Northern Lights Lugger P984 Operator's Manual
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Northern Lights Lugger P984 Operator's Manual

Marine generators | marine diesel engines | land-based generators
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P984
For Models: M984K, ML984, L984,
M30C, M984W and M33CW
OPERATOR'S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators

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Summary of Contents for Northern Lights Lugger P984

  • Page 1 P984 For Models: M984K, ML984, L984, M30C, M984W and M33CW OPERATOR’S MANUAL Marine Generators | Marine Diesel Engines | Land-Based Generators...
  • Page 2 4420 14th Avenue N.W. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455 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.: P984 09/05...

  • Page 3: Table Of Contents

    PARTS CATALOG PARTS CATALOG for Models M984K, ML984, L984, M30C, M33C, for Models M984K, ML984, L984, M30C, M33C, M984W, and M33CW M984W, and M33CW Please read thoroughly before att empting to use this manual: Table of Contents ............................I Model Designation & Serial Numbers ......................II Reading a Parts Page ..........................III T able of Contents able of Contents...

  • Page 4: Model Numbers

    NORTHERN LIGHTS NORTHERN LIGHTS Northern Lights generator sets with PSL generators have two data plates and two serial numbers. One serial number is for the generator end, and it is found on the Generator End Data Plate. The other serial number, found with the Generator Set Data Plate, should be used when ordering parts for sets using PSL generators.

  • Page 5: Reading A Parts Page

    Reading a Parts Page 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. ELECTRICAL SYSTEM ALTERNATOR ASSEMBLY: M - NL844 ALTERNATOR ASSEMBLY: M - NL844 PART NUMBER...

  • Page 6: Group 1 - Engine

    GROUP 1 – ENGINE Cylinder Block Cylinder Block P984 01-00: 1105 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION ENGINE BLOCK S/N ENGINE BLOCK S/N 11401-78700-71 Cylinder Block Assembly up to S/N - 0042812 11461-78700-71 Cylinder Liner (Dry Type) (Mark A) 11461-78701-71 Cylinder Liner (Dry Type) (Mark B) 11475-78300-71...

  • Page 7: Engine

    GROUP 1 – ENGINE Cylinder Block Cylinder Block P984 01-00: 1105 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION ENGINE BLOCK S/N ENGINE BLOCK S/N 11401-78702-71 Cylinder Block Assembly from S/N 0042813 - (includes Pressure Relief Valve & standard Crankshaft Bearings) 11461-78700-71 Cylinder Liner (Dry Type) (Mark A) 11461-78701-71...

  • Page 8: Crankshaft, Pistons & Connecting Rods

    GROUP 1 – ENGINE Crankshaft, Pistons & Connecting Rods Crankshaft, Pistons & Connecting Rods P984 01-02: A-5201 / B-3989 + 1301 P984 09/05 1 - 2...
  • Page 9 GROUP 1 – ENGINE Crankshaft, Pistons & Connecting Rods Crankshaft, Pistons & Connecting Rods PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION ENGINE BLOCK S/N ENGINE BLOCK S/N 13201-78300-71 Connecting Rod Assembly up to S/N - 0042812 90384-32951-71 Wrist Pin Bushing 13265-68010 Connecting Rod Bolt 90179-12015 13101-78700-71...
  • Page 10 GROUP 1 – ENGINE Crankshaft, Pistons & Connecting Rods Crankshaft, Pistons & Connecting Rods A-5201 / B-3989 + 1301 P984 09/05 1 - 4...
  • Page 11 GROUP 1 – ENGINE Crankshaft, Pistons & Connecting Rods Crankshaft, Pistons & Connecting Rods PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION ENGINE BLOCK S/N ENGINE BLOCK S/N 13201-78300-71 Connecting Rod Assembly from S/N 0042813 - 90384-32951-71 Wrist Pin Bushing 13265-68010 Connecting Rod Bolt 90179-12015 13101-78702-71 Piston Assembly, Standard...

  • Page 12: Flywheel & Housing

    GROUP 1 – ENGINE Flywheel and Housing Flywheel and Housing 01-01: 3101 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 11351-78302-71 Flywheel Housing - SAE #4 13405-78302-71 Flywheel Assembly - SAE #10 13453-22060-71 Ring Gear - 108 Teeth 90105-12039 Washer Based Head Hexagon Bolt 90116-12950-71...

