Northern Lights P864 Parts Manual

P864

For Models: M864K, M864W, and M864W3

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: [phone]
Fax: [phone]

Copyright ©2007 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.: P864 09/07

PARTS CATALOG

for Models M864K, M864W, and M864W3

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 ............................................. 0

Flywheel & Housing ..................................... 1

Crankshaft, Pistons & Connecting Rods ...... 2 - 3

Lubrication System ........................................ 4

Timing Cover ................................................ 5

Camshaft & Valve Train ............................ 6 - 7

Cylinder Head & Valve Cover ......................... 8

Oil Drain / Oil Drain Kit ................................ 9

GROUP 2 - INTAKE & EXHAUST SYSTEM

Intake Manifold & Air Filter ...................... 0 - 1

Exhaust Manifold ......................................... 2

Wet Exhaust Elbow ........................................ 3

Dry Exhaust Elbow ........................................ 4

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 5 - ELECTRICAL SYSTEM

Engine ..................................................... 0 - 3

Stop Solenoid & Mounting ............................. 4

Alternator Mounting ................................. 5 - 8

Alternator Assembly ...................................... 9

Starter ................................................. 10 - 12

Control Panels ...................................... 13 - 16

Belt Guard ........................................... 17 - 19

GROUP 6 - GASKET SETS

Gasket Sets ..........................................................0

GROUP 8 - FRAME & MOUNTING

Engine Lifting Brackets ................................. 1

Base Frame ................................................... 2

GROUP 9 - ACCESSORIES

GROUP 9 - & OPTIONAL EQUIPMENT

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

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

Oil Level Switch ........................................... 3

Oil Drain Kit ................................................. 4

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

GROUP 4 - FUEL SYSTEM

Injection Pump & Piping ............................... 0

Fuel Injectors .................................. 1 - 2, 8 - 9

Double Wall Fuel Lines .................................. 3

Fuel Filter & Lines .................................. 4 - 7

Fuel Feed Pump ................................... 10 - 11

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. 2007. All rights reserved. Litho U.S.A. Publication number: P864 09/07.

P864 09/07

I

Model Designation

MODELS INCLUDED

This manual covers the operating instructions for:

M864K , M864W, and M864W3

Model Numbers

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

M 864 K W

M - Northern Lights Marine

generator set

M864K

Northern Lights Marine diesel generator

=

set with a 864 engine and a PX-325K1
generator.

Model number of engine block
Bore Cylinders
86 mm 4

Additional letters

designate a

generator series

M864W

Designates a

new winding in

generator

Northern Lights Marine diesel generator

=

set with a 864 engine and a PX-325K2
generator.

Serial Numbers

NORTHERN LIGHTS

Northern Lights generator sets 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. Units with PXK generators have just one
plate. Serial numbers for Northern Lights marine units are nine digits in length (e.g. 8642-56781).

Generator End Serial Number

P864 09/07

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

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 9

10

3

2

13

P844 06/96

5-2

14

1211

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: 3 Arrows always point toward the front of the engine.

P864 09/07

III

GROUP 1 – ENGINE

Cylinder Block

Fig. 1105

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

1 11401-78209-71 1 Cylinder Block Assembly (includes keys 2-12) ­ 2 90910-02061 10 Bolt ­ 3 90253-15950-71 2 Pin ­ 4 96411-44000 4 Expansion Plug ­ 5 90345-51003 ** Plug ­ 6 90360-14950-71 2 Ball ­ 7 90331-51032 1 Expansion Plug ­ 8 96411-42000 4 Expansion Plug ­ 9 96411-43500 2 Expansion Plug ­ 10 90250-01820 6 Pin ­ 11 90250-06068 2 Pin ­ 12 96411-11400 2 Expansion Plug ­ 13 96431-53828 1 Drain Cock ­ 14 96432-23814 1 Drain Cock Plug ­ 15 96341-11000 1 Bolt ­ 16 90430-10027 1 Gasket ­ 17 21-00050 1 Plug 1/8 BSPT ­ 18 15301-78207-71 1 Dipstick Guide ­ 19 11452-78700-71 1 Dipstick -

