Northern Lights NL843NW3 Parts Manual

P843-3

For Models: M843NW3 and NL843NW3

PARTS CATALOG

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.: P843-3 04/08

PARTS CATALOG

for Models

M843nw3 and NL843nw3

Please read thoroughly before aempting 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 Assembly ......................... 0 - 1

Crankshaft and Flywheel Assembly ........... 2 - 3

Camshaft and Oil Pump ............................4 - 5

Cylinder Head .......................................... 6 - 7

Rocker Arm Assembly ............................8 - 10

GROUP 2 - INTAKE & EXHAUST SYSTEM

Air Filter and Housing ................................... 1

Air Filter and Mounting ................................. 2

Exhaust Manifold and Mufer ........................ 3

GROUP 3 - COOLING SYSTEM

Exhaust Manifold and Heat Exchanger ....... 0 - 1

Coolant Pump ............................................... 2

Coolant Pump, Fan, & Thermostat Housing ..... 3

Raw Water Pump and Mounting ................. 4 - 5

Radiator and Guard ................................... 6 - 7

GROUP 4 - FUEL SYSTEM

Injection Pump and Lines ......................... 0 - 1

Governor and Timing Gear Case ................ 2 - 3

Fuel Filter and Piping ................................ 4 - 5

Fuel Line Connection ..................................... 6

Fuel Injector .................................................. 7

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

GROUP 5 - ELECTRICAL SYSTEM

12 & 24 Volt Engine ................................. 0 - 4

Alternator, Starter, and Flywheel Housing ........ 5

Alternator ..................................................... 6

Starter Assembly ........................................... 7

Alternator Assembly ...................................... 8

Control Panels ........................................ 9 - 12

Belt Guard Assembly ................................... 13

GROUP 6 - GASKET SETS

Gasket Kit ...........................................................0

GROUP 7 - GEAR AND ADAPTER SETS

Not available at this time.

GROUP 8 - FRAME & MOUNTING

Base Frame Assembly .................................... 1

GROUP 9 - ACCESSORIES

GROUP 9 - & OPTIONAL EQUIPMENT

PTO Adapter ................................................ 1

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

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

Keel Cooling Conversion ............................... 4

Coolant Recovery Tank .................................. 5

Remote Expansion Tank ................................. 6

Low Coolant Level Switch/Gauge ................... 7

Proprietary Information

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

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

P843-3 04/08

I

INTRODUCTION

Model Designation

MODELS INCLUDED

This manual covers the operating instructions for:

M843nw3 and NL843nw3, which both use the 843 engine.

Model Numbers

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

M - NL 843 N, W, 3

M - Northern Lights marine generator set

NL - Northern Lights industrial generator set

M843nw3

Northern Lights marine diesel generator set

= =

with an 843 engine and a PX-312K2 generator, Tier II compliant.

Model number of engine block Bore Cylinders 84 mm 3

NL843nw3

N - series designation W - winding in gen. end 3 - Tier III compliant

Northern Lights industrial diesel generator set with an 843 engine and a PX-312K2 generator, Tier III compliant.

Serial Numbers

NORTHERN LIGHTS

Your set has three serial numbers: 1 an engine number stamped on the block, 2 a generator plate, and 3 a generator set plate. Use the serial number on the generator set plate when ordering parts or in correspondence. The generator set plate is found on the service side of the generator and resembles the drawing below.

Generator Set Serial Number

for units with PXK

generators

P843-3 04/08

II

INTRODUCTION

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 - NL843

4

6

5

KEY PART NUMBER QTY. DESCRIPTION SERIALNUMBER

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

23

9

13

11

P843-2 11/05

5-2

14

12

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 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 identi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: a Arrows always point toward the front of the engine.