  • Page 13: Lubrication System

    GROUP 1 – ENGINE Lubrication System Components Lubrication System Components 01-04: 1105 / 1501 / 1502 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION ENGINE BLOCK S/N ENGINE BLOCK S/N 15100-78700-71 Oil Pump Assembly up to S/N - 004812 15310-78300-71 Oil Pressure Relief Valve (M18 Thread) 15104-78700-71 Strainer 24-05401...
  • Page 14 GROUP 1 – ENGINE Lubrication System Components Lubrication System Components 01-04: 1105 / 1501 / 1502 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION ENGINE BLOCK S/N ENGINE BLOCK S/N 15100-78700-71 Oil Pump Assembly from S/N 0042813 - 15310-78700-71 Oil Pressure Relief Valve (M16 Thread) 15104-78700-71 Strainer 24-05401...

  • Page 15: Timing Cover

    GROUP 1 – ENGINE Timing Cover - P.T.O. & Rear Seal Timing Cover - P.T.O. & Rear Seal A-5035 / C-2607 + 1106 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 12180-76002-71 Filler Cap 15773-78300-71 Filler Neck 11314-78700-71 PTO Housing 11307-78302-71 PTO Assembly 9T...

  • Page 16: Camshaft & Valve Train

    GROUP 1 – ENGINE Camshaft & Valve Train Camshaft & Valve Train P984 01-06 P984 09/05 1 - 10...
  • Page 17 GROUP 1 – ENGINE Camshaft & Valve Train Camshaft & Valve Train PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION ENGINE BLOCK S/N ENGINE BLOCK S/N 13901-78300-71 Shaft up to S/N - 0042812 13810-78300-71 Rocker Shaft Assembly (includes keys 20, 22-25, & 56-59) 13811-78300-71 Rocker Arm 90913-05020...
  • Page 18 GROUP 1 – ENGINE Camshaft & Valve Train Camshaft & Valve Train P984 01-06 P984 09/05 1 - 12...
  • Page 19 GROUP 1 – ENGINE Camshaft & Valve Train Camshaft & Valve Train PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION ENGINE BLOCK S/N ENGINE BLOCK S/N 13901-78700-71 Shaft from S/N 0042813 - 13810-78700-71 Rocker Shaft Assembly (includes keys 22-25, & 56-59) 13811-78300-71 Rocker Arm 90913-05020 Valve Adjusting Screw...

  • Page 20: Cylinder Head & Valve Cover

    GROUP 1 – ENGINE Cylinder Head & Valve Cover Cylinder Head & Valve Cover P984 01-09: 1104 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION ENGINE BLOCK S/N ENGINE BLOCK S/N 11101-78302-71 Cylinder Head up to S/N - 0042812 (includes keys #2 - #8) 11122-46010 Valve Guide 11131-68020...
  • Page 21 GROUP 1 – ENGINE Cylinder Head & Valve Cover Cylinder Head & Valve Cover P984: TOYOTAROCKERCOVER PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION ENGINE BLOCK S/N ENGINE BLOCK S/N 11101-78700-71 Cylinder Head from S/N 0042813 - (includes keys #2 - #8) 11122-46010 Valve Guide 11131-68020...

  • Page 22: Oil Drain Kit

    GROUP 1 – ENGINE Oil Drain Kit Oil Drain Kit Northern Lights Application A-4348 / B-3669 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 36-75402 Oil Pan Drain Fitting 21-62508 Male Elbow 90° 3/8 NPT x 1/2-37T 18-75400 Hose Assembly 1/2"...
  • Page 23 GROUP 1 – ENGINE Notes Notes P984 09/05 1 - 17...

  • Page 24: Group 2 - Intake & Exhaust System

    GROUP 2 – INTAKE & EXHAUST SYSTEM Air Intake & Vent Hose Air Intake & Vent Hose Early Production Generator Sets and L984D A-7044, A-7378, A-7869 / C-2334A PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 10-25401 Air Intake Manifold (Marine) 10-25402 Air Intake Manifold...
  • Page 25 GROUP 2 – INTAKE & EXHAUST SYSTEM Intake Noise Reduction Intake Noise Reduction Marine Application - Early Production P984 02-01: B-4821 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 10-25401 Intake Manifold 28-25401 Cover Plate 24-25402 Air Filter Element 11-25401 Gasket 18-25403...
  • Page 26 GROUP 2 – INTAKE & EXHAUST SYSTEM Air Intake & Vent Hose Air Intake & Vent Hose Marine Application - Late Production A-7708 / C-4057 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 10-25402 Air Intake Manifold 11-25400 Gasket 00-75482 Lifting Eye, Rear...
  • Page 27 GROUP 2 – INTAKE & EXHAUST SYSTEM Intake Noise Reduction Intake Noise Reduction Marine Application - Late Production A-8483, A-8498 / C-4063 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 18-25402 Air Intake Hose, 2" ID x 54" (1800 RPM units) 18-25403 Air Intake Hose, 2"...