**As required

P864 09/07

1 - 0

GROUP 1 – ENGINE

Flywheel and Housing

Fig. 3101-137

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 11351-78200-71 1 Flywheel Housing SAE #4 ­ 2 90116-12950-71 2 Stud ­ 3 94115-51200 2 Nut ­ 4 94512-01200 2 Washer ­ 5 91619-61240 2 Bolt ­ 6 13405-78203-71 1 Flywheel Assembly SAE #7-1/2 ­ 7 13453-22060-71 1 Ring Gear (108 Teeth) ­ 8 90105-12039 6 Bolt ­ 9 90341-20002 ** Plug, Socket Head M20 x 1.5 -

**

As required

P864 09/07

1 - 1

GROUP 1 – ENGINE

Crankshaft, Pistons & Connecting Rods

P864 09/07

1 - 2

Fig. 1301

GROUP 1 – ENGINE

Crankshaft, Pistons & Connecting Rods

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

1 13201-78201-71 4 Connecting Rod Assembly ­ 2 90999-73950-71 4 Connecting Rod Bushing ­ 3 13265-76002-71 8 Connecting Rod Bolt ­ 4 90179-10042 8 Nut ­ 5 13101-78202-71 4 Piston Assembly, Standard
13103-78202-71 4 Piston Assembly, 0.50 mm O/S
6 90521-29003 8 Snap Ring ­ 7 13204-78200-71 1 Connecting Rod Bearing Set, 0.25 mm, Undersize ­ 13205-78200-71 1 Connecting Rod Bearing Set, 0.50 mm, Undersize ­ 8 13041-78200-71 4 Connecting Rod Bearing, Mark 1 - Standard ­ 13041-78201-71 4 Connecting Rod Bearing, Mark 2 - Standard ­ 13041-78202-71 4
Note: Standard size connecting rod bearings must be matched to rods

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

9 11704-78201-71 1 Main Bearing Set, 0.25 mm, Undersize ­ 11705-78201-71 1 Main Bearing Set, 0.50 mm, Undersize ­ 11706-78201-71 1 Main Bearing Set, 0.75 mm, Undersize ­ 11707-78201-71 1 Main Bearing Set, 1.00 mm, Undersize ­ 10 11701-78203-71 5 Main Bearing, Mark 1 - Standard ­ 11701-78204-71 5 Main Bearing, Mark 2 - Standard ­ 11701-78205-71 5 Main Bearing, Mark 3 - Standard ­ 11701-78206-71 5 Main Bearing, Mark 4 - Standard
11701-78207-71 5 Main Bearing, Mark 5 - Standard
11701-78208-71 5 Main Bearing, Mark 6 - Standard

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

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

11 13011-78202-71 1 Piston Ring Set, Standard ­ 13013-78202-71 1 Piston Ring Set, 0.50 mm, Oversize ­ 12 11011-78201-71 1 Thrust Washer Set, Standard Only ­ 11012-78201-71 1 Thrust Washer Set O/S, 0.125 mm ­ 11013-78201-71 1 Thrust Washer Set O/S, 0.25 mm ­ 13 13411-78201-71 1 Crankshaft ­ 14 13471-78205-71 1 Crankshaft Pulley - Standard ­ 15 95161-10519 1 Key ­ 16 13521-78202-71 1 Crankshaft Timing Gear ­ 17 95161-10519 1 Key ­ 18 91511-61435 1 Bolt ­ 19 90201-14007 1 Plate Washer -

Connecting Rod Bearing, Mark 3 - Standard

(includes key #21A) -

(includes key #21A) -

P864 09/07

1 - 3

GROUP 1 – ENGINE

Lubrication System Components

Fig. 1501/1502

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 15100-78202-71 1 Oil Pump Assembly ­ 2 91511-60825 3 Bolt ­ 3 15310-76002-71 1 Oil Regulator ­ 4 15104-78201-71 1 Oil Strainer ­ 5 90430-17950-71 1 Gasket ­ 6 91621-60814 3 Bolt ­ 7 24-08701 1 Oil Filter ­ 8 90404-20173 1 Union ­ 9 12101-78200-71 1 Oil Pan ­ 10 36-75402 1 Adapter, Oil Drain Connection
11 90430-25003 1 Gasket
12 90119-08951-71 14 Bolt w/ Washer ­ 13 90116-08112 2 Stud ­ 14 90179-08061 2 Nut -

