PARTS CATALOG. P844-2 For Models: L844D, M844K2, M844W2, M844LK2, M844LW2, NL844K2, NL844LK2, NL844W2, NL844LW2, M20CR2, and M20CRW2

Transcription

1 P844-2 For Models: L844D, M844K2, M844W2, M844LK2, M844LW2, NL844K2, NL844LK2, NL844W2, NL844LW2, M20CR2, and M20CRW2 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 2007 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 L844D, M844K2, M844W2, M844LK2, M844LW2, NL844K2, NL844LK2, NL844W2, NL844LW2, M20CR2, & M20CRW2 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... 8 Cylinder Head... 9 Rocker Arm Cover & Assembly GROUP 2 - INTAKE & EXHAUST SYSTEM Air Filter & Housing Air Intake & Filter... 2 Air Filter & Mounting - Industrial... 3 Exhaust Manifold & Muffler... 4 GROUP 3 - COOLING Heat Exchanger & Exhaust Manifold Expansion Tank KC & Exhaust Manifold Coolant Pump Raw Water Pump & Mounting... 7 Raw Water Pump Assembly... 8 Radiator & Guard... 9 GROUP 4 - FUEL SYSTEM General Arrangement Governor & Timing Gear Case Fuel Filter & Piping... 8 Fuel Line Connection... 9 Coast Guard Fuel Line Connection... 9 Fuel Injector Fuel Feed Pump Throttle Assembly GROUP 5 - ELECTRICAL SYSTEM 12 & 24 Volt Engine Starter Mounting & Flywheel Housing Relay Board & Circuit Breaker Starting Motor Assembly Alternator & Mounting Control Panels Belt Guard Assembly GROUP 6 - GASKET SETS Gasket Sets GROUP 7 - GEAR AND ADAPTER SETS Not available at this time. GROUP 8 - FRAME & MOUNTING Front Engine Mounting... 0 Gear Attaching Parts... 1 Base Frame Assemblies GROUP 9 - ACCESSORIES GROUP 9 - & OPTIONAL EQUIPMENT PTO... 1 Electric Clutch... 2 Oil Drain Kits Coolant Recovery Tank... 5 Remote Expansion Tank... 6 Low Water Level Switch... 7 Low Coolant Level Switch... 8 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: L844D, M844K2, M844W2, M844LK2, M844LW2, M20CR2, M20CRW2, NL844K2, NL844LK2, NL844W2, and NL844LW2. Model Numbers Model numbers give the unit's application, block model, aspiration, and RPM: L - M - NL 844 L W L - Lugger Propulsion engine M - Northern Lights Marine generator set NL - Northern Lights Industrial generator set Model number of engine block Bore Cylinders 84 mm 4 Designates a Long Stroke engine. Designates a new winding in the generator. M 844K2 M 844LK2 M 844W2 = = = Northern Lights marine diesel generator set with an 844 engine and a PXK generator, Tier II. Northern Lights marine diesel generator set with an 844L engine and a PXK generator, Tier II. Northern Lights marine diesel generator set with an 844 engine and a generator with a different winding, Tier II. M 20CRW2 NL 844K2 NL 844LK2 = = = Northern Lights 20 kw commercial grade marine diesel generator with a generator with a different winding, Tier II. Northern Lights industrial diesel generator set with an 844 engine and a radiator, Tier II. Northern Lights industrial diesel generator set with an 844L engine and a radiator, Tier II. M 20CR2 = Northern Lights 20 kw commercial grade marine diesel generator with a special generator,tier II. NL 844LW2 = Northern Lights industrial diesel generator set with an 844L engine with a different winding in the generator, and a radiator, Tier II. 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 844 Marine Application Only Industrial Application Only 1-0