  • Page 28: Intake Manifold

    GROUP 2 – INTAKE & EXHAUST SYSTEM Intake Manifold Intake Manifold P984 02-04: 1701 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION ENGINE BLOCK S/N ENGINE BLOCK S/N 17111-78300-71 Intake Manifold up to S/N -0042812 17171-78300-71 Intake Manifold Gasket 90179-08061 Lock Nut, Flanged M8 x 1.25 90116-08131 Stud M8 x 1.25 x 20 mm (30 mm LOA) 91611-60825...

  • Page 29: Air Inlet

    GROUP 2 – INTAKE & EXHAUST SYSTEM Air Inlet Air Inlet Commercial Application A-5546/ C-2716 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 24-20001 Air Filter 31-25401 Air Inlet Adapter 11-25400 Gasket 12-00712 Capscrew, Hex Head M8 x 1.25 x 25 mm 15-00702 Lock Washer M8 18-71010...

  • Page 30: Exhaust Manifold

    GROUP 2 – INTAKE & EXHAUST SYSTEM Exhaust Manifold Exhaust Manifold A-4213 / C-2337 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 10-35400 Exhaust Manifold 11-35402 Exhaust Manifold Gasket 17173-78300-71 Exhaust Manifold Gasket (replaced by #11-35402) 13-35401 Stud, M10 x 1.25 x 35 mm (47 mm LOA) 14-00816 Hex Nut, M10 x 1.25...

  • Page 31: Wet Exhaust Elbow

    GROUP 2 – INTAKE & EXHAUST SYSTEM Wet Exhaust Elbow Wet Exhaust Elbow A-4246J / B-3608B PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 27-35400 Wet Exhaust Elbow (Cast Iron) 11-35401 Exhaust Gasket 12-00753 Capscrew, Hex Head M8 x 1.25 x 30 mm 15-35401 Flat Washer, Special 15-00701...

  • Page 32: Dry Exhaust Elbow

    GROUP 2 – INTAKE & EXHAUST SYSTEM Dry Exhaust Elbow Dry Exhaust Elbow A-4267 / B-3632A PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 27-35405 Dry Exhaust Elbow 31-35401 Dry Exhaust Adapter 2" NPT Female 11-35401 Exhaust Elbow Gasket 15-00702 Lock Washer, Helical M8 12-00711...

  • Page 33: Group 3 - Cooling

    Capscrew, Hex Head M10 x 1.25 x 100 mm 12-00803 Capscrew, Hex Head M10 x 1.25 x 65 mm 18-15401 Bypass Hose, 1" ID x 5-1/4" Silicon 19-00016 Hose Clamp #16 00-00006 “Northern Lights” Decal 00-71000 “Lugger” Decal 11-10015 Seal Ring 15-00805 Flat Washer, M10 21-00530...

  • Page 34: Heat Exchanger & Mounting

    DESCRIPTION SERIAL NUMBER SERIAL NUMBER 20-15410 Heat Exchanger Assembly - Lugger (see parts detail) 20-15420 Heat Exchanger Assembly - Northern Lights (see parts detail) 12-00211 Capscrew, Hex Head 5/16 - 18 x 3/4" 15-00211 Flat Washer, 5/16" 18-15402 Hose - Northern Lights...

  • Page 35: Heat Exchanger Assembly

    A-4219 / C-2339 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 20-15410 Heat Exchanger Assembly - Northern Lights (includes all Keys) •• 20-15420 Heat Exchanger Assembly - Lugger (includes all Keys) 20-15400 Heat Exchanger - Northern Lights 20-15401...

  • Page 36: Coolant Pump

    GROUP 3 – COOLING SYSTEM Coolant Pump Coolant Pump P984 03-04: 1601 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 16100-78700-71 Coolant Pump Assembly (parts not available separately - includes Key #2) 21-15402 Elbow Fitting with 3/8 BSPT Heater Outlet 16271-78302-71 Gasket 16371-78300-71...

  • Page 37: Keel Cooling Outlet

    GROUP 3 – COOLING SYSTEM Keel Cooling Outlet Keel Cooling Outlet A-4400 / B-1700 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 31-15402 Keel Cooling Adapter 11-12203 Gasket 15-00202 Lock Washer, 5/16" 12-00212 Capscrew, 5/16 - 18 x 1" P984 09/05 3 - 5...