P843-3 04/08

III

GROUP 1 – ENGINE

Cylinder Block Assembly

P843-3 04/08

1 - 0

843NW3cylblock

GROUP 1 – ENGINE

Cylinder Block Assembly

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 110101290 1 Cylinder Block Assembly (Marine, includes keys #3 - 18, 28) -

110101310 1 Cylinder Block Assembly 3 064210025 1 Expansion Plug 25 mm 4 064210040 4 Expansion Plug 40 mm 5 198466010 2 Plug 6 198466020 4 Plug 7 198466030 4 Plug 8 165296220 1 Idle Gear Shaft Assembly 9 198517222 1 Bushing, Standard 198517226 1 Bushing, Undersized 0.25 mm 198517229 1 Bushing, Undersized 0.50 mm 10 040306203 1 Bearing 11 064100045 1 Expansion Plug 12 030500612 2 Dowel Pin 13 030500616 2 Dowel Pin 14 030501025 2 Dowel Pin 15 030309005 2 Spring Pin 16 012110820 2 Stud 17 012110635 1 Stud 18 012110660 1 Stud 19 110996820 1 Gasket 20 198636170 1 Oil Seal 21 198486770 1 Bushing 22 140546020 1 Filter Joint 23 24-03100 1 Oil Filter Assembly 24 120116160 6 Tappet 25 120456250 6 Push Rod 26 140036220 1 Relief Valve Assembly 27 052109078 1 O-ring 28 042309013 1 Needle Bearing 29 198736050 1 Drain Cock 30 068105250 1 Tube 31 052109113 2 O-ring 32 110756140 1 Dipstick Tube 33 011310612 1 Bolt 34 198416320 1 Dipstick 35 110707450 1 Oil Pan 110707390 1 Oil Pan 36 010109235 26 Bolt

(Marine) - (Industrial) -

(Marine & Industrial) -

37 010411212 2 Plug, Hex Head M12 x 1 38 025100012 2 Seal Washer

(Industrial) -

39 18-72004 1 Oil Drain Hose 40 21-00003 1 Cap 41 23-78601 1 Bracket 42 12-00311 1 Capscrew, Hex Head 3/8- 16 x 3/4” 43 15-00302 1 Lock Washer 3/8” -

(Industrial, includes keys #3- 18, 28) -

(Industrial) -

P843-3 04/08

1 - 1

GROUP 1 – ENGINE

Crankshaft and Flywheel Assembly

P843-3 04/08

1 - 2

843NW3crankshaft

GROUP 1 – ENGINE

Crankshaft and Flywheel Assembly

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 115256580 1 Crankshaft Assembly (includes keys 2- 5) -

2 115276200 1 Crankshaft Gear 3 034100508 1 Key 4 030509020 1 Dowel Pin 5 030300816 1 Spring Pin 6 110156171 1 Bearing Holder Assembly 7 110156181 1 Bearing Holder Assembly 8 110156191 1 Bearing Holder Assembly 9 030500612 6 Dowel Pin 10 198517232 3 Bearing; Standard 198517236 3 Bearing; Undersized 0.25 mm 198517239 3 Bearing; Undersized 0.50 mm 11 198517242 3 Bearing; Standard 198517246 3 Bearing; Undersized 0.25 mm 198517249 3 Bearing; Undersized 0.50 mm 12 010109406 6 Bolt 13 010109667 2 Bolt 14 010700865 2 Bolt 15 199266200 2 Thrust Washer 16 115107970 3 Piston Ring Kit, Standard 17 115017541 3 Piston Kit, Standard 18 115326220 3 Piston Pin 19 036500028 6 Snap Ring 20 115026251 3 Connecting Rod Assembly 21 198517265 3 Bushing 22 115176140 6 Connecting Rod Bolt 23 020109120 6 Nut 24 198517252 6 Bearing, Standard 198517256 6 Bearing, 0.25 mm 198517259 6 Bearing, 0.50 mm 25 115397390 1 Crankshaft Pulley 115396810 1 Crankshaft Pulley 26 020109086 1 Nut 27 115357040 1 Flywheel Assembly 28 115376040 1 Ring Gear

(109 Teeth) -

29 010109341 6 Bolt -

(includes keys 9 &12) -

(Upper) -

(Upper) - (Upper) -

(Lower) -

(formerly #115017540) -

(includes keys 21-23) -

(Marine) - (Industrial) -

(includes key 28) -

P843-3 04/08

1 - 3

GROUP 1 – ENGINE

Camshaft and Oil Pump

P843-3 04/08

1 - 4

843NW3oilpump

GROUP 1 – ENGINE

Camshaft and Oil Pump

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 120026740 1 Camshaft Assembly (includes keys 2- 6) -

2 120016050 1 Cam Gear 3 034100508 1 Key 4 120736081 1 Gear 5 199216230 3 Spacer 6 040156304 1 Bearing 7 125256120 1 Slider 8 199566651 1 Plate 9 011310612 2 Bolt 10 165026230 1 Idle Gear Assembly 11 199266270 1 Thrust Washer 12 198217760 1 Spring 13 140166250 1 Rotor 14 140116220 1 Oil Pump Cover 15 199286150 1 Shim; t = 0.10 199286160 1 Shim; t = 0.15 199286170 1 Shim; t = 0.20 199286180 1 Shim; t = 0.50 16 198216720 1 Spring 17 199236540 1 Collar 18 036800010 1 Snap Ring 19 165166640 1 Front Plate - Marine 165166630 1 Front Plate - Industrial 20 165996540 1 Gasket 21 011300612 2 Bolt 22 052109076 1 O-ring 23 140986970 1 Oil Pipe 24 140406310 1 Suction Filter Assembly 25 011310612 2 Bolt -

(includes key #12) -

(white) -

(blue) -

P843-3 04/08

1 - 5

GROUP 1 – ENGINE

Cylinder Head

P843-3 04/08

1 - 6

843NW3cylhead

GROUP 1 – ENGINE

Cylinder Head

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 111011260 1 Cylinder Head Assembly (Marine, includes keys 1-14) -

111011280 1 Cylinder Head Assembly 2 064210018 5 Expansion Plug, 18 mm 3 064210030 2 Expansion Plug, 30 mm 4 064210025 4 Expansion Plug, 25 mm 5 064210010 2 Expansion Plug, 10 mm 6 120166350 3 Intake Valve 7 120176360 3 Exhaust Valve 8 120406070 3 Valve Guide Seal - Intake 9 198216700 6 Spring 10 120186080 6 Retainer 11 120226070 12 Cotter 12 120406050 3 Valve Guide Seal - Exhaust 13 120216041 6 Cap 14 110136400 3 Valve Seat - Intake 15 111147491 1 Head Gasket t=1.3 mm 111147501 1 Head Gasket t=1.4 mm 16 111136480 11 Head Bolt 17 111136490 3 Head Bolt 18 195816340 1 Lifting Eye 195816030 1 Lifting Eye

(Marine) - (Industrial) -

19 011510816 1 Bolt -

(Industrial, includes keys 1-14) -

P843-3 04/08

1 - 7

GROUP 1 – ENGINE

Rocker Arm Assembly

843NW3rockerarm

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 120036990 1 Rocker Arm Assembly (Marine, includes keys 2-7, 16-17) -

120037070 1 Rocker Arm Assembly

(Industrial, includes keys 2-7, 16-17) -

2 120356131 3 Intake Rocker Arm 3 120356141 3 Exhaust Rocker Arm 4 199486220 6 Screw 5 020109076 6 Nut 6 120316281 1 Rocker Arm Shaft 7 198217170 2 Spring 8 011310635 2 Bolt 9 012109044 3 Stud 10 023100010 3 Nut 11 1 Oil Pressure Switch

(see Electrical System) -

12 140606941 1 Oil Pipe Assembly 13 140996260 4 Sealing Washer 14 198486780 1 Banjo Bolt 15 120996140 1 Gasket 16 052109076 1 O-ring 17 199280300 4 Shim 18 198487590 1 Banjo Bolt

(Tapped 1/8 NPT) -

19 064500010 1 Plug -

P843-3 04/08

1 - 8

GROUP 1 – ENGINE

Rocker Arm Cover

Marine

843NW3rockercover

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 111217780 1 Rocker Arm Cover -

2 111996410 1 Gasket 3 110666210 1 Oil Stopper 4 110666060 1 Steel Wool 5 015600406 6 Screw 6 140996270 3 Gasket 7 024600010 3 Cap Nut 8 198436010 1 Cap 9 052100400 1 O-ring 10 110566080 1 Breather Valve 11 011100408 4 Bolt 12 011310660 2 Bolt 13 011310640 2 Bolt 14 190196630 1 Caution Plate -

