PARTS MANUAL P For Models: M773LW3, M773LW3G and NL773LW3.

Transcription

1 PARTS MANUAL P773-3 For Models: M773LW3, M773LW3G and NL773LW3

2 CALIFORNIA Proposition 65 Warning: Breathing Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. * Always start and operate the engine in a well-ventilated area. * If in an enclosed area, vent the exhaust to the outside. * Do not modify or tamper with the exhaust system. * Do not idle the engine except as necessary. For more information, go to Northern Lights th Avenue NW Seattle, WA Tel: (206) Fax: (206) Copyright 2018 Northern Lights, Inc. All rights reserved. Northern Lights, and the Northern Lights logo are trademarks of Northern Lights, Inc. Printed in U.S.A. PART NO.: P /18

3 PARTS MANUAL for Models M773LW3, M773LW3G and NL773LW3 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 Oil Drain and Valve... 6 Oil Pump & Pick-up... 7 Camshaft... 8 Cylinder Head... 9 Rocker Arm Cover & Assembly GROUP 2 - INTAKE & EXHAUST SYSTEM Air Filter & Housing Muffler... 2 GROUP 3 - COOLING Coolant Recovery Tank... 0 Exhaust Manifold & Heat Exchanger Coolant Pump Raw Water Pump & Mounting... 6 Raw Water Pump Assembly... 7 Radiator & Guard GROUP 4 - FUEL SYSTEM Injection Pump & Lines Governor & Timing Gear Case Fuel Filter & Piping Fuel Lines Fuel Injector Fuel Feed Pump GROUP 5 - ELECTRICAL SYSTEM 12 Volt Standard Ground Volt Isolated Ground Volt Standard Ground Volt Isolated Ground Small Frame Alternator & Starter Medium Frame Alternator & Starter Starter, Alternator, & Flywheel Housing Control Panels Belt Guard Assembly GROUP 6 - GASKET SETS Gasket Sets...0 GROUP 7 - FRAME & MOUNTING Base Frame Assembly Base Pan with Mounting GROUP 8 - ACCESSORIES 9 & OPTIONAL EQUIPMENT Oil Drain Kit... 0 Keel Cooling Conversion 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: P /18 I

4 Model Designation MODELS INCLUDED This manual covers the parts and components used in: M773LW3, M773LW3G and NL773LW3 Model Numbers Model numbers give the unit's application, block model, aspiration, and RPM: M - NL 773 L, G, 2, 3 M - Northern Lights marine generator set NL - Northern Lights industrial generator set Model number of engine block Bore Cylinders 77 mm 3 L - Long stroke engine G- GEM Series base frame 2 - US EPA Tier II 3 - US EPA Tier III M773LW3 = Northern Lights marine diesel generator set with an 773 engine and a PX-309K2 NL773LW3 = generator with a different winding, Tier III. Northern Lights industrial diesel generator set with an 773 engine and a PX-309K2 generator with a different winding, 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 drawing below. II

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. 15 Updated ELECTRICAL SYSTEM ALTERNATOR ASSEMBLY: M - NL KEY PART NUMBER QTY. DESCRIPTION SERIAL NUMBER Alternator Assembly Flywheel, complete Plate, complete Plate Stator, complete Bearing Nut Spring washer Washer Clamp Screw Screw Collar P773 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 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. 15. Date of most recent update NOTE: a Arrows always point toward the front of the engine. III

6 GROUP 1 ENGINE Cylinder Block Assembly M773LW3 773cyl 1-0

7 Updated GROUP 1 ENGINE Cylinder Block Assembly M773LW3 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 (Use with drain hose #43) up to S/N xxxxx Oil Pan (Use with oil drain valve-see parts detail pg.1-6) from S/N xxxxx Bushing; S.T.D Bushing; U.S Bushing; U.S Bearing Expansion Plug, 45 mm Bearing Snap Ring Dowel Pin Dowel Pin Dowel Pin Spring Pin Stud Stud Stud Gasket Oil Seal Drain Cock Joint Oil Filter Tappet Push Rod Relief Valve Assembly O-ring Tube Bushing Capscrew, Hex Head M6 x 1.0 x 14 mm (with Lock Washer) Dipstick Tube Bolt Dipstick O-ring Cap } Bracket Lock Washer 3/ Capscrew, Hex Head 3/8-16 x 3/4" up to S/N xxxxx Oil Drain Hose - 1-1

