P843-2 For Models: M843NW2 and NL843NW2 PARTS MANUAL. Marine Generators Marine Diesel Engines Land-Based Generators

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1 P843-2 For Models: M843NW2 and NL843NW2 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. Northern Lights th Avenue N.W. Seattle, WA Tel: (206) Fax: (206) Copyright 2005 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 M843nw₂ and NL843nw₂ 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 and Flywheel Assembly Camshaft and Oil Pump Cylinder Head Rocker Arm Assembly GROUP 2 - INTAKE & EXHAUST SYSTEM Air Filter and Housing... 1 Air Filter and Mounting... 2 Exhaust Manifold and Muffler... 3 GROUP 3 - COOLING SYSTEM Exhaust Manifold and Heat Exchanger Coolant Pump... 2 Coolant Pump, Fan, & Thermostat Housing... 3 Raw Water Pump and Mounting Radiator and Guard GROUP 4 - FUEL SYSTEM Injection Pump and Lines Governor and Timing Gear Case Fuel Filter and Piping Fuel Line Connection... 6 Coast Guard Fuel Line Connection... 7 Fuel Injector... 8 Fuel Feed Pump... 9 GROUP 5 - ELECTRICAL SYSTEM 12 & 24 Volt Engine Alternator, Starter, and Flywheel Housing... 5 Alternator... 6 Starter Assembly... 7 Alternator Assembly... 8 Control Panels Belt Guard Assembly GROUP 6 - GASKET SETS Gasket Kit...0 GROUP 7 - GEAR AND ADAPTER SETS Not available at this time. GROUP 8 - FRAME & MOUNTING Base Frame Assembly GROUP 9 - ACCESSORIES GROUP 9 - & OPTIONAL EQUIPMENT PTO Adapter... 1 Electric Clutch... 2 Oil Drain Kit... 3 Keel Cooling Conversion... 4 Coolant Recovery Tank... 5 Remote Expansion Tank... 6 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: M843NW2 and NL843NW2, which both use the 843 engine. Model Numbers Model numbers give the unit's application, block model, aspiration, and RPM: M - NL 843 N, W, 2 M - Northern Lights marine generator set NL - Northern Lights industrial generator set Model number of engine block Bore Cylinders 84 mm 3 N - series designation W - new winding in gen. end 2 - Tier II compliant M843NW2 = Northern Lights marine diesel generator set with an 843 engine and a PX-312K2 NL843NW2 = generator, Tier II compliant. Northern Lights industrial diesel generator set with an 843 engine and a PX-312K2 generator, 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 P / 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 843NW2cylblock 1-0

7 GROUP 1 ENGINE Cylinder Block Assembly Cylinder Block Assembly (Marine, includes keys #2-18, 28) Cylinder Block Assembly (Industrial, includes keys #2-18, 28) Expansion Plug 15 mm Expansion Plug 25 mm Expansion Plug 40 mm Plug Plug Plug Idle Gear Shaft Assembly Bushing, Standard Bushing, Undersized 0.25 mm Bushing, Undersized 0.50 mm Bearing Expansion Plug Dowel Pin Dowel Pin Dowel Pin Spring Pin Stud Stud Stud Gasket Oil Seal Bushing Filter Joint Oil Filter Assembly Tappet Push Rod Assembly Relief Valve Assembly O-ring Needle Bearing Drain Cock Tube O-ring Dipstick Holder Bolt Dipstick Oil Pan (Marine) Oil Pan (Industrial, formerly # ) Bolt (Marine & Industrial) Plug, Hex Head M12 x 1 (Industrial) Seal Washer (Industrial) Oil Drain Hose Cap Bracket Capscrew, Hex Head 3/8-16 x 3/ Lock Washer 3/

