Northern Lights Lugger P984, Lugger M984K, Lugger ML984, Lugger L984, Lugger M30C Owner's Manual

P984

For Models: M984K, ML984, L984,

M30C, M984W and M33CW

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constitu-

ents are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

Northern Lights

4420 14th Avenue N.W. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455

Printed in U.S.A. PART NO.: P984 09/05

TTable of Contents

PARTS CATALOG

for Models M984K, ML984, L984, M30C, M33C,

M984W, and M33CW

for Models M984K, ML984, L984, M30C, M33C,

M984W, and M33CW

Please read thoroughly before a empting to use this manual:

Table of Contents .......................................................................................................................................I

Model Designation & Serial Numbers .........................................................................................................II

Reading a Parts Page ................................................................................................................................III

able of Contents

GROUP 1 - ENGINE

Cylinder Block ........................................0 - 1

Crankshaft, Pistons & Connecting Rods ......2 - 5

Flywheel & Housing .....................................6

Lubrication System ...................................7 - 8

Timing Cover ................................................9

Camshaft & Valve Train ........................10 - 13

Cylinder Head & Valve Cover ................14 - 15

Oil Drain Kit ...............................................16

GROUP 2 - INTAKE & EXHAUST SYSTEM

Air Intake & Intake Noise Reduction ..........0 - 3

Intake Manifold .............................................4

Air Inlet .......................................................5

Exhaust Manifold .........................................6

Wet Exhaust Elbow ........................................ 7

Dry Exhaust Elbow ........................................8

GROUP 3 - COOLING

Expansion T ank & Thermostat Housing ...........1

Heat Exchanger & Mounting ..........................2

Heat Exchanger Assembly

Coolant Pump ...............................................4

Keel Cooling Outlet .......................................5

Raw Water Pump & Mounting ........................6

Raw Water Pump Detail .................................7

GROUP 4 - FUEL SYSTEM

Injectors & Lines .....................................0 - 1

Injection Pump & Piping ...........................2 - 3

Fuel Filter & Piping .................................4 - 5

Fuel System .................................................6

Coast Guard Approved Fuel System ................7

Fuel Feed Pump Assembly .............................8

..............................3

GROUP 5 - ELECTRICAL SYSTEM

Engine .....................................................0 - 5

Dual Station Relay Board ...............................6

Circuit Breaker & Relay Assembly ..................7

Stop Solenoid & Mounting .............................8

Alternator Mounting ...............................9 - 10

Alternator ............................................11 - 13

Starter ........................................................14

Control Panels ......................................15 - 25

Belt Guard ...........................................26 - 30

GROUP 6 - GASKET SETS

Gasket Sets ..........................................................1

GROUP 7 - GEAR AND ADAPTER SETS

Gear & Adapter .............................................0 - 3

GROUP 8 - FRAME & MOUNTING

Base Frame Assemblies ..............................0 - 3

Front Engine Mounts .....................................4

Lifting Eye ....................................................5

GROUP 9 - ACCESSORIES

GROUP 9 - & OPTIONAL EQUIPMENT

PTO Adapter ............................................0 - 1

Electric Clutch ..............................................2

Oil Drain Kit .................................................3

Low Oil Level Switch ....................................4

Water Level Switch ........................................ 5

Pre-Alarm Switches .......................................6

Raw Water Flow Switch .................................7

It may not be reproduced in whole or part without the expressed written permission of Alaska Diesel Electric, Inc.

Proprietary Information

This publication is the sole property of Alaska Diesel Electric, Inc.

P984 09/05

I

Model Designation

NORTHERN LIGHTS

Model Numbers

Serial Numbers

MODELS INCLUDED

This manual covers the operating instructions for M984K, ML984, L984, M33C, M984W, and M33CW which use the 984 engine.

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:

M - L 984 C W

M - Northern Lights marine

generator set

L - Lugger propulsion engine

M984K

ML984

L984

Serial Numbers

NORTHERN LIGHTS

Northern Lights marine diesel generator set

=

with a 984 engine and a PX-332K generator.

Northern Lights marine diesel generator set

=

with a 984 engine and a PSL generator.

=

Lugger propulsion engine with a 984 engine.

Model number of engine block Bore Cylinders 98 mm 4

M33C

M984W

M33CW

Additional letters

designate a series within

a model number.

Northern Lights 33 kW commercial grade

=

marine diesel generator set. Northern Lights marine diesel generator set with

=

a 984 engine and a PX-332K2 generator. Northern Lights marine diesel generator set with

=

a 984 engine and a PX-332K2 generator.