8 GROUP 1 ENGINE Cylinder Block Assembly NL773LW3 NL773cylblock 1-2

9 GROUP 1 ENGINE Cylinder Block Assembly NL773LW Cylinder Block Assembly - (includes keys #2-21) Plug Expansion Plug, 25 mm Expansion Plug, 35 mm Expansion Plug, 15 mm Expansion Plug, 40 mm Plug Plug Idle Gear Shaft Oil Pan Bushing, Standard Bushing, Undersize 0.25 mm Bushing, Undersize 0.50 mm Bearing Expansion Plug, 45 mm Needle Bearing Snap Ring Dowel Pin Dowel Pin Dowel Pin Spring Pin Stud Bolt Stud Bolt Stud Bolt Gasket Oil Seal Drain Cock Filter Joint Oil Filter Tappet Push Rod Relief Valve Assembly O-ring Tube Bushing Bolt Plug Seal Washer Dipstick Tube O-ring Bolt Dipstick - 1-3

10 GROUP 1 ENGINE Crankshaft Assembly 773crankshaft 1-4

11 Updated GROUP 1 ENGINE Crankshaft 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 & 13) Dowel Pin Bearing; Lower S.T.D Bearing; Lower U.S mm Bearing; Lower U.S mm Bearing; Upper S.T.D Bearing; Upper Undersized 0.25 mm Bearing; Upper Undersized 0.50 mm Bolt 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 #21-23) Bushing Connecting Rod Bolt Nut Bearing; S.T.D Bearing; Undersized Bearing; Undersized Crankshaft Pulley Nut Flywheel Assembly (includes key #28) Ring Gear, 96 Teeth Bolt - 1-5

12 Updated GROUP 1 ENGINE Kit, Oil Drain and Valve M773LW3 From S/N xxxx-4632c to S/N xxxx KEY PART NUMBER QTY DESCRIPTION S/N Ball valve, Brass 90 Deg 1/4NPT Male X 1/4NPT Female Male Connector Brass 1/4NPT X 3/8HB Push-On Hose 3/8 ID X 7 Push-On Plug, Hex Head, Brass 1/4NPT Male Connector, Stl. 1/4NPT X 3/8-37T Female Swivel, Brass. 3/8HB X 3/8-37T Push-On - B

13 Updated From S/N xxxx GROUP 1 ENGINE Kit, Oil Drain and Valve KEY PART NUMBER QTY DESCRIPTION S/N Ball Valve,Brass 90 Degree Flow 1/4NPT Male X 1/4NPT Female Male Connector, Brass 1/4NPT X 3/8HB PUSH-ON HOSE 3/8 ID X 6-1/2 PUSH-ON PLUG,Hex Head, Brass. 1/4NPT Male Connector STL. 1/4NPT X 3/8-37T Female SWIVEL,Brass 3/8HB X 3/8-37T PUSH-ON - B-9826A 1-7

14 GROUP 1 ENGINE Oil Pump & Pick-up Updated Fig Idle Gear Assembly (former # ) 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 (Marine) Front Plate (Industrial) Gasket Bolt O-ring Oil Pipe Pick-up Bolt - **As required 1-8

15 Updated GROUP 1 ENGINE Camshaft Fig Cam Shaft Assembly (includes keys #2-6) Cam Gear Assembly Key Gear Spacer Bearing Slider Plate Bolt Bolt - 1-9

16 Updated GROUP 1 ENGINE Cylinder Head 773cylhead Cylinder Head Assembly (Marine, includes keys #2-3, 6-13, & 19) Cylinder Head Assembly (Industrial, includes keys #2-3, 6-13, & 19) Expansion Plug Expansion Plug Intake Valve Exhaust Valve Valve Guide Seal - Intake Spring Retainer Cotter Valve Guide Seal - Exhaust Cap Head Gasket, t=1.2 mm Head Gasket, t=1.3 mm Head Bolt Head Bolt Lifting Eye (Marine) Lifting Eye (Industrial) Bolt Valve Seat - Intake (Marine)