8 GROUP 1 ENGINE Crankshaft and Flywheel Assembly 843NW2crankshaft 1-2

9 GROUP 1 ENGINE Crankshaft and Flywheel Assembly Crankshaft Assembly (includes keys 2-5) Crankshaft Gear Key Dowel Pin Spring Pin Bearing Holder Assembly (includes keys 9 &12) Bearing Holder Assembly (includes keys 9 &12) Bearing Holder Assembly (includes keys 9 &12) Dowel Pin Bearing; Standard (Upper) Bearing; Undersized 0.25 mm (Upper) Bearing; Undersized 0.50 mm (Upper) Bearing; Standard (Lower) Bearing; Undersized 0.25 mm (Lower) Bearing; Undersized 0.50 mm (Lower) Bolt Bolt Bolt Thrust Washer Piston Ring Kit, Standard Piston Kit, Standard (formerly # ) Piston Pin Snap Ring Connecting Rod Assembly (includes keys 21-23) Bushing Connecting Rod Bolt Nut Bearing, Standard Bearing, 0.25 mm Bearing, 0.50 mm Crankshaft Pulley (Marine) Crankshaft Pulley (Industrial) Nut Flywheel Assembly (includes key 28) Ring Gear (109 Teeth) Bolt - 1-3

10 GROUP 1 ENGINE Camshaft and Oil Pump 843NW2oilpump 1-4

11 GROUP 1 ENGINE Camshaft and Oil Pump Camshaft Assembly (includes keys 2-6) Cam Gear Key Gear Spacer Bearing Slider Plate Bolt Idle 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 - Marine (white) Front Plate - Industrial (blue) Gasket Bolt O-ring Oil Pipe Suction Filter Assembly Bolt - 1-5

12 GROUP 1 ENGINE Cylinder Head 843NW2cylhead 1-6

13 GROUP 1 ENGINE Cylinder Head Cylinder Head Assembly (Marine, includes keys 1-14) Cylinder Head Assembly (Industrial, includes keys 1-14) 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 Cotter Valve Guide Seal - Exhaust Cap Valve Seat - Intake Head Gasket t=1.3 mm Head Gasket t=1.4 mm Head Bolt Head Bolt Lifting Eye (Marine) Lifting Eye (Industrial) Bolt Spacer (Marine only) Bolt (Marine only) - 1-7

14 GROUP 1 ENGINE Rocker Arm Assembly 843NW2rockerarm Rocker Arm Assembly (Marine, includes keys 2-7, 16-17) Rocker Arm Assembly (Industrial, includes keys 2-7, 16-17) Intake Rocker Arm Exhaust Rocker Arm Screw Nut Rocker Arm Shaft Spring Bolt Stud Nut Oil Pressure Switch (see Electrical System) Oil Pipe Assembly Sealing Washer Banjo Bolt Gasket O-ring Shim Banjo Bolt (Tapped 1/8 NPT) - 1-8

15 GROUP 1 ENGINE Rocker Arm Cover Marine 843NW2rockercover Rocker Arm Cover Gasket Oil Stopper Steel Wool Screw Gasket Cap Nut Cap O-ring Breather Valve Bolt Bolt Bolt Caution Plate - 1-9

16 GROUP 1 ENGINE Rocker Arm Cover Industrial 843NW2rockercoverind Rocker Arm Cover Gasket Oil Stopper Steel Wool Screw Gasket Cap Nut Cap O-ring Breather Valve Bolt Bolt Bolt Caution Plate Gasket Air Intake Bolt

17 GROUP 2 INTAKE AND EXHAUST Air Filter and Housing Marine A-10262, A / C Connector, Air Inlet Gasket, Air Intake Mounting Capscrew, Hex Head M6 x 1.0 x 20 mm Wave Washer M6 S/S Hose 1-3/4" ID x 2-1/4" Hose Clamp # Front Cover, Air Filter Housing Plate, Air Filter Baffl e Element, Air Filter Screen, Air Filter Retaining Rear Cover, Air Filter Housing Capscrew, Hex Head M6 x 1.0 x 85 mm S/S Wave Washer M6 S/S Bracket, Air Filter Support Capscrew, Hex Head M8 x 1.25 x 16 mm S/S Wave Washer M8 S/S Hose, Air Intake (Molded) Hose Clamp # Cushion Clamp # Capscrew, Hex Head M6 x 1.0 x 16 mm S/S Flat Washer, M6 S/S - 2-1

18 GROUP 2 INTAKE AND EXHAUST Air Filter and Mounting Industrial Air Filter Assembly (includes keys #13-16) Clamp # Hose Bracket Bracket Lifting Eye Bolt Bolt Bolt Washer Bolt Bolt Housing Element Cover Assembly Valve - 843NW2aircleaner 2-2