(for Oil Pan drain plug joint) -

P864 09/07

-

1 - 4

GROUP 1 – ENGINE

Timing Cover & Rear Seal

Fig. 1106-136

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 11311-78207-71 1 Timing Gear Case ­ 2 11321-78209-71 1 Timing Gear Cover ­ 3 90311-45950-71 1 Oil Seal ­ 4 11383-78201-71 1 Gasket, Rear Oil Seal Retainer ­ 5 11381-78201-71 1 Rear Oil Seal Retainer ­ 6 90311-95951-71 1 Seal, Engine Rear Oil ­ 7 13519-78203-71 1 Pump Drive Gear ­ 8 97103-06006 1 Bearing, Pump Drive Gear, No. 1 ­ 9 90363-30950-71 1 Bearing, Pump Drive Gear, No. 2 ­ 10 90250-08120 3 Pin ­ 11 91511-60820 5 Bolt ­ 12 90105-08951-71 8 Bolt ­ 13 91511-60820 6 Bolt ­ 14 90345-52950-71 1 Plug, With Head Taper Screw ­ 15 90109-08950-71 1 Bolt ­ 16 91511-60835 1 Bolt ­ 17 12180-13030 1 Oil Fill Cap ­ 18 90430-37140 1 Gasket ­ 19 91511-60825 7 Bolt ­ 20 90210-07006 1 Washer -

P864 09/07

1 - 5

GROUP 1 – ENGINE

Camshaft & Valve Train

P864 09/07

1 - 6

Fig. 1302

GROUP 1 – ENGINE

Camshaft & Valve Train

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 13901-78200-71 1 Shaft ­ 2 90502-16004 2 Spring ­ 3 90524-15008 2 Spring (
4 13811-78200-71 8 Valve Rocker Arm, No. 1 ­ 5 90913-05020 8 Valve Adjusting Screw ­ 6 90501-16163 3 Spring ­ 7 90170-08094 8 Nut ­ 8 11802-78200-71 1 Camshaft Bearing Set, Standard ­ 11803-78200-71 1 Camshaft Bearing Set, 0.125 mm ­ 11804-78200-71 1 Camshaft Bearing Set, 0.25 mm ­ 9 13511-78201-71 1 Camshaft ­ 10 90331-51032 1 Plug ­ 11 13523-78202-71 1 Camshaft Timing Gear ­ 12 13781-78200-71 8 Push Rod ­ 13 13711-78200-71 4 Intake Valve ­ 14 90913-02053 8 Seal ­ 15 13715-78200-71 4 Exhaust Valve ­ 16 13751-78700-71 8 Valve Lifter ­ 17 90501-40950-71 8 Valve Spring ­ 18 13741-76005-71 8 Valve Spring Retainer ­ 19 90913-03950-71 16 Valve Lock ­ 20 13613-78205-71 1 Injection Pump Drive Gear ­ 21 13571-78200-71 1 Camshaft Thrust Plate ­ 22 13525-78202-71 1 #1 Idler Gear ­ 23 13581-78200-71 1 Idler Gear Shaft ­ 24 13951-78200-71 3 #1 Valve Rocker Support ­ 25 13952-78200-71 1 #2 Valve Rocker Support ­ 26 13572-76001-71 1 Idler Gear Thrust Plate ­ 27 90105-10327 2 Bolt ­ 28 13509-78202-71 1 #2 Idler Gear Sub-Assembly ­ 29 13573-78301-71 1 #2 Idler Gear Thrust Plate ­ 30 90105-10950-71 2 Hexagon Bolt ­ 31 13582-78200-71 1 #2 Idler Gear Shaft ­ 32 90201-12006 1 Plate Washer ­ 33 90151-40010 1 Screw ­ 34 91511-60816 2 Bolt ­ 35 13716-78200-71 8 Cap, Valve Stem ­ 36 90201-50950-71 2 Plate Washer ­ 37 91512-61060 4 Capscrew, Hex Head Flanged M10 x 1.25 x 60 mm ­ 38 95161-10519 1 Key ­ 39 91619-61250 1 Bolt with Washer -