17 GROUP 1 ENGINE Rocker Arm Assembly 773rockercover Rocker Arm Assembly (Marine, includes keys #2-7, 16,17,19, & 20) Rocker Arm Assembly (Industrial, 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

18 Updated GROUP 1 ENGINE Rocker Arm Cover M773LW3 773rockerarmcover Rocker Arm Cover Gasket Baffle Vent Filter Screw Gasket Cap nut Cap O-ring Valve Bolt Bolt Bolt Air Intake Gasket Bolt Caution Label

19 GROUP 1 ENGINE Rocker Arm Cover & Intake NL773LW Rocker Arm Cover Gasket Baffle Breather Element Screw Gasket Cap Nut Cap O-ring Valve, Breather Bolt Bolt Bolt Air Intake Gasket Bolt - 773rockerarmcover 1-13

20 GROUP 2 INTAKE AND EXHAUST Air Filter and Housing M773LW3 A-10836C / C Housing Hose 1-5/8 ID x 1-3/4 3 Ply Silicone Hose Clamp # Silencer Plate Cover Capscrew, Hex Head M6 x 1.0 x 50 mm S/S Flat Washer M6 S/S Screen Air Filter Element Cover Capscrew, Hex Head M6 x 1.0 x 20 mm S/S 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 M8 S/S Flat Washer M8 S/S - 2-0

21 GROUP 2 INTAKE & EXHAUST SYSTEM Air Filter and Housing NL773LW3 773aircleaner Air Cleaner Assembly (includes keys #9-12) Hose Band Hose Bracket Collar Bolt Bolt Bracket Filter Housing Element Cover Valve - 2-1

22 Updated GROUP 2 INTAKE & EXHAUST SYSTEM Exhaust Manifold & Muffler NL773L3 773exhmanifold Exhaust Manifold Assembly (includes keys #2-5) Exhaust Manifold Gasket Housing Bolt Gasket Spring Washer Stud Nut Bolt Nut Washer Band Bolt Exhaust Elbow Exhaust Elbow, 1-1/4 NPT (optional) Bolt - 2-2

23 This Page Left Intentionally Blank

24 GROUP 3 COOLING SYSTEM Coolant Recovery Tank Updated 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 - 3-0

25 This Page Left Intentionally Blank

26 GROUP 3 COOLING SYSTEM Exhaust Manifold and Heat Exchanger M773LW3 A-9289/ D

27 Updated GROUP 3 COOLING SYSTEM Exhaust Manifold and Heat Exchanger M773LW Exhaust Manifold/ Expansion Tank Heat Exchanger Element Wet Exhaust Elbow, Stainless Steel Wet Exhaust Elbow, Cast Iron up to S/N xxxxx 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 3-3

28 GROUP 3 COOLING SYSTEM Coolant Pump Updated M773LW3 Fig Coolant Pump Assembly Gasket Bolt Nut Bolt Pulley Spacer Bolt Cap Clamp - 3-4

29 Updated GROUP 3 COOLING SYSTEM Coolant Pump and Thermostat Housing NL773LW3 NL773coolantpump Coolant Pump Assembly Gasket Bolt Bolt Nut Hose Clamp # Plug Temperature Switch 230 o F (see Electrical System) Gasket Thermostat Housing Bolt Thermostat Thermostat Cover Gasket Bolt Fan Pulley Spacer Cooling Fan (Blower 330 mm OD) Bolt - 3-5

30 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

31 Updated GROUP 3 COOLING SYSTEM Raw Water Pump Assembly 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 #

32 GROUP 3 COOLING SYSTEM Radiator and Guard, Aluminum NL773LW3 Base Frame A-11840/ D-3494z 3-8

33 GROUP 3 COOLING SYSTEM Radiator and Guard, Aluminum NL773LW Radiator Side Panel, Left hand Side Panel, Right hand Top Panel Radiator Support Grille Hose, Radiator Outlet Hose, Radiator Inlet Hose Clamp # Hose Clamp # Capscrew, Hex Head M8 x 1.25 x 16 mm Capscrew, Hex Head M8 x 1.25 x 20 mm Capscrew, Hex Head M8 x 1.25 x 30 mm (left hand side) Capscrew, Hex Head M8 x 1.25 x 40 mm (right hand side) Lock Washer, Helical M Flat Washer M Capscrew, Hex Head M6 x 1.0 x 16 mm Lock Washer, Helical M Flat Washer M Capscrew, Hex Head M6 x 1.0 x 20 mm Decal, Northern Lights Shroud with Fan Guard Bolt Filler Cap Overflow Hose Drain Cock O-ring - 3-9