Designates a new

winding in the

generator.

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.

found with the Generator Set Data Plate, should be used when ordering parts for sets using PSL generators. Units with PXK generators have just one plate. Serial numbers for Northern Lights units are

The other serial number,

eight digits in length (e.g. 1234-5678).

LUGGER

When ordering Lugger parts, please refer to the serial number located on the ﬂ ywheel housing.

Generator Set Serial Number

for units with PX K and PSL

generators

Generator End Serial Number

for units with PSL generators

Lugger Serial Number

P984 09/05

II

Reading a Parts Page

ALTERNATOR ASSEMBLY: M - NL844

KEY PART NUMBER QTY. DESCRIPTION SERIALNUMBER

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 - NL844

4

6

KEY PART NUMBER QTY. DESCRIPTION SERIALNUMBER

5

0 185046210 1 Alternator Assembly 1 185446219 1 Flywheel, complete 2 185446217 1 Plate, complete 3 185716200 1 Plate 4 185446218 1 Stator, complete 5 040126210 2 Bearing 6 020210010 1 Nut 7 027100010 1 Spring washer 8 026100010 1 Washer 9 185446220 1 Clamp 10 015140408 1 Screw 11 015140425 2 Screw 12 199236510 1 Collar -

7

8

10

3

2

9

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 ﬁ ts.

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 identiﬁ cation. 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.



13

P844 06/96

5-2

P984 09/05

III

14

1211

GROUP 1 – ENGINE

Cylinder Block

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

Cylinder Block

P984 01-00: 1105

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

1 11401-78700-71 1 Cylinder Block Assembly up to S/N - 0042812 2 11461-78700-71 4 Cylinder Liner 11461-78701-71 4 Cylinder Liner 11475-78300-71 ** Liner Shim T = 0.05" 11476-78300-71 ** Liner Shim T = 0.10"

(Dry Type) (Mark A) - (Dry Type) (Mark B) -

(not shown) - (not shown) -

3 90105-14950-71 10 Bolt 4 90253-15950-71 2 Pin 5 90360-14950-71 2 Expansion Plug 6 96411-45000 2 Expansion Plug 7 90331-55950-71 1 Plug 8 96411-43500 7 Expansion Plug 9 90250-08120 6 Pin 10 90345-51003 1 Plug 11 90250-06068 2 Pin 12 96431-53828 1 Drain Cock

(includes Key #13) -

13 96432-23814 1 Drain Cock Plug 14 90341-10002 1 Plug 15 90430-10027 1 Gasket 16 11459-78301-71 1 Dipstick Tube Support 17 11452-78301-71 1 Dipstick Tube 18 15301-78700-71 1 Dipstick -

**As required.

P984 09/05

1 - 0

GROUP 1 – ENGINE

Cylinder Block

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

Cylinder Block

P984 01-00: 1105

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

1 11401-78702-71 1 Cylinder Block Assembly (includes Pressure Relief Valve & from S/N 0042813 -

standard Crankshaft Bearings)

2 11461-78700-71 4 Cylinder Liner (Dry Type) (Mark A) - 11461-78701-71 4 Cylinder Liner 11475-78300-71 ** Liner Shim T = 0.05" 11476-78300-71 ** Liner Shim T = 0.10"

(Dry Type) (Mark B) -

(not shown) - (not shown) -

3 90105-14950-71 10 Bolt 4 90253-15950-71 2 Pin 5 90360-14950-71 2 Expansion Plug 6 96411-45000 2 Expansion Plug 7 90331-55950-71 1 Plug 8 96411-43500 7 Expansion Plug 9 90250-08120 6 Pin 10 90345-51003 1 Plug 11 90250-06068 2 Pin 12 96431-53828 1 Drain Cock

(includes key #13) -

13 96432-23814 1 Drain Cock Plug 14 90341-10002 1 Plug 15 90430-10027 1 Gasket 16 11459-78301-71 1 Dipstick Tube Support 17 11452-78301-71 1 Dipstick Tube 18 15301-78700-71 1 Dipstick -

