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NL498D2
Parts Manual
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Northern Lights NL498D2 Parts Manual

P498-2

For Model: NL498D2

PARTS CATALOG

Marine Generators | Marine Diesel Engines | Land-Based Generators

— 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.

Northern Lights

4420 14th Avenue N.W.

Seattle, WA 98107

Tel: (206) 789-3880

Fax: (206) 782-5455

Copyright ©2007 Alaska Diesel Electric, Inc. All rights reserved. Northern Lights™, and the Northern Lights logo are trademarks of Alaska Diesel Electric, Inc.

Printed in U.S.A.

PART NO.: P498-2 10/07

PARTS CATALOG

for Model

NL498D2

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

0 - 1

GROUP 5 - ELECTRICAL SYSTEM

 

Cylinder Block..........................................

Engine Electrical, 12 Volt................................

1

Flywheel Housing and Oil Pan........................

2

Starting Motor..........................................

2 - 3

Crankshaft and Piston.....................................

3

Alternator and Mounting............................

4 - 5

Camshaft and Driving Gear........................

4 - 5

Control Panel................................................

6

Timing Gear Housing................................

6 - 7

Relay Board..................................................

7

Lubricating System...................................

8 - 9

 

 

Cylinder Head and Rocker Arm Cover .. 10 - 11

GROUP 6 - GASKETS

0 - 1

GROUP 2 - INTAKE & EXHAUST

 

Gasket Set................................................

0

 

 

Intake Manifold and Air Filter.........................

GROUP 8 - FRAME & MOUNTING

 

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

1

UCI224C16 Frame Generator.....................

0 - 1

GROUP 3 - COOLING SYSTEM

0 - 1

 

 

General Arrangement.................................

 

 

Radiator and Modular Guard......................

2 - 3

 

 

GROUP 4 - FUEL SYSTEM

0

 

 

Fuel Lines & Injectors ...................................

 

 

Injection Pump...............................................

1

 

 

General Arrangement ................................

2 - 3

 

 

Fuel Lines, Filters, & Supply Pump Mtg ..........

4

 

 

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 P498-2 10/07

P498-2 10/07

I

INTRODUCTION

Model Designation

ModelS INCLUDED

This manual covers the operating instructions for:

NL498D2, which uses the Yanmar model 4TNV98-GGE.

Model Numbers

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

NL

NL - Northern Lights industrial generator set

498

Model number of engine block

Cylinders

Bore

4

98 mm

 

NL498D2

 

=

Northern Lights industrial diesel generator set

 

 

 

 

 

 

with a 498 engine, naturally aspirated, Tier II.

 

 

 

 

Serial Numbers

NORTHERN LIGHTS

Your set has three serial numbers: 1 an engine number stamped on the block, 2 a generator plate, and 3 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

P498-2 10/07

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: NL498

 

 

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

 

 

 

 

 

11

12

 

 

 

 

 

5-2

 

 

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: 4 Arrows always point toward the front of the engine.

P498-2 10/07

III

GROUP 1 – engine

Cylinder Block

Ycyl.block

P498-2 10/07

1 - 0

 

 

 

 

 

GROUP 1 – engine

 

 

 

 

 

 

 

 

 

 

 

Cylinder Block

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

729907-01560

1

Cylinder Block Assembly (includes all keys)

-

2

129900-01250

1

Plug, 55 mm

-

3

171051-01921

1

Plug

-

4

129900-02020

10

Capscrew

-

5

129900-02410

1

Camshaft Bushing

-

6

22351-060012

2

Spring Pin, 6 x 12

-

7

23876-030000

3

 

Plug, 3/8 BSPT

-

8

27241-300000

8

 

Plug, 30 mm

-

9

729900-02800

5

 

Main Bearing, Standard

-

 

129900-02340

5

 

Main Bearing, Undersize 0.25

-

10

129900-02930

2

 

Thrust Bearing, Standard

-

 

129900-02940

2

 