34 GROUP 4 FUEL SYSTEM Injection Pump and Lines Fig

35 Updated GROUP 4 FUEL SYSTEM Injection Pump and Lines 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 ** Solenoid, 12 Volt Isolated Ground Solenoid, 24 Volt Isolated Ground Feed Pump Bolt Bolt - 4-1

36 GROUP 4 FUEL SYSTEM Governor and Timing Gear Case M773LW3 773governor,timinggearcase 4-2

37 Updated 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 (former # ) Bolt O-ring Holder O-ring Cap Plate Nut Spring - M773LW3 4-3

38 GROUP 4 FUEL SYSTEM Governor Housing and Timing Gear Case NL773LW3 773governor,timinggearcase 4-4

39 Updated GROUP 4 FUEL SYSTEM Governor Housing and Timing Gear Case NL773LW Timing Gear Case ( includes key #2) Spring Pin Gasket Oil Seal Governor Lever Assembly (includes keys #6, 7, 8) Tension Lever Snap Ring Washer Snap Pin Spring Armature O-ring Governor Lever Bolt Nut Shaft O-ring Snap Ring Bracket Bolt Bolt Armature Snap Ring O-ring Spring Washer Nut Stop Lever Bolt Bolt Bolt Bolt Start Spring Cover Gasket (former # ) O-ring Nut Spring - 4-5

40 GROUP 4 FUEL SYSTEM Fuel Filter and Piping 773fuelfilter 4-6

41 Updated GROUP 4 FUEL SYSTEM Fuel Filter and Piping Fuel Filter Assembly (includes keys #3-6) Caution Label Fuel Filter Gasket Plug Joint Bolt Bolt Bracket, Filter Support & Lifting Eye (Marine) Bracket (Industrial) Bolt Return Pipe Screw Seal Washer Bolt Gasket Valve Assembly (includes keys 16-18) Connector Steel Ball Rubber Bolt Gasket Pipe (Marine) Pipe (Industrial) Pipe Pipe (Marine) Pipe (Industrial) Spring Washer - 4-7

42 GROUP 4 FUEL SYSTEM USCG SAE J1527 ISO 7840 Fuel Lines M773LW3 Up to S/N xxxx-46361c NL773LW3 All Updated A / B Fuel Manifold 1/4 NPT Capscrew, Hex Head M6 x 1.0 x 16 mm S/S Lock Washer, Helical M6 S/S Plug, Hex Head Brass 1/4 NPT Male Elbow 90, Brass 1/4 NPT x 5/16-45T Male Elbow 90 0, Brass 1/4 NPT x 1/4-45T Hose Assembly 1/4" ID x 12-1/ Hose Assembly 1/4" ID x

43 Updated GROUP 4 FUEL SYSTEM USCG SAE J1942 ABS Fuel Lines M773LW3 Up to S/N xxxx-46361c A-10003/ B Fuel Manifold 1/4 NPT Capscrew, Hex Head M6 x 1.0 x 16 mm S/S Lock Washer, Helical M6 S/S Plug, Hex Head Brass 1/4 NPT Male Elbow 90, Steel 1/4 NPT x 5/16-37T Male Elbow 90 0, Steel 1/4 NPT x 1/4-37T Hose Assembly 1/4" ID x 12-1/ Hose Assembly 3/16" ID x

44 Updated GROUP 4 FUEL SYSTEM USG A-1 SAE J1527 ISO 7840 Fuel Lines M773LW3 From S/N xxxx-46362c B-9827 Key Part Number Qty Description Serial Number Plug, Hex Head Brass 1/4 NPT Male Elbow, 45, Brass. 1/4NPT X 5/16-45T Male Elbow, 45, Brass. 1/4NPT X 1/4-45T Hose Assembly 1/4 ID x 12-1/ Hose Assembly 1/4 ID x