Retainer for Valve Rocker Shaft) -

P864 09/07

1 - 7

GROUP 1 – ENGINE

Cylinder Head & Valve Cover

Fig 1104

KEY PART NUMBER QTY DESCRIPTION ENGINE BLOCK S/N

1 11101-78202-71 1 Cylinder Head (includes keys #2- 5 & 8) ­ 2 11126-76004-71 4 Intake Valve Guide
11127-76003-71 4 Intake Valve Guide Intake
3 96411-42500 11 Plug ­ 4 90440-15141 4 Tube ­ 5 96411-45000 2 Expansion Plug ­ 6 90105-11950-71 18 Bolt ­ 7 90116-08131 2 Stud ­ 8 11106-78201-71 4 Precombustion Chamber Insert ­ 9 11115-78204-71 1 Gasket ­ 10 91621-60865 4 Bolt with washer ­ 11 90210-08007 4 Washer ­ 12 12180-76002-71 1 Oil Fill Cap ­ 13 90430-37140 1 Gasket ­ 14 11201-78202-71 1 Cylinder Head Cover ­ 15 11213-78200-71 1 Gasket ­ 16 00-08711 1 Label "864" ­ 17 90345-54005 1 Plug -

(Standard) -

(O/S 0.05)

P864 09/07

1 - 8

GROUP 1 – ENGINE

Oil Drain

A-9502 / B-7340

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 90430-25003 1 Gasket ­ 2 36-75402 1 F. Adapter, Steel, 3/8 NPT x M25 x 1.5 ­ 3 21-62508 1 M. Elbow, 90

0

, Steel, 3/8 NPT X 1/2-37T ­ 4 18-75400 1 Hose Assembly, 1/2" ID x 18-1/2" ­ 5 21-00003 1 Cap, Hex Head, Brass 1/2 NPT ­ 6 23-09502 1 Bracket ­ 7 12-00712 1 Capscrew, Hex Head M8 x 1.25 x 25 mm ­ 8 15-00702 1 Lock Washer, M8 ­ 9 15-00701 1 Flat Washer ­ 10 23-78601 1 Oil Drain Hose Support Bracket ­ 11 12-00776 1 Capscrew, Hex Head M8 x 1.25 x 20 mm S/S ­ 12 15-00705 1 Lock Washer, M8 S/S ­ 13 15-00706 1 Flat Washer, M8 S/S -

P864 09/07

1 - 9

GROUP 2 – INTAKE & EXHAUST SYSTEM

Intake Manifold & Air Filter

P864 09/07

2 - 0

A-9503 / C-4964

GROUP 2 – INTAKE & EXHAUST SYSTEM

Intake Manifold & Air Filter

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 10-28701 1 Intake Manifold ­ 2 17171-78200-71 1 Gasket ­ 3 90116-08131 2 Stud ­ 4 90179-08061 2 Nut ­ 5 91511-60825 6 Capscrew, Hex Head Flanged M8 x 1.25 x 25 mm ­ 6 10-28702 1 Air Filter Housing ­ 7 11-28701 1 Gasket ­ 8 12-00712 7 Capscrew, Hex Head M8 x 1.25 x 25 mm ­ 9 15-00707 7 Wave Washer M8 ­ 10 23-28701 1 Bracket, Air Filter Housing Support ­ 11 12-00711 4 Capscrew, Hex Head M8 x 1.25 x 20 mm ­ 12 15-00701 4 Flat Washer ­ 13 15-00702 4 Lock Washer ­ 14 21-26802 1 Male Connector, Brass, 1/4 NPT x 3/8 HB ­ 15 41-01020 5 Hose, 3/8" ID Push-On ­ 17 24-28702 1 Screen ­ 18 24-28701 1 Air Filter Element ­ 19 28-28701 1 Plate, Intake Cover ­ 20 18-28701 1 Hose, Air Inlet ­ 21 19-00028 1 Hose Clamp #28 ­ 22 19-70034 1 Cushion Clamp #34 ­ 23 12-00029 1 Capscrew, Hex Head M6 x 1.0 x 10 mm S/S ­ 24 15-00610 1 Lock Washer M6 S/S ­ 25 15-01134 1 Flat Washer M6 S/S ­ 26 90467-15120 2 Clamp -