7 GROUP 1 ENGINE Cylinder Block Assembly Cylinder Block Assembly - Marine (includes keys #2-21) Cylinder Block Assembly - Industrial (includes keys #2-21) Expansion Plug 25 mm Expansion Plug 40 mm Plug Plug Plug Idle Gear Shaft Assembly Plug Bush; Standard Bush; Undersize 0.25 mm Bush; 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 ** Wear Sleeve; Repair Type Drain Cock Filter Joint Oil Filter Tappet Push Rod Relief Valve Assembly O-ring Tube Bushing Oil Pan - Marine Oil Pan - Industrial Bolt Dipstick Tube O-ring Bolt Dipstick O-ring Oil Pipe Suction Filter Bolt Drain Hose* Hose Clamp* Gasket* Cap* Seal Washer - Industrial Plug M12 x Industrial - *Marine Application Only **As required 1-1

8 GROUP 1 ENGINE Cylinder Block Assembly 844L & M20CR Marine Application Only Industrial Application Only 1-2

9 GROUP 1 ENGINE Cylinder Block Assembly 844L & M20CR Cylinder Block Assembly - Marine (includes keys #2-21) Cylinder Block Assembly - Industrial (includes keys #2-21) Expansion Plug 25 mm Expansion Plug 40 mm Plug Plug Plug Idle Gear Shaft Assembly Plug Bush; Standard Bush; Undersize 0.25 mm Bush; 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 ** Wear Sleeve; Repair Type Drain Cock Filter Joint Oil Filter Tappet Push Rod Relief Valve Assembly O-ring Tube Bushing Oil Pan - Marine Oil Pan - Industrial Bolt Dipstick Tube O-ring Bolt Dipstick O-ring Oil Pipe Suction Filter Bolt Drain Hose* Hose Clamp* Gasket* Cap* Seal Washer - Industrial Plug M12 x Industrial - *Marine Application Only **As required 1-3

10 GROUP 1 ENGINE Crankshaft Assembly

11 GROUP 1 ENGINE Crankshaft Assembly Crankshaft Assembly (includes keys #2-5) 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 Bearing; Undersize 0.25 mm Bearing; Undersize 0.50 mm Bearing; Standard Bearing; Undersize 0.25 mm Bearing; Undersize 0.50 mm Thrust Washer Bolt Bolt Ring Kit; Standard Piston Kit; Standard (formerly # ) 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 (Marine) Pulley (Industrial) Nut Flywheel Assembly (includes key #30) SAE #7-1/ Ring Gear (109 Teeth) Bolt (not shown) Drive Belt (with 12V/ 35A alternator) Drive Belt (with 12V/ 51A and 24V/ 35A alternators) - 1-5

12 GROUP 1 ENGINE Crankshaft Assembly 844L & M20CR 1-6

13 GROUP 1 ENGINE Crankshaft Assembly 844L & M20CR Crankshaft Assembly (includes keys #2-5) 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 Bearing; Undersize 0.25 mm Bearing; Undersize 0.50 mm Bearing; Standard Bearing; Undersize 0.25 mm Bearing; Undersize 0.50 mm Thrust Washer Bolt (formerly # ) Bolt Ring Kit; Standard Piston Kit; Standard (includes key #17, formerly # ) 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 (Marine) Pulley (Industrial) Nut Flywheel Assembly (includes key #30) SAE #7-1/ Ring Gear (126 Teeth) Bolt (not shown) Drive Belt (with 12V/ 35A alternator) Drive Belt (with 24V/ 35A alternator) - Note: Earlier design pistons may not be substituted for new pattern items. 1-7

14 GROUP 1 ENGINE Camshaft & Oil Pump 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 - 1-8

15 GROUP 1 ENGINE Cylinder Head Cylinder Head Assembly (Marine, includes keys #2-12, & 20) Cylinder Head Assembly (Industrial, 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 = 1.2 mm (844) Head Gasket; t = 1.3 mm (844) Head Gasket; t = 0.4 mm (844L & M20CR, formerly # ) Head Gasket; t = 0.5 mm (844L & M20CR, formerly # ) Head Bolt Head Bolt Hanger Bolt Valve Seat, Intake Bolt - 1-9

