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M944W3
Operator's Manual
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Parts Manual
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Northern Lights M944W3, M30CW3 Parts Manual

P944-3

For Models: M944W3 and M30CW3

PARTS CATALOG

Marine Generators | Marine Diesel Engines | Land-Based Generators

— 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

4420 14th Avenue N.W.

Seattle, WA 98107

Tel: (206) 789-3880

Fax: (206) 782-5455

Copyright ©2008 Alaska Diesel Electric, Inc. All rights reserved. Northern Lights™, and the Northern Lights logo are trademarks of Alaska Diesel Electric, Inc.

Printed in U.S.A.

PART NO.: P944-3 04/08

PARTS CATALOG

for Models M944W3 and M30CW3

Please read thoroughly before attempting to use this manual:

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

I

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

II

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

III

Table of Contents

 

GROUP 1 - ENGINE

 

Cylinder Block ..............................................

0

Flywheel Housing .........................................

1

Crankshaft, Pulley, and Flywheel.....................

2

Main Bearing.......................................................

3

Piston & Connecting Rod..............................

4 - 5

Timing Gear & Cover................................

6 - 7

Camshaft.......................................................

8

Oil Pump & Pick-up............................................

9

Side Cover & Relief Valve...............................

10

Oil Filter............................................................

11

Oil Pan & Dipstick...........................................

12

Oil Drain Hose..................................................

13

Cylinder Head...................................................

14

Valve Train...............................................

16 - 17

Rocker Arm Cover............................................

18

GROUP 2 - INTAKE & EXHAUST SYSTEM

Intake Manifold ............................................

1

Air Filter & Mounting.........................................

2

Air Filter & Connector........................................

3

Exhaust Manifold ..........................................

4

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

5

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

6

GROUP 3 - COOLING

 

Expansion Tank & Thermostat Housing......

0 - 1

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

2

Heat Exchanger Assembly...............................

3

Coolant Pump................................................

4

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

5

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

6

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

7

GROUP 4

- FUEL SYSTEM

 

Fuel System Assembly..............................

0 - 1

Injection Pump..........................................

2 - 3

Double Wall Fuel Lines..................................

4

USCG Fuel Lines..........................................

5 - 6

Fuel Lines............................................................

7

Fuel Feed Pump.............................................

8

Fuel Injector..............................................

10 - 11

GROUP 5

- ELECTRICAL SYSTEM

 

Engine

.....................................................

0 - 9

Starter..................................................

 

10 - 11

Alternator ..............................Mounting

12 - 13

Alternator .....................................Assembly

14

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

15

Relay Logic ............................................Board

16

Drive Belt....................................................

17

Belt Guard............................................

18 - 21

Control ......................................Panels

22 - 25

GROUP 6

- GASKET SETS

 

Gasket ....................................................Sets

0 - 1

GROUP 8

- FRAME & MOUNTING

 

Engine .........................................Lifting Eye

0

Base Frame...............................................

1 - 3

GROUP 9

- ACCESSORIES

 

GROUP 9

- & OPTIONAL EQUIPMENT

 

PTO Adapter..................................................

0

Electric ...............................................Clutch

1

Low Coolant ...................Level Switch/ Gauge

2

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

3

Low Oil .........................Level Switch/ Gauge

4

Proprietary Information

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

It may not be reproduced in whole or part without the expressed written permission of Alaska Diesel Electric, Inc. © Alaska Diesel Electric, Inc. 2008. All rights reserved. Litho U.S.A. Publication number: P944-3 04/08

P944-3 04/08

I

Model Designation

Models INCLUDED

This manual covers the operating instructions for:

M944W3 and M30CW3

Model Numbers

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

 

 

M

 

 

 

C

 

 

 

 

 

 

 

 

 

 

 

 

M - Northern Lights Marine

 

 

C - Commercial

 

generator set

 

 

 

set

 

M944W3

 

=

Northern Lights marine diesel generator

 

 

 

 

set with a 944 engine and a PX-332K2

 

 

 

 

generator end.

T, W

T - Turbocharger

W - designates winding in generator

 

M30CW3

=

Northern Lights commercial diesel

 

 

 

generator set with a 944 engine and an

 

 

 

UCI224 or PX-332K2 generator end.

Serial Numbers

NORTHERN LIGHTS

Northern Lights generator sets have two serial numbers. One serial number is for the generator end, and it is found on the Generator End Data Plate. One is for the generator set and it looks like the below (figure 1). Please have your generator set serial number ready when you call in for service or parts.

Generator End Serial Number

Figure 1. Generator Set Serial Number Plate

P944-3 04/08

II

 

 

 

 

 

 

 

 

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 - NL844

 

 

4

 

 

 

 

3

2

 

 

6

7

 

8

 

 

9

5

KEY

PART NUMBER

QTY.

 

DESCRIPTION

 

SERIALNUMBER

 

0

185046210

1

Alternator Assembly

10

-

 

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

 

 

 

-

 

 

 

13

P844

06/96

14

 

 

 

 

 

 

 

 

 

 

 

 

11

5 - 2

12

 

 

REFERENCES:

1.Grouping section title.

2.Model designation of equipment that uses parts listed on this page.

3.Title and description of assembly.

4.Drawing numbers that correspond to key column numbers for parts identification.

5.Key column for locating parts shown on drawing.

6.Part number.

NOTE: a Arrows always point toward the front of the engine.

7.Quantity of parts used.

8.Description of each component part.

9.Serial number of unit the part fits.

10.Assembly or kit designated by Key 0 or ••/•.

11.Grouping index number.

12.Page number within the grouping index.

13.Manual title.

14.Page publication date.

P944-3 04/08

III

GROUP 1 – engine

Cylinder Block

 

 

 

 

Dwg. #32B0710

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

••

32A0741010

1

Cylinder Block Assembly (includes keys 1- 16)

-

1

0482623500

10

Expansion Plug

-

2

 

4

Bearing Cap*

-

3

 

1

Bearing Cap, Rear*

-

4

32A0702600

10

Bolt, Bearing Cap

-

5

0482621800

4

Expansion Plug

-

6

 

1

Plug*

-

7

MS661142

1

Plug, Tapered

-

8

3430702100

1

Plug, Cam

-

9

32A0701501

2

Dowel Pin

-

10

F284612000

2

Dowel Pin

-

11

F284605000

2

Dowel Pin

-

12

F285004008

6

Spring Pin

-

13

MS661140

7

Plug, Tapered

-

14

0560501410

1

Bushing

-

15

32A2303500

1

Idler Shaft

-

16

MD000269

1

Plug, Tapered

-

17

32A0711700

2

Side Seal

-

18

0482790170

1

Plug, Tapered

-

 

 

 

*Part unavailable separately

 

 

 

 

 

 

 

 

 

P944-3 04/08

 

1 - 0

GROUP 1 – engine

Flywheel Housing

 

 

 

 

Dwg. #32B1209

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

32A1201100

1

Flywheel Housing SAE #4

-

2

32A0714201

1

Rear Gasket

-

3

MF241282

10

Bolt with washer

-

4

MF241284

2

Bolt with washer

-

5

3440711090

1

Rear Main Crankshaft Seal

-

6

13-05001

2

Stud, M10 x 1.5 x 25 mm (37 mm LOA)

-

7

14-00811

2

Nut, M10 x 1.5

-

8

15-00802

2

Lock Washer M10

-

9

MD001404

1

Drain Plug

-

10

MD00312

1

Gasket

-

 

 

 

 

 

P944-3 04/08

1 - 1

GROUP 1 – engine

Crankshaft, Pulley, and Flywheel

 

 

 

 

Dwg. #32B2016, 32B2111

 

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

 

SERIAL NUMBER

1

32A2000014

1

Crankshaft Assembly (includes keys 2-5)

 

-

2

F284610000

2

Dowel Pin

 

-

3

F287007022

2

Woodruff Key

 

-

4

32A2300101

1

Gear

 

-

5

32A2002901

1

Nut

 

-

6

32A2002101

1

Pulley

 

-

7

32A2111011

1

Flywheel Assembly (includes key 8)

 

-

8

3062161300

1

Ring Gear (113 Teeth)

 

-

9

F103512035

4

Bolt

 

-

10

F251512000

4

Spring Washer

 

-

 

 

 

 

 

 

 

 

 

P944-3 04/08

 

 

1 - 2

GROUP 1 – engine

Main Bearing

 

 

 

 

Dwg. #32B0903

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

32A09-00010

1

Main Bearing Set, Standard

-

 

32A09-00020

1

Main Bearing Set, Undersize 0.25 mm

-

 

32A09-00030

1

Main Bearing Set, Undersize 0.50 mm

-

 

32A09-00040

1

Main Bearing Set, Undersize 0.75 mm

-

2

32B09-08101

3

Thrust Bearing, Standard

-

 

32B09-08201

3

Thrust Bearing, Oversize 0.15 mm

-

 

32B09-08301

3

Thrust Bearing, Oversize 0.30 mm

-

 

 

 

 

 

P944-3 04/08

1 - 3

GROUP 1 – engine

Piston & Connecting Rod

Dwgs. 32B1905 & 32B1718

P944-3 04/08

1 - 4

GROUP 1 – engine

Piston & Connecting Rod

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

32A1710100

4

Piston, Standard

-

 

32A1710200

4

Piston, Oversize 0.25 mm

-

 

32A1710300

4

Piston, Oversize 0.50 mm

-

2

32A1702010

4

Ring Set, Piston, Standard

-

 

32A1702020

4

Ring Set, Piston, Oversize 0.25 mm

-

 

32A1702030

4

Ring Set, Piston, Oversize 0.50 mm

-

3

32A1708300

4

Piston Pin

-

4

F320203000

8

Snap Ring

-

5

32A1900012

4

Connecting Rod Assembly (includes keys 6- 9)

-

6

32A1900400

8

Bolt, Connecting Rod

-

7

3061910501

8

Connecting Rod Nut

-

8

32A1900501

4

Bushing, Connecting Rod

-

9

32A1909011

1

Bearing Set, Connecting Rod, Standard

-

 

32A1909021

1

Bearing Set, Connecting Rod, Undersize 0.25

-

 

32A1909031

1

Bearing Set, Connecting Rod, Undersize 0.50

-

 

32A1909041

1

Bearing Set, Connecting Rod, Undersize 0.75

 

P944-3 04/08

1 - 5

GROUP 1 – engine

Timing Gear Cover

 

 

 

 

Dwg. #32B1107

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

32A1103100

1

Front Plate

-

2

32A1110100

1

Timing Gear Cover

-

3

32A0704100

1

Gasket

-

4

MF241251

5

Bolt with Washer

-

5

32A1100200

1

Gasket

-

6

MF241264

13

Bolt with Washer

-

7

32A1101100

1

Cover (M30CW3 only)

-

8

0601613140

1

O-ring

-

9

MF241266

5

Bolt with Washer

-

10

32A1104010

1

Crankshaft Seal Assembly

-

 

 

 

 

 

 

 

 

P944-3 04/08

 

1 - 6

GROUP 1 – engine

Timing Gear

 

 

 

 

Dwg. #32B2304

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

32A2301101

1

Camshaft Gear

-

2

32A2312301

1

Injection Pump Gear

-

3

32A2303010

1

Idler Gear Assembly

-

4

3432300801

1

Thrust Plate

-

5

MF241280

1

Bolt with Washer

-

6

32A3512101

1

Oil Pump Gear

-

7

32A2300101

1

Crankshaft Gear

-

 

 

 

 

 

P944-3 04/08

1 - 7

GROUP 1 – engine

Camshaft

 

 

 

 

 

Dwg. #32B0504

 

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

 

SERIAL NUMBER

1

32A0500101

1

Camshaft

 

-

2

F287007022

1

Woodruff Key

 

-

3

3040531403

1

Thrust Plate

 

-

4

MF241251

2

Bolt with Washer

 

-

5

32A0502101

8

Tappet

 

-

6

32A0513100

8

Push Rod

 

-

7

32A2301101

1

Camshaft Gear

 

 

 

 

 

 

 

 

 

 

 

 

P944-3 04/08

1 - 8

GROUP 1 – engine

Oil Pump and Pick-up

 

 

 

 

Dwg. #32B3503 & 32B3504

 

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

 

SERIAL NUMBER

1

32A3516101

1

Oil Pick-up

 

-

2

F315002000

1

O-ring

 

-

3

MF241251

2

Bolt with washer

 

-

4

32A3510012

1

Oil Pump Assembly

 

-

5

32A3500600

1

O-ring

 

-

6

MF240053

4

Bolt with Washer

 

-

7

F232010000

1

Jam Nut

 

-

8

F251510000

1

Spring Washer

 

-

9

32A3512101

1

Oil Pump Gear

 

-

 

 

 

 

 

 

 

 

 

P944-3 04/08

 

 

1 - 9

GROUP 1 – engine

Side Cover and Relief Valve

 

 

 

 

Dwgs. # 32B3906 & 32B3606

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

32A3901100

1

Cover

-

2

32A3911200

1

Gasket

-

3

MF240051

14

Bolt with washer

-

4

32A3605012

1

Relief Valve Assembly

-

5

3434000700

1

Gasket

-

P944-3 04/08

1 - 10

Corrected 5-20-08

GROUP 1 – engine

Oil Filter

 

 

 

 

32B4006

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

24-01201

1

Oil Filter (formerly #24-01202)

-

2

32A4001101

1

Union

-

 

 

 

 

 

P944-3 04/08

1 - 11

GROUP 1 – engine

Oil Pan and Dipstick

 

 

 

 

Dwg. #: 32B1306

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

32A1300011

1

Oil Pan (includes keys 2 & 3)

-

2

MD050316

**

Plug, M14 x 1.5

-

3

MD050317

**

Gasket

-

4

MF240051

24

Bolt with Washer

-

5

32A4205100

1

Dipstick

-

 

 

 

**As required

 

 

 

 

 

 

 

 

 

P944-3 04/08

 

1 - 12

Northern Lights M944W3, M30CW3 Parts Manual

GROUP 1 – engine

Oil Drain Hose

 

 

 

 

A-11229 / B-9066

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

21-54901

1

Male Elbow, 900 Steel M14 x 1.5 x 3/8- 37T

-

2

18-71201

1

Hose Assembly 1/2” I.D. x 19- 1/2”

-

3

21-00003

1

Cap, Hex Head Brass 1/2 NPT

-

4

23-72003

1

Bracket, Oil Drain Hose Support (without PTO)

-

 

23-75415

1

Bracket, Oil Drain Hose Support (with PTO)

-

5

19-00010

1

Hose Clamp (with PTO)

-

 

 

 

 

 

P944-3 04/08

1 - 13

GROUP 1 – engine

Cylinder Head

 

 

 

 

32B0106

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

32A0121020

1

Cylinder Head Assembly (includes keys 2-10)

-

2

0482622000

12

Expansion Plug

-

3

0482622500

7

Expansion Plug

-

4

32A0101600

8

Valve Guide

-

5

32A0103100

4

Valve Seat, Intake

-

6

32A0103200

4

Valve Seat, Exhaust

-

7

 

1

Plug (Not available separately)

-

8

MM316248

1

Drain Plug

-

9

3063625901

1

Gasket

-

10

32A0301100

4

Combustion Chamber

-

11

32A0102204

1

Head Gasket

-

12

32A0101400

17

Cylinder Head Bolt

-

 

 

 

 

 

 

 

 

P944-3 04/08

 

