arm Screw Nut Rocker Arm Shaft Spring Bolt Stud Bolt Nut Oil Pressure Switch (see Electrical System) Oil Pipe Gasket Eye Bolt Gasket O-ring Shim Banjo Bolt (Tapped 1/8 NPT Female) Plug Screw - 1-7

14 GROUP 1 ENGINE Rocker Arm Cover 773LW2rockerarmcover Rocker Arm Cover Gasket Retainer Vent Filter Screw Gasket Cap nut Cap O-ring Valve Bolt Bolt Bolt Air Intake Gasket Bolt - 1-8

15 GROUP 2 INTAKE AND EXHAUST Air Filter and Housing A-10836A / C Air Filter Assembly (includes keys #1-18) Air Filter Housing Hose 1-5/8 ID x 1-3/4 3 Ply Silicone Hose Clamp # Intake Silencer Plate Cover, Lower Air Intake Capscrew, Hex Head M6 x 1.0 x 50 mm Flat Washer M Screen Air Filter Element Cover, Air Filter Housing Capscrew, Hex Head M6 x 1.0 x 20 mm Hose, Air Intake Cushion Clamp # Capscrew, Hex Head M8 x 1.25 x 16 mm S/S Flat Washer M8 S/S Capscrew, Hex Head M8 x 1.25 x 25 mm Lock Washer, Helical M Flat Washer M

16 GROUP 3 COOLING SYSTEM Exhaust Manifold and Heat Exchanger A-9289/ D

17 GROUP 3 COOLING SYSTEM Exhaust Manifold and Heat Exchanger Exhaust Manifold/ Expansion Tank Heat Exchanger Element Wet Exhaust Elbow, Stainless Steel Wet Exhaust Elbow, Cast Iron Heat Exchanger End Cap Thermostat Cover Plate Filler Cap Thermostat Gasket Gasket Spring Northern Lights Decal Coolant Pump Inlet Hose " Hose 3/4" ID x 18-1/2" Union 3/4" Hose Barb Socket Head Plug 1/2 BSPT, Steel Connector 1/2 BSPT x 3/4 HB, Steel Hose Clamp # Hose Clamp # Hose Clamp # ** Hex Head Plug, Brass 3/8 NPT Capscrew, Hex Head M6 x 1.0 x 90 mm S/S Capscrew, Hex Head M6 x 1.0 x 95 mm S/S Capscrew, Hex Head M8 x 1.25 x 25 mm S/S Flat Washer M6 S/S Flat Washer M8 S/S Gasket Hose Clamp # Stud M8 x 1.25 x 25 mm (35 mm LOA S/S) Hex Nut, M8 x 1.25 S/S Filler Neck Switch, High Exhaust Temperature Harness, Exhaust Temperature Switch (not shown) - **As required 3-1

18 GROUP 3 COOLING SYSTEM Coolant Pump Fig Coolant Pump Assembly Gasket Bolt Nut Bolt Pulley Spacer Bolt Cap Clamp - 3-2

19 GROUP 3 COOLING SYSTEM Raw Water Pump and Mounting A-4779/ B-3842B O-Ring Nut M10 x Lock Washer M Fitting 1/2 NPT x 3/4 Hose Barb Raw Water Pump (see parts detail) Drive Gear Capscrew, Hex Head M8 x 1.25 x 70 mm Capscrew, Hex Head M8 x 1.25 x 65 mm Hex Nut M8 x 1.25, Flanged Lock Washer M

20 GROUP 3 COOLING SYSTEM Raw Water Pump Detail A-3706/ C Raw Water Pump Assembly (includes keys #1-17) Repair Kit (includes keys #3-9, & 11) Raw Water Pump Body Shaft Impeller Cam Wear Plate End Cover Bearing Lip Seal Mechanical Seal Spline Seal O-ring Retaining Ring Retaining Ring Washer Pan Head Screw #10-32 x 3/ Hex Head Screw #10-32 x 3/ Split Lock Washer #

21 GROUP 3 COOLING SYSTEM Coolant Recovery Tank A-9347/ B Coolant Recovery Tank Coolant Recovery Tank Mounting Bracket Hose Clamp Capscrew, Hex Head, M6 x 1.0 x 16 mm Lock Washer Tube 5/16" ID x 23" Polyurethane Hose 5/16" ID x 28" Polyvinyl Hose Clamp - 3-5