**As required

P984 09/05

1 - 1

GROUP 1 – ENGINE

Crankshaft, Pistons & Connecting Rods

P984 01-02: A-5201 / B-3989 + 1301

P984 09/05

1 - 2

GROUP 1 – ENGINE

Crankshaft, Pistons & Connecting Rods

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

Crankshaft, Pistons & Connecting Rods

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

20 13201-78300-71 4 Connecting Rod Assembly up to S/N - 0042812 20A 90384-32951-71 4 Wrist Pin Bushing 20B 13265-68010 8 Connecting Rod Bolt 20C 90179-12015 8 Nut 21 13101-78700-71 4 Piston Assembly, Standard 13103-78700-71 4 Piston Assembly, 0.50 mm O/S 13105-78700-71 4 Piston Assembly, 1.00 mm O/S

(includes Key #21A) -

(includes Key #21A) - (includes Key #21A) -

21A 90521-34004 8 Snap Ring 30 13204-78300-71 1 Connecting Rod Bearing Set, 0.25 mm, Undersize 13205-78300-71 1 Connecting Rod Bearing Set, 0.50 mm, Undersize 13206-78300-71 1 Connecting Rod Bearing Set, 0.75 mm, Undersize 13207-78300-71 1 Connecting Rod Bearing Set, 1.00 mm, Undersize 30A 13041-68040-01 4 Connecting Rod Bearing, Mark 1 - Standard 13041-68040-02 4 Connecting Rod Bearing, Mark 2 - Standard -

Note: matched to rods stamped with Mark 1 or Mark 2.

Note: Standard size connecting rod bearings must be

31 11704-78700-71 1 Main Bearing Set, 0.25 mm, Undersize 11705-78700-71 1 Main Bearing Set, 0.50 mm, Undersize 11706-78700-71 1 Main Bearing Set, 0.75 mm, Undersize 11707-78700-71 1 Main Bearing Set, 1.00 mm, Undersize 31A 11701-78700-71 5 Main Bearing, Size 1 - Standard 11701-78701-71 5 Main Bearing, Size 2 - Standard 11701-78702-71 5 Main Bearing, Size 3 - Standard -

Note: with bearing caps stamped with Mark 1, Mark 2 or Mark 3.

Note: Standard size main bearings must be matched to cylinder blocks

32 13011-78700-71 1 Piston Ring Set, Standard 13013-78700-71 1 Piston Ring Set, 0.50 mm, Oversize 13015-78700-71 1 Piston Ring Set, 1.00 mm, Oversize 34 11011-78300-71 1 Thrust Washer Set, Standard Only 11012-78300-71 1 Thrust Washer Set O/S, 0.125 mm 11013-78300-71 1 Thrust Washer Set O/S, 0.25 mm 40 13411-78700-71 1 Crankshaft 41 13471-78701-71 1 Crankshaft Pulley - Standard 34-65401 1 Crankshaft Pulley - Optional 41A 95161-10519 1 Key 42 13521-78700-71 1 Crankshaft Timing Gear 42A 95161-10519 1 Key 43 34-65402 1 Mounting Flange 44 15-00701 4 Flat Washer M8 45 12-00712 4 Capscrew, Hex Head M8 x 1.25 x 25 mm AC 90105-16950-71 1 Retaining Bolt - Standard Pulley 90105-16951-71 1 Retaining Bolt - Optional Pulley -

P984 09/05

1 - 3

Crankshaft, Pistons & Connecting Rods

GROUP 1 – ENGINE

Crankshaft, Pistons & Connecting Rods

A-5201 / B-3989 + 1301

P984 09/05

1 - 4

GROUP 1 – ENGINE

Crankshaft, Pistons & Connecting Rods

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

Crankshaft, Pistons & Connecting Rods

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

20 13201-78300-71 4 Connecting Rod Assembly from S/N 0042813 20A 90384-32951-71 4 Wrist Pin Bushing 20B 13265-68010 8 Connecting Rod Bolt 20C 90179-12015 8 Nut 21 13101-78702-71 4 Piston Assembly, Standard 13103-78701-71 4 Piston Assembly, 0.50 mm O/S 13105-78701-71 4 Piston Assembly, 1.00 mm O/S

(includes key #21A) -

(includes key #21A) - (includes key #21A) -

21A 90521-34004 8 Snap Ring 30 13204-78300-71 1 Connecting Rod Bearing Set, 0.25 mm, Undersize 13205-78300-71 1 Connecting Rod Bearing Set, 0.50 mm, Undersize 13206-78300-71 1 Connecting Rod Bearing Set, 0.75 mm, Undersize 13207-78300-71 1 Connecting Rod Bearing Set, 1.00 mm, Undersize 30A 13041-68040-01 4 Connecting Rod Bearing, Mark 1 - Standard 13041-68040-02 4 Connecting Rod Bearing, Mark 2 - Standard -

Note: matched to rods stamped with Mark 1 or Mark 2.