16 GROUP 1 ENGINE Rocker Arm Assembly Rocker Arm Assembly, Marine Rocker Arm Assembly, Industrial Rocker Arm - Intake Rocker Arm - Exhaust Screw Nut Rocker Arm Shaft Spring Bolt Stud Bolt Nut Oil Pressure Switch (see Electrical) Oil Pipe (844) Oil Pipe (844L & M20CR) Gasket Banjo Bolt Gasket O-ring Shim Banjo Bolt (tapped 1/8 NPT)

17 GROUP 1 ENGINE Rocker Arm Cover Rocker Arm Cover ( L Marine, formerly # ) Rocker Arm Cover ( L Industrial & M20CR) Gasket Baffl e Breather Element Screw Gasket Cap Nut Cap O-ring Valve, Breather Bolt Bolt Bolt

18 GROUP 2 INTAKE & EXHAUST SYSTEM Air Filter and Housing L844 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, Housing Separater 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 Hose Clamp #28 Extended Band S/S - 2-0

19 GROUP 2 INTAKE & EXHAUST SYSTEM Air Filter and Housing M844 & M844L 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 (844) Plate, Air Filter Baffl e (844L) 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

20 GROUP 2 INTAKE & EXHAUST SYSTEM Air Intake & Filter M20CR & NL K2AIRINTAKE Intake Manifold Gasket Bolt Air Filter (M20CR) Hose Clamp - 2-2

21 GROUP 2 INTAKE & EXHAUST SYSTEM Air Filter & Mounting NL844 & 844L 844aircleaner Air Cleaner Assembly (includes keys #13-16) Hose Clamp # Hose Bracket Bracket Lifting Eye Bolt Bolt Bolt Washer Bolt Bolt Housing Element Cover Assembly Valve - 2-3

22 GROUP 2 INTAKE & EXHAUST SYSTEM Exhaust Manifold & Muffler Industrial Muffl er Assembly (includes keys #1-4) Exhaust Manifold Muffl er Element Gasket Capscrew, Hex Head with Washer M6 x 1.0 x 12 mm Exhaust Pipe Gasket Capscrew, Hex Head with Washer M6 x 1.0 x 25 mm Capscrew, Socket Head M8 x 1.25 x Gasket ** Capscrew, Hex Head M8 x 1.25 x 70 mm ** Stud M8 x 1.25 x 75 mm Lock Washer, Hi-Collar M ** Hex Nut M8 x Exhaust Elbow 1-1/2 NPT, Female Exhaust Elbow, Plain Clamp Flat Washer M Lock Washer M Hex Nut M8 x Capscrew, Hex Head M8 x 1.25 x 65 mm - **As required 2-4

23 GROUP 2 INTAKE & EXHAUST SYSTEM Notes 2-5

24 GROUP 3 COOLING SYSTEM Heat Exchanger & Exhaust Manifold A-6256, A-6509 / D

25 GROUP 3 COOLING SYSTEM Heat Exchanger & Exhaust Manifold Exhaust Manifold/Expansion Tank Heat Exchanger Element Wet Exhaust Elbow (stainless steel) Wet Exhaust Elbow (cast iron) End Cap Cover Plate Filler Cap (7 PSI) Thermostat (82 C) Gasket Gasket (can use # ) Spring Nameplate, Northern Lights Nameplate, "Lugger" (L844 only) Hose Hose 3/4" ID x 18-1/2" Hose 5/16" ID x 25" Union 3/4 Hose Barb x 3/4 Hose Barb Plug, Socket Head 1/2 NPT Connector, Male 1/2 BSPT x 3/4 Hose Barb Hose Clamp # Hose Clamp # Hose Clamp # ** Hex Head Plug 3/8 NPT Capscrew, Hex Head M8 x 1.25 x 110 mm Capscrew, Hex Head M6 x 1.0 x 110 mm Capscrew, Hex Head M8 x 1.25 x 25 mm Flat Washer M Flat Washer M Gasket Hose Clamp # Stud M8 x 1.25 x 20 x 25 mm (35 mm OAL) Hex Nut M8 x Drain Cock 1/4 NPT - **As required 3-1