P843-3 04/08

1 - 9

GROUP 1 – ENGINE

Rocker Arm Cover

Industrial

843NW3rockercoverind

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 111217820 1 Rocker Arm Cover -

2 111996410 1 Gasket 3 110666210 1 Oil Stopper 4 110666060 1 Steel Wool 5 015600406 6 Screw 6 140996270 3 Gasket 7 024600010 3 Cap Nut 8 198436010 1 Cap 9 052100400 1 O-ring 10 110566080 1 Breather Valve 11 011100408 4 Bolt 12 011310660 2 Bolt 13 011310640 2 Bolt 14 190196630 1 Caution Plate 15 135996950 1 Gasket 16 135566550 1 Air Intake 17 011310620 2 Bolt -

P843-3 04/08

1 - 10

GROUP 2 – INTAKE AND EXHAUST

Air Filter and Housing

Marine

A-10262, A-10312 / C-5444

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 10-22004 1 Connector, Air Inlet 2 135996950 1 Gasket, Air Intake Mounting 3 12-01131 2 Capscrew, Hex Head M6 x 1.0 x 20 mm 4 15-99131 2 Wave Washer M6 S/S 5 18-22002 1 Hose 1-3/4" ID x 2-1/4" 6 19-01028 2 Hose Clamp #28 7 10-22006 1 Front Cover, Air Filter Housing -

 8 28-22001 1 Plate,AirFilterBafe -

9 24-22009 1 Element, Air Filter 10 24-22011 1 Screen, Air Filter Retaining 11 10-22003 1 Rear Cover, Air Filter Housing 12 12-09132 4 Capscrew, Hex Head M6 x 1.0 x 85 mm S/S 13 15-99131 4 Wave Washer M6 S/S 14 23-22001 1 Bracket, Air Filter Support 15 12-09751 4 Capscrew, Hex Head M8 x 1.25 x 16 mm S/S 16 15-99707 4 Wave Washer M8 S/S 17 18-22001 1 Hose, Air Intake (Molded) 18 19-01028 1 Hose Clamp #28 19 19-70028 1 Cushion Clamp #28 20 12-01102 1 Capscrew, Hex Head M6 x 1.0 x 16 mm S/S 21 15-01134 1 Flat Washer, M6 S/S -

P843-3 04/08

2 - 1

GROUP 2 – INTAKE AND EXHAUST

Air Filter and Mounting

Industrial

843NW3aircleaner

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 135016300 1 Air Filter Assembly (includes keys #13 - 16) -

2 19-00036 2 Clamp #36 3 135597860 1 Hose 4 135876600 1 Bracket 5 135976420 1 Bracket 6 195816100 1 Lifting Eye 7 011510820 2 Bolt 8 011510816 4 Bolt 9 011510825 1 Bolt 10 026100008 4 Washer 11 011510825 2 Bolt 12 011510820 1 Bolt 13 135326197 1 Housing 14 24-27302 1 Element 15 135326199 1 Cover Assembly 16 314531163 1 Valve -

P843-3 04/08

2 - 2

GROUP 2 – INTAKE AND EXHAUST

Exhaust Manifold and Mufer

Industrial

843NW3mufer

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 314011660 1 MuferAssembly(includes keys #2 - 8) -

2 011140612 10 Bolt -

 3 135406230 1 MuferElement -

4 135996900 1 Gasket 5 135616701 1 Exhaust Manifold 6 135996550 1 Gasket 7 314120300 1 Flange 8 011310620 4 Bolt 9 135996590 1 Gasket 10 011310670 4 Bolt 11 012110670 2 Stud 13 023100006 2 Nut 14 135606340 1 Exhaust Elbow 27-33103 1 Exhaust Elbow 1-1/2 NPT 15 314410020 1 Clamp 16 026100008 2 Washer 17 027100008 1 Spring Washer 18 020900008 1 Nut 19 010310865 1 Bolt -

(can use #27-33102) -

P843-3 04/08

2 - 3

Northern Lights NL843NW3 Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual