Northern Lights NL378K Parts Manual

PARTS

CATALOG P378

for Model NL378

ALASKA DIESEL ELECTRIC, INC. 4420 14th AVE. N.W.

P.O. BOX 70543

SEATTLE, WA 98107-5043 USA

TEL: [phone]

FAX: [phone] http://www.northern-lights.com

PARTS CATALOG

for Model

NL378

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 .............................................	0 - 1	Engine Electrical, 12 Volt ............................		0 - 1
Flywheel Housing and Oil Sump .................	2 - 3	Starting Motor ..............................................		2 - 3
Crankshaft and Piston ...................................	4 - 5	Alternator and Mounting ..............................		4 - 5
Camshaft and Driving Gear ..........................	6 - 7	Control Panel / Relay Board .........................		6 - 9
Timing Gear Housing ...................................	8 - 9
Lubricating System .................................	10 - 11	GROUP 6	- GASKETS
Cylinder Head and Rocker Arm Cover ...	12 - 13	Gasket Set .....................................................		0 - 1
GROUP 2 - INTAKE & EXHAUST		GROUP 8	- FRAME & MOUNTING
Intake Manifold and Air Cleaner .................	0 - 1	Modular Base Frames
Exhaust Manifold and Muffler .....................	2 - 3	164	Frame Generators .............................	0 - 1
		281	Frame Generators .............................	2 - 3
GROUP 3 - COOLING SYSTEM
Cooling Water System .................................	0 - 1
Radiator and Modular Guard ........................	2 - 3
GROUP 4 - FUEL SYSTEM
General Arrangement ...............................	0 - 1
Fuel Lines and Filter Mounting ....................	2 - 3

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 P378 07/98

P378 07/98

I

INTRODUCTION

MODEL DESIGNATION

MODELS INCLUDED

This manual covers the operating instructions for:

NL378, which uses the Yanmar model 3TNE78A-ADCL engine.

MODEL NUMBERS

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

M - NL

378

N

M - Northern Lights marine generator set

Model number of engine block

Additional letters

Cylinders

Bore

designate a series

NL - Northern Lights industrial generator set

3

78 mm

within model number.

Northern Lights industrial diesel generator set

NL378

with a 378 engine.

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 PXG, PXK, BCI, and PSL generators

P378 07/98

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 - NL844
		4				3	2
		6	7	8			9
5	KEY	PART NUMBER	QTY.	DESCRIPTION			SERIAL NUMBER
	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	P844 06/96		14
			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.

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III

GROUP 1 – ENGINE

Cylinder Block

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						GROUP 1 – ENGINE
					Cylinder Block
KEY	PART NUMBER	QTY		DESCRIPTION		SERIAL NUMBER
1	719822-01560	1		Cylinder Block Assembly (Includes Keys #2 - #12)		-
2	119810-02800	4		Main Bearing, Standard		-
	119810-02870	4		Main Bearing, Under-sized (U.S. = 0.25) part		-
3	119810-02930	2		Thrust Bearing, Standard		-
	119810-02940	2		Thrust Bearing, Over-sized (O.S. = 0.25) part		-
4	124160-01910	2		Plug PT 1/4 BSPT		-
5	171051-01921	1	Plug			-
6	23871-010000	1		Plug PT 1/8 BSPT		-
7	27231-500000	1		Expansion Plug, 50 mm		-
8	27241-120000	2		Expansion Plug, 12 mm		-
9	27241-300000	6		Expansion Plug, 30 mm		-
10	119620-02020	8	Bolt			-
11	129795-02411	1		Camshaft Bearing		-
12	23887-120002	1		Plug, 12 mm		-
13	119810-01200	14		Head Bolt		-
14	119818-01330	1		Head Gasket		-

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GROUP 1 – ENGINE

Flywheel Housing and Oil Sump

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					GROUP 1 – ENGINE
				Flywheel Housing and Oil Sump
KEY	PART NUMBER	QTY		DESCRIPTION	SERIAL NUMBER
1	171420-01600	1		Flywheel Housing	-
2	129100-01580	2		Parallel Pin 8 x 16	-
3	119620-01750	1		Cap, Flywheel Cover	-
4	26206-100252	6		Bolt, M10 x 25	-
5	26206-100302	4		Bolt, M10 x 30	-
6	119810-01730	1	Spacer		-
7	119810-01770	1		Oil Sump Assembly	-
8	119640-01640	1		Drain Plug M22	-
9	26106-080302	6		Bolt, M8 x 30 Plated	-
10	22190-220002	1		Seal Washer 22S	-
11	26106-080162	6		Bolt, M8 x 16 Plated	-
12	26106-080452	22		Bolt, M8 x 45 Plated	-
13	129100-01580	2		Parallel Pin 8 x 16	-
14	719810-01650	1		Rear Main Seal Assembly (IncIudes Key #15)	-
15	119810-01780	1		Oil Seal	-
16	26106-080352	3		Bolt, M8 x 35 Plated	-
17	977770-01212	**		Liquid Gasket	-
				**As Required.