1 - 14

GROUP 1 – engine

Notes

P944-3 04/08

1 - 15

GROUP 1 – engine

Valve Train

32b0410

P944-3 04/08

1 - 16

GROUP 1 – engine

Valve Train

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

32A0420100

4

Intake Valve

-

2

32A0421100

4

Exhaust Valve

-

3

3060421402

8

Valve Spring

-

4

3060431601

8

Upper Retainer

-

5

3440402901

16

Valve Cotter

-

6

3130411700

8

Cap

-

7

32A0402801

8

Valve Stem Seal

-

8

MF241255

4

Bolt with washer

 

9

MF522010

2

Snap Ring

-

10

32A0404011

1

Rocker Shaft Assembly (includes key 11)

-

11

0482621200

2

Sealing Cap

-

12

32CO404501

3

Spring

-

13

32A0404701

4

Rocker Stand

-

14

32A0404801

4

Bolt

-

15

32A0422010

8

Rocker Arm Assembly (includes keys 16-18)

-

16

F232508000

8

Jam Nut

-

17

32A0402401

8

Adjusting Screw

-

P944-3 04/08

1 - 17

GROUP 1 – engine

Rocker Arm Cover

 

 

 

 

32B4302, 32B0411

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

32A0413012

1

Rocker Cover

-

2

MD008784

1

Cap, Oil Filler

-

3

32A0413200

1

Gasket, Rocker Cover

-

4

MF241261

5

Bolt with washer

-

5

00-01203

1

Label “944”

-

6

41-01020

9

Hose 3/8” I.D. (Sold per inch)

-

 

 

 

 

 

 

 

 

P944-3 04/08

 

1 - 18

GROUP 2 – INTAKE & EXHAUST SYSTEM

Intake Manifold

 

 

 

 

32B3006

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

32A3016012

1

Intake Manifold (includes key 6)

-

2

32A3000201

1

Gasket

-

3

01435-00840

14

Capscrew, Hex Head Flanged M8 x 1.25 x 40 mm

-

4

01435-00890

2

Capscrew, Hex Head Flanged M8 x 1.25 x 90 mm

-

5

 

1

Pipe*

-

 

 

 

*Not available separately

 

 

 

 

 

 

P944-3 04/08

2 - 1

GROUP 2 – INTAKE & EXHAUST SYSTEM

Air Filter and Mounting M944

A-11218/ B-8916

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

10-21201

1

Housing, Air Filter

-

2

3433004300

1

Gasket

-

3

12-09712

4

Capscrew, Hex Head M8 x 1.25 x 25 mm S/S

-

4

15-99707

4

Wave Washer M8 S/S

-

5

23-21201

1

Bracket

-

6

12-00776

2

Capscrew, Hex Head M8 x 1.25 x 20 mm S/S

-

7

15-99707

2

Wave Washer M8 S/S

-

8

12-00821

2

Capscrew, Hex Head M10 x 1.5 x 20 mm S/S

-

9

15-00808

2

Lock Washer, Helical M10 S/S

-

10

24-21201

1

Screen

-

11

24-21202

1

Element

-

12

10-21202

1

Cover

-

13

12-09801

4

Capscrew, Hex Head M8 x 1.25 x 70 mm S/S

-

14

15-99707

4

Wave Washer M8 S/S

-

15

18-21201

1

Hose, Air Intake

-

16

19-70040

1

Cushion Clamp #40

-

17

12-01102

1

Capscrew, Hex Head M6 x 1.0 x 16 mm S/S

-

18

15-00610

1

Lock Washer, Helical M6 S/S

-

19

15-01134

1

Flat Washer M6 S/S

-

 

 

 

P944-3 04/08

 

2 - 2

GROUP 2 – INTAKE & EXHAUST SYSTEM

Air Filter and Connector M30CW

 

 

 

 

944airinlet

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

24-20001

1

Air Filter

-

2

19-00040

1

Hose Clamp #40

-

3

27-21201

1

Connector, Air Inlet

-

4

3433004300

1

Gasket

-

5

12-09712

1

Capscrew, Hex Head M8 x 1.25 x 25 mm S/S

-

6

15-00705

1

Lock Washer M8 S/S

-

 

 

 

 

 

P944-3 04/08

2 - 3

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