19 GROUP 2 INTAKE AND EXHAUST Exhaust Manifold and Muffler Industrial 843NW2muffl er Muffl er Assembly (includes keys #2-8) Bolt Muffl er Element Gasket Exhaust Manifold Gasket Flange Bolt Gasket Bolt Stud Nut Exhaust Elbow (can use # ) Exhaust Elbow 1-1/2 NPT Clamp Washer Spring Washer Nut Bolt - 2-3

20 GROUP 3 COOLING SYSTEM Exhaust Manifold and Heat Exchanger Marine A-4760B/ D-2106C 3-0

21 GROUP 3 COOLING SYSTEM Exhaust Manifold and Heat Exchanger Marine Exhaust Manifold / Expansion Tank Heat Exchanger Element Wet Exhaust Elbow S/S Wet Exhaust Elbow (Cast Iron) Heat Exchanger End Cap Thermostat Housing Cover Plate Pressure Cap (formerly # ) Thermostat, 180 F / 82 C Exhaust Manifold Gasket Wet Exhaust Elbow Gasket Spring Northern Lights Decal Formed Hose Hose 3/4" ID x 18-1/2" Overfl ow Hose 5/16" ID x 25" Union 3/4 HB x 3/4 HB Socket Head Plug 1/2 NPT Connector 1/2 NPT x 3/4 HB Hose Clamp # Hose Clamp # Hose Clamp # Hex Head Plug, Brass 3/8 NPT Capscrew, Hex Head M6 x 1.0 x 105 mm S/S Capscrew, Hex Head M6 x 1.0 x 110 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 Thermostat Gasket Hose Clamp # Stud M8 x 1.25 x 20 x 10 S/S (35 mm OAL) Hex Nut, M8 x 1.25 S/S Filler Neck Switch, High Exhaust Temperature (not shown) - 3-1

22 GROUP 3 COOLING SYSTEM Coolant Pump Marine Fig Coolant Pump Assembly (includes keys #2-5) Backing Plate Gasket Plug Screw Gasket Bolt Nut Pulley Spacer Bolt - 3-2

23 GROUP 3 COOLING SYSTEM Coolant Pump, Fan, and Thermostat Housing Industrial 843NW2coolantpumpind Coolant Pump Assembly (includes keys #2-5) Backing Plate Gasket Plug Screw Gasket Bolt Nut Bolt Gasket Spring Thermostat, 180 F / 82 C Thermostat Housing Plug Temperature Switch, F/ C Nut Stud Hose Hose Clamp # Pulley Spacer Fan (Blower) Bolt, M6 x 1.0 x 35 mm - 3-3

24 GROUP 3 COOLING SYSTEM Raw Water Pump and Mounting Marine A-4779/ B O-ring 2-1/2 x 2-3/4 x 1/ Nut M10 x Lock Washer M Fitting 1/2 NPT x 3/4 HB Raw Water Pump (see parts detail) Drive Gear Capscrew, Hex Head M8 x 1.25 x 90 mm Capscrew, Hex Head M8 x 1.25 x 85 mm Lock Washer, Helical M Hex Nut M8 x

25 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 #

26 GROUP 3 COOLING SYSTEM Z Radiator and Guard Early Production 10 A-6501/ B-9154z 3-6

27 GROUP 3 COOLING SYSTEM Radiator and Guard Early Production Top Panel up to xxxx-37736c Side Panel Radiator Support Radiator Assembly, Copper (includes keys 23-28) Spacer, Radiator Support Capscrew, Hex Head M6 x 1.0 x 12 mm Capscrew, Hex Head M6 x 1.0 x 20 mm Flat Washer M Lock Washer, Helical M Capscrew, Hex Head M8 x 1.25 x 16 mm Capscrew, Hex Head M8 x 1.25 x 20 mm Flat Washer M Lock Washer, Helical M Hex Nut, Nylock M8 x Capscrew, Hex Head M10 x 1.5 x 16 mm Lock Washer, Helical M Flat Washer M Hose, Radiator Inlet Hose, Radiator Outlet Hose Clamp # Label Northern Lights (not shown) Grille Drain Cock Filler Cap Overfl ow Tube 1/ Gasket Shroud w/ fan guard Bolt Continuous Grommet 3-7

