Northern Lights NL488W2 Parts Manual

PARTS

CATALOG P488-2

for Model s NL488K2 & NL488W2

— 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.: 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		GROUP 5 - ELECTRICAL SYSTEM	0 - 1
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 .. ......................................	6 - 7
Timing Gear Housing ...................................	8 - 9	GROUP 6 - GASKETS
Lubricating System .................................	10 - 11	GROUP 6 - GASKETS	0 - 1
Cylinder Head and Rocker Arm Cover ...	12 - 13	Gasket Set .....................................................	0 - 1
GROUP 2 - INTAKE & EXHAUST		GROUP 8 - FRAME & MOUNTING	0 - 1
Intake Manifold and Air Cleaner .................	0 - 1	PX-320K2 Frame Generator....................	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

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 P488-2 10/04

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 - Northern Lights industrial generator set

488

Model number of engine block

Cylinders	Bore
4	88 mm

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.

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

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.
							1	ELECTRICAL SYSTEM
							ALTERNATOR ASSEMBLY: M - NL488
		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	P488	06/96		14
				P488	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.

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 (Includes keys #7 & 9)	-
7	119640-01640	1		Drain Plug M22 x 1.5	-
	36-77300	1	Oil Drain Valve with 5/8" Hose Barb (Optional - not shown)		-
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 (Includes keys #16 & 17)	-
16	129795-01780	1		Rear Main Seal	-
17	26106-080352	3		Bolt, M8 x 35 Plated	-
18	927770-01212	**		Liquid Gasket	-
				**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 (Includes key #10)		-
10	124550-21600	1		Ring Gear (127 Teeth)		-
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 (Includes keys #17 - #19)		-
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		-

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 (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	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 (Includes key #10)		-
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			-

P488-2 10/04

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