Northern Lights NL498K Parts Manual
PARTS
PARTS
CATALOG
CATALOG
P498K
for Model NL498K
— 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 AVE. N.W.
SEATTLE, WA 98107-5043
USA
TEL: (206) 789-3880
FAX: (206) 782-5455
http://www.northern-lights.com
PARTS CATALOG
for Model
NL498K
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
Fuel Injection Pump, Injectors and Lines .... 0 - 1
Fuel Filter and Supply & Return Lines ........2 - 3
GROUP 5 - ELECTRICAL SYSTEM
Engine Electrical - 12 Volt...........................0 - 1
Stop Solenoid - 12 Volt ................................2 - 3
Alternator - 12 Volt/40 Amp ........................4 - 5
Starting Motor - 12 Volt...............................6 - 7
Series 1-B Control Panel ..............................8 - 9
Series 3-B Control Panel ......................... 10 - 11
GROUP 6 - GASKETS
Gasket Set.....................................................0 - 1
GROUP 8 - FRAME & MOUNTING
Base Frame Assembly ..................................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.
© Alaska Diesel Electric, Inc. All rights reserved. Litho U.S.A. Publication number P498K 12/99
P498K 12/99
I
INTRODUCTION
MODEL DESIGNATION
MODELS INCLUDED
This manual covers the operating instructions for:
NL498, which uses the Yanmar model 4TNE98-AD engine.
MODEL NUMBERS
Model numbers give the unit's application, block model, aspiration, and RPM:
M - NL 498 N
M - Northern Lights marine generator set
NL - Northern Lights industrial generator set
NL498
Northern Lights industrial diesel generator set
with a 498 engine.
Model number of engine block
Cylinders Bore
498 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
P498K 12/99
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
6
5
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 -
7
8 9
10
3
2
13
11
P844 06/96
5-2
14
12
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.
P498K 12/99
III
GROUP 1 – ENGINE
Cylinder Block
Figure 1
P498K 12/99
1 - 0
GROUP 1 – ENGINE
Cylinder Block
KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER
1 729902-01560 1 Cylinder Block Assembly
2 23871-030000 1 Plug, 3/8 BSPT 3 171051-01921 1 Plug 4 129900-02020 10 Main Cap Bolt 5 129900-02410 1 Camshaft Bush 6 22351-060012 2 Spring Pin 7 23871-030000 1 Plug, 3/8 BSPT 8 27231-550000 1 Expansion Plug, 55 mm -
9 23871-030000 1 Plug 10 27241-300000 8 Expansion Plug, 30 mm 11 129900-02800 5 Main Bearing, Standard -
129900-02340 5 Main Bearing, Under-sized 0.25 mm -
12 129900-02930 2 Thrust Bearing, Standard -
129900-02940 2 Thrust Bearing, Over-sized 0.25 mm 13 129900-01200 18 Head Bolt 14 129902-01330 1 Head Gasket -
(Includes Keys #2 - #12) -
P498K 12/99
1 - 1
GROUP 1 – ENGINE
Flywheel Housing and Oil Sump
Figure 2
P498K 12/99
1 - 2
GROUP 1 – ENGINE
Flywheel Housing and Oil Sump
KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER
1 129955-01600 1 Flywheel Housing 2 129100-01580 2 Parallel Pin 3 119620-01750 1 Plug 4 26206-100702 3 Bolt, M10 x 70 Plated 5 26206-100352 9 Bolt, M10 x 35 Plated 6 124411-01780 1 Seal 7 129902-01710 1 Oil Sump Assembly 8 119640-01640 1 Drain Plug, M22 x 1.5 -