28 GROUP 3 COOLING SYSTEM Radiator and Guard Late Production 10 A-6501/ B

29 GROUP 3 COOLING SYSTEM Radiator and Guard Late Production Top Panel from xxxx-37737c Side Panel Radiator Support Radiator Assembly, Aluminum (includes keys 23-25) Spacer, Radiator Support Capscrew, Hex Head M6 x 1.0 x 16 mm Capscrew, Hex Head M6 x 1.0 x 20 mm Flat Washer M Lock Washer, Helical M Capscrew, Hex Head M8 x 1.25 x 16 mm Capscrew, Hex Head M8 x 1.25 x 20 mm Flat Washer M Lock Washer, Helical M Hex Nut, Nylock M8 x Capscrew, Hex Head M10 x 1.5 x 16 mm Lock Washer, Helical M Flat Washer M Hose, Radiator Inlet Hose, Radiator Outlet Hose Clamp # Label Northern Lights (not shown) Grille Drain Cock Filler Cap Vent Hose 3-9

30 GROUP 4 FUEL SYSTEM Injection Pump and Lines 843NW2injectionlines 4-0

31 GROUP 4 FUEL SYSTEM Injection Pump and Lines Injection Pump Assembly Shim Set Nut Bolt Gasket Injector Assembly Return Line Injection Line # Injection Pipe # Injection Pipe # Clamp Bolt Nut Glow Plug, 12 Volt Glow Plug, 24 Volt Connector Gasket Feed Pump Assembly (see parts detail) Bolt Solenoid, 12V Standard Ground Solenoid, 12V Isolated Ground Solenoid, 24V Isolated Ground Seal Washer Seal Washer Screw Wire Harness Spring Washer Nut - 4-1

32 GROUP 4 FUEL SYSTEM Governor and Timing Gear Case 843NW2timinggear 4-2

33 GROUP 4 FUEL SYSTEM Governor and Timing Gear Case Timing Gear Case - Marine (white) - (includes key #2) Timing Gear Case - Industrial (blue) Spring Pin Gasket Oil Seal Governor Lever Assembly (includes keys 6-8) 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 (**as required) Cover (Marine only, Keel Cooled) Cover (Industrial only) Gasket Nut O-ring Start Spring Spring Bolt } Oil Fill O-ring Marine only Cap Caution Plate - } 4-3

34 GROUP 4 FUEL SYSTEM Fuel Filter and Piping 843NW2fuelfi lter 4-4

35 GROUP 4 FUEL SYSTEM Fuel Filter and Piping Fuel Filter Assembly (includes keys #2-5) Fuel Filter Gasket Joint Bolt Plug Bracket (Marine) Bracket (Industrial) Bracket (Marine) Bracket (Industrial) Bolt Nut Spring Washer Nut Bracket - Industrial only Bolt - Industrial only ** Bolt Pipe Pipe Connector, Fuel Inlet Bolt Washer Gasket Joint Bolt Joint Bolt Seal Washer Joint Bolt Sealing Washer M ** Washer Spacer (Marine) Lifting Eye - **As required 4-5

36 GROUP 4 FUEL SYSTEM Fuel Line Connection Marine and Industrial A-4922/ B Fuel Manifold 1/4 NPT Capscrew, Hex Head M6 x 1.0 x 20 mm Lock Washer M Plug, Hex Head, brass 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 x 24" push-on Hose 1/4" ID x 15" push-on Female Swivel, brass 1/4 HB x 5/16-45T Female Swivel, steel 1/4 HB x 1/4-37T - 4-6

37 GROUP 4 FUEL SYSTEM Coast Guard Fuel Line Connection USCGA-1 - J ISO 7840 A-4925/ B Fuel Manifold 1/4 NPT Capscrew, Hex Head M6 x 1.0 x 20 mm Lock Washer M Hex Head plug, brass 1/4 NPT (for shipping) Male Elbow 90, steel 1/4 NPT x 1/4-37T Male Elbow 90, steel 1/4 NPT x 5/16-37T Hose Assembly 1/4" ID x 24" with 90, 1/4 JIC x 1/4 JIC Hose Assembly 1/4" ID x 15" 5/16 JIC Both Ends Adelle Clamp (not shown) Flat Washer (not shown) - 4-7

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

39 GROUP 4 FUEL SYSTEM Fuel Feed Pump 843NW2fuelfeedpump Feed Pump Assembly (includes keys #2-6) Joint Bolt Gasket Screw Gasket Diaphragm - 4-9

