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: (206) 789-3880 FAX: (206) 782-5455 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

Cylinder Block .............................................0 - 1

Flywheel Housing and Oil Sump .................2 - 3

Crankshaft and Piston...................................4 - 5

Camshaft and Driving Gear..........................6 - 7

Timing Gear Housing...................................8 - 9

Lubricating System ................................. 10 - 11

Cylinder Head and Rocker Arm Cover ... 12 - 13

GROUP 2 - INTAKE & EXHAUST

Intake Manifold and Air Cleaner .................0 - 1

Exhaust Manifold and Muffler .....................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

GROUP 5 - ELECTRICAL SYSTEM

Engine Electrical, 12 Volt ............................0 - 1

Starting Motor ..............................................2 - 3

Alternator and Mounting ..............................4 - 5

Control Panel / Relay Board.........................6 - 9

GROUP 6 - GASKETS

Gasket Set.....................................................0 - 1

GROUP 8 - FRAME & MOUNTING

Modular Base Frames

164 Frame Generators .............................0 - 1

281 Frame Generators .............................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.

P378 07/98

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

NL - Northern Lights industrial generator set

NL378

Northern Lights industrial diesel generator set with a 378 engine.

Model number of engine block

Cylinders Bore

378 mm

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 PXG, PXK, BCI,

and PSL generators

P378 07/98

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 - NL844

KEY PART NUMBER QTY. DESCRIPTION SERIAL NUMBER

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

P844 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.

P378 07/98

III

GROUP 1 – ENGINE

Cylinder Block

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1 - 0

GROUP 1 – ENGINE

Cylinder Block

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 719822-01560 1 Cylinder Block Assembly 2 119810-02800 4 Main Bearing, Standard -

119810-02870 4 Main Bearing, Under-sized

3 119810-02930 2 Thrust Bearing, Standard -

119810-02940 2 Thrust Bearing, Over-sized 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 -

(Includes Keys #2 - #12) -

(U.S. = 0.25) part -

(O.S. = 0.25) part -

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1 - 1

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 15 119810-01780 1 Oil Seal 16 26106-080352 3 Bolt, M8 x 35 Plated 17 977770-01212 ** Liquid Gasket -

(IncIudes Key #15) -

**As Required.

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GROUP 1 – ENGINE

Crankshaft and Piston

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1 - 4

GROUP 1 – ENGINE

Crankshaft and Piston

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 119813-21000 1 Crankshaft Assembly 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 11 124550-21600 1 Ring Gear 12 119818-22080 3 Piston Assembly, Standard

119818-22900 3 Piston Assembly, Over-sized 0.25 mm

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 -

(Includes Keys #2 - #4) -

(Includes Key #11) -

(Includes Key #13) -

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1 - 5

GROUP 1 – ENGINE

Camshaft and Driving Gear

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1 - 6

GROUP 1 – ENGINE

Camshaft and Driving Gear

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 119810-14580 1 Camshaft Assembly 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 -

(Includes Keys #2 - #4) -

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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 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 -

(Includes Key #2) -

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