36-77300 1 Oil Drain Valve with 5/8" Hose Barb
9 22190-220002 1 Seal Washer 10 26106-080122 21 Bolt, M8 x 12 Plated 11 977770-01212 1 Liquid Gasket -
(optional - not shown) -
P498K 12/99
1 - 3
GROUP 1 – ENGINE
Crankshaft and Piston
Figure 3
P498K 12/99
1 - 4
GROUP 1 – ENGINE
Crankshaft and Piston
KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER
1 129902-21000 1 Crankshaft Assembly
2 121850-21920 1 Parallel Pin -
3 129900-21200 1 Crankshaft Gear -
4 121850-21290 1 Parallel Pin -
5 22512-070140 1 Key -
6 24341-000530 1 O-Ring -
7 129900-21670 1 Crankshaft Pulley -
8 129960-21640 1 Washer -
9 121850-21680 1 Bolt 10 129955-21590 1 Flywheel Assembly
11 129900-21600 1 Ring Gear 12 121850-21130 6 Bolt 13 129902-22080 4 Piston with Rings, Standard -
129902-22900 4 Piston with Rings, Over-sized 0.25 mm -
14 129903-22050 4 Piston Ring Set, Standard -
129903-22950 4 Piston Ring Set, Over-sized 0.25 mm 15 120130-22301 4 Piston Pin 16 22252-000300 8 Snap Ring 17 129900-23000 4 Connecting Rod Assembly
18 129900-23910 4 Piston Pin Bush 19 129900-23200 8 Connecting Rod Bolt 20 129900-23600 4 Bearing, Standard -
129900-23610 4 Bearing, Under-sized 0.25 mm -
(Includes Keys #2 - #5) -
(Includes Key #11) -
(Includes Keys #18 - #20) -
P498K 12/99
1 - 5
GROUP 1 – ENGINE
Camshaft and Driving Gear
Figure 4
P498K 12/99
1 - 6
GROUP 1 – ENGINE
Camshaft and Driving Gear
KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER
1 129900-14580 1 Camshaft Assembly
2 129150-02450 1 Thrust Plate 3 129900-14100 1 Camshaft Gear 4 22512-070140 1 Key 5 129150-14200 8 Tappet 6 129900-14400 8 Push Rod 7 26106-080162 2 Bolt, M8 x 16 Plated 8 129900-25060 1 Idler Shaft -
9 129900-25100 1 Idle Gear Assembly
10 129150-25920 1 Bushing 11 26106-080552 2 Bolt, M8 x 55 Plated 12 129900-25900 1 Injection Pump Drive Gear 13 1 Lock Washer 14 1 Hex Nut 15 1 O-Ring -
(Includes Keys #2 - #4) -
(Includes Key #10) -
P498K 12/99
1 - 7
GROUP 1 – ENGINE
Timing Gear Housing
Figure 5
P498K 12/99
1 - 8
GROUP 1 – ENGINE
Timing Gear Housing
KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER
1 729900-01570 1 Timing Cover Assembly
2 129900-01780 1 Oil Seal -
3 24341-000240 1 O-Ring -
4 129900-01740 1 Cover -
5 26106-060162 2 Bolt, M6 x 16 Plated -
6 129900-01820 1 Timing Gear Housing Assembly
7 24311-000320 1 O-Ring -
8 129900-32000 1 Oil Pump Assembly
9 26216-100302 4 Stud 10 129900-32030 1 O-Ring 11 129900-32040 1 O-Ring 12 22312-080160 4 Parallel Pin 13 26366-100002 4 Nut, M10 14 26106-080162 1 Bolt, M8 x 16 Plated 15 26106-080202 3 Bolt, M8 x 20 Plated 16 26106-080302 1 Bolt, M8 x 30 Plated 17 26106-080402 5 Bolt, M8 x 40 Plated 18 26106-080402 5 Bolt, M8 x 40 Plated 19 26106-080452 3 Bolt, M8 x 45 Plated 20 129001-91810 6 Bolt, M8 x 70 Plated 21 129001-91810 1 Bolt, M8 x 70 Plated 22 124160-01751 1 Oil Filler Cap 23 24311-000070 1 O-Ring 24 121023-01550 1 Cover 25 977770-01212 1 Liquid Gasket -
(Includes Key #2) -
(Includes Keys #8 - #9) -
(Parts not available separately) -
P498K 12/99
1 - 9
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