45 Updated GROUP 4 FUEL SYSTEM USG A-1 SAE J1942 ABS Fuel Lines M773LW3 From S/N xxxx-46362c B-9827 Key Part Number Qty Description Serial Number Plug, Hex Head Brass 1/4 NPT Male Elbow, 45, Steel. 1/4NPT X 5/16-37T Male Elbow, 45, Steel. 1/4NPT X 1/4-37T Hose Assembly 1/4 ID x 12-1/ Hose Assembly 3/16 ID x

46 Updated GROUP 4 FUEL SYSTEM USG A-1 SAE J1527 ISO 7840 Fuel Lines M773LW3 From S/N xxxx D-5044 Key Part Number Qty Description Serial Number Fuel Manifold for 1/4-37T and 5/16-37T union elbow Capscrew Hex Head M8x1.25 X 16mm S/S LOCK WASHER,HELICAL M8 S/S Bulkhead Union Elbow 90,STL. 5/16-37T (w/o Locking Nut) Bulkhead Union Elbow 90,STL. 1/4-37T (w/o Locking Nut) Hose Assy 5/16 ID X 12 5/16FMS X 5/16FMS Hose Assy 1/4 ID X 19 1/4FMS X 1/4FMS Jam Nut 1/2-20 STL Jam Nut 7/16-20 STL Cap, Hex Head STL 5/16-37T Cap, Hex STL 1/4-37T

47 GROUP 4 FUEL SYSTEM This Page Left Intentionally Blank

48 GROUP 4 FUEL SYSTEM Fuel Injector Fig Injector Assembly (includes keys #1 - #5) Nut (Marine) Nut (Industrial) Gasket Shim Spring Nozzle

49 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

50 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Standard Ground Marine Units A-6258 / C-2490A 5-0

51 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Standard Ground Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/8 NPT * Temperature Switch 95 C M16 X Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 12 Volt SPDT Relay Base Retainer Circuit Breaker 15 Amp - Screw mount type * Circuit Breaker 15 Amp - Snap-in Type Control Panel S-1B (not shown,see detail) Engine Wire Harness - Round Merc Plug Connector Diode, 6 Amp 50 Volt PIV Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" S/S 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) Alternator 12 Volt (see mounting detail) Banjo Bolt - M8 x 1.25 x 18mm (Tapped 1/8 NPT) Oil Line Starter 12 Volt (see mounting detail) ** Elbow 90 Steel 1/8 NPT x 1/8 NPT (not shown) - * Replaces (NLA) Required 3/8 x 1/8 NPT Bushing **As required Marine Units 5-1

52 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Standard Ground B+ System Marine Units A-6258 / C-2490A 5-2

53 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Standard Ground Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/8 NPT * Temperature Switch 95 C M16 X Oil Pressure Switch 1/8 NPT 14.2 PSI Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 12 Volt SPDT Terminal Retainer Retainer Circuit Breaker DC 15 Amp - Screw mount type * Control Panel S-1B (not shown,see detail) Engine Wire Harness - Round Merc Plug Connector Diode, 1 Amp 200 Volt PIV Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" S/S 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) Alternator 12 Volt (see mounting detail) Banjo Bolt - M8 x 1.25 x 18mm (Tapped 1/8 NPT) Oil Line Starter 12 Volt (see mounting detail) ** Elbow 90 Steel 1/8 NPT x 1/8 NPT (not shown) - * Replaces (NLA) Requires 3/8 x 1/8 NPT Bushing B+ System Marine Units **As required 5-3

54 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Isolated Ground Marine Units A-6258 / C-2490A 5-4

55 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Isolated Ground Marine Units Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/4 NPT * Temperature Switch 95 C M16 x Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 12 Volt SPDT Relay Base Retainer Circuit Breaker 15 Amp (Screw Mount Type) Circuit Breaker 15 Amps (Snap-In Type) Control Panel, S1-B (see detail) Engine Wire Harness - Round Merc Plug Connector Harness Ground Circuit Addition Diode, 6 Amp 50 Volt PIV (included in Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" S/S 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) Alternator 12 Volt (see mounting detail) Banjo Bolt M8 x 1.25 x 18mm (Tapped 1/8 NPT) Oil Line Starter 12 Volt (see mounting detail) ** Street Tee Steel 1/8 NPT x 1/8 NPT (not shown) ** Plug 1/8 NPT (not shown) - * Replaces (NLA) Requires 3/8 x 1/4 Bushing **As required 5-5