40 GROUP 5 ELECTRICAL SYSTEM Engine Electrical - 12 & 24 Volt Standard Ground Marine Applications A-4786, A-4985/ C

41 GROUP 5 ELECTRICAL SYSTEM Engine Electrical - 12 & 24 Volt Standard Ground Marine Applications Temperature Sender Temperature Switch 95 C Oil Pressure Switch Oil Pressure Sender Relay, 12 Volt SPDT Relay, 24 Volt SPDT Relay Base Retainer (not shown) Circuit Breaker, DC 15 Amp Control Panel, S1-B (see panel detail) Engine Wire Harness (includes key #10) Diode, 6 Amp 50 Volt PIV Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/4" Stainless Steel Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 12 Volt (see also Fuel System) Stop Solenoid 24 Volt Alternator 12 Volt (see parts detail) Alternator 24 Volt (see mounting detail) Banjo Bolt Oil Line Starter 12 Volt (marked #M001T66081) (see parts detail) Starter 24 Volt (supercedes ) Elbow, 1/8 NPT (not shown) - 5-1

42 GROUP 5 ELECTRICAL SYSTEM Engine Electrical - 12 & 24 Volt Isolated Ground Marine Applications A-6054, A-5777/ C

43 GROUP 5 ELECTRICAL SYSTEM Engine Electrical - 12 & 24 Volt Isolated Ground Marine Applications Temperature Sender Temperature Switch 95 C Oil Pressure Switch Oil Pressure Sender Relay, 12 Volt SPDT Relay, 24 Volt SPDT Relay Base Retainer (not shown) Circuit Breaker, DC 15 Amp Control Panel, S1-B (see panel detail) Engine Wire Harness (includes key #10) Diode, 6 Amp 50 Volt PIV Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/4" Stainless Steel Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 12 Volt (see also Fuel System) Stop Solenoid 24 Volt Alternator 12 Volt (see mounting detail) Alternator 24 Volt (see mounting detail) Banjo Bolt Oil Line Starter 12 Volt (see parts detail) Starter 24 Volt Street Tee 1/8 NPT (not shown) - 5-3

44 GROUP 5 ELECTRICAL SYSTEM Engine Electrical - 12 Volt Standard Ground Industrial 5-4 A-4786/ C-2490Bnl Temperature Sender, F Single Station 3/8 NPT Temperature Switch 230 F/ 110 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 (see parts detail) Fuel Solenoid -

45 GROUP 5 ELECTRICAL SYSTEM Alternator, Starter, and Flywheel Housing 843NW2alternator Tensioning Arm Alternator, 12 Volt 40 Amp Standard Ground Alternator, 12 Volt 40 Amp Isolated Ground Bolt Washer Bracket Bolt Bolt Nut Spring Washer Drive Belt Bolt Flywheel Housing (Marine) Flywheel Housing (Industrial) Bolt Starter, 12 Volt Standard Ground Starter, 12 Volt Isolated Ground Bolt Washer Spring Washer Bracket, Drain Hose Support Spring Washer Bolt - 5-5

46 GROUP 5 ELECTRICAL SYSTEM Alternator Isolated and Standard Ground A-7631, A-7632, A-7633/ D Alternator (12V/51A ISO Ground) Alternator (24V/40A Standard Ground) Alternator (24V/35A ISO Ground) Pulley, 1-A x 2-1/2" x 5/8" ID Alternator Mounting Bracket Capscrew, Hex Head M8 x 1.25 x 20 mm Lock Washer, Helical M Capscrew, Hex Head 1/2-13 x 2-3/4" Spacer Flat Washer 1/2 SAE Hex Nut, Nylock 1/ Tensioning Arm Tensioning Arm (24 Volt 35 Amp Alternator only) Capscrew, Hex Head 5/16-18 x 1" Stud Washer 5/ Lock Washer, Helical 5/ Diode Harness Addition Drive Belt D.C. Voltage Regulator 12 Volt Wire Harness, 36" Machine Screw, BH Slotted #10-32 x 3/4" S/S Flat Washer #10 S/S Hex Nut, Nylock #10-32 S/S - 5-6

47 GROUP 5 ELECTRICAL SYSTEM 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 - 5-7

48 GROUP 5 ELECTRICAL SYSTEM Alternator Assembly 12 Volt / 40 Amp Standard Ground 843alternator assembly Alternator Assembly (includes keys #1-14) Nut Pulley Assembly Screw Set Front Cover Assembly Screw Set Bearing Rotor Assembly Bearing Stator Assembly Rear Cover Assembly Connector Regulator Assembly Brush Rectifi er Assembly - 5-8