  • Page 38: Raw Water Pump & Mounting

    GROUP 3 – COOLING SYSTEM Raw Water Pump & Mounting Raw Water Pump & Mounting A-4706 / C-2459 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 25-15405 Raw Water Pump (see parts detail) 00-15401 Mounting Clip 16-15401 O-Ring 12-34800 Capscrew, Hex Head M10 x 1.5 x 160 mm 21-00129...

  • Page 39: Raw Water Pump Detail

    GROUP 3 – COOLING SYSTEM Raw Water Pump Detail Raw Water Pump Detail A-4761 / C-2477 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 25-15405 Raw Water Pump Assembly (includes all keys) • 25-12004 Repair Kit (includes keys #3 - #9, #11) 25-15407 Pump Housing 25-15406...
  • Page 40 GROUP 4 – FUEL SYSTEM Injectors & Lines: M984 Injectors & Lines: M984 P984 04-00: 2201 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 23600-78300-71 Injector 23620-78300-71 Nozzle (marked DLLA150P35) 23624-58010 Nozzle Retaining Nut 23625-58230 Banjo Bolt 90201-08106 Washer 11176-56020 Injection Nozzle Seat...
  • Page 41 GROUP 4 – FUEL SYSTEM Injectors & Lines: L984 Injectors & Lines: L984 P984 04-01: 2201 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 23600-78700-71 Injector, Complete (previously #23600-78301-71) 23620-78700-71 Nozzle (marked DLLA144P700 - for injector 23600-78700-71) 23620-78301-71 Nozzle (marked DLLA150P602 - for injector 23600-78301-71) 23624-58010...
  • Page 42 Injection Pump & Piping: M984 P984 04-02: 2202 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 22100-78705-71 Injection Pump Assembly 1800 RPM - Northern Lights 23701-78301-71 Injection Line #1 23702-78301-71 Injection Line #2 23703-78301-71 Injection Line #3 23704-78301-71 Injection Line #4...
  • Page 43 GROUP 4 – FUEL SYSTEM Injection Pump, Piping & Throttle: L984 Injection Pump, Piping & Throttle: L984 P984 04-03: 2202 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 22100-78719-71 Injection Pump Assembly (formerly #22100-78704-71) 90301-99950-71 O-Ring 91611-61028 Bolt 22811-78300-71 Bracket 91651-60820...
  • Page 44 GROUP 4 – FUEL SYSTEM Fuel Filter & Piping / Injection Pump & Piping: M984 Fuel Filter & Piping / Injection Pump & Piping: M984 P984 04-04: 1502 / 2302 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER ••...

  • Page 45: Fuel Filter

    GROUP 4 – FUEL SYSTEM Fuel Filter Fuel Filter Propulsion Engines P984 04-04A: 2302 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 23300-78200-71 Fuel Filter Assembly w/Primer Pump (includes keys #1, #7, & #10 - #19) 24-52020 Fuel Filter 23-55406 Bracket, Fuel Filter Mtg.

  • Page 46: Fuel System

    GROUP 4 – FUEL SYSTEM Fuel System Fuel System Marine Generator Application A-4247A / C-2348 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 10-51099 Fuel Manifold, 1/4 NPT 21-52245 Male Elbow 90° Brass, 1/4 NPT x 5/16-45T 12-00111 Capscrew, Hex Head 1/4 - 20 x 3/4"...

  • Page 47: Coast Guard Approved Fuel System

    GROUP 4 – FUEL SYSTEM Fuel System - U.S. Coast Guard Approved Fuel System - U.S. Coast Guard Approved Marine Generator Application A-4297 / C-2362A PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 18-52212 Hose Assembly 1/4" ID x 14" 18-55402 Hose Assembly 1/4"...