56 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Isolated Ground B+ System Marine Units A-6258 / C-2490A 5-6

57 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Isolated Ground Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/4 NPT * Temperature Switch 95 C M16 x Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 12 Volt SPDT Relay Base Terminal Retainer Circuit Breaker, 10 Amp (Screw Mount Type) Control Panel, S1-B (see detail) Engine Wire Harness - Square Deutsch Plug Connector Harness Ground Circuit Addition Diode, 1 Amp 200 Volt PIV (included in ) Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" S/S 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) Alternator 12 Volt (see mounting detail) Banjo Bolt M8 x 1.25 x 18mm (Tapped 1/8 NPT) Oil Line Starter 12 Volt (see mounting detail) ** Branch Tee Steel 1/8 NPT x 1/8 NPT (not shown) ** Plug 1/8 BSPT - **As required Updated * Replaces (NLA) requires 3/8 NPT x 1/4 NPT Bushing B+ System Marine Units 5-7

58 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground Marine Units A-6258 / C-2490A 5-8

59 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground Marine Units Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/8 NPT * Temperature Switch 95 C M16 X Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 24 Volt SPDT Relay Base Terminal Retainer Circuit Breaker, 15 Amp (Screw Mount Type) Circuit Breaker 15 Amp (Snap-In Type) Control Panel, S1-B (see detail) Engine Wire Harness - with Round Merc Plug Connector Wire Harness, Glow Plug Pulse Circuit Diode, 6 Amp 50 Volt PIV (included in ) Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" S/S Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 24 Volt (see also Fuel System) Alternator 24 Volt 40 Amp (see mounting detail) up to S/N xxxx-46361c Alternator 24 Volt 25 Amp from S/N xxxx-46362c Banjo Bolt M8 x 1.25 x 18mm (Tapped 1/8 NPT) Oil Line Starter 24 Volt (see mounting detail) ** Branch Tee Steel 1/8 NPT x 1/8 NPT (not shown) Timer Soleniod 24 VDC 85 Amp Bracket, Solenoid Mounting Capscrew, Hex Head M6 x 1.0 x 16mm Flat Washer M Hex Nut, Nylock M12 x Capscrew, Hex Head M12 x 1.25 x 20mm S/S Laco Washer M Capscrew, Hex Head M6 x 1.0 x 30mm S/S Flat Washer M6 S/S Hex Nut, Nylock M6 x ** Plug 1/8 BSPT - * Replaces (NLA) requires 3/8 NPT x 1/8 NPT Bushing ** As required 5-9

60 GROUP 5 ELECTRICAL SYSTEM Updated Engine Electrical 24 Volt Standard Ground B+ System Marine Units A-6258 / C-2490A 5-10

61 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/8 NPT * Temperature Switch 95 C M16 X Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 24 Volt SPDT Relay Base Terminal Retainer Circuit Breaker, DC 10 Amp (Screw Mount Type) Control Panel, S1-B (see detail) Engine Wire Harness - with Square Deutsch Plug Connector Wire Harness, Glow Plug Pulse Circuit Diode, 1 Amp 200 Volt PIV (included in ) Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" S/S Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 24 Volt (see also Fuel System) Alternator 24 Volt 25 Amp Banjo Bolt M8 x 1.25 x 18mm (Tapped 1/8 NPT) Oil Line Starter 24 Volt (see mounting detail) Branch Tee Steel 1/8 NPT x 1/8 NPT (not shown) Timer Soleniod 24 VDC 85 Amp Bracket, Solenoid Mounting Caprescrew, Hex Head M6 x 1.0 x 16mm Flat Washer M Hex Nut, Nylock M12 x Capscrew, Hex Head M12 x 1.25 x 20mm S/S Laco Washer M Capscrew, Hex Head M6 x 1.0 x 30mm S/S Flat Washer M6 S/S Hex Nut, Nylock M6 x Plug 1/8 BSPT - * Replaces (NLA) requires 3/8 NPT x 1/8 NPT Bushing B+ System Marine Units 5-11