Note: Standard size connecting rod bearings must be

31 11704-78700-71 1 Main Bearing Set, 0.25 mm, Undersize 11705-78700-71 1 Main Bearing Set, 0.50 mm, Undersize 11706-78700-71 1 Main Bearing Set, 0.75 mm, Undersize 11707-78700-71 1 Main Bearing Set, 1.00 mm, Undersize 31A 11701-78703-71 5 Main Bearing, Size 1 - Standard 11701-78704-71 5 Main Bearing, Size 2 - Standard 11701-78705-71 5 Main Bearing, Size 3 - Standard 11701-78706-71 5 Main Bearing, Size 4 - Standard 11701-78707-71 5 Main Bearing, Size 5 - Standard 11701-78708-71 5 Main Bearing, Size 6 - Standard -

Note: with bearing caps stamped with Mark 1 through Mark 6.

Note: Standard size main bearings must be matched to cylinder blocks

32 13011-78701-71 1 Piston Ring Set, Standard 13013-78701-71 1 Piston Ring Set, 0.50 mm, Oversize 13015-78701-71 1 Piston Ring Set, 1.00 mm, Oversize 34 11011-78300-71 1 Thrust Washer Set, Standard Only 11012-78300-71 1 Thrust Washer Set O/S, 0.125 mm 11013-78300-71 1 Thrust Washer Set O/S, 0.25 mm 40 13411-78701-71 1 Crankshaft 41 13471-78701-71 1 Crankshaft Pulley - Standard 34-65401 1 Crankshaft Pulley - Optional 41A 95161-10519 1 Key 42 13521-78701-71 1 Crankshaft Timing Gear 42A 95161-10519 1 Key 43 34-65402 1 Mounting Flange 44 15-00701 4 Flat Washer M8 45 12-00712 4 Capscrew, Hex Head M8 x 1.25 x 25 mm AC 90105-16950-71 1 Retaining Bolt - Standard Pulley 90105-16951-71 1 Retaining Bolt - Optional Pulley -

P984 09/05

1 - 5

GROUP 1 – ENGINE

Flywheel and Housing

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

Flywheel and Housing

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 11351-78302-71 1 Flywheel Housing - SAE #4 2 13405-78302-71 1 Flywheel Assembly - SAE #10 3 13453-22060-71 1 Ring Gear - 108 Teeth 4 90105-12039 6 Washer Based Head Hexagon Bolt 5 90116-12950-71 2 Stud 21-11002 ** Plug, 3/4-16 6 94512-01200 2 Washer 7 94115-51200 2 Nut 8 91619-61240 2 Bolt -

**As required.

(not shown) -

P984 09/05

1 - 6

01-01: 3101

GROUP 1 – ENGINE

Lubrication System Components

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

Lubrication System Components

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

1 15100-78700-71 1 Oil Pump Assembly up to S/N - 004812 2 15310-78300-71 1 Oil Pressure Relief Valve (M18 Thread) 3 15104-78700-71 1 Strainer 4 24-05401 1 Oil Filter 5 15060-78300-71-A 1 Oil Filter Mount 6 15702-78700-71 1 Tube Assembly 7 15691-78301-71 1 Gasket 8 90404-10023 2 Fitting 9 90430-17950-71 1 Gasket 10 12101-78700-71 1 Oil Pan 11 90179-08061 2 Nut 12 90116-08112 2 Stud 13 90119-08951 22 Bolt with Washer 14 90430-25003 1 Gasket -

01-04: 1105 / 1501 / 1502

(formerly #15060-78300-71) -

P984 09/05

1 - 7

GROUP 1 – ENGINE

Lubrication System Components

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

Lubrication System Components

01-04: 1105 / 1501 / 1502

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

1 15100-78700-71 1 Oil Pump Assembly from S/N 0042813 2 15310-78700-71 1 Oil Pressure Relief Valve (M16 Thread) 3 15104-78700-71 1 Strainer 4 24-05401 1 Oil Filter 5 15608-78300-71 1 Oil Filter Mount 6 15702-78700-71 1 Tube Assembly 7 15691-78301-71 1 Gasket 8 90404-10023 2 Fitting 9 90430-17950-71 1 Gasket 10 12101-78700-71 1 Oil Pan 11 90179-08061 2 Nut 12 90116-08112 2 Stud 13 90119-08951 22 Bolt with Washer 14 90430-25003 1 Gasket -