  • Page 48: Fuel Feed Pump Assembly

    GROUP 4 – FUEL SYSTEM Fuel Feed Pump Assembly Fuel Feed Pump Assembly Marine Generator Application P984 04-08: PH0091 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 26-55404 Feed Pump Assembly (includes keys #1 - #20) • 192290-0060 Overhaul Kit 092120-0340...
  • Page 49 GROUP 4 – FUEL SYSTEM Notes Notes P984 09/05 4 - 9...
  • Page 50 GROUP 5 – ELECTRICAL SYSTEM Engine Electrical - 12 Volt Lugger Standard Ground Engine Electrical - 12 Volt Lugger Standard Ground Propulsion Engine Applications A-7714 / C-2452 P984 09/05 5 - 0...
  • Page 51 GROUP 5 – ELECTRICAL SYSTEM Engine Electrical - 12 Volt Lugger Standard Ground Engine Electrical - 12 Volt Lugger Standard Ground Propulsion Engine Applications PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 22-41016 Oil Pressure Sender, Single Station 0-80 PSI 22-44871 Oil Pressure Sender, Single Station 0-150 PSI 22-40233...
  • Page 52 GROUP 5 – ELECTRICAL SYSTEM Engine Electrical 12 Volt & 24 Volt Standard Ground Engine Electrical 12 Volt & 24 Volt Standard Ground Generator Set Applications A-4202 / C-2451A P984 09/05 5 - 2...
  • Page 53 GROUP 5 – ELECTRICAL SYSTEM Engine Electrical 12 Volt & 24 Volt Standard Ground Engine Electrical 12 Volt & 24 Volt Standard Ground Generator Set Applications PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 22-70083 Dual Station Relay Board, 12 Volt* (includes keys #5 - #11 –...
  • Page 54 GROUP 5 – ELECTRICAL SYSTEM Engine Electrical 12 Volt & 24 Volt Isolated Ground Engine Electrical 12 Volt & 24 Volt Isolated Ground Generator Set Applications P984 05-04 P984 09/05 5 - 4...
  • Page 55 GROUP 5 – ELECTRICAL SYSTEM Engine Electrical 12 Volt & 24 Volt Isolated Ground Engine Electrical 12 Volt & 24 Volt Isolated Ground Generator Set Applications PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 22-70083 Relay Board 12 Volt* (includes keys #5 - #11 –...
  • Page 56 GROUP 5 – ELECTRICAL SYSTEM Dual Station Relay Board Dual Station Relay Board 12 Volt and 24 Volt A-8851, A-8852, A-8854, A-8855 / C-2041 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 22-70083 12 Volt Relay Logic Board, Manual Start (Includes all keys) ••...

  • Page 57: Circuit Breaker & Relay Assembly

    GROUP 5 – ELECTRICAL SYSTEM Wire Harness Circuit Breaker & Relay Assembly - 12 & 24 Volt Wire Harness Circuit Breaker & Relay Assembly - 12 & 24 Volt Propulsion Units A-4404 / B-3139 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER ••...

  • Page 58: Stop Solenoid & Mounting

    GROUP 5 – ELECTRICAL SYSTEM Stop Solenoid & Mounting Stop Solenoid & Mounting A-4667 / C-2450 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 22-42054 Stop Solenoid 12 Volt 22-40007 Stop Solenoid 24 Volt with Intregral Stud 00-42501 Straight Ball Joint 1/4 - 28 15-00018 Lock Washer, Helical 1/4 High Collar...

  • Page 59: Alternator Mounting

    GROUP 5 – ELECTRICAL SYSTEM Alternator Mounting Alternator Mounting 12 Volt / 40 Amp - Standard or Isolated Ground A-4243F / C-2346F PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 23-45401 Alternator Mounting Bracket (without PTO) 23-45409 Alternator Mounting Bracket (with PTO) 12-50051 Capscrew, Hex Head M10 x 1.25 x 90 mm...
  • Page 60 GROUP 5 – ELECTRICAL SYSTEM Alternator and Mounting - 12 Volt / 40 Amp Alternator and Mounting - 12 Volt / 40 Amp Propulsion Units A-7847 / B-6952 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 27060-78301-71 Alternator, 12V/40A (see parts detail) 23-45411 Bracket, Alternator Mtg.
  • Page 61 GROUP 5 – ELECTRICAL SYSTEM Alternator - 12 Volt / 40 Amp Alternator - 12 Volt / 40 Amp Standard Ground P984 05-11: 1903 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 27060-78301-71 Alternator Assembly with Regulator (includes all keys) 27330-78301-71 Alternator Rotor Assembly 90099-78001-71...
  • Page 62 GROUP 5 – ELECTRICAL SYSTEM Alternator Options Alternator Options Northern Lights Application - Early Production C-2366A PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 22-40332 Alternator 12 Volt / 90 Amp 22-40278 Alternator 24 Volt / 40 Amp...
  • Page 63 GROUP 5 – ELECTRICAL SYSTEM Alternator Options Alternator Options Northern Lights Application - Late Production A-7589D, A-7590D, A-7591D/ C-4879 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 22-40332 Alternator 12 Volt / 90 Amp 22-40278 Alternator 24 Volt / 40 Amp...