26 GROUP 3 COOLING SYSTEM Expansion Tank & Exhaust Manifold M844 & M844L Keel Cooled Applications A-6420, A-6510 / D

27 GROUP 3 COOLING SYSTEM Expansion Tank & Exhaust Manifold M844 & M844L Keel Cooled Applications Exhaust Manifold/Expansion Tank End Cap Cover Plate Filler Cap (7 PSI) Thermostat (82 C) Gasket Spring Decal, Northern Lights Drain Cock 1/4 NPT Hose, Overfl ow 5/16" ID x 25" Hose Clamp # Plug, Hex Head 3/8 NPT Capscrew, Hex Head M8 x 1.25 x 110 mm (M-844L & M-20CR) Capscrew, Hex Head M6 x 1.0 x 110 mm (M-844L & M-20CR) Flat Washer M6 (M-844L & M-20CR) Flat Washer M Gasket Plug, Socket Head 1/8 NPT Hose Male Connector 3/8 NPT x 1/2 HB Hose Clamp # Gasket Adapter, Dry Exhaust Straight 1-1/2 NPT (M20CR only) Elbow, Dry Exhaust Heat Shield (used with Straight Adapter - M20CR only) Lagging (used with Dry Elbow) - 3-3

28 GROUP 3 COOLING SYSTEM Coolant Pump Industrial Applications NL844 & 844L P844waterpump 3-4

29 GROUP 3 COOLING SYSTEM Coolant Pump Industrial Applications NL844 & 844L 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 (221 F/ C) Hose Hose Clamp # Thermostat Cover Gasket Bolt Pulley Cooling Fan Spacer Bolt, M6 x 1.0 x 35 mm - **As required 3-5

30 GROUP 3 COOLING SYSTEM Coolant Pump, Marine Coolant Pump Assembly Backing Plate Gasket Plug Screw Gasket Bolt Nut Pulley Spacer Bolt - 3-6

31 GROUP 3 COOLING SYSTEM Raw Water Pump & Mounting All Marine Applications A-4779 / B O-ring 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 65 mm Capscrew, Hex Head M8 x 1.25 x 60 mm Lock Washer, Helical M Hex Nut M8 x

32 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) Housing 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 3/8" Hex Head Screw #10-32 x 3/8" Lock Washer #

33 GROUP 3 COOLING SYSTEM Radiator & Guard Copper NL844 & 844L A-6306 / D-2457A Top Panel up to xxxx C Side Panel Radiator Support Radiator Assembly, Copper (includes keys #20-26) Bracket, Upper Radiator Support Spacer, Radiator Support Capscrew, Hex Head M8 x 1.25 x 20 mm Flat Washer M Lock Washer M Capscrew, Hex Head M10 x 1.5 x 20 mm Lock Washer M Capscrew, Hex Head M6 x 1.0 x 12 mm Lockwasher M Flat Washer M Capscrew, Hex Head M6 x 1.0 x 20 mm Hex Nut M6 x Hose, Radiator Inlet Hose, Radiator Outlet Hose Clamp Radiator Cap Bolt Shroud with Fan Guard Drain Cock O-ring Hose Decal Northern Lights (not shown) ** Air Duct Adapter (optional - not shown) **as required ** Grille **as required Bracket, Radiator Side Panel Mounting - 3-9

34 GROUP 3 COOLING SYSTEM Radiator & Guard Aluminum NL844 & 844L A-6306 / D-2457b 3-10

35 GROUP 3 COOLING SYSTEM Radiator & Guard Aluminum NL844 & 844L Top Panel from s/n xxxx-38046c Side Panel Radiator Support Radiator Assembly, Aluminum (includes keys #20-26) Bracket, Upper Radiator Support Spacer, Radiator Support Capscrew, Hex Head M8 x 1.25 x 20 mm Flat Washer M Lock Washer M Capscrew, Hex Head M10 x 1.5 x 20 mm Lock Washer M Capscrew, Hex Head M6 x 1.0 x 16 mm Lock Washer M Flat Washer M Capscrew, Hex Head M6 x 1.0 x 20 mm Hex Nut M6 x Hose, Radiator Inlet Hose, Radiator Outlet Hose Clamp # Radiator Cap Bolt Shroud with Fan Guard Drain Cock Hose Label Northern Lights (not shown) ** Grille ** Air Duct Adapter (optional - not shown) Bracket, Radiator Mounting - ** As required 3-11

36 GROUP 4 FUEL SYSTEM General Arrangement L

37 GROUP 4 FUEL SYSTEM General Arrangement L 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 12 Volt* Glow Plug 24 Volt* Connector Gasket Feed Pump Assembly (see parts detail page) Bolt Stop Solenoid - 12 Volt (Standard Ground)* Stop Solenoid - 12 Volt (Isolated Ground)* Stop Solenoid - 24 Volt (Isolated Ground)* Screw Seal Washer Seal Washer Wire Harness Spring Washer Nut - *Note: See Electrical System 4-1

38 GROUP 4 FUEL SYSTEM General Arrangement M - NL

39 GROUP 4 FUEL SYSTEM General Arrangement M - NL 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 12 Volt* Glow Plug 24 Volt* Connector Gasket Feed Pump Assembly (see parts detail page) Bolt Stop Solenoid - 12 Volt (Standard Ground)* Stop Solenoid - 12 Volt (Isolated Ground)* Stop Solenoid - 24 Volt (Isolated Ground)* Screw Seal Washer Seal Washer Wire Harness Spring Washer Nut - *Note: See Electrical System 4-3

40 GROUP 4 FUEL SYSTEM General Arrangement M - NL844L & M20CR 4-4

41 GROUP 4 FUEL SYSTEM General Arrangement M - NL844L & M20CR Injection Pump Assembly (see parts detail page- formerly # ) 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 12 Volt* Glow Plug 24 Volt* Connector Gasket Feed Pump Assembly (see parts detail page) Bolt Stop Solenoid - 12 Volt (Standard Ground)* Stop Solenoid - 12 Volt (Isolated Ground)* Stop Solenoid - 24 Volt (Isolated Ground)* Screw Seal Washer Seal Washer Wire Harness Spring Washer Nut - *Note: See Electrical System 4-5

42 GROUP 4 FUEL SYSTEM Governor & Timing Gear Case 4-6

43 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 - L Governor Spring - M- NL844 & 844L 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 Gasket Hex Nut O-ring Spring Oil Fill Elbow O-ring Cap Bolt Lock Washer - 4-7

44 GROUP 4 FUEL SYSTEM Fuel Filter & Piping Fuel Filter Assembly (includes keys #2-5) Fuel Filter Cartridge Gasket Banjo Bolt Plug Bracket Bracket Bolt Nut Spring Washer Nut Bolt Pipe Pipe Pipe Bolt Washer Gasket Banjo Bolt Banjo Bolt Gasket Banjo Bolt Gasket Washer - 4-8

45 GROUP 4 FUEL SYSTEM Fuel Line Connection A-6426 / C Manifold Capscrew, Hex Head M6 x 1.0 x 20 mm Lock Washer M Plug, 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 26" Female Swivel, brass 1/4 HB x 5/16-45T - U.S. Coast Guard Approved Fuel Lines A-6684 A-6495 / C Manifold 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, 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 26-1/2" Hose Assembly 1/4" ID x 26" (844L) Hose Assembly 1/4" ID x 17" (844) - 4-9

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

47 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 Banjo Bolt

48 GROUP 4 FUEL SYSTEM Throttle Assembly A-10414/ B Throttle Bracket Cable Clamp Clamp Shim Capscrew, Hex Head M5 x 0.8 x 14 mm Lock Washer, Helical M Capscrew, Hex Head M6 x 1.0 x 16 mm Lock Washer, Helical M Throttle Pivot Flat Washer 1/4" USS S/S Cotter Pin, Brass 3/32 x 1/

49 GROUP 4 FUEL SYSTEM Notes 4-13

50 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Standard Ground Propulsion Units Propulsion Units A / C