P984 09/05

1 - 8

GROUP 1 – ENGINE

Timing Cover - P.T.O. & Rear Seal

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

Timing Cover - P.T.O. & Rear Seal

A-5035 / C-2607 + 1106

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 12180-76002-71 1 Filler Cap 2 15773-78300-71 1 Filler Neck 3 11314-78700-71 1 PTO Housing 10 11307-78302-71 1 PTO Assembly 9T

(includes keys #3, #48, #48A, #48B & #AB) -

10B 90301-81950-71 1 O-Ring 20 11321-78306-71 1 Timing Gear Cover 20A 90311-55950-71 1 Front Crankshaft Seal 23 11311-78700-71 1 Timing Gear Case 41 11328-78700-71 1 Gasket, Timing Gear Cover 42 11312-78330-71 1 Gasket, Timing Gear Case 44 11391-46010 1 Timing Pointer 45 11-75401 1 Gasket, Hydraulic Pump Flange 45A 11383-78700-71 1 Gasket, Rear Main Seal Retainer 46 11381-78700-71 1 Retainer, Rear Main Seal

(formerly #11381-78300-71) -

46A 00-05408 1 Wear Sleeve, Repair Type 90311-95951-71 1 Rear Main Seal

(previously #90311-95950-71) -

(formerly #11383-78330-71) -

(use with standard seal) -

48 13519-78302-71 1 PTO/Raw Water Pump Drive Gear 9T 48A 90363-35950-71 1 Bearing 48B 97103-06006 1 Bearing 49 12-00837 2 Capscrew, Hex Head M10 x 1.5 x 150 mm 50 15-00802 2 Lock Washer M10 51 14-00811 2 Hex Nut M10 x 1.5 52 28-75403 1 Cover, Keel Cooling without Raw Water Pump 53 11-75402 1 Gasket AA 90250-08120 3 Dowel Pin AB 96150-03000 1 Snap Ring BC 90341-10002 1 Plug BJ 90340-11027 1 Gasket CR 28-75001 1 PTO Cover

(not shown) -

P984 09/05

1 - 9

GROUP 1 – ENGINE

Camshaft & Valve Train

P984 01-06

P984 09/05

1 - 10

GROUP 1 – ENGINE

Camshaft & Valve Train

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

Camshaft & Valve Train

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

20 13901-78300-71 1 Shaft up to S/N - 0042812 21 13810-78300-71 1 Rocker Shaft Assembly 22 13811-78300-71 8 Rocker Arm 23 90913-05020 8 Valve Adjusting Screw 24 90501-16163 4 Compression Spring 25 90170-08094 8 Nut 26 90099-04557 5 Capscrew, Hex Head M8 x 1.25 x 60 mm 30 11802-78301-71 1 Camshaft Bearing Set, Standard 11803-78300-71 1 Camshaft Bearing Set, 0.125 mm 11804-78300-71 1 Camshaft Bearing Set, 0.25 mm 40 13511-78300-71 1 Camshaft 40B 90331-55950-71 1 Plug 41 13523-78700-71 1 Camshaft Timing Gear 42 13781-78300-71 8 Push Rod 43 13711-78300-71 4 Intake Valve 43A 90913-02044 8 Valve Stem Oil Seal 44 13715-78300-71 4 Exhaust Valve 45 13751-44030 8 Lifter, Standard 13755-47011 8 Lifter O/S, 0.05 mm 46 90501-45228 8 Valve Spring 47 13741-46010 8 Valve Spring Retainer 47A 90913-03018 16 Valve Lock 48 13613-78700-71 1 Injection Pump Drive Gear 13613-78701-71 1 Injection Pump Drive Gear 49 13571-68010 1 Camshaft Thrust Plate 54 13525-78700-71 1 #1 Idler Gear 55 13581-78300-71 1 #1 Idler Gear Shaft 56 13951-78300-71 1 #1 Valve Rocker Support 57 13952-78300-71 2 #2 Valve Rocker Support 58 13953-78300-71 1 #3 Valve Rocker Support 59 13954-78300-71 1 #4 Valve Rocker Support 60 13572-78300-71 1 Idler Gear Thrust Plate 60A 90105-10950-71 2 Washer Based Head Hexagon Bolt 62 13509-78700-71 1 #2 Idler Gear Sub-Assembly 63 13573-78301-71 1 #2 Idler Gear Thrust Plate 63A 90105-10950-71 2 Washer Based Head Hexagon Bolt 64 13582-78700-71 1 #2 Idler Gear Shaft AA 91611-40816 2 Bolt AC 95161-10519 1 Key AD 91619-61250 1 Bolt with Washer AF 90201-12006 1 Washer BG 91611-61020 2 Bolt with Washer BI 13716-78300-71 8 Valve Stem Cap CU 90201-50950-71 2 Washer -