22 GROUP 4 FUEL SYSTEM General Arrangement Fig

23 GROUP 4 FUEL SYSTEM General Arrangement Injection Pump Assembly Shim Set Nut Bolt Gasket Injector Assembly Return Line Injection Line # Injection Line # Injection Line # Clamp Bolt Nut Glow Plug, 12 Volt Nut Connector Wire Harness Gasket Seal Washer Screw Seal Washer Solenoid, 12 Volt Standard Ground Feed Pump Bolt Bolt - 4-1

24 GROUP 4 FUEL SYSTEM Governor and Timing Gear Case Fig

25 GROUP 4 FUEL SYSTEM Governor and Timing Gear Case Timing Gear Case (includes key #2) Spring Pin Gasket Oil Seal Governor Lever Assembly (includes keys 7, 9, 10) Tension Lever Snap Ring Washer Snap Pin Spring Arm O-ring Governor Lever Bolt Nut Shaft O-ring Snap Ring Bracket Bolt Bolt Arm Snap Ring O-ring Spring Washer Nut Stop Lever Bolt Bolt Bolt Bolt Start Spring Cover (Keel Cooled Units Only) Gasket Bolt O-ring Holder O-ring Cap Plate Nut Spring - 4-3

26 GROUP 4 FUEL SYSTEM Fuel Filter and Piping Fig

27 GROUP 4 FUEL SYSTEM Fuel Filter and Piping Fuel Filter Assembly (includes keys #3-6) Fuel Filter Gasket Plug Joint Bolt Bolt Bracket, Filter Support & Lifting Eye Bolt Return Pipe Screw Seal Washer Bolt Gasket Valve Assembly (includes keys 16-18) Connector Steel Ball Rubber Bolt Gasket Pipe Pipe Pipe Spring Washer - 4-5

28 GROUP 4 FUEL SYSTEM Fuel Line Connection A-9317/ B Fuel Manifold 1/4 NPT Capscrew, Hex Head M6 x 1.0 x 20 mm S/S Lock Washer M Plug, Plastic, 1/4 NPT (for shipping) Male Elbow 90, brass 1/4 NPT x 1/4-45T Female Swivel, brass 1/4 HB x 1/4-45T " Hose 1/4" ID Push-on " Hose 1/4" ID Push-on Female Swivel, brass 1/4 HB x 5/16-45T Female Swivel, steel 1/4 HB x 1/4-37T Fitting, Fuel Inlet M8 Banjo x 5/16-37T Sealing Washer (not shown) - 4-6

29 GROUP 4 FUEL SYSTEM Fuel Injector Fig Injector Assembly (includes keys #1 - #8) Nut Gasket Shim Spring Nozzle - 4-7

30 GROUP 4 FUEL SYSTEM Fuel Feed Pump Feed Pump Assembly (includes keys #1-15) Housing* Spring* Piston* Spring* Diaphragm Pin* Lever* O-ring* Spring* Guide* Gasket* Cap* Screw Gasket Joint Bolt - *Not available separately Fig

31 GROUP 5 ELECTRICAL SYSTEM Engine Electrical - 12 Volt Standard Ground A-4786/ C-2490B Temperature Sender, F Single Station 3/8 NPT Temperature Switch 95 C Oil Pressure Sender 0-80 PSI, Single Station 1/8 NPT Oil Pressure Switch Relay, 12 Volt SPDT Relay Base Circuit Breaker Terminal Retainer Engine Wire Harness (includes key #10) Diode, 6 Amp 50 Volt Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" Stainless Steel Flat Washer # Hex Nut, # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Street Elbow 90 0, 1/8 NPT Steel Alternator 12 Volt (see parts detail) Oil Line Banjo Bolt (Tapped 1/8 NPT Female) Starter 12 Volt (marked #M001T66081, see parts detail) Fuel Solenoid - 5-1