P864 09/07

2 - 1

GROUP 2 – INTAKE & EXHAUST SYSTEM

Exhaust Manifold

A-9505 / B-7227

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 10-38701 1 Exhaust Manifold (includes key #9) ­ 2 17173-78200-71 1 Exhaust Manifold Gasket ­ 3 12-00800 8 Capscrew, Hex Head M10 x 1.25 x 100 mm ­ 4 15-00805 8 Flat Washer M10 ­ 5 21-31003 ** Plug, Hex Head Brass 3/8 NPT ­ 6 21-00530 ** Plug, Hex Head Brass 1/2 NPT ­ 7 21-10002 1 Drain Cock 1/4 NPT ­ 8 21-51098 1 Street Elbow 90

0

Brass 1/4 NPT -

9 17-10002 5 Expansion Plug -

**As required

P864 09/07

2 - 2

GROUP 2 – INTAKE & EXHAUST SYSTEM

Wet Exhaust Elbow

A-9506 / B-7344

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 27-35400 1 Wet Exhaust Elbow ­ 2 11-35401 1 Gasket ­ 3 12-09753 4 Capscrew, Hex Head M8 x 1.25 x 30 mm S/S ­ 4 15-00706 4 Flat Washer, M8 S/S ­ 5 21-31902 1 Male Elbow 90°, 1/2 NPT x 3/4 Hose Barb ­ 6 19-00010 2 Hose Clamp, #10 ­ 7 18-18401 1 Hose, 3/4" ID x 43" Wire Reinforced ­ 8 19-71030 2 Adelle Clamp ­ 9 12-00821 1 Capscrew, Hex Head M10 x 1.25 x 20 mm S/S ­ 10 12-00776 1 Capscrew, Hex Head M8 x 1.25 x 20 mm S/S ­ 11 15-00705 1 Lock Washer M8 S/S ­ 12 15-70004 1 Flat Washer S/S ­ 13 22-42014 1 Switch, High Exhaust Temperature 205

°

F up to xxxx-32320
22-42070 1 Switch, High Exhaust Temperature 205°F from xxxx-32321
14 15-09805 1 Flat Washer M10 S/S ­ 15 15-00705 4 Lock Washer M8 S/S ­ 16 22-40482 1 Harness, High Exhaust Temperature Connection

(not shown) from xxxx-32321

P864 09/07

2 - 3

GROUP 2 – INTAKE & EXHAUST SYSTEM

Dry Exhaust

A-4267 / B-3632A

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 27-35405 1 Dry Exhaust Elbow, 2" NPT Female ­ 31-35401 1 Dry Exhaust Adapter 2" NPT Female ­ 2 11-35401 1 Exhaust Elbow Gasket ­ 3 15-00702 4 Lock Washer, Helical M8 ­ 4 12-00711 4 Capscrew, Hex Head M8 x 1.25 x 20 mm ­ 5 00-35402 1 Heat Shield -

P864 09/07

2 - 4

GROUP 3 – COOLING SYSTEM

Expansion Tank & Thermostat Housing

A-9507 / C-4881

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 10-12205 1 Expansion Tank ­ 2 12-00819 4 Capscrew, Hex Head M10 x 1.5 x 75 mm ­ 3 15-00805 4 Flat Washer, M10 ­ 4 11-10015 1 Thermostat Seal Ring ­ 5 35-10002 1 Thermostat 180

0

F/ 820C ­ 6 10-18701 1 Thermostat Housing ­ 7 11-18701 1 Gasket, Thermostat Housing ­ 8 12-00826 2 Capscrew, Hex Head M10 x 1.5 x 105 mm ­ 9 12-00050 2 Capscrew, Hex Head M10 x 1.5 x 85 mm ­ 10 15-00805 4 Flat Washer, M10 ­ 11 12-00047 1 Capscrew, Hex Head M8 x 1.25 x 100 mm ­ 12 12-00750 2 Capscrew, Hex Head M8 x 1.25 x 80 mm ­ 13 15-00701 2 Flat Washer M8 ­ 14 18-18701 1 Hose, 1" ID x 6", 3 Ply Silicone ­ 15 19-01016 2 Hose Clamp #16 Extended Band S/S ­ 17 21-12013 1 Filler Cap ­ 18 18-00130 1 Hose, 1/4" ID X 30" Polyvinyl ­ 19 21-00530 2 Hex Head Plug, Brass 1/2 NPT ­ 20 00-00006 1 Nameplate, "Northern Lights" ­ 21 21-18601 1 Cap ­ 22 19-18601 1 Clamp -

P864 09/07

3 - 1