(includes keys 20, 22-25, & 56-59) -

(Generator Drive Units) - (Propulsion Units) -

P984 09/05

1 - 11

GROUP 1 – ENGINE

Camshaft & Valve Train

P984 01-06

P984 09/05

1 - 12

GROUP 1 – ENGINE

Camshaft & Valve Train

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

Camshaft & Valve Train

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

20 13901-78700-71 1 Shaft from S/N 0042813 21 13810-78700-71 1 Rocker Shaft Assembly 22 13811-78300-71 8 Rocker Arm 23 90913-05020 8 Valve Adjusting Screw 24 90501-16098 3 Compression Spring 25 90170-08094 8 Nut 26 91512-61060 4 Capscrew, Hex Head M10 x 1.25 x 60 mm 30 11802-78301-71 1 Camshaft Bearing Set, Standard 11803-78300-71 1 Camshaft Bearing Set, 0.125 mm 11804-78300-71 1 Camshaft Bearing Set, 0.25 mm 40 13511-78700-71 1 Camshaft 40B 90331-55950-71 1 Plug 41 13523-78701-71 1 Camshaft Timing Gear 42 13781-78300-71 8 Push Rod 43 13711-78300-71 4 Intake Valve 43A 90913-02044 8 Valve Stem Oil Seal 44 13715-78300-71 4 Exhaust Valve 45 13751-78700-71 8 Lifter 13755-47011 8 Lifter O/S, 0.05 mm 46 90501-40950-71 8 Valve Spring 47 13741-46010 8 Valve Spring Retainer 47A 90913-03018 16 Valve Lock 48 13613-78702-71 1 Injection Pump Drive Gear 13613-78703-71 1 Injection Pump Drive Gear 49 13571-68010 1 Camshaft Thrust Plate 54 13525-78701-71 1 #1 Idler Gear 55 13581-78300-71 1 #1 Idler Gear Shaft 56 13951-78700-71 3 Rocker Support 57 13952-78700-71 2 Rocker Support 58 90502-16004 1 Spring 59 90524-15008 2 Spring Clip 60 13572-78300-71 1 Idler Gear Thrust Plate 60A 90105-10950-71 2 Washer Based Head Hexagon Bolt 62 13525-78701-71 1 #2 Idler Gear 63 13573-78301-71 1 #2 Idler Gear Thrust Plate 63A 90105-10950-71 2 Washer Based Head Hexagon Bolt 64 13582-78700-71 1 #2 Idler Gear Shaft AR Bolt AA 91611-40816 2 Bolt AC 95161-10519 1 Key AD 91619-61250 1 Bolt with Washer AF 90201-12006 1 Washer BG 91611-61020 2 Bolt with Washer BI 13716-78300-71 8 Valve Stem Cap CU 90201-50950-71 2 Washer -

(not shown) -

(includes keys 22-25, & 56-59) -

(Generator Drive Units) - (Propulsion Units) -

P984 09/05

1 - 13

GROUP 1 – ENGINE

Cylinder Head & Valve Cover

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

Cylinder Head & Valve Cover

P984 01-09: 1104

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

1 11101-78302-71 1 Cylinder Head (includes keys #2 - #8) up to S/N - 0042812 2 11122-46010 8 Valve Guide 3 11131-68020 4 Intake Valve Seat 4 11135-68010 4 Exhaust Valve Seat 5 96411-43000 8 Expansion Plug 6 96411-45000 2 Expansion Plug 7 96411-43000 3 Expansion Plug 8 90440-15141 4 Tube 9 11201-78300-71 1 Rocker Arm Cover 10 12180-13030 1 Oil Filter Cap 11 90430-37140 1 Gasket 12 91631-40840 4 Capscrew, Hex Head w/Washer M8 x 1.25 x 40 mm 13 90210-08007 4 Sealing Washer 14 90910-02070 18 Head Bolt M12 x 1.25 x 117 mm 15 90345-54005 1 Plug 16 11213-78300-71 1 Rocker Arm Cover Gasket 17 11115-78701-71 1 Cylinder Head Gasket 18 00-05404 1 Label -