  • Page 64: Starter

    GROUP 5 – ELECTRICAL SYSTEM Starter - 12 Volt Starter - 12 Volt Standard Ground P984 05-13: 1904 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 28100-78502-71 Starter Assembly 28160-47040 Starter Armature Assembly 90099-10119 Armature Bearing #1 90099-10107 Armature Bearing #2 28120-47040 Starter Yoke Assembly...
  • Page 65 GROUP 5 – ELECTRICAL SYSTEM Main Instrument Panel “Vanguard” Main Instrument Panel “Vanguard” 12 Volt Lugger Applications A-7687/ B-4734-2 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 22-95455 12 Volt Main Instrument Panel (includes all keys)* 28-96801 Panel Plate 37-90022 Voltmeter, 12 Volt...
  • Page 66 GROUP 5 – ELECTRICAL SYSTEM Main Instrument Panel “Vanguard” Main Instrument Panel “Vanguard” 24 Volt Lugger Applications A-7687/ B-4734-2 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 22-95465 24 Volt Main Instrument Panel (includes all keys) 28-96801 Panel Plate 37-90073 Voltmeter, 18 - 32 VCD, Square Bezel...
  • Page 67 Page added 12-19-08 GROUP 5 – ELECTRICAL SYSTEM Flybridge Panel Flybridge Panel A-9863/ B-4734-3a PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 22-95495 Flybridge Panel Kit 12 Volt (includes all keys) • 22-95494 Flybridge Panel 12 Volt (includes keys 1-16) 28-96802 Plate, Flybridge Panel...

  • Page 68: Control Panels

    GROUP 5 – ELECTRICAL SYSTEM Series 1 Control Panel - 12 & 24 Volt Series 1 Control Panel - 12 & 24 Volt Marine Generator Application A-2863 + A-4793 / B-2873 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER ••...
  • Page 69 GROUP 5 - ELECTRICAL SYSTEMS S-1 Control Panel 12 & 24 Volt S-1 Control Panel 12 & 24 Volt A-8551, A-8552/ B-5970 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• •• 22-92110 S-1 Start/Stop Control Panel, 12 Volt (includes all keys) ••...
  • Page 70 GROUP 5 - ELECTRICAL SYSTEMS Series 1-B Control Panel - 12 & 24 Volt Series 1-B Control Panel - 12 & 24 Volt Marine Generator Application A-4791 + A-3171 / C-1911 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER ••...
  • Page 71 GROUP 5 - ELECTRICAL SYSTEMS S-1B Control Panel 12 & 24 Volt S-1B Control Panel 12 & 24 Volt A-8553-4 / B-5971 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 22-92120 S-1B Control Panel Assembly, 12 Volt (includes all keys) ••...
  • Page 72 GROUP 5 - ELECTRICAL SYSTEMS Flush Mount S-3C Control Panel 12 & 24 Volt Flush Mount S-3C Control Panel 12 & 24 Volt Generator Set Applications A-4597, A-4597 / C-2441 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER ••...
  • Page 73 GROUP 5 - ELECTRICAL SYSTEMS Flush Mount S-3C Control Panel 12 & 24 Volt Flush Mount S-3C Control Panel 12 & 24 Volt Generator Set Applications A-9329, A-9330 / C-2441 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER ••...
  • Page 74 GROUP 5 - ELECTRICAL SYSTEMS S-3B Control Panel 12 Volt & 24 Volt S-3B Control Panel 12 Volt & 24 Volt Generator Set Applications A-4721, A-4695, A-4722 , A4723 / C-2470 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER ••...
  • Page 75 GROUP 5 - ELECTRICAL SYSTEMS S-3B Control Panel 12 Volt & 24 Volt S-3B Control Panel 12 Volt & 24 Volt Generator Set Applications A-4721, A-4695, A-4722 , A-4723 / C-2470 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER ••...