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GROUP 1 – ENGINE

Crankshaft and Piston

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					GROUP 1 – ENGINE
				Crankshaft and Piston
KEY	PART NUMBER	QTY		DESCRIPTION	SERIAL NUMBER
1	119813-21000	1		Crankshaft Assembly (Includes Keys #2 - #4)	-
2	129100-01580	1		Pin 8 x 16	-
3	22512-070140	1		Key 7 x 14	-
4	129150-21200	1		Crankshaft Gear	-
5	22351-040010	1		Spring Pin 4 x 10	-
6	129550-21650	1		Crankshaft Pulley	-
7	129795-21661	1		Washer	-
8	121850-21680	1	Bolt		-
9	121111-21501	6		Flywheel Bolt	-
10	171301-21590	1		Flywheel Assembly (Includes Key #11)	-
11	124550-21600	1		Ring Gear	-
12	119818-22080	3		Piston Assembly, Standard (Includes Key #13)	-
	119818-22900	3		Piston Assembly, Over-sized 0.25 mm (Includes Key #13)	-
13	119818-22500	3		Ring Set, Standard	-
	119818-22950	3		Ring Set, Over-sized 0.25 mm	-
14	119813-22300	3		Piston Pin	-
15	129792-22400	6		Snap Ring	-
16	719810-23100	3		Connecting Rod Assembly	-
17	119810-23910	3		Piston Pin Bush	-
18	119810-23200	6		Connecting Rod Bolt	-
19	119810-23600	3		Bearing, Standard	-
	119810-23610	3		Bearing, Under-sized 0.25 mm	-

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GROUP 1 – ENGINE

Camshaft and Driving Gear

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						GROUP 1 – ENGINE
					Camshaft and Driving Gear
KEY	PART NUMBER	QTY		DESCRIPTION		SERIAL NUMBER
1	119810-14580	1		Camshaft Assembly (Includes Keys #2 - #4)		-
2	129150-02450	1		Thrust Bearing		-
3	129150-14101	1		Camshaft Gear		-
4	22512-070140	1		Key 7 x 14		-
5	129795-02411	1		Cam Bearing		-
6	129150-14200	6	Tappet			-
7	119810-14400	6		Push Rod		-
8	26106-080162	2		Bolt, M8 x 16 Plated		-
9	129100-25061	1		Idle Gear Shaft		-
10	129150-25101	1		Gear with Bushing		-
11	129150-25920	1	Bushing			-
12	26106-080452	2		Bolt, M8 x 45 Plated		-
13	129150-25900	1		Fuel Injection Pump Gear		-
14	22217-120000	1		Spring Washer 12		-
15	26716-120002	1		Nut, M12		-

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GROUP 1 – ENGINE

Timing Gear Housing

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						GROUP 1 – ENGINE
					Timing Gear Housing
KEY	PART NUMBER	QTY		DESCRIPTION		SERIAL NUMBER
1	719810-01500	1		Timing Gear Housing (Includes Key #2)		-
2	129795-01800	1		Oil Seal		-
3	26106-060122	2		Bolt, M6 x 12 Plated		-
4	129400-01520	1		Front Plate		-
5	121450-01560	3		Stud, M8 x 22		-
6	124160-01751	1		Oil Cap		-
7	124240-01871	1		Cover		-
8	124240-01883	1	Gasket			-
9	129795-01950	2	Pipe			-
10	129150-03100	1	Retainer			-
11	22190-080002	1		Seal Washer		-
12	121850-51960	1		O-Ring		-
13	24311-000160	2		O-Ring		-
14	24311-000320	1		O-Ring		-
15	26106-080122	4		Bolt, M8 x 12 Plated		-
16	26106-080162	1		Bolt, M8 x 16 Plated		-
17	26106-080202	2		Bolt, M8 x 20 Plated		-
18	26106-080452	6		Bolt, M8 x 45 Plated		-
19	26106-080552	3		Bolt, M8 x 55 Plated		-
20	26106-080852	4		Bolt, M8 x 85 Plated		-
21	26366-080002	3		Nut, M8		-
22	22190-080002	4		Seal Washer		-
23	26106-080162	3		Bolt, M8 x 16 Plated		-
24	121023-01550	1		Cover		-
25	24341-000240	1		O-Ring		-

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