Thrust Bearing, Oversize 0.25

-

11

129900-01200

18

 

Head Bolt

-

12

129907-01331

1

 

Cylinder Head Gasket

-

13

129907-01190

1

 

Spacer

-

 

 

 

 

 

 

P498-2 10/07

1 - 1

GROUP 1 – engine

Flywheel Housing and Oil Pan

 

 

 

 

Yflywheelhsg

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

129915-01610

1

Flywheel Housing SAE #3

-

2

129100-01580

2

Pin

-

3

119000-01840

1

Plug

-

4

26206-100352

9

Bolt, M10 x 35 Plated

-

5

977770-01212

1

Liquid Gasket

-

6

124411-01780

1

Rear Main Seal

-

7

129982-01710

1

Pan Assembly (includes keys 8-10)

-

8

119640-01640

1

Drain Plug M22 x 1.5

-

9

22190-220002

1

Seal Washer

-

10

26106-080122

16

Bolt, M8 x 12 Plated

-

 

 

 

 

 

 

 

 

P498-2 10/07

 

1 - 2

GROUP 1 – engine

Crankshaft and Piston

 

 

 

 

Ycrankshaft

 

 

 

 

 

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

129902-21000

1

Crankshaft (includes keys 2- 5)

-

2

129900-21200

1

Gear

-

3

121850-21290

1

Pin

-

4

121850-21920

1

Pin

-

5

22512-070140

1

Key

-

6

129907-21660

1

Pulley

-

7

129900-21640

1

Washer

-

8

121850-21680

1

Bolt

-

9

121850-21130

6

Bolt

-

10

129907-22090

4

Piston Assembly, Standard (includes key #11)

-

 

729907-22910

4

Piston Assembly, Oversize 0.25 (includes key #11)

-

11

129907-22050

4

Piston Ring Set, Standard

-

 

729907-22950

4

Ring Set, Oversize 0.25

-

12

120130-22301

4

Piston Pin

-

13

22252-000300

8

Circlip

-

14

129900-23000

4

Connecting Rod Assembly (includes keys 15-17)

-

15

129900-23910

4

Bushing, Standard

-

16

129900-23200

8

Connecting Rod Bolt

-

17

129900-23600

4

Connecting Rod Bearing, Standard

-

 

129900-23610

4

Connecting Rod Bearing, Undersize 0.25

-

18

129920-21580

1

Flywheel

-

19

127410-21480

2

Ring Gear, 129 Teeth

-

 

 

 

 

 

 

 

 

P498-2 10/07

 

1 - 3

GROUP 1 – engine

Camshaft and Drive Gear

Ycamshaft

P498-2 10/07

1 - 4

GROUP 1 – engine

Camshaft and Drive Gear

KEY

PART NUMBER

QTY

DESCRIPTION

SERIAL NUMBER

1

129150-14200

8

Tappet

-

2

129907-14400

8

Push Rod

-

3

129907-14581

1

Camshaft Assembly (includes keys 4-6)

-

4

129150-02450

1

Thrust Washer

-

5

129900-14100

1

Camshaft Gear

-

6

22512-070140

1

Key

-

7

26106-080162

2

Bolt, M8 x 16 Plated

-

8

123900-25060

1

Idle Gear Shaft

-

9

129900-25100

1

Idle Gear Assembly

-

10

129150-25920

1

Bushing, Idle Gear

-

11

26106-080552

3

Bolt, M8 x 55 Plated

-

12

123907-25909

1

Injection Pump Gear

-

13

129953-25300

4

Bolt

-

14

158563-51150

1

Flange

-

15

22217-180000

1

Spring Washer

-

16

26776-180002

1

Lock Nut, M18

-

 

 

 

 

 

P498-2 10/07

1 - 5

Northern Lights NL498D2 Parts Manual

GROUP 1 – engine

Timing Gear Housing

Ytiminggearhsg

P498-2 10/07

1 - 6

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