Northern Lights M773LK Parts Manual

PARTS

CATALOG

Publication #P773LK for model:

M773LK

— 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

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		GROUP 5 - ELECTRICAL SYSTEM
Cylinder Block Assembly ............................	0 - 1	12 Volt Engine ..................................................	0
Crankshaft Assembly ...................................	2 - 3	Alternator and Starter ........................................	1
Oil Pump ...........................................................	4	Alternator .....................................................	2 - 3
Camshaft............................................................	5	Starter Assembly ...............................................	4
Cylinder Head ...................................................	6	Series 1 Control Panel, 12 and 24 Volt .............	5
Rocker Arm .......................................................	7	Series 1-B Control Panel, 12 and 24 Volt .........	6
Rocker Arm Cover ............................................	8	Belt Guard Assembly ........................................	7
GROUP 2 - INTAKE & EXHAUST SYSTEM		GROUP 6 - GASKET SETS
Air Intake and Filter ..........................................	0	Gasket Kit ..........................................................	0
GROUP 3 - COOLING SYSTEM		GROUP 8 - FRAME & MOUNTING
Exhaust Manifold and Heat Exchanger ........	0 - 1	Base Frame Assembly .......................................	1
Coolant Pump ....................................................	2
Raw Water Pump and Mounting .......................	3	GROUP 9 - ACCESSORIES
Raw Water Pump ..............................................	4	GROUP 9 - & OPTIONAL EQUIPMENT
Coolant Recovery Tank .....................................	5	Flush Mount Dual Station Panel .......................	0
		S 3-B Control Panel..........................................	1
GROUP 4 - FUEL SYSTEM		Oil Drain Kit......................................................	2
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

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. © Alaska Diesel Electric, Inc. All rights reserved. Litho U.S.A. Publication number P773LK 09/03

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:

773

M - Northern Lights marine generator set

Model number of engine block

Additional letters

Bore

Cylinders

designate a series

77 mm

within model number.

Northern Lights marine diesel generator set

M773LK

with an 773 engine and a PX309K generator.

SERIAL NUMBERS

NORTHERN LIGHTS

Your set has three serial numbers: an engine number stamped on the block, a generator plate, and 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.
						1	ELECTRICAL SYSTEM
						ALTERNATOR ASSEMBLY: M - NL844K
		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	P844K 06/96		14
				P844K 06/96
			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.

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.

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

GROUP 1 – ENGINE


				Cylinder Block Assembly	M773LK

KEY	PART NUMBER	QTY	DESCRIPTION			S/N
1	110103541	1	Cylinder Block Assembly (Includes keys #2 - #21, formerly #110103540)			-
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 (with Lock Washer)
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			-

P773LK 09/03

1 - 1

GROUP 1 – ENGINE

Crankshaft Assembly

Fig. 1-2

P773LK 09/03

1 - 2

							GROUP 1 – ENGINE


						Crankshaft Assembly

KEY	PART NUMBER	QTY		DESCRIPTION			SERIAL NUMBER
1	115256830	1		Crankshaft Assembly (includes keys #2 - 4 & #24)			-
2	115276180	1		Crankshaft Gear			-
3	034100508	1	Key				-
4	030509020	1		Dowel Pin			-
5	110156400	1		Bearing Holder Assembly (includes keys #6 & #7)			-
6	010810840	4	Bolt				-
7	030500612	6		Dowel Pin			-
8	110156410	1		Bearing Holder Assembly (includes keys #6 & #7)			-
9	110156420	1		Bearing Holder Assembly (includes keys #6 & #7)			-
10	198517571	3		Bearing; Upper S.T.D. (formerly #198517571)			-
	198517575	3		Bearing; Upper U.S. 0.25 mm (formerly #198517574)			-
	198517578	3		Bearing; Upper U.S. 0.50 mm (formerly #198517577)			-
11	198517581	3		Bearing;	Lower S.T.D. (formerly #198517580)		-
	198517585	3		Bearing;	Lower U.S. 0.25 mm (formerly #198517584)		-
	198517588	3		Bearing;	Lower U.S. 0.50 mm (formerly #198517587)		-
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 (includes keys #20 - #22)			-
20	198517125	3	Bushing				-
21	115176150	6		Connecting Rod Bolt			-
22	020109075	6	Nut				-
23	198517601	6		Bearing; S.T.D. (formerly #198517600)			-
	198517605	6		Bearing; U.S. 0.25 (formerly #198517604)			-
	198517608	6		Bearing; U.S. 0.50 (formerly #198517607)			-
24	030300816	1		Spring Pin			-
25	115396650	1		Crankshaft Pulley			-
26	020800018	1	Nut				-
27	115356720	1		Flywheel Assembly (includes key #28)			-
28	115376130	1		Ring Gear			-
29	010109340	6	Bolt				-

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 - (Includes keys #1 - #14)		-
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		-

			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 (includes keys #3 - #5)		-
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

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