Northern Lights M773LK Parts Manual

PARTS

CATALOG

Publication #P773

for model:

M773

— 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.

Alaska Diesel Electric, Inc.

4420 14th Avenue N.W. P.O. Box 70543 Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455

Copyright ©2003 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.: P773LK 09/03

PARTS CATALOG

for Model

M773LK

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 Assembly ............................0 - 1

Crankshaft Assembly ...................................2 - 3

Oil Pump ........................................................... 4

Camshaft............................................................ 5

Cylinder Head ................................................... 6

Rocker Arm ....................................................... 7

Rocker Arm Cover ............................................ 8

GROUP 2 - INTAKE & EXHAUST SYSTEM

Air Intake and Filter .......................................... 0

GROUP 3 - COOLING SYSTEM

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

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

Raw Water Pump and Mounting ....................... 3

Raw Water Pump .............................................. 4

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

GROUP 4 - FUEL SYSTEM

General Arrangement ............................... 0 - 1

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

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

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

Fuel Injector ...................................................... 8

Fuel Feed Pump................................................. 9

GROUP 5 - ELECTRICAL SYSTEM

12 Volt Engine .................................................. 0

Alternator and Starter ........................................ 1

Alternator .....................................................2 - 3

Starter Assembly ............................................... 4

Series 1 Control Panel, 12 and 24 Volt ............. 5

Series 1-B Control Panel, 12 and 24 Volt ......... 6

Belt Guard Assembly ........................................ 7

GROUP 6 - GASKET SETS

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

GROUP 8 - FRAME & MOUNTING

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

GROUP 9 - ACCESSORIES

GROUP 9 - & OPTIONAL EQUIPMENT

Flush Mount Dual Station Panel ....................... 0

S 3-B Control Panel.......................................... 1

Oil Drain Kit...................................................... 2

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.

P773LK 09/03

INTRODUCTION

MODEL DESIGNATION

MODELS INCLUDED

This manual covers the operating instructions for:

M773LK which uses the 773LK engine

MODEL NUMBERS

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

M 773 LK

M - Northern Lights marine generator set

M773LK

Northern Lights marine diesel generator set with an 773 engine and a PX309K generator.

Model number of engine block

Bore Cylinders

77 mm 3

Additional letters

designate a series

within model number.

SERIAL NUMBERS

NORTHERN LIGHTS

Your set has three serial numbers: ➀ an engine number stamped on the block, ➁ a generator plate, and ➂ 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

P773LK 09/03

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.

ELECTRICAL SYSTEM

ALTERNATOR ASSEMBLY: M - NL844K

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 -

8 9

P844K 06/96

5-2

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 fits.

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 identification. 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: ➡ Arrows always point toward the front of the engine.

P773LK 09/03

III

GROUP 1 – ENGINE

Cylinder Block Assembly M773LK

P773LK 09/03

1 - 0

Fig. 01-00

GROUP 1 – ENGINE

Cylinder Block Assembly M773LK

KEY PART NUMBER QTY DESCRIPTION S/N

1 110103541 1 Cylinder Block Assembly 2 198466050 1 Blank Plug 3 064210025 1 Expansion Plug, 25 mm 4 064210035 2 Expansion Plug, 35 mm 5 064210015 1 Expansion Plug, 15 mm 6 198466010 4 Blank Plug 7 064210040 2 Expansion Plug, 40 mm 8 198466030 4 Blank Plug -

9 165296142 1 Idle Gear Shaft Assembly 10 110708620 1 Oil Pan 11 198517591 1 Bush; S.T.D. -

198517595 1 Bush; U.S. 0.25 -

198517598 1 Bush; U.S. 0.50 12 040106203 1 Bearing 13 064100045 1 Expansion Plug, 45 mm 14 042303015 1 Bearing 15 030500512 2 Dowel Pin 16 030500616 2 Dowel Pin 17 030501025 2 Dowel Pin 18 030309005 2 Spring Pin 19 012100620 2 Stud 20 012100635 1 Stud 21 012110660 1 Stud 22 010109235 20 Capscrew, Hex Head M6 x 1.0 x 14 mm 23 110996800 1 Gasket 24 050209107 1 Oil Seal 25 198736050 1 Drain Cock 26 140546020 1 Joint 27 24-02001 1 Oil Filter 28 120116160 6 Tappet 29 120456222 6 Push Rod 30 140036220 1 Relief Valve Assembly 31 052109078 1 O-Ring 32 198486770 1 Bushing 33 036509005 1 Snap Ring 34 198466060 1 Plug 35 110756490 1 Dipstick Tube 36 011310612 1 Bolt 37 198416270 1 Dipstick 38 052100100 2 O-ring 39 21-00003 1 Cap 40 23-78601 1 Bracket 41 15-00302 1 Lock Washer 3/8 42 12-00311 1 Capscrew, Hex Head 3/8-16 x 3/4" 43 18-72004 1 Oil Drain Hose 44 068115200 1 Tube -

(Includes keys #2 - #21, formerly #110103540) -

(with Lock Washer)

P773LK 09/03

1 - 1

GROUP 1 – ENGINE

Crankshaft Assembly

P773LK 09/03

1 - 2

Fig. 1-2

GROUP 1 – ENGINE

Crankshaft Assembly

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 115256830 1 Crankshaft Assembly 2 115276180 1 Crankshaft Gear 3 034100508 1 Key 4 030509020 1 Dowel Pin 5 110156400 1 Bearing Holder Assembly 6 010810840 4 Bolt 7 030500612 6 Dowel Pin 8 110156410 1 Bearing Holder Assembly 9 110156420 1 Bearing Holder Assembly

10 198517571 3 Bearing; Upper S.T.D.

198517575 3 Bearing; Upper U.S. 0.25 mm 198517578 3 Bearing; Upper U.S. 0.50 mm

11 198517581 3 Bearing; Lower S.T.D.

198517585 3 Bearing; Lower U.S. 0.25 mm

198517588 3 Bearing; Lower U.S. 0.50 mm 12 010810845 2 Bolt 13 011510840 2 Bolt 14 010700835 2 Bolt 15 115107900 3 Ring Kit; S.T.D. -

115107430 3 Ring Kit; O.S. 0.50 mm 16 115017460 3 Piston Kit; S.T.D. -

115017450 3 Piston Kit; O.S. 0.50 17 115326231 3 Piston Pin 18 036500021 6 Snap Ring 19 115026340 3 Connecting Rod Assembly 20 198517125 3 Bushing 21 115176150 6 Connecting Rod Bolt 22 020109075 6 Nut 23 198517601 6 Bearing; S.T.D.

198517605 6 Bearing; U.S. 0.25

198517608 6 Bearing; U.S. 0.50 24 030300816 1 Spring Pin 25 115396650 1 Crankshaft Pulley 26 020800018 1 Nut 27 115356720 1 Flywheel Assembly 28 115376130 1 Ring Gear 29 010109340 6 Bolt -

(includes keys #2 - 4 & #24) -

(includes keys #6 & #7) -

(includes keys #6 & #7) - (includes keys #6 & #7) -

(formerly #198517571) -

(formerly #198517574) - (formerly #198517577) -

(formerly #198517580) -

(formerly #198517584) - (formerly #198517587) -

(includes keys #20 - #22) -

(formerly #198517600) -

(formerly #198517604) - (formerly #198517607) -

(includes key #28) -

P773LK 09/03

1 - 3

GROUP 1 – ENGINE

Oil Pump & Pick-up

Fig. 1-4

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 165026100 1 Idle Gear Assembly 2 199266180 1 Thrust Washer 3 198216821 1 Spring 4 140166130 1 Rotor 5 140116140 1 Oil Pump Cover 6 199286150 ** Shim, 0.1 mm -

199286160 ** Shim, 0.15 mm 199286170 ** Shim, 0.2 mm -

199286180 ** Shim, 0.5 mm 7 198216720 1 Spring 8 199236540 1 Collar 9 036800010 1 Snap Ring -

10 165166240 1 Front Plate 11 165996520 1 Gasket 12 011310612 3 Bolt 13 052109076 1 O-ring 14 140986830 1 Oil Pipe 15 140406500 1 Pick-up 16 011310612 2 Bolt -

As required

P773LK 09/03

1 - 4

GROUP 1 – ENGINE

Camshaft

Fig. 1-5

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 120026570 1 Cam Shaft Assembly 2 120016021 1 Cam Gear Assembly 3 034100508 1 Key 4 120736081 1 Gear 5 199216230 3 Spacer 6 040109059 1 Bearing 7 125256120 1 Slider 8 199566651 1 Plate 9 010700610 1 Bolt -

10 011310612 1 Bolt -

P773LK 09/03

1 - 5

GROUP 1 – ENGINE

Cylinder Head

Fig. 1-6

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

•• 111010290 1 Cylinder Head Assembly - 1 110136300 3 Valve Seat 2 110136280 3 Valve Seat 3 064210015 2 Expansion Plug, 15 mm 4 064210030 2 Expansion Plug, 30 mm 5 064210018 6 Expansion Plug, 18 mm 6 198466030 2 Plug 7 120166360 3 Intake Valve 8 120176250 3 Exhaust Valve 9 120406070 3 Intake Valve Guide Seal -

10 120406050 3 Exhaust Valve Guide Seal 11 198216700 6 Spring 12 120186080 6 Retainer 13 120226070 12 Cotter 14 120216040 6 Cap 15 111147560 1 Head Gasket; t = 1.2 -

111147570 1 Head Gasket; t = 1.3 -

16 111136440 11 Head Bolt 17 111136450 3 Head Bolt -

(Includes keys #1 - #14) -

P773LK 09/03

1 - 6

GROUP 1 – ENGINE

Rocker Arm Assembly

Fig. 1-7

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

•• 120036880 1 Rocker Arm Assembly

(includes keys #1-10) -

1 120356200 3 Intake Rocker Arm 2 120356210 3 Exhaust Rocker Arm 3 199486220 6 Screw 4 020109076 6 Nut 5 120316300 1 Rocker Arm Shaft 6 199486320 1 Screw 7 052100120 1 O-ring 8 198436150 1 Plug -

9 198216780 2 Spring 10 199280280 4 Shim 11 015100412 1 Screw 12 052109101 1 Gasket 13 011310625 2 Bolt 14 012109177 3 Stud 15 023100008 3 Nut 16 140607270 1 Oil Pipe 17 198486780 1 Banjo Bolt 18 198487590 1 Banjo Bolt

(Tapped 1/8 NPT Female) -

19 140996260 4 Sealing Washer 20 1 Oil Pressure Switch

(see Electrical System) -

P773LK 09/03

1 - 7

GROUP 1 – ENGINE

Rocker Arm Cover

Fig. 1-8

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 111217470 1 Rocker Arm Cover Assembly 2 052109099 1 Gasket 3 110666050 1 Retainer 4 110666060 1 Vent Filter 5 010110610 2 Bolt 6 024600008 3 Cap Nut 7 140996260 3 O-ring 8 198436010 1 Cap -

9 052100400 1 O-ring 10 390190460 1 Caution Label 11 011100408 4 Bolt 12 110566080 1 Breather Valve 13 064510020 1 Plug 14 21-28601 1 Bushing -

P773LK 09/03

(includes keys #3 - #5) -

1 - 8

+ 32 hidden pages