62 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Isolated Ground Marine Units A-6398, A-6402 / C-2490A 5-12

63 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Isolated Ground Marine Units Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/4 NPT * Temperature Switch 95 C M16 x Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 24 Volt SPDT Relay Base Retainer Circuit Breaker, 15 Amp (Screw Mount Type) Circuit Brealer, 15 Amp (Snap-in Type) Control Panel, S1-B (see detail) Engine Wire Harness - Round Merc Plug Connector Harness Assembly, Glow Plug Pulse Circuit Diode, 6 Amp 50 Volt PIV Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" S/S Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 24 Volt (see also Fuel System) Alternator 24 Volt 35 Amp (see mounting detail) up to S/N xxxx-46361c Alternator 24 Volt 25 Amp from S/N xxxx-46362c Banjo Bolt M8 x 1.25 x 18mm (Tapped 1/8 NPT) Oil Line Starter 24 Volt (see mounting detail) ** Branch Tee Steel 1/8 NPT x 1/8 NPT (not shown) Timer Soleniod 24 Volt 85 Amp Bracket, Solenoid Mounting Caprescrew, Hex Head M6 x 1.0 x 16mm Flat Washer M Hex Nut, Nylock M12 x Capscrew, Hex Head M12 x 1.25 x 20mm S/S Laco Washer M Capscrew, Hex Head M6 x 1.0 x 30mm S/S Flat Washer M6 S/S Nylock Nut, Nylock M6 x Plug 1/8 BSPT - * Replaces (NLA) requires 3/8 NPT x 1/4 NPT Bushing

64 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Isolated Ground B+ System Marine Units A-6398, A-6402 / C-2490A 5-14

65 Updated GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Isolated Ground B+ System Marine Units Temperature Sender 250 F 3/8 NPT Dual Station Temperature Sender 250 F 1/4 NPT * Temperature Switch 95 C M16 x Oil Pressure Switch 1/8 NPT Oil Pressure Sender 1/8 NPT Dual Station Oil Pressure Sender 1/8 NPT Relay, 24 Volt SPDT Relay Base Terminal Retainer Circuit Breaker, DC 10 Amp (Screw Mount Type) Control Panel, S1-B (see detail) Engine Wire Harness - Square Deutsch Plug Connector Harness Assembly, Glow Plug Pulse Circuit Diode, 1 Amp 200 Volt PIV (included in ) Wire Harness Extension 20' (not shown) Grommet Machine Screw #10-32 x 3/8" S/S Flat Washer # Hex Nut, Nylock # Hex Nut, M8 x Lock Washer M Hex Nut, M5 x Lock Washer M Stop Solenoid 24 Volt (see also Fuel System) Alternator 24 Volt 25 Amp Banjo Bolt M8 x 1.25 x 18mm (Tapped 1/8 NPT) Oil Line Starter 24 Volt (see mounting detail) Branch Tee Steel 1/8 NPT x 1/8 NPT (not shown) Timer Soleniod 24 Volt 85 Amp Bracket, Solenoid Mounting Caprescrew, Hex Head M6 x 1.0 x 16mm Flat Washer M Hex Nut, Nylock M12 x Capscrew, Hex Head M12 x 1.25 x 20mm S/S Laco Washer M Capscrew, Hex Head M6 x 1.0 x 30mm S/S Flat Washer M6 S/S Nylock Nut, Nylock M6 x ** Plug 1/8 BSPT - Note: #26-36 Required for glow plug operation * Replaces (NLA) requires 3/8 NPT x 1/4 NPT Bushing

66 GROUP 5 ELECTRICAL SYSTEM Small Frame Alternators and Starter Updated altandstarter 5-16

67 Updated GROUP 5 ELECTRICAL SYSTEM Small Frame Alternators and Starter Alternator 12 Volt, 40 Amp Standard Ground Alternator 12 Volt, 40 Amp Isolated Ground Alternator 24 Volt 25 Amp Standard Ground Alternator 24 Volt 25 Amp Isolated Ground 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 (use with & ) Drive Belt (use with & ) Lock Washer M6 S/S Flywheel Housing Starter, 12 Volt (see parts detail) Starter, 12 Volt Isolated Ground Starter, 24 Volt Standard Ground (former # ) Starter, 24 Volt Isolated Ground (former # ) Capscrew, Hex Head M10 x 1.5 x 45 mm (use with starters - # & ) Capscrew, Hex Head M10 x 1.5 x 50 mm (use with starters - # & )) Bolt Spring Washer Nut Plug (Marine) Plug (Industrial) Bracket up to S/N xxxx Spring Washer up to S/N xxxx Bolt up to S/N xxxx