(includes key #11) -

(formerly #11115-78700-71) -

P984 09/05

1 - 14

GROUP 1 – ENGINE

Cylinder Head & Valve Cover

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

Cylinder Head & Valve Cover

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

1 11101-78700-71 1 Cylinder Head (includes keys #2 - #8) from S/N 0042813 - 2 11122-46010 8 Valve Guide 3 11131-68020 4 Intake Valve Seat 4 11135-68010 4 Exhaust Valve Seat 5 96411-43000 8 Expansion Plug 6 96411-45000 2 Expansion Plug 7 96411-43000 3 Expansion Plug 8 90440-15141 4 Tube 9 11201-78700-71 1 Rocker Arm Cover 10 12180-13030 1 Oil Filter Cap 11 90430-37140 1 Gasket 12 91621-60865 4 Capscrew, Hex Head w/Washer M8 x 1.25 x 65 mm 13 90210-08007 4 Sealing Washer 14 90910-02070 18 Head Bolt M12 x 1.25 x 117 mm 15 90345-54005 1 Plug 16 11213-78700-71 1 Rocker Arm Cover Gasket 17 11115-78701-71 1 Cylinder Head Gasket 18 00-05404 1 Label -

P984: TOYOTAROCKERCOVER

(includes key #11) -

(not shown) -

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GROUP 1 – ENGINE

Oil Drain Kit

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

Oil Drain Kit

Northern Lights Application

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 36-75402 1 Oil Pan Drain Fitting 2 21-62508 1 Male Elbow 90° 3/8 NPT x 1/2-37T 3 18-75400 1 Hose Assembly 1/2" ID x 1/2 NPT x 1/2-37T 4 21-00003 1 Pipe Cap, 1/2 NPT 5 19-00010 1 Hose Clamp 6 23-75415 1 Oil Drain Hose Support Bracket 7 90430-25013 1 Gasket -

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A-4348 / B-3669

GROUP 1 – ENGINE

Notes

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GROUP 2 – INTAKE & EXHAUST SYSTEM

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

Air Intake & Vent Hose

Early Production Generator Sets and L984D

A-7044, A-7378, A-7869 / C-2334A

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 10-25401 1 Air Intake Manifold (Marine) 10-25402 1 Air Intake Manifold 2 11-25400 1 Gasket 3 00-75402 1 Rear Lifting Eye 4 24-25401 1 Air Filter Element 24-25402 1 Air Filter Element 5 12-00809 2 Capscrew, Hex Head M10 x 1.25 x 25 mm 6 15-00802 2 Helical Lock Washer M10 7 21-25401 1 Male Connection 3/8 NPT x 5/8 HB 8 12-00754 2 Capscrew, Hex Head M8 x 1.25 x 85 mm 9 15-00701 4 Flat Washer, M8 10 16-25400 4 O-Ring 11 12-00713 2 Capscrew, Hex Head M8 x 1.25 x 35 mm 12 12261-78301-71 1 Vent Hose 13 90467-23002 2 Hose Clamp -

(Lugger) -

(Lugger) - (Marine - see Intake Noise Reduction Assembly)

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GROUP 2 – INTAKE & EXHAUST SYSTEM

Intake Noise Reduction

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

-

Intake Noise Reduction

Marine Application - Early Production

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 10-25401 1 Intake Manifold 2 28-25401 1 Cover Plate 3 24-25402 1 Air Filter Element 4 11-25401 1 Gasket 7 18-25403 1 Hose, Air Intake 2" ID x 65" (1500 RPM units) 18-25402 1 Hose, Air Intake 2" ID x 54" (1800 RPM units) 8 19-00032 1 Hose Clamp #32 9 24-25403 1 Screen

P984 02-01: B-4821

-

P984 09/05

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GROUP 2 – INTAKE & EXHAUST SYSTEM