  • Page 76: Belt Guard

    GROUP 5 – ELECTRICAL SYSTEM Belt Guard & Mounting - Small Frame Alternators Belt Guard & Mounting - Small Frame Alternators Propulsion Units without PTO A-7848 / B-6997 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 00-75479 Belt Guard for Small Frame Alternators - Heat Exchanged units 23-05405 Bracket 23-05406...
  • Page 77 GROUP 5 – ELECTRICAL SYSTEM Belt Guard & Mounting - Small Frame Alternators Belt Guard & Mounting - Small Frame Alternators Propulsion Units with PTO A-8391 / B-6981 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 00-75484 Belt Guard for Small Frame Alternators - Heat Exchanged units 23-05403 Bracket...
  • Page 78 GROUP 5 – ELECTRICAL SYSTEM Belt Guard & Mounting - Large Frame Alternators Belt Guard & Mounting - Large Frame Alternators Propulsion Units without PTO A-7832 / B-7004 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 00-75481 Belt Guard for Large Frame Alternators - Heat Exchanged units 23-05405 Bracket 23-05409...
  • Page 79 GROUP 5 – ELECTRICAL SYSTEM Belt Guard & Mounting - Small & Medium Frame Alternators Belt Guard & Mounting - Small & Medium Frame Alternators Generator Sets without PTO A-4248 / C-2351 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 00-05414 Guard for Medium Frame Alternators - Heat Exchanged units...
  • Page 80 GROUP 5 – ELECTRICAL SYSTEM Belt Guard & Mounting - Medium Frame Alternators Belt Guard & Mounting - Medium Frame Alternators Generator Sets with PTO A-6485B, A-6906C/ B-7003 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• •• 23-45409 Bracket for Small Frame Alternator 00-05403...
  • Page 81 GROUP 6 – GASKET SETS Overhaul Gasket Set Overhaul Gasket Set PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 29-05410 Overhaul Gasket Set 04111-20220-71 Gasket Kit - Engine Overhaul (components not listed) 16271-78301-71 Coolant Pump 11-75401 PTO Cover 11-25400 Air Intake 16-25400...
  • Page 82 GROUP 7 – GEAR & ADAPTER SETS Gear and Adapter Sets Gear and Adapter Sets HSW630V1 A-7831/ B-7022 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 500-018 Adapter SAE #4 x Hurth 34-61043 Drive Damper, Dual Element SAE #10 12-00312 Capscrew, Hex Head 3/8-16 x 1"...
  • Page 83 GROUP 7 – GEAR & ADAPTER SETS Gear and Adapter Sets Gear and Adapter Sets HSW630A & H A-7952/ B-7027 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 500-018 Adapter SAE #4 x Hurth 34-61043 Drive Damper, Dual Element SAE #10 12-00312 Capscrew, Hex Head 3/8-16 x 1"...
  • Page 84 GROUP 7 – GEAR & ADAPTER SETS Gear and Adapter Sets Gear and Adapter Sets HSW450A A-8461/ B-7029 PART NUMBER DESCRIPTION SERIAL NUMBER 500-018 Adapter SAE #4 x Hurth 34-61043 Drive Damper, Dual Element SAE #10 12-00312 Capscrew, Hex Head 3/8-16 x 1" 15-00302 Lock Washer 15-00301...
  • Page 85 GROUP 7 – GEAR & ADAPTER SETS Gear and Adapter Sets Gear and Adapter Sets HSW450A Keel Cooled A-8134/ B-7031 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 500-018 Adapter SAE #4 x Hurth 34-61043 Drive Damper, Dual Element SAE #10 12-00312 Capscrew, Hex Head 3/8-16 x 1"...

  • Page 86: Base Frame

    GROUP 8 – FRAME & MOUNTING Base Frame Base Frame 361 - 363 Generators A-7476 / D-2917 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 39-85422 Base Frame, Steel 39-85423 Base Frame, Aluminum 23-85418 Engine Mounting Bracket, Left Hand 23-85419 Engine Mounting Bracket, Right Hand 33-83106...

  • Page 87: Base Frame

    GROUP 8 – FRAME & MOUNTING Base Frame Base Frame PX-332K1 & K2 Generators A-8449 / D-3149 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 39-85422 Base Frame, Steel, Plateform Mounts 23-85418 Front Engine Mounting Bracket, LH 23-85419 Front Engine Mounting Bracket, RH 12-00809 Capscrew, Hex Head M10 x 1.25 x 25 mm...
  • Page 88 GROUP 8 – FRAME & MOUNTING Base Frame Base Frame M30C, M30CS, and M32C Commercial Marine Units with 224 Generator A- 6696, A-7741 / D-2918 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 39-85421 Base Frame 23-85411 Front Engine Mounting Bracket, Left Hand 23-85412 Front Engine Mounting Bracket, Right Hand 12-00809...
  • Page 89 GROUP 8 – FRAME & MOUNTING Base Frame M33C with PX-332K1 Generator A-9772 / D-3498 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 39-85428 Base Frame 23-85418 Front Engine Mounting Bracket, Left Hand 23-85412 Front Engine Mounting Bracket, Right Hand 12-00809 Capscrew, Hex Head M10 x 1.25 x 25 mm 15-00802...
  • Page 90 GROUP 8 – FRAME & MOUNTING Front Engine Mounts Front Engine Mounts Lugger Application A-7867 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 23-85421 Engine Front Mount Bracket, Right Hand 23-85420 Engine From Mount Bracket, Left Hand 15-00802 Lock Washer, Helical M10 12-00823 Capscrew, Hex Head M10 x 1.25 x 55 mm...