51 GROUP 5 ELECTRICAL SYSTEM Engine Wire Harness Oil Pressure Sender 0-80 PSI, Standard Ground Oil Pressure Switch, Standard Ground Temperature Sender 250 F, Standard Ground Temperature Switch 95 C Bracket, Circuit Breaker and Relays Capscrew, M14 x 1.5 x 30 S/S Flat Washer, M14 S/S Capscrew, Hex Head M6 x 1.0 x 20 mm Flat Washer M Hex Nut M6 x Relay 12 Volt 50 Amp Cover, Circuit Breaker and Relays Machine Screw, BH Slotted #10-32 x 3/8" S/S Flat Washer #10 S/S Magnetic Pick-up, M18 x 1.5 x 58 mm ' Wire Harness Extension (not shown) Solenoid 12 VDC 65 Amp Bracket, Relay Mounting Capscrew, Hex Head M6 x 1.0 x 16 mm Flat Washer M Hex Nut, Nylock M6 x Capscrew, Hex Head M14 x 1.5 x 30 mm S/S Lock Washer, M14 S/S Control Panel 12 Volt (not shown, see parts detail) Starter 12 Volt (see parts detail) Capscrew, Hex Head M10 x 1.5 x 30 mm Wave Washer M Stop Solenoid 12 Volt Glow Plug 12 Volt Alternator 12V/ 40 Amp Street Elbow, 90 1/8 NPT Capscrew, M6 x 1.0 x 16 mm S/S Lock Washer Flat Washer M Exhaust Temperature Switch 205 F ** Harness Assembly, High Exhaust Temperature (not shown) Banjo Bolt - **As required Engine Electrical 12 Volt Standard Ground Propulsion Units 5-1

52 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground Propulsion Units A / C

53 GROUP 5 ELECTRICAL SYSTEM Engine Wire Harness Oil Pressure Sender 0-80 PSI, Standard Ground Oil Pressure Switch, Standard Ground Temperature Sender 250 F, Standard Ground Temperature Switch 95 C Bracket, Circuit Breaker and Relays Capscrew, M14 x 1.5 x 30 S/S Flat Washer, M14 S/S Capscrew, Hex Head M6 x 1.0 x 20 mm Flat Washer M Hex Nut M6 x Relay 24 Volt 20 Amp Cover, Circuit Breaker and Relays Machine Screw, BH Slotted #10-32 x 3/8" S/S Flat Washer #10 S/S Magnetic Pick-up, M18 x 1.5 x 58 mm ' Wire Harness Extension (not shown) Solenoid 24 VDC 65 Amp Bracket, Relay Mounting Capscrew, Hex Head M6 x 1.0 x 16 mm Flat Washer M Hex Nut, Nylock M6 x Capscrew, Hex Head M14 x 1.5 x 30 mm S/S Lock Washer, Helical M14 S/S Main Instrument Panel 24 Volt (not shown - see parts detail) Starter 24 Volt (see parts detail) Capscrew, Hex Head M10 x 1.5 x 30 mm Wave Washer M Stop Solenoid 24 Volt Glow Plug 24 Volt Alternator 24V/ 40 Amp Street Elbow, 90 1/8 NPT Capscrew, M6 x 1.0 x 16 mm S/S Lock Washer Flat Washer M Exhaust Temperature Switch, 205 F ** Harness Assembly, High Exhaust Temperature (not shown) Banjo Bolt - **As required Engine Electrical 24 Volt Standard Ground Propulsion Units 5-3

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

55 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Standard Ground Temperature Sender 250 F Dual Station Temperature Sender 250 F Temperature Switch 95 C Oil Pressure Switch Oil Pressure Sender Dual Station Oil Pressure Sender Relay, 12 Volt SPDT Relay Base Circuit Breaker DC 15 Amp Control Panel S-1B (not shown,see detail) Engine Wire Harness Diode, 6 Amp 50 Volt PIV Wire Harness Extension 20' (not shown) Universal Bushing, Plastic 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 - Used with #25 only Oil Line Starter 12 Volt (see mounting detail) ** Elbow 90 Steel 1/8 NPT x 1/8 NPT (not shown) - **As required Generator Units 5-5