49 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 5-9

50 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

51 GROUP 5 ELECTRICAL SYSTEM Flush Mount Dual Station Control Panel 12 & 24 Volt Marine Application - 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 5-11

52 GROUP 5 ELECTRICAL SYSTEM S-3B Control Panel 12 & 24 Volt Marine and Industrial Applications 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

53 GROUP 5 ELECTRICAL SYSTEM Belt Guard Assembly Marine A-5004, A-5020/ B Belt Guard, Small Frame Alternators (without PTO) Belt Guard, Small Frame Alternators (with PTO) Belt Guard, Medium Frame Alternators (without PTO) Belt Guard, Medium Frame Alternators (with PTO) Stud, All Thread M8 x 1.25 x 110 mm Stud, All Thread M6 x 1.0 x 140 mm Hex Nut M8 x Lock Washer M Flat Washer M Hex Nut M6 x Lock Washer M Flat Washer M Stud, All Thread M6 x 1.0 x 70 mm Hex Nut, X-L M6 x 1.0 x 19 mm ** Bracket (used with only not shown) ** Bracket (used with and only not shown) PTO Guard (not shown) - **As required 5-13

54 GROUP 6 GASKET SETS Gasket Kit Gasket Kit (Marine, includes all keys) Gasket Kit (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 Shaft O-ring O-ring 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, Lower side Injector Gasket, Upper side injector O-ring, Rocker Arm Shaft Gasket, Rocker Arm Bracket Gasket, Rocker Arm Cover Gasket, Rocker Arm Cover O-ring, Oil Fill Cap Gasket, Air Intake Gasket, Coolant Pump Set Plate Gasket, Coolant Pump Gasket, Thermostat Housing Gasket, Fuel Pump Joint Bolt Gasket, Fuel Feed Pump O-ring, Dipstick Tube Seal Washer, Solenoid O-ring, Relief Valve Gasket, Fuel Feed Pump Joint Bolt Gasket Gasket Gasket, Exhaust Manifold Gasket, Elbow O-ring, Gear Case Cover Gasket, Exhaust Manifold/ Expansion Tank Gasket, Thermostat Cover O-ring, Raw Water Pump - 6-0

55 GROUP 8 FRAME AND MOUNTING Base Frame Assembly Marine Application - PX-312K2 Generators A-7843 & A-7893 / D Base Frame, Steel Base Frame, Aluminum Bracket Capscrew, Hex Head M14 x 1.5 x 30 mm Lock Washer, Helical M Plateform Mount, 220 lb. Standard Plateform Mount, 250 lb. (with PTO) Plateform Mount, 220 lb Capscrew, Hex Head M8 x 1.25 x 20 mm, Stainless Steel Lock Washer, Helical M8, Stainless Steel ** Snubbing Washer Capscrew, Hex Head 1/2-13 x 3" Stainless Steel Capscrew, Hex Head 1/2-13 x 3-1/2" Stainless Steel Flat Washer 1/2 Stainless Steel Hex Nut, Nylock 1/2-13 Stainless Steel Capscrew, Hex Head 3/8-16 x 1-1/4" Lock Washer, Helical 3/ Capscrew, Hex Head 5/16-18 x 1-1/ Lock Washer, Helical 5/16 (**As required) - 8-1

56 GROUP 8 FRAME AND MOUNTING Base Frame Assembly Industrial Application A-7930/ B Base Frame Bracket Capscrew, Hex Head M14 x 1.5 x 30 mm Lock Washer, Helical M Capscrew, Hex Head M10 x 1.5 x 55 mm Flat Washer M Mount, Centerbonded 200 lb Head/Tail Washer Hex Nut, Nylock M10 x Capscrew, Hex Head M10 x 1.5 x 60 mm Flat Washer M Head/Tail Washer Mount, Centerbonded 200 lb Head/Tail Washer Hex Nut, Nylock M10 x Capscrew, Hex Head 3/8-16 x 1-1/4" Lock Washer, Helical 3/ Capscrew, Hex Head 5/16-18 x 1-1/4" Lock Washer, Helical 5/ Flat Washer M

57 GROUP 9 ACCESSORIES AND OPTIONAL EQUIPMENT PTO Adapter Parts A-8091/ D PTO Adapter (includes all keys) PTO Clutch Housing, H-28 B-Pad Engine/ PTO Support Bracket, Right Hand Engine/ PTO Support Bracket, Left Hand Capscrew, Socket Head M10 x 1.5 x 25 mm Lock Washer, High Collar M Capscrew, Hex Head with Tapered Seat, M14 x 1.5 x 30 mm PTO Drive Adapter Capscrew, Socket Head M12 x 1.75 x 25 mm Lock Washer, High Collar M Coupling Assembly (with hardware, size 22 model) Hub Capscrew, Socket Head M12 x 1.75 x 40 mm Capscrew, Socket Head M12 x 1.75 x 35 mm Steel Elbow, 45 degrees, Brass 1/2 NPT x 1/2 NPT Taper Pin #4 x 1" - 9-1

58 GROUP 9 ACCESSORIES AND OPTIONAL EQUIPMENT Electric Clutch A-6291 & A-6346/ C Electric Clutch Assembly (12 volt) Electric Clutch Assembly (24 volt) Capscrew, Hex Head 1/2-13 x 1-1/ Flat Washer M Grommet Capscrew, Socket Head 3/8-24 x 3/

59 GROUP 9 ACCESSORIES AND OPTIONAL EQUIPMENT Oil Drain Kit Marine Application A-5024/ B Oil Drain Kit Complete (includes all keys) Hand Pump Adapter, Oil Drain O-ring - Oil Drain Industrial Application A Drain Valve - 9-3

60 GROUP 9 ACCESSORIES AND OPTIONAL EQUIPMENT Keel Cooling Conversion Marine Application - with Dry Exhaust A-11305/ P843 kc Cover (see Governor & Timing Gear Case) Gasket (see Governor & Timing Gear Case) End Cap Hose Clamp # Elbow, Dry Exhaust 1-1/2 NPT Gasket Lagging Male Connector, Brass, 3/8 NPT x 1/2 HB Hose Hose Clamp # Plug, Socket Head, Steel, 1/8 NPT - 9-4

61 GROUP 9 ACCESSORIES AND OPTIONAL EQUIPMENT Coolant Recovery Tank A-10342/ B Coolant Recovery Tank Coolant Recovery Tank Mounting Bracket Capscrew, Hex Head, M6 x 1.0 x 12 mm Flat Washer, M Hose, 5/16 x 26 Polyurethane Hose, 5/16" x 26 Polyvinyl Hose Clamp - 9-5

62 GROUP 9 ACCESSORIES AND OPTIONAL EQUIPMENT Remote Expansion Tank Marine A-5931A/ D Tank Assembly (includes keys #2 & #16 - #17) Male Elbow, Brass 1/4 NPT x 5/16-45T Male Connector, Brass 1/2 NPT x 1/2 HB Male Connector, Brass 3/8 NPT x 1/2 HB Port Adapter (requires key #11) Filler Cap Male Elbow, Steel 3/8 Port x 5/16-37T Hose Clamp Female Swivel, Brass 5/16 HB x 5/16-45T Female Swivel, Brass 1/2 HB x 1/2-45T O-ring (for Port Adapter) Female Swivel, Brass 5/16 HB x 5/16-37T Capscrew, Hex Head M8 x 1.25 x 16 mm Flat Washer M Lock Washer M Mounting Foot Hose Clamp #64 (for tank mounting) - 9-6

63 GROUP 9 ACCESSORIES AND OPTIONAL EQUIPMENT Low Coolant Level Switch/ Gauge A-10948/ C Coolant Level Switch/ Gauge Bracket, Coolant Level Switch/ Gauge Lifting Eye, Front Capscrew, Hex Head M8 x 1.25 x 25 mm Lock Washer, Helical M Capscrew, Hex Head M6 x 1.0 x 25 mm Flat Washer M Hex Nut, Nylock M6 x Bushing, Brass 1/2 NPT x 1/4 NPT Male Elbow 90 0 Steel 1/4 NPT x 1/4-37T Hose Assembly 1/4 I.D. x Male Elbow 90 0 Steel 1/8 NPT x 1/4-37T Bushing, Brass 3/8 NPT x 1/8 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. x 13 Push-on Male Elbow 900 Steel 1/8 NPT x 1/4-37T Adelle Clamp 3/8 I.D. x 3/8 Stud Flat Washer M Strain Relief Connection 1/2 NPT - 9-7

64 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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