P445
P445
- -TABLE OF CONTENTS
Please read thoroughly before attempting to use this manual.
Table of Contents ....................................................... 1 GROUP 6 • GASKET SETS
Model Designation & Serial Numbers ........................ 2 Engine Ovemaul (Marine)......................... ............ o
Reading a Parts Page ................................................ 3 Engine Overhaul (Industrial) ..................... ...... ........... 1
GROUP 1 • ENGINE
Cylinder Block Assembly ............................................. 1 GROUP 7 • GEAR AND ADAPTER PARTS
Flywheel Housing SAE 4 ............................................. 2 Consult dealer or factory.
Crankshaft, Idler Gears & Main Bearings .................... 3
C ylinder Liner Assembly & Connecting Rod ............... 4 GROUP 8 • FRAME & MOUNTING
Camshaft ..................................................................... 5 Base Frame with Centerbonded Mounts .... ,.......... o - 1
BalanceShaft .............................................................. 5 Base Frame Assembly C·Series .. ,..............................2
Valve Train Components ............................................. 6 Base Frame with Hydrolastic Mounts ....................3 -4
Front Plate.............. ......................... 6
Timing Gear Cover ........... ......................................... 7 GROUP 9 • ACCESSORIES &
Oil Pan... .................... 8 OPTIONAL EQUIPMENT
Single Oil Filter Housing .. .............. 8 Series 1 Control Panel ..................................... 1
Engine Oil Pump ........... 9 -10 Series 1 B Control Panel .............................................. 1
Oil Drain .............. . ... 10 S·3C Flush Control Panel. .......... 2
Cylinder Head.... . .. 11 Electric Clutch & PTO Assembly.... .............3
Rocker Cover .... . . .. 12 Crankshaft Pulley ......... . ............ 4
GROUP 2 • INTAKE & EXHAUST SYSTEM
Air Intake Manifold & Air Filter (Marine) ...................... 1
Air Intake & Turbocharger (Mar ine) ....................... 2 -3
Air Intake & Air Filter (Industrial) ........................... 4 -5
Turbocharger & Oil Lines (Industrial) ..... 4
Exhaust Manifold & Exhaust Adapters (Marine) .......... 7
Exhaust Manifold (Industrial)........ ............ 8 - 9
Df)I Exhaust Elbow (Marine)........ . ..... 10
Wet Exhaust Elbow (Marin e) ............................ 11 - 12
Turbocharger Assembly (Marine) ....... 13
PROPRIETARY INFORMATION: This publication is the sole property of Northern Lights, Inc. and may not be reproduced in
whole or part without the expressed written permission of Northern Lights, Inc.
P445 2/17
1
INTRODUCTION
Refer to the cate ory designations below to find the correct parts pages for your mo el.
g d
M - NL 445 D -T Q
::], ___ _ -,-
M- Northern Lights marine generator set Base Model# Aspiration Q 1200 RPM
Nl- Northern Lights industrial genera or set (Deere 4045 Series D Natural Generator Set
t
engin e block) T Turbo-charged
65C-4
--,--
� <>Series
kW for Commercial
Application. (Deere
4045 engine block)
[__ ill___�':'_[) __ I Northern Lights naturally aspirated 1800 rpm marine diesel generator set. John Deere 4045 T engine.
r---- ------·--,
l_!ll__445 T
_ M 445 Q
Northern Lights turbocharged 1800 rpm marine diesel generator set. John Deere 4045 T engine.
Northern Lights naturally aspirated 1200 rpm marine diesel gene ator set. John Deere 4045 T engine.
r
I M 65C-4 J Northern Lights turbocharged 1800 rpm C-SERIES commercial marine dies l generator set. John Deere 4045 T
j
e
It is Alaska Diesel Electric's policy to build all 4045 series models on Deere engines intended for
turbocharging. This is important when internal components are required. Check also John Deere ID plate
on side of block to verify. Every effort lo note correct base engine will be made in parts text. All model
l_I
numbers in parentheses will indicate John Deere base engine. All variations requiring serial numbers for
1iiiMIW@
proper identification will be noted as ADE or John Deere.
G
, numbe �-1
ordering Lugger parts, refer to this serial
caled on flywheel housing. Serial numbers
!or all Luggers and Northern Lights are eight digits,
e.g. i 234-5678. -��-------'
ALASKA O!ESEL EtfCllUC, Inc,
«J,o, HlHW(; NW.SliAlltE,WA USA
0
0 0
l_
0 Seat�e. WA 9$107 {206) 799-3880 O
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P445 2/17
2
INTRODUCTION
IMPORTANT:
Before selecting parts be sure that you are choosing parts from
the correct pege. Check the model designation at the page top.
(Do not us� this illustration for parts purchasing.}
Gl-
� ELECTRICAL SYSTEM
M'i5ia:Jffii·iif'h13M•IS11it1Ufi1f:ill
I
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---�---[ - 12
�-
KEV PART NUMBER---+O_T_Y. ! _____ .c._
DESCRIPTJON _ __ ,cS E Rl1ALNUMBER
1 c:C::
_,
P445 2/17
3
INTRODUCTION
L____________
P445 2/17
4
ENGINE
--1
iHW•M;l =l!•MtffJM1=1!
·'4:"'"""'"
.. RE50671
[m.
I 1 I
i i
DESCRIPTION
Cylinder Block (marked R108755 -includes Keys 1-13 & 17-20,
also requires R83169, T27658, R111135, R111137 & R112867)"
SERIAL NUMBER
u
14H826 Nut 1/2-13
I 24
·Replaces earlier pre-Common Lube Block.
**As required.
P445 2/17
1 -1
ENGINE
10 --
@
11----
12
�1
13-o
14-->� / ., )
/
V
�--,"--
---·· ... . ..
P445 2/17
1 -2
updated 11-6-17
ENGINE
P445 12/93
1-3
updated 11-6-17
ENGINE
P445 12/93
1 •4
updated 11-6-17
ENGINE
TP42714
KEY PART NUMBER QTY. DESCRIPTION SERIAL NUMBER
1 R54565 2 Plug
2 R54987 1 Shaft
3 120316 2 Washer
4 T20314 3 Spring
5 T203·15 4 Support
6A RE31973 8 Rocker Arm Up to 379968
6B RE62148 8 Rocker Arm Assembly (includes Key 11) (former #R E43384) From 379969
7 12-00318 4 Capscrew, Hex Head 3/8-16 x 2-1/2"
8 R42729 4 Washer
9A R83429 8 Push Rod (former #R82896) Up to 379968
9B R107731 8 Push Rod (former #R107732) From 379969
10 T20073 8 Tappet
11 R119314 4 lock Nut 3/8-24 Grade 8 From 379969
P445 12/93
1 -6
page added 11-6 -17
ENGINE
Oil Pan
T P 2 8 3 9 9 co de 19 0 8
P445
1- 8
page added 11-6 -17
ENGINE
P445
1- 8 A
page added 11-6 -17
ENGINE
P445
1- 8 B
updated 11-6-17
ENGINE
. .
El\l�II\IE l'ill12 llll9MR _
Early Production
Up To Serial Number-XXXXX-427006
1-�
1 \
P445 12/93
1 •9
updated 11-6-17
ENGINE
Late Production
From Serial Number XXXXX-427007
l
16
A605/B-1907
KEY PART NUMBER QTY. DESCRIPTION SERIAL NUMBER
1 36-71003 1 Drain Fitting
2 35-71002 1 Shut Off Valve
3 18-71035 1 Hose 1/2"ID x 18"
4 21-71042 2 Female Swivel, Brass 1/2 Hose Barb x 1/2-45T
5 21-71040 Male Connector, Brass 1/2NPT x 1/4-45T
6 21-10005 Plug, Hex Head Steel 1/2NPT
7 T13213 Washer
P445 12/93
1 · 10
updated 11-6-17
ENGINE
TP42629
P445 12/93
1 - 11
updated 11-6-17
ENGINE
I I
I
!