56 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Isolated Ground Generator Units A-6258 / C-2490A 5-6

57 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 12 Volt Isolated Ground Temperature Sender 250 F Dual Station Temperature Sender 250 F Temperature Switch 95 C Oil Pressure Switch Oil Pressure Sender Dual Station Oil Pressure Sender Relay, 12 Volt SPDT Relay Base Circuit Breaker, DC 15 Amp Control Panel, S1-B (see detail) Engine Wire Harness Diode, 6 Amp 50 Volt PIV Wire Harness Extension 20' (not shown) Universal Bushing, Plastic 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 Oil Line Starter 12 Volt (see mounting detail) ** Street Tee Steel 1/8 NPT x 1/8 NPT (not shown) - **As required Generator Units 5-7

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

59 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Standard Ground Generator Units Temperature Sender 250 F Dual Station Temperature Sender 250 F Temperature Switch 95 C Oil Pressure Switch Oil Pressure Sender Dual Station Oil Pressure Sender Relay, 24 Volt SPDT Relay Base Circuit Breaker, DC 15 Amp Control Panel, S1-B (see detail) Engine Wire Harness Diode, 6 Amp 50 Volt PIV Wire Harness Extension 20' (not shown) Universal Bushing, Plastic 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 (see mounting detail) Banjo Bolt Oil Line Starter 24 Volt (see mounting detail) Street Tee Steel 1/8 NPT x 1/8 NPT (not shown) - 5-9

60 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Isolated Ground Generator Units A-6398, A-6402 / C-2490A 5-10

61 GROUP 5 ELECTRICAL SYSTEM Engine Electrical 24 Volt Isolated Ground Generator Units Temperature Sender 250 F Dual Station Temperature Sender 250 F Temperature Switch 95 C Oil Pressure Switch Oil Pressure Sender Dual Station Oil Pressure Sender Relay, 24 Volt SPDT Relay Base Circuit Breaker, DC 15 Amp Control Panel, S1-B (see detail) Engine Wire Harness Diode, 6 Amp 50 Volt PIV Wire Harness Extension 20' (not shown) Universal Bushing, Plastic 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 (see mounting detail) Banjo Bolt Oil Line Starter 24 Volt (see mounting detail) Street Tee Steel 1/8 NPT x 1/8 NPT (not shown)

62 GROUP 5 ELECTRICAL SYSTEM Starter & Flywheel Housing L - M - NL flywheelhsg Flywheel Housing - Marine SAE # Flywheel Housing - Industrial SAE # Bolt Starter - 12 Volt - Standard Ground (marked M001T66081)* Starter - 12 Volt - Isolated Ground Starter - 24 Volt - Standard Ground (formerly # ) Starter - 24 Volt - Isolated Ground (formerly # ) Bolt Washer Bracket Lock Washer Bolt Bracket, Drain Hose Support Bolt Spacer (used with 24 Volt starters # & only, not shown) - *See parts detail. 5-12

63 GROUP 5 ELECTRICAL SYSTEM Starter & Flywheel Housing M - NL844 & M20CR 844flywheelhsg Flywheel Housing - Marine SAE #4 (used with 24 Volt starters only) Flywheel Housing - Marine SAE # Flywheel Housing - Industrial Back Plate - Marine Back Plate - Industrial Starter - 12 Volt - Standard Ground (marked M001T66081)** Starter - 12 Volt - Isolated Ground Starter - 24 Volt - Standard Ground (formerly # ) Starter - 24 Volt - Isolated Ground (formerly # ) Bolt Bolt Bolt Bolt Nut Lock Washer Bolt Bolt Washer Bracket, Drain Hose Support* Bolt* Bracket* Bolt* Spacer (used with 24 Volt starters # & only, not shown) Cover (for , not shown) - *NOTE: #13-16 Marine application only. **See parts detail 5-13