  • Page 91: Lifting Eye

    GROUP 8 – FRAME & MOUNTING Lifting Eye - Front Lifting Eye - Front A-4542 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 00-75401 Lifting Eye, Front 12-00808 Capscrew, Hex Head M10 x 1.25 x 20 mm 15-00802 Lock Washer, Helical M10 P984 09/05 8 - 5...
  • Page 92 GROUP 9 – ACCESSORIES & OPTIONAL EQUIPMENT P.T.O. Adapter P.T.O. Adapter Marine - Early Production & M32C with 224 Frame Generator A-6290 / D-2588C PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 10-65401 Housing 23-65402 Bracket 23-65403 Bracket 12-34803 Capscrew, Socket Head M10 x 1.5 x 25 mm 15-00803...
  • Page 93 GROUP 9 – ACCESSORIES & OPTIONAL EQUIPMENT P.T.O. Adapter P.T.O. Adapter Marine - Late Production & M32CR A-7731A / D-3155A PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 10-65401 PTO Clutch Housing 23-65414 Engine/PTO Support Bracket (Right Hand, formerly 23-65404) 23-65416 Engine/PTO Support Bracket (Left Hand, formerly 23-65406)

  • Page 94: Electric Clutch

    GROUP 9 – ACCESSORIES & OPTIONAL EQUIPMENT Electric Clutch Electric Clutch 12 Volt and 24 Volt H-28 B-Spline A-6291 + A-6346 / C-3020 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 34-60031 Electric Clutch Assembly (12 volt) 34-60032 Electric Clutch Assembly (24 volt) 12-00513 Capscrew, Hex Head 1/2-13 x 1-1/4...

  • Page 95: Oil Drain Kit

    GROUP 9 – ACCESSORIES & OPTIONAL EQUIPMENT Oil Drain Kit Oil Drain Kit A-5024 / B-3990 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER •• 34-70010 Oil Drain Kit Complete (includes all keys) 36-72002 Hand Pump 31-70001 Adapter, Oil Drain 16-70001 O-Ring P984 09/05...

  • Page 96: Low Oil Level Switch

    GROUP 9 – ACCESSORIES & OPTIONAL EQUIPMENT Low Oil Level Switch/Gauge Low Oil Level Switch/Gauge A-4361B / C-2373 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 22-10004 Oil Level Switch/Gauge, Isolated Ground 23-75402 Mounting Bracket 12-00100 Capscrew, Hex Head 1/4-20 x 1/2" 15-00102 Lock Washer, Helical 1/2"...

  • Page 97: Water Level Switch

    GROUP 9 – ACCESSORIES & OPTIONAL EQUIPMENT Water Level Switch/Gauge Water Level Switch/Gauge Tank Mounted A-4888 / C-2515A PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 22-10003 Coolant Level Switch Gauge, Isolated Ground 21-71044 Male Elbow, 90° Brass 1/4 NPT x 1/4-45T 21-71045 Female Swivel, Brass 1/4-45T x 1/4 HB 18-51007...

  • Page 98: Pre-Alarm Switches

    GROUP 9 – ACCESSORIES & OPTIONAL EQUIPMENT Pre-Alarm Switches Pre-Alarm Switches A-4299F / C-2415B PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 22-40907 Engine Temperature Switch, 205°F 22-40901 Oil Pressure Switch, 25PSI 10-85401 Oil Pressure Manifold 21-71053 Elbow 90° Steel 1/8 NPT x 1/4-37T 18-05401 Hose Assembly 21-74406...

  • Page 99: Raw Water Flow Switch

    GROUP 9 – ACCESSORIES & OPTIONAL EQUIPMENT Raw Water Flow Switch Raw Water Flow Switch A-7560 / C-4560 PART NUMBER PART NUMBER DESCRIPTION DESCRIPTION SERIAL NUMBER SERIAL NUMBER 37-15401 Flow Switch 23-15405 Bracket, Flow Switch Mounting 19-11001 U-Bolt Clamp 14-00101 Lock Nut 21-10023 Bushing, Brass 1"...
  • Page 100 4420 14th Ave. NW., Seattle WA 98107 Tel: (206) 789-3880 • 1-800-762-0165 • Fax: (206) 782-5455 Northern Lights and Lugger are registered trademarks of Northern Lights, Inc. www.northern-lights.com © 2005 All rights reserved. Litho USA.

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