32 GROUP 5 ELECTRICAL SYSTEM Alternator and Starter Fig

33 GROUP 5 ELECTRICAL SYSTEM Alternator and Starter Alternator 12 Volt, 40 Amp (see parts detail) Bracket, Alternator Mounting Capscrew, Hex Head M8 x 1.25 x 25 mm S/S Capscrew, Hex Head M10 x 1.5 x 35 mm S/S Flat Washer M10 S/S Tensioning Arm Capscrew, Hex Head M6 x 1.0 x 16 mm S/S Capscrew, Hex Head M8 x 1.25 x 40 mm S/S Lock Washer M8 S/S Spacer Drive Belt Lock Washer M6 S/S Flywheel Housing Starter, 12 Volt (see parts detail) Washer Bolt Bolt Spring Washer Nut Plug Bracket Spring Washer Bolt - 5-3

34 GROUP 5 ELECTRICAL SYSTEM Alternator Assembly 12 Volt / 40 Amp Standard Ground Fig

35 GROUP 5 ELECTRICAL SYSTEM Alternator Assembly 12 Volt / 40 Amp Standard Ground Alternator Assembly (includes keys #1-29) Frame Sub Assembly (includes keys #3,4,6) Retainer Plate Ball Bearing Stud Bolt Rear End Frame Rectifi er Holder Brush Holder (includes keys #10-11) Brush Spring Regulator Assembly Rear End Cover Nut Insulation Brush Bolt Nut Rotor Assembly (includes keys #20-21) Ball Bearing Bearing Cover Pulley Collar Bolt Screw Screw Screw Screw - 5-5

36 GROUP 5 - ELECTRICAL SYSTEMS 12 Volt Starter Assembly Fig Starter (includes all keys) Screw Set Front Housing Lever Assembly Solenoid Ball Packing Ring Armature Bolt Set Drive Assembly (includes keys #11-16) Stopper Set Pinion Assembly Internal Gear Assembly Washer Shaft Assembly Gear Assembly Housing and Field Coil Assembly Brush Assembly Brush Holder Assembly Spring Rear Housing - 5-6

37 GROUP 5 - ELECTRICAL SYSTEMS S-1 Control Panel 12 & 24 Volt A-8551, A-8552/ B S-1 Start/Stop Control Panel, 12 Volt (includes all keys) S-1 Start/Stop Control Panel, 24 Volt (includes all keys) Plate, S-1 Control Panel Rocker Switch Rocker Switch Wire Harness, 12 Volt Wire Harness, 24 Volt Label "12 Volt" * Label "24 Volt" * Resistor, 200 Ohm, 3 Watt (24 Volt Panel only) * - *Not shown 5-7

38 GROUP 5 ELECTRICAL SYSTEM Series 1-B Start-Stop Control Panel 12 and 24 Volts A-8553/ B S 1-B Start/Stop Control Panel - 12 Volt (includes all keys) S 1-B Start/Stop Control Panel - 24 Volt (includes all keys) Plate Rocker Switch Rocker Switch Hour Meter Machine Screw, Round Head Philips #6-32 x 1/2" Star Washer, Internal #6, Stainless Steel Hex Nut #6-32, Stainless Steel Wire Harness - 12 Volt Panels Wire Harness - 24 Volt Panels - 5-8

39 GROUP 5 ELECTRICAL SYSTEM Flush Mount Dual Station Control Panel 12 & 24 Volt VDO Standard Line Black Bezel Gauges A-4732, A-4597/ C S-3C Control Panel, 12 Volt (includes all keys) S-3C Control Panel, 24 Volt (includes all keys) Panel Plate Oil Pressure Gauge, 0-80 PSI Engine Temperature Gauge, F DC Voltmeter, 12 Volt DC Voltmeter, 24 Volt Hourmeter Panel Wire Harness (not shown) ** Self Tapping Screw, Oval Head Phillips #6 x 3/4" Toggle Switch Resistor Kit (24 volt panel only) ** 12 Volt Bulb (not shown) ** 24 Volt Bulb (not shown) - **As required 5-9