64 GROUP 5 ELECTRICAL SYSTEM Wire Harness, Circuit Breaker, & Relay Panel L Wire Harness Assembly (includes keys #1-6) Bracket AMP Circuit Breaker Relay Base Terminal Retainer (not shown) Machine Screw, Flathead Countersunk #10-32 x 3/8" Hex Nut, # Machine Screw, Flathead Countersunk #10-32 x 1" Relay, 12 Volt SPST Relay, 24 Volt SPST

65 GROUP 5 ELECTRICAL SYSTEM Starter 12 Volt Standard Ground Starter (includes keys #1-21) Screw Set Front Cover Lever Assembly Switch Assembly Ball Packing Armature Set Bolt Set Clutch Shaft Assembly (includes keys #11-16) Stopper Set Pinion Set Internal Gear Assembly Washer Gear Shaft Assembly Gear Assembly Yoke Assembly Brush Assembly Brush Holder Assembly Brush Spring Set Rear Bracket Assembly

66 GROUP 5 ELECTRICAL SYSTEM Small Frame Alternators & Mounting 12 Volt / 40 Amp Standard & Isolated Ground Alternator 12 Volt/ 40 Amp Standard Ground (see parts detail) Alternator 12 Volt/ 40 Amp Isolated Ground Tensioner Bolt Washer Bracket Bolt Bolt Nut Drive Belt (844) Drive Belt (844L & M20CR, formerly # )

67 GROUP 5 ELECTRICAL SYSTEM Medium Frame Alternator Options 12V/51 Amp & 24V/35 & 40 Amp A-7631, A-7632, A-7633, A-7634, A-7635, A-7636 & D Alternator 12 Volt/51 Amp Isolated Ground Alternator 24 Volt/40 Amp Standard Ground Alternator 24 Volt/35 Amp Isolated Ground Pulley 1-A x 2-1/2" x 5/8" ID Bracket, Alternator Mounting 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 (used with 24 Volt/35 Amp Alternator) Tensioning Arm (used with 12 Volt/51 Amp & 24 Volt/40 Amp Alternators) Capscrew, Hex Head 5/16-18 x 1" Stud Washer 5/ Lock Washer, Helical 5/ Diode Harness Addition Drive Belt (844) Drive Belt (844L & M20CR, formerly # ) D.C. Voltage Regulator, 12V, Adjustable Wire Harness 36" Machine Screw #10-32 x 3/4" S/S }12 Volt / 51 Amp - Alternator Only Flat Washer #10 S/S Hex Nut, Nylock #10 S/S - **As required 5-17

68 GROUP 5 ELECTRICAL SYSTEM Alternator Assembly 12 Volt/35 Amp: Standard Ground Alternator Assembly Nut Screw Set Front Cover Assembly Screw Set Ball Bearing Rotor Assembly Ball Bearing Stator Assembly Rear Cover Assembly Rectifi er Assembly Regulator Assembly Brush Set Connector Pulley Assembly

69 GROUP 5 ELECTRICAL SYSTEM Main Instrument Panel Vanguard Gauges 12 & 24 Volt L844 A-10901/ B Volt Main Instrument Panel (includes all keys) Volt Main Instrument Panel (includes all keys) Panel Plate Voltmeter, 12 Volt Voltmeter, 24 Volt Hourmeter Temperature Gauge, 12 Volt Temperature Gauge, 24 Volt Oil Pressure Gauge 0-80 PSI, 12 Volt Oil Pressure Gauge 0-80 PSI, 24 Volt Alarm Horn, 12/24 Volt Tachometer RPM, 12 Volt Fault Lamp Holder, Amber ** Bulb, Clear 12 Volt ** Bulb, Clear 24 Volt Key Switch Toggle Switch (for Panel Lights) Diode (not shown) Fuse Holder, In-Line Fuse, 7-1/2 Amp Plug Wire Harness Screw, Self Tapping #8 x 1" Type AB Phillips ** Bulb, Red 12 Volt ** Bulb, Red 24 Volt Resistor Kit (not shown, for Tachometer - 24 Volt only) ** Key - **As required 5-19

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