Northern Lights NL488W2 Parts Manual

PARTS

CATALOG

for Model s NL488K2 & NL488W2

P488-2

— 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 ©2004 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.: P488-2 10/04

PARTS CATALOG

for Models

NL488K2 and NL488W2

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

General Arrangement ...................................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 .. ...................................... 6 - 7

GROUP 6 - GASKETS

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

GROUP 8 - FRAME & MOUNTING

PX-320K2 Frame Generator....................0 - 1

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.

P488-2 10/04

INTRODUCTION

MODEL DESIGNATION

MODELS INCLUDED

This manual covers the operating instructions for:

NL488K2 and NL488W2, which uses the Yanmar model 4TNV88-GGE.

MODEL NUMBERS

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

NL 488

NL - Northern Lights industrial generator set

NL488K2

NL488W2

Northern Lights industrial diesel generator set with a 488 engine, Tier II.

Northern Lights industrial diesel generator set with a 488 engine and a new winding generator end, Tier II.

Model number of engine block

Cylinders Bore

488 mm

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

P488-2 10/04

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 - NL488

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 -

P488 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.

P488-2 10/04

III

GROUP 1 – ENGINE

Cylinder Block

Figure 1

P488-2 10/04

1 - 0

GROUP 1 – ENGINE

Cylinder Block

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 729602-01560 1 Cylinder Block Assembly 2 129795-02411 1 Camshaft Bush 3 124160-01910 2 Plug, 1/4 BSPT 4 124160-01910 1 Plug, 1/4 BSPT 5 171051-01921 1 Plug 6 124060-01050 1 Plug, 1/8 7 129001-01250 1 Plug 50 mm 8 27241-120000 2 Plug 12 mm -

9 27241-300000 8 Plug 30 mm 11 129150-02020 10 Bearing Cap Bolt 12 129001-02930 5 Main Bearing, Standard -

129150-02870 5 Main Bearing, Under-sized 0.25 mm -

13 129150-02930 2 Thrust Bearing, Standard -

129150-02940 2 Thrust Bearing, Over-sized 0.25 mm 16 129150-01200 18 Cylinder Head Bolt 17 129407-01340 1 Cylinder Head Gasket 18 129004-01190 1 Spacer -

P488-2 10/04

1 - 1

GROUP 1 – ENGINE

Flywheel Housing and Oil Sump

Figure 2

P488-2 10/04

1 - 2

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 3 119620-01750 1 Plug 4 26206-100252 6 Bolt, M10 x 25 5 26206-100302 4 Bolt, M10 x 30 6 129400-01770 1 Oil Sump Assembly 7 119640-01640 1 Drain Plug M22 x 1.5 -

36-77300 1 Oil Drain Valve with 5/8" Hose Barb

8 129486-01670 1 Bolt, M8 x 30 -

9 29190-220002 1 Seal Washer 10 129400-01730 1 Oil Sump Spacer 11 26106-080162 4 Bolt, M8 x 16 Plated 12 26106-080252 2 Bolt, M8 x 25 Plated 13 26106-080452 24 Bolt, M8 x 45 Plated 14 129100-01580 2 Parallel Pin 8 x 16 15 129100-01640 1 Rear Main Seal Retainer 16 129795-01780 1 Rear Main Seal 17 26106-080352 3 Bolt, M8 x 35 Plated 18 927770-01212 ** Liquid Gasket -

(Includes keys #7 & 9) -

(Optional - not shown) -

(Includes keys #16 & 17) -

**As required.

P488-2 10/04

1 - 3

GROUP 1 – ENGINE

Crankshaft and Piston

Figure 3

P488-2 10/04

1 - 4

GROUP 1 – ENGINE

Crankshaft and Piston

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 129601-21002 1 Crankshaft Assembly -

2 129100-01580 1 Pin -

3 119802-21202 1 Crankshaft Gear -

4 22512-070140 1 Key -

5 22351-030010 1 Spring Pin -

6 119802-21660 1 Crankshaft Pulley -

7 129795-21661 1 Washer -

8 121850-21680 1 Bolt -

9 171420-21590 1 Flywheel Assembly 10 124550-21600 1 Ring Gear 11 121111-21501 6 Bolt 12 129005-22080 4 Piston with Rings, Standard -

129005-22900 4 Piston with Rings, Over-sized 0.25 mm -

13 129005-22500 4 Piston Ring Set, Standard -

129005-22950 4 Piston Ring Set, Over-sized 0.25 mm 14 129202-22300 4 Piston Pin 15 22252-000260 8 Snap Ring 16 729402-23100 4 Connecting Rod Assembly 17 129100-23910 4 Piston Pin Bush 18 121550-23200 8 Connecting Rod Bolt 19 129150-23600 4 Bearing, Standard -

129150-23610 4 Bearing, Under-sized 0.25 mm -

(127 Teeth) -

(Includes key #10) -

(Includes keys #17 - #19) -

P488-2 10/04

1 - 5

GROUP 1 – ENGINE

Camshaft and Driving Gear

Figure 4

P488-2 10/04

1 - 6

GROUP 1 – ENGINE

Camshaft and Driving Gear

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 729601-14580 1 Camshaft Assembly 2 129150-02450 1 Thrust Bearing 3 129150-14101 1 Camshaft Gear 4 22512-070140 1 Key, 7 x 14 5 129150-14200 8 Tappet 6 129150-14400 8 Push Rod 7 26106-080142 2 Bolt, M8 x 14 Plated 8 119802-25051 1 Idle Gear Shaft -

9 119802-25100 1 Idle Gear 10 119802-25070 1 Bushing 11 26106-080402 3 Bolt, M8 x 40 Plated 12 119802-25901 1 Gear, Injection Pump Drive 13 22217-140000 1 Spring Washer, M14 14 26776-140002 1 Lock Nut, M14 Plated 15 129150-25301 4 Bolt 16 158552-51151 1 Flange -

(Includes key #10) -

(Includes keys #2 - 4) -

P488-2 10/04

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+ 30 hidden pages