40 GROUP 5 ELECTRICAL SYSTEM S-3B Control Panel 12 & 24 Volt A-4722, A-4723/ C S-3B Control Panel, 12 Volt (includes all keys) S-3B Control Panel, 24 Volt (includes all keys) Enclosure Oil Pressure Gauge, 0-80 PSI Engine Temperature Gauge, F DC Voltmeter, 12 Volt DC Voltmeter, 24 Volt Hourmeter Panel Decal Terminal Board Toggle Switch Number Strip Resistor Kit (24 volt panel only) ** 12 Volt Bulb (not shown) ** 24 Volt Bulb (not shown) Wire Harness (not shown) Plastic Bushing Connection Harness - **As required 5-10

41 GROUP 5 ELECTRICAL SYSTEM Belt Guard Assembly Standard Small Frame Alternators A-9314/ B Belt Guard Capscrew, Hex Head M6 x 1.0 x 15 mm - (Head tapped M6 x 1.0 x 10 mm Special) Stud, M6 x 1.0 x mm Stud, M10 x 1.5 x mm Flat Washer M6 S/S Lock Washer, Helical M6 S/S Hex Nut M6 x 1.0 S/S Flat Washer M10 S/S Lock Washer, Helical M10 S/S Hex Nut M10 x 1.5 mm S/S

42 GROUP 6 GASKET SETS Gasket Kits Gasket Kit (includes all keys) Oil Seal, Rear O-ring, Suction Oil Pipe Gasket, Oil Pan Gasket, Front Plate O-ring, Governor Shaft O-ring, Rocker Arm O-ring, Rocker Arm Gasket, Timing Gear Case Oil Seal, Front Gasket, Gear Case Cover Adjusting Shim Set Seal Washer Gasket 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, Rocker Arm Cover Gasket, Rocker Arm Cover O-ring, Oil Filter Cap Gasket, Air Intake Gasket, Water Pump Gasket Gasket, Fuel Pump O-ring, Gauge Guide Seal Washer, Solenoid O-ring, Relief Valve Gasket Gasket, Valve Assembly O-ring, Gear Case Cover Gasket Gasket, Exhaust Gasket, Thermostat Cover O-ring, Raw Water Pump - 6-0

43 GROUP 8 FRAME AND MOUNTING Base Frame Assembly A-9314/ D Base Frame, Steel Bracket Capscrew, Hex Head M12 x 1.25 x 30 mm Lock Washer, Helical M Plateform Mount, 155 lb Plateform Mount, 155 lb Capscrew, Hex Head M8 x 1.25 x 20 mm, Stainless Steel Lock Washer, Helical M8, S/S Snubbing Washer 2.88 x 0.52 x Capscrew, Hex Head M12 x 1.75 x 65 mm, S/S Flat Washer M12, S/S Capscrew, Hex Head M12 x 1.75 x 65 mm S/S Hex Nut, Nylock M12 x 1.75, S/S Capscrew, Hex Head 3/8-16 x 1-1/4" Lock Washer, Helical 3/ Capscrew, Hex Head M8 x 1.25 x 30 mm Lock Washer, Helical M

44 GROUP 9 ACCESSORIES AND OPTIONAL EQUIPMENT Oil Drain Kit A-5024/ B Oil Drain Kit Complete (includes all keys) Hand Pump Adapter, Oil Drain O-ring - 9-0

45 Corrected page GROUP 9 ACCESSORIES AND OPTIONAL EQUIPMENT Keel Cooling Conversion Marine Application - with Dry Exhaust A-10008/ B Cover (white) O-ring End Cap, Rubber Hose Clamp, # Elbow, Dry Exhaust 1-1/2" NPT Gasket, Exhaust Outlet Mtg Exhaust Lagging (not shown) Male Connector, Brass 3/8 NPT x 5/8 HB Hose, Coolant By-pass Adapter, 3/8 NPT x 3/8 NPT Hose Clamp # Hose, Coolant Pump Inlet Hose, Expansion Tank Outlet Male Elbow, 45, Copper 1-1/8" HB x 1-1/4" HB Hose Clamp # Plug, Socket Head 1/8 NPT Male Elbow, 3/8 NPT x 5/8 Hose Barb - 9-1

46 th Ave. NW., Seattle WA Tel: (206) Fax: (206) Northern Lights and Lugger are registered trademarks of Northern Lights, Inc All rights reserved. Litho USA.

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