Air Intake & Vent Hose

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

Air Intake & Vent Hose

Marine Application - Late Production

A-7708 / C-4057

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 10-25402 1 Air Intake Manifold 2 11-25400 1 Gasket 3 00-75482 1 Lifting Eye, Rear 4 24-25402 1 Air Filter Element 5 12-00809 2 Capscrew, Hex Head M10 x 1.25 x 25 mm 6 15-00802 2 Lock Washer, Helical M10 7 21-25401 1 Nipple, Plain, BP, 3/8 NPT x 1-1/4 8 12-00754 2 Capscrew, Hex Head M8 x 1.25 x 85 mm 9 15-00701 4 Flat Washer M8 10 16-25400 4 O-Ring, 8.5 mm x 18 mm x 3.2 mm 11 12-00713 2 Capscrew, Hex Head M8 x 1.25 x 35 mm 12 12261-78301-71 1 S-Hose 13 90467-23002 2 Hose Clamp 14 24-25405 1 Screen 15 11-25402 1 Gasket 16 28-25402 1 Plate 17 12-00209 3 Capscrew, Hex Head 5/16-18 x 3/4" 18 15-00203 3 Star Washer, Internal 5/16" 19 00-25401 ** Rubber Cushion Strip 7/8" LOA 00-25402 ** Cushioned Steel U-Channel -

** As required.

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GROUP 2 – INTAKE & EXHAUST SYSTEM

Intake Noise Reduction

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

Intake Noise Reduction

Marine Application - Late Production

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 18-25402 1 Air Intake Hose, 2" ID x 54" (1800 RPM units) 18-25403 1 Air Intake Hose, 2" ID x 65" (1500 RPM units) 2 19-00032 1 Hose Clamp #32 3 19-71035 2 Adelle Clamp 2-14" ID x 1/2" Stud 4 12-09516 1 Capscrew, Hex Head 1/2-13 x 2" Stainless Steel 5 15-00508 2 Flat Washer 1/2 SAE Stainless Steel 6 21-21004 1 Spacer, BP. 1/2 SCHD 40 x 13/16" 7 12-00776 1 Capscrew, Hex Head M8 x 1.25 x 20 mm Stainless Steel 8 15-00705 1 Lock Washer, Helical M8 Stainless Steel 9 15-00706 1 Flat Washer M8 Stainless Steel -

A-8483, A-8498 / C-4063

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GROUP 2 – INTAKE & EXHAUST SYSTEM

Intake Manifold

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

Intake Manifold

P984 02-04: 1701

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

1 17111-78300-71 1 Intake Manifold up to S/N -0042812 2 17171-78300-71 1 Intake Manifold Gasket 3 90179-08061 3 Lock Nut, Flanged M8 x 1.25 4 90116-08131 3 Stud M8 x 1.25 x 20 mm (30 mm LOA) 5 91611-60825 3 Capscrew, Hex Head with Washer M8 x 1.25 x 25 mm 6 91611-60865 3 Capscrew, Hex Head with Washer M8 x 1.25 x 65 mm

1 17111-78700-71 1 Intake Manifold from S/N 0042813 2 17171-78700-71 1 Intake Manifold Gasket 3 90179-08061 3 Lock Nut, Flanged M8 x 1.25 4 90116-08131 3 Stud M8 x 1.25 x 20 mm (30 mm LOA) 5 91611-60825 6 Capscrew, Hex Head with Washer M8 x 1.25 x 25 mm

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GROUP 2 – INTAKE & EXHAUST SYSTEM

Air Inlet

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

Air Inlet

Commercial Application

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 24-20001 1 Air Filter -

2 31-25401 1 Air Inlet Adapter 3 11-25400 1 Gasket 4 12-00712 4 Capscrew, Hex Head M8 x 1.25 x 25 mm 5 15-00702 4 Lock Washer M8 6 18-71010 1 Hose, 5/8" ID x 11" 7 19-00008 2 Hose Clamp #8 8 19-00040 1 Hose Clamp #40 -

A-5546/ C-2716

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GROUP 2 – INTAKE & EXHAUST SYSTEM

Exhaust Manifold

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

Exhaust Manifold

A-4213 / C-2337

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 10-35400 1 Exhaust Manifold 2 11-35402 4 Exhaust Manifold Gasket 17173-78300-71 1 Exhaust Manifold Gasket 3 13-35401 8 Stud, M10 x 1.25 x 35 mm (47 mm LOA) 4 14-00816 8 Hex Nut, M10 x 1.25 5 15-00805 8 Flat Washer, M10 6 21-00530 ** Hex Plug, brass 1/2 NPT 7 21-31003 ** Hex Plug, brass 3/8 NPT 8 21-10002 1 Drain Cock 1/4 NPT 9 17-10006 1 Expansion Plug 3/4"

**As required

(replaced by #11-35402)

(14 mm Hex) -

(not shown) -

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Northern Lights Lugger P984, Lugger M984K, Lugger ML984, Lugger L984, Lugger M30C Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual