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M984K
Operator's Manual
34 pgs7.44 Mb0
Parts Manual
97 pgs6.89 Mb1

Northern Lights M984K, ML984, L984, M30C, M33C Parts Manual

...
4 (1)
Northern Lights M984K, ML984, L984, M30C, M33C Parts Manual

PARTS

CATALOG P984

for Models M984K, ML984, L984, M30C, M33C, M984W, and M33CW

— 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 ©2005 Alaska Diesel Electric, Inc. All rights reserved. Alaska Diesel Electric™,

the Alaska Diesel Electric logo, Northern Lights™, and the Northern Lights logo are all trademarks of Alaska Diesel Electric, Inc.

Printed in U.S.A.

PART NO.: P984 09/05

PARTS CATALOG

for Models M984K, ML984, L984, M30C, M33C, M984W, and M33CW

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 - 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 Tank & Thermostat Housing ...........

1

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

2

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

3

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

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 - 23

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

24 - 28

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

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. 2005. All rights reserved. Litho U.S.A. Publication number: P984 09/05.

P984 09/05

I

Model Designation

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

 

 

 

L, C

 

 

 

W

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

M - Northern Lights marine

 

 

Model number of engine block

 

 

Additional letters

 

 

Designates a new

 

generator set

 

 

Bore

 

Cylinders

 

 

designate a series within

 

 

winding in the

 

L - Lugger propulsion engine

 

 

98 mm

4

 

 

a model number.

 

 

generator.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

M984K

ML984

L984

=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.

M33C

M984W

M33CW

=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.

Serial Numbers

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. Units with PXK generators have just one plate. Serial numbers for Northern Lights units are eight digits in length (e.g. 1234-5678).

LUGGER

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

Lugger Serial Number

Generator Set Serial Number for units with PX K and PSL generators

Generator End Serial Number

for units with PSL generators

P984 09/05

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: 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.

P984 09/05

III

GROUP 1 – ENGINE

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 (Dry Type) (Mark A)

-

 

11461-78701-71

4

Cylinder Liner (Dry Type) (Mark B)

-

 

11475-78300-71

**

Liner Shim T = 0.05" (not shown)

-

 

11476-78300-71

**

Liner Shim T = 0.10" (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

 

 

 

 

 

 

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 (Dry Type) (Mark B)

-

 

11475-78300-71

**

Liner Shim T = 0.05" (not shown)

-

 

11476-78300-71

**

Liner Shim T = 0.10" (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

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 (includes Key #21A)

-

 

13103-78700-71

4

 

Piston Assembly, 0.50 mm O/S (includes Key #21A)

-

 

13105-78700-71

4

 

Piston Assembly, 1.00 mm O/S (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: Standard size connecting rod bearings must be

 

 

 

 

 

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

 

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: Standard size main bearings must be matched to cylinder blocks

 

 

 

 

 

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

 

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

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

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 (includes key #21A)

-

 

13103-78701-71

4

Piston Assembly, 0.50 mm O/S (includes key #21A)

-

 

13105-78701-71

4

Piston Assembly, 1.00 mm O/S (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: Standard size connecting rod bearings must be

 

 

 

 

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

 

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: Standard size main bearings must be matched to cylinder blocks

 

 

 

 

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

 

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

 

 

 

 

 

 

01-01: 3101

 

 

 

 

 

 

 

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 (not shown)

 

 

-

6

94512-01200

2

Washer

 

 

-

7

94115-51200

2

Nut

 

 

-

8

91619-61240

2

Bolt

 

 

-

 

 

 

**As required.

 

 

 

 

 

 

 

 

 

 

 

 

 

P984

09/05

 

 

1 - 6

GROUP 1 – ENGINE

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

 

 

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 (formerly #15060-78300-71)

 

-

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 - 7

GROUP 1 – ENGINE

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

 

 

 

 

 

 

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 (formerly #11383-78330-71)

-

46

11381-78700-71

1

 

Retainer, Rear Main Seal (formerly #11381-78300-71)

-

46A

00-05408

1

 

Wear Sleeve, Repair Type (use with standard seal)

-

 

90311-95951-71

1

 

Rear Main Seal (previously #90311-95950-71)

-

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

 

-

 

 

 

 

 

 

 

 

 

 

 

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

20

13901-78300-71

1

 

Shaft

up to S/N - 0042812

21

13810-78300-71

1

 

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

-

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 (Generator Drive Units)

-

 

13613-78701-71

1

 

Injection Pump Drive Gear (Propulsion Units)

-

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

-

 

 

 

 

 

 

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

20

13901-78700-71

1

 

Shaft

 

from S/N 0042813 -

21

13810-78700-71

1

 

Rocker Shaft Assembly (includes keys 22-25, & 56-59)

 

-

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 (Generator Drive Units)

 

-

 

13613-78703-71

1

 

Injection Pump Drive Gear (Propulsion Units)

 

-

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

 

-

 

 

 

 

 

 

 

P984 09/05

1 - 13

GROUP 1 – ENGINE

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 (includes key #11)

-

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 (formerly #11115-78700-71)

-

18

00-05404

1

Label

 

 

-

 

 

 

 

 

 

 

 

 

 

P984

09/05

 

 

1 - 14

GROUP 1 – ENGINE

Cylinder Head & Valve Cover

 

 

 

 

 

 

P984: TOYOTAROCKERCOVER

 

 

 

 

 

 

 

 

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 (includes key #11)

 

-

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

09/05

 

 

1 - 15

GROUP 1 – ENGINE

Oil Drain Kit

Northern Lights Application

 

 

 

 

 

A-4348 / B-3669

 

 

 

 

 

 

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

 

-

 

 

 

 

 

 

 

 

 

P984

09/05

 

1 - 16

GROUP 1 – ENGINE

Notes

P984 09/05

1 - 17

GROUP 2 – INTAKE & EXHAUST SYSTEM

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 (Lugger)

 

-

2

11-25400

1

Gasket

 

 

-

3

00-75402

1

Rear Lifting Eye

 

 

-

4

24-25401

1

Air Filter Element (Lugger)

 

 

-

 

24-25402

1

Air Filter Element (Marine - see Intake Noise Reduction Assembly)

 

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

 

 

-

 

 

 

 

 

 

 

 

 

 

P984

09/05

 

 

2 - 0

GROUP 2 – INTAKE & EXHAUST SYSTEM

Intake Noise Reduction

Marine Application - Early Production

 

 

 

 

 

P984 02-01: B-4821

 

 

 

 

 

 

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

09/05

 

2 - 1

GROUP 2 – INTAKE & EXHAUST SYSTEM

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.

 

 

 

 

 

 

 

 

 

 

 

P984

09/05

 

2 - 2

GROUP 2 – INTAKE & EXHAUST SYSTEM

Intake Noise Reduction

Marine Application - Late Production

 

 

 

 

 

A-8483, A-8498 / C-4063

 

 

 

 

 

 

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

-

 

 

 

 

 

 

 

 

 

P984

09/05

 

2 - 3

GROUP 2 – INTAKE & EXHAUST SYSTEM

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

 

P984 09/05

2 - 4

GROUP 2 – INTAKE & EXHAUST SYSTEM

Air Inlet

Commercial Application

 

 

 

 

A-5546/ C-2716

 

 

 

 

 

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

-

 

 

 

 

 

P984 09/05

2 - 5

GROUP 2 – INTAKE & EXHAUST SYSTEM

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 (replaced by #11-35402)

 

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 (14 mm Hex)

-

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" (not shown)

-

 

 

 

**As required

 

 

 

 

 

 

 

 

 

 

 

 

 

P984

09/05

 

 

2 - 6

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