\ '·. \ '.,·
/,__ HUMP
� / HOSE
A3805F, A3819D/C-2220C
KEY PART NUMBER QTY. DESCRIPTION SERIAL NUMBER
1 10-71009 1 Rocker Arm Cover
2 R73521 1 Gasket
3 12-00112 8 Capscrew, Hex Head 1 /4-20 x 1"
4 15-00121 8 Flat Washer 1/4 SAE
5 R92154 Elbow (former #AT25192) (order also O-ring R56463)
6 18-00011 Hose 3/4" ID x 4" (w/o Turbo)
18-72509 Hose 3/4" ID x 9-1/2" (w Turbo)
7 21-00025 PVC Elbow 90', 3/4 HB x 3/4 HB
8 R56463 1 O-Ring (used with elbow R92154
P445 12/93
1 - 12
updated 11-6-17
INTAKE & EXHAUST SYSTEM
26 21-00606 1 Male Elbow 90° Steel 3/8N PT x 3/8-37T (horizontal oil filter) -
21 -52800 1 Male Connector, Steel 3/8 NPT x 3/8-37 T (vertical oil filter) "
27 27-31406 1 Tube Assembly, Turbo Oil Supply (horizontal oil filter) "
27- 01401 1 Tube Assy, Turbo Oil Supply (vertical oil filter) "
Oil Return Pipe. Upper Ha�
28 27-31602 1 Gasket
"
33 19-00012 2 "
Adapter, O-Ring Seal x 1/2NPT -
34 R41285 1
O-Ring
35 16-01000 1 "
Intake Tube Assembly (former # 27-21072)
36 27-21010 1 "
Hose, 2" ID x 2"
37 18-21016 2 "
38 21-49999 1
Bushing 7/8-14 x 1/4NPTF
Drain Cock 1/4NPT
-
39 21-10002 1
Capscrew, Hex Head 3/8-16 x 3/4"
-
40 12-00311 2 "
Lock Washer 3/8
41 15-00302 2 -
Hose, 2"ID x 2-3/8" -
42 18-21014 1
43 13-00814 4 Stud, M10 x 1.5 x 40mm -
P445 12/93
2-3
updated 11-6-17
INTAKE & EXHAUST SYSTEM
----1
1--�
5
3
2�
6
7
4'
i-7
9--------
�� 8
/
4
3��
----6
P445 12/93
2-4
updated 11-6-17
updated 11-6-17
A4656. A4657,
A4658/C26J2
11
KEY PART NUMBER 'QTY. DESCRIPTION I SERIAL NUMBER
1 10·31000 1 I Exhaust Manttold Assembly w/ Diy Flange •
10-31001 1 Exhaust Manifold Assembly w/ Wet Flange •
10-31002 1 Exhaust Manifold Assembly w/ Wet Elbow Adapter •
2 : 27-11101 1 Coolant Connector
3 16-31000 1 O.Ring
R54641 1 Gasket
5 13-00337 5 Stud 3/8-24 x 3/8-16 x 2" (special)
13-00336 3 Stud 3/8·24 X 3/8-16 X 2"
7 15-00300 10 Washer 3/8 (special)
14-00321 8 Hex Nut 3/8-24
9 11-31011 4 Gasket
10 12·00325 2 Capscrew, 12 point 3/8-16 x 1 •
11 17-10001 1 Expansion Plug
• See Exhaust Manifold & Adapter Detail for components
' <:;�\\ 1 i
1 ' �,#··"
' '� •�
I
.
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6�
.-
h-4
A4653, A4654,
A4655/C-2648
i
3 11-30013 1 Gasket
4 12-00414 4 Capscrew, Hex Head 7/16-14 x 1·1/2"
15-00402 4 Lock Washer 7/16 .
6 21-10001 1 ; Drain Cock 1/SNPT .
P445 12/93
2•7
updated 11-6-17
INTAKE & EXHAUST SYSTEM
A213C, A6297,
A6295/B-1532B
KEY PART NUMBER QTY. DESCRIPTION SERIAL NUMBER
1 12-00313 8 Capscrew, Hex Head 3/8-16 x 1-1 /4"
2 24H1304 8 Flat Washer, Special
3 T20200 1 Exhaust Manifold, Rear Outlet
T20249 1 Exhaust Manifold, Front Outlet
4 R90658 4 Gasket
5 31-31310 1 Exhaust Adapter 2" NPT
31-31003 Exhaust Adapter 3" NPT
31-31008 1 Exhaust Adapter, S/S 18" x 4" Flange
6 AT63B13 2 Half Clamp with Integral Nut
7 12-00214 2 Capscrew, Hex Head 5/16-18 x 1-1/2"
P445 12/93
2·8
updated 11-6-17
INTAKE & EXHAUST SYSTEM
A457DIB-1725
-4
A912D/B-2910
KEY PART NUMBER QTY. DESCRIPTION SERIAL NUMBER
1 19-31401 V-Clamp
2 21-31002 Plug, Brass 3/8 NPT
3 27-31415 Dry Exhaust Elbow
4 12-00916 4 Capscrew, Hex Head 5/8-11 x 2"
5 15-00902 4 Lock Washer, 5/8
6 14-00911 4 Hex Nut, 5/8-11
7 11-31094 1 Gasket
P445 12/93
2 - 10
INTAKE & EXHAUST SYSTEM
�---1
-+4---11
,_,,.,_-1-----13
---13
·-- --12
A458J/B-1728C
KEY PART NUMBER QTY. DESCRIPTION SERIAL NUMBER
1 27·31412 Wet Exhaust Elbow 4"
2 19-31401 V-Clamp
3 18-11601 Hose 1-1/8"ID x 20"
4 19-00016 4 Hose Clamp #16
5 27-11000 Tube
6 23-62516 Bracket
7 19-71031 Adelle Clamp
8 18-11607 Hose 1-1/8"ID x 2-1/2"
9 21-31006 Male Elbow 90°, 1" NPT x 1-1/8 HB
10 12-11003 Capscrew, Hex Head 5/16-18 x 7/8"
11 12-00312 Capscrew, Hex Head 3/8-16 x 1"
12 14-00312 1 Nylock Nut 3/8-16
13 15-00301 2 Flat Washer 3/8"
14 15-00202 1 lock Washer 5/16"
P445 12/93
2 - 11
updated 11-6-17
.
INTAKE & EXHAUST SYSTEM
' ''
---l-l----11
�1---:l�-13
�--7
�--12
A9l3EIB-2888
KEY PART NUMBER QTY. DESCRIPTION SERIAL NUMBER
1 27·31412 Wet Exhaust Elbow 4"
2 19·31401 V-Clamp
3 18·11601 1 Hose H/8 ID x 20"
4 19-00016 4 Hose Clamp #16
5 27-11000 1 Tube
6 23·62516 Bracket
7 19-71031 Adelle Clamp
8 18·11607 Hose 1-1/8" ID x 2·1/2"
9 21·31006 Male Elbow 90', 1" NPT x 1-1/8 HB
10 12·11003 Capscrew, Hex Head 5/16-18 x 7/8"
11 12-00312 Capscrew, Hex Head 3/8-16 x 1" Nylock
12 14-00312 Nut 3/8-16
13 15-00301 Flat Washer 3/8"
14 15-00211 Flat Washer 5/16"
15 15-00202 Lock Washer 5/16"
P445 12/93
2 · 12
updated 11-6-17
. .
lEl!l�flU\l!i!fi!Alil�El!R
. AS'SEMBlli¥ M!fi!Sill 81 & ei,-Series
.
2
7
-•
KEV PART NUMBER
30-21400
30-31430
QTY. DESCRIPTION
Turbocharger Assembly (ID Tag #5326 970 60 90 - includes all Keys)
Repair Kit (includes Keys 4, 5, 11-17, 19-22, 24 & 28)
SERIAL NUMBER
P445 12/93
2 • 13
updated 11-6-17
COOLING SYSTEM
..
EXR'AIIISIE!lll@r�NK}lSSEMBl12¥- l\lllHllllllE AE!F!J.;ICAllilOIII
..
23 18-12102 1 Overflow Hose 3/8" x 30" -
24 21-31031 1 Special Nipple 3/4 NPT x 1-1/2" -
25 21-00530 Brass Hex Plug 1/2 NPT -
26 21-31008 1 Hex Plug 3/8 NPT -
27 21-11003 1 Plug, Socket Head 1/2 NPT -
28 21-11004 1 Plug, Socket Head 3/4 NPT .
31 15-00222 2 Lock Washer, Stainless Steel 5/16 -
32 15-11000 2 Flat Washer, Stainless Steel 5/16 -
33 10-11025 1 Blocking Plate (low fill) .
34 10-11031 1 Thermostat Cover (low fill) -
35 18-00130 1 Hose 1/4" x 30" (low fill) .
36 12-00111 6 Capscrew, Hex Head 1/4-20 x 3/4" (low fill) -
37 15-00102 6 Lock Washer 1/4" (low fill, remote fill) -
38 31-01002 1 Expansion tank adapter (remote fill) -
39 18-11606 1 Hose -
40 19-00020 2 Hose Clamp -
41 12-00312 2 Capscrew, Hex Head 3/8-16 x 1" .
42 23-11401 1 Bracket -
43 11-11043 1 Gasket -
44 10-11006 1 Keel Cooling Connector (Keel Cooled Application Only) -
45 12-00313 2 Capscrew, Hex Head 3/8-16 x 1-1 /4" -
46 17-10001 4 Expansion Plug, Brass -
P445 12/93
3- 1
updated 11-6-17
COOLING SYSTEM
17
ToExpanslonTank"- / 16
�0/
TP26804
..
KEY PART NUMBER
AR77142
T20243
QTY. DESCRIPTION
Circulating Pump Assembly (includes Keys 2-11 & 14)
Gasket
SERIAi. NUMBER
2 R56070 Cover
3 R56809 Gasket
4 R56812 Impeller
5 AR101549 1 Seal Kit
6 JD8643 1 Bearing & Shaft Assembly
21-00531 1 Plug, Square Head 1/2NPT
8 12-00314 5 Capscrew, Hex Head 3/8-16 x 1-1/2"
12-00317 Capscrew, Hex Head 3/8-16 x 2-1/4"
12-00312 Capscrew, Hex Head 3/8-16 x 1"
9 R34985 line
10 AR80116 Housing (marked R90784 or R104648)
11 R56810 1 Pulley
12 14-00311 1 Hex Nut 3/8-16
13 15-00302 1 Lock Washer 3/8
14 12-00315 1 Capscrew, Hex Head 3/8-16 x 1-3/4"
12-00318 1 Capscrew, Hex Head 3/8-16 x 2-1/2"
12-00310 1 Capscrew, Hex Head 3/8-16 x 3"
15 T25701 Stud
16 R56461 O-Ring
17 R55967 Bypass Tube
P445 12/93
3-3
updated 11-6-17
page added 11-7-17
COOLING SYSTEM
(Johnson)
IC
C-2016A
P445 12/93
3-5
page added 11-7-17
COOLING SYSTEM
* N o t ava i l ab l e se par at el y
P445
3 - 5A
page added 11-7-17
COOLING SYSTEM
RAW WATER PUMP ASSEMBLY
A-9495/ A-9496
P445 12/93
3 - 5B
page added 11-7-17
COOLING SYSTEM
P445
3 - 5C
updated 11-6-17
COOLING SYSTEM
.
IHERM©SIAI HOUSING
(Industrial Application)
A221/B-1543B
P445 12/93
3 · 10
page added 11-7-17
COOLING SY STEM
C-3100
P445
3- 1 1 A
page added 11-7-17
COOLING SY STEM
P445
3- 1 1 B
updated 11-7-17
FUEL SYSTEM
TO
FUEL
PUMP
----
I - 13
-
12
'
��
'----"'---- j 4
0 15
�-----
7 - _,__
-
KEY PART NUMBER QTY. DESCRIPTION SERIAL NUMBER
P445 03/95
4-5
updated 11-7-17
ELECTRICAL SYSTEM
§ I '" 8 • ff @ ' • •
•
· ··� . ..,
11
A6070, A607l, A6072
A6073/D-2132
KEY PART NUMBER QTY. DESCRIPTION SERIAL NUMBER
22-41110 Wire Harness, Standard Ground
22-41115 Wire Harness, Isolated Ground
2 22-70007 Dual Station Relay Board 12Volt (see parts detail)
22-70018 1 Dual Station Relay Board 24Volt (see parts detail)
3 12-00001 4 Machine Screw, Binding Head #10-32 x 3/4"
4 14-00032 4 Nylock Hex Nut #10-32
5 22-40915 1 Oil Pressure Switch 15 PSI 1/8 NPT
6 22-41016 Oil Pressure Sender, Standard Ground 1/8 NPT
22-71016 Oil Pressure Sender, Dual Gauge Standard Ground 1/8 NPT
22-42803 Oil Pressure Sender, Isolated Ground 1/8 NPT
22-74803 Oil Pressure Sender, Dual Gauge Isolated Ground 1/8 NPT
7 22-41026 Temperature Sender, Standard Ground 1/8 NPT
22-71026 Temperature Sender, Dual Gauge Standard Ground 1/8 NPT
22-42802 Temperature Sender, Isolated Ground 1/8 NPT
22-74802 Temperature Sender, Dual Gauge Isolated Ground 1/8 NPT
8 22-40925 Temperature Switch 215° F 1/8 NPT(Marine)
22-40923 Temperature Switch 225° F (Industrial)
9 21-41101 Brass Bushing 1" NPT x 1/2 NPT
10 RE68470 Starter 12Volt Standard Ground (see mounting detail-former #RE19275)
22-41078 Starter 12Volt Isolated Ground (see mounting detail -former #22-41406)
RE52120 Starter 24Volt Standard Ground (see mounting detail -former #RE19737) *
22-41414 Starter 24Volt Standard or Isolated Ground (see mounting detail
-former #22-41407, 22-41088 & 22-41411)
11 00-41015 Bushing
12 21-00023 Adapter 1/8 NPT x 1/8 NPT
13 22-40402 Ground Wire #8 AWG x 16" (not shown)
14 RE31694 Alternator 12VolV78AMP Std Ground (not shown--,;ee mounting detail)
10-134 Alternator 12Vo1V72AMP lSOGround (not shown-see mounting detail)
22-71051 Alternator 24Volt/42AMP Std Ground (not shown--,;ee mounting detail)
22-71052 Alternator 24Volt/35AMP lSO Ground (not shown-see mounting detail)
• Altern ate for 22-41 411 in Standard Ground application.
u As Required
P445 12/93
5• 1
updated 11-7-17
ELECTRICAL SYSTEM
21
.. As Required
P445 12/93
5-3
updated 11-7-17
ELECTRICAL SYSTEM
Supplied With
Alternator
10
P445 12193
5-5
updated 11-7-17
ELECTRICAL SYSTEM
12 2 5
\��-7 I
I
I
1--. Ol
lj
24 Volt
12 Voll
P445 12/93
5-6
updated 11-7-17
ELECTRICAL SYSTEM
2
2
9�
11
/
8
/ 5
�10
P445 12/93
5-7
updated 11-7-17
ELECTRICAL SYSTEM
\
10
:(··· -
.\ ··.··�
<: ""
,_:;-,c'� -
7
A4722, A4723/C-2470
** As required
P445 12/93
5-8
updated 11-7-17
GASKET SETS
P445 12/93
6-0
FRAME & MOUNTING
Engine/Generator
Coupling Detail
1�
�---1\
�
·�� 12
13
3 Generator 12
A3383B, A3390/C-2234A
KEY PART NUMBER QTY. DESCRIPTION SERIAL NUMBER
P445 12/93
8-4
added 11-7-17
8- 5
page added 11-7-17
D-2495A
P445
8- 6
page added 11-7-17
P445
8- 7
page added 11-7-17
D-2500A
P445
8- 8
page added 11-7-17
P445
8- 9
added 11-7-17
9-0
revised 11-7-17
ACCESSORIES & OPTIONAL EQUIPMENT
SAE 5/C-108
14
17
** As required
P445 12/93
9-3
page added 11-7-17
P445
9-5
4420 14th Ave. NW., Seattle WA 98107
Tel: (206) 789-3880 • 1-800-762-0165 • www.northern-lights.com
Northern Lights and Lugger are registered trademarks of Northern Lights, Inc.
© 2017 All rights reserved. Litho USA.