68 GROUP 5 ELECTRICAL SYSTEM Medium Frame Alternators 24 V/ 40 Amp & 24V/ 35 Amp A-9711, A Alternator 24 Volt, 35 Amp Isolated Ground Alternator 24 Volt, 40 Amp Standard Ground Pulley Bracket, Medium Frame Alternator Mtg Capscrew, Hex Head M8 x 1.25 x 20 mm S/S Lock Washer, Helical M8 S/S Capscrew, Hex Head 1/2-13 x 2-1/ Flat Washer 1/2 SAE Hex Nut, Nylock 1/ Tensioning Arm Capscrew, Hex Head 5/16-18 x 1 S/S Stud Washer 5/ Lock Washer, Helical 5/16 S/S Diode Harness Addition (not shown) Drive Belt

69 Updated GROUP 5 ELECTRICAL SYSTEM Starter, Alternator, and Flywheel NL773LW Alternator, 12 Volt 40 Amp Bracket Drive Belt (former # ) Tensioning Arm Collar Bolt Washer Bolt Bolt Spring Washer Nut Bolt Flywheel Housing Bolt Starting Motor 12 Volt Washer Bolt Spring Washer Nut Plug Lifting Eye NL773alt&starter

70 GROUP 5 ELECTRICAL SYSTEM 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 5-20

71 Updated GROUP 5 ELECTRICAL SYSTEM S-1 Control Panel 12 & 24 Volt B+ Electrical Systems S-1 Start/Stop Control Panel (includes all keys) Plate, S-1 Control Panel Rocker Switch, Momentary (On)-Off Rocker Switch, Momentary (On)-Off-(On) Green Lamp Wire Harness Label "12-24 Volt" (Not Shown)

72 GROUP 5 ELECTRICAL SYSTEM Updated Series 1-B Start-Stop Control Panel 12 & 24 Volt 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

73 Updated GROUP 5 ELECTRICAL SYSTEM Series 1-B Start/Stop Control Panel B+ Electrical Systems Series 1-B Start/Stop Control Panel 12 & 24 Volt (includes all keys) Plate Rocker Switch, Momentary (On)-Off Rocker Switch, Green LED (On)-Off-(On) Green Lamp Hour Meter Machine Screw, Round Head Phillips #6-32 x 1/2" Star Washer, Internal #6, Stainless Steel Hex Nut #6-32, Stainless Steel Wire harness Label Volts (Not shown)

74 GROUP 5 ELECTRICAL SYSTEM S-3C Control Panel 12 & 24 Volt VDO Ocean Line Black Bezel Gauges A-11322, A-11323/ 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 12 Volt Oil Pressure Gauge, 0-80 PSI 24 Volt Temperature Gauge, F 12 Volt Temperature Gauge, F 24 Volt DC Voltmeter, 8-16 VDC DC Voltmeter, VDC Hourmeter 12/ 24 Volt Panel Wire Harness Self Tapping Screw, Oval Head Phillips #6 x 3/ Toggle Switch Label 12 Volt (not shown) Label 24 Volt (not shown) ** 12 Volt Bulb (not shown) ** 24 Volt Bulb (not shown) - **As required 5-24

75 Updated GROUP 5 ELECTRICAL SYSTEM S-3C Control Panel 12 Volt VDO Viewline Black Bezel Gauges 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 12/24 Volt * Temperature Gauge, F 12/24 Volt * DC Voltmeter, 8-16 VDC * Voltmeter VDC * Hourmeter 12/ 24 Volt Panel Wire Harness Self Tapping Screw, Oval Head Phillips #6 x 3/ Toggle Switch Label 12 Volt (not shown) Bezel - * Note Bezel supplied separately 5-25