Northern Lights NL498K Parts Manual
PARTS
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 |
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GROUP 4 - FUEL SYSTEM |
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Cylinder Block ............................................. |
0 - 1 |
Fuel Injection Pump, Injectors and Lines |
.... 0 - 1 |
Flywheel Housing and Oil Sump ................. |
2 - 3 |
Fuel Filter and Supply & Return Lines ........ |
2 - 3 |
Crankshaft and Piston ................................... |
4 - 5 |
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Camshaft and Driving Gear .......................... |
6 - 7 |
GROUP 5 - ELECTRICAL SYSTEM |
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Timing Gear Housing ................................... |
8 - 9 |
Engine Electrical - 12 Volt ........................... |
0 - 1 |
Lubricating System ................................. |
10 - 11 |
Stop Solenoid - 12 Volt ................................ |
2 - 3 |
Cylinder Head and Rocker Arm Cover ... |
12 - 13 |
Alternator - 12 Volt/40 Amp ........................ |
4 - 5 |
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Starting Motor - 12 Volt ............................... |
6 - 7 |
GROUP 2 - INTAKE & EXHAUST |
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Series 1-B Control Panel .............................. |
8 - 9 |
Intake Manifold and Air Cleaner ................. |
0 - 1 |
Series 3-B Control Panel ......................... |
10 - 11 |
Exhaust Manifold and Muffler ..................... |
2 - 3 |
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GROUP 6 - GASKETS |
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GROUP 3 - COOLING SYSTEM |
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Gasket Set ..................................................... |
0 - 1 |
General Arrangement ................................... |
0 - 1 |
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Radiator and Modular Guard ........................ |
2 - 3 |
GROUP 8 - FRAME & MOUNTING |
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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:
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M - NL |
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498 |
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N |
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M - Northern Lights marine generator set |
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Model number of engine block |
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Additional letters |
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Cylinders |
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Bore |
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designate a series |
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NL - Northern Lights industrial generator set |
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4 |
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98 mm |
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within model number. |
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Northern Lights industrial diesel generator set |
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NL498 |
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with a 498 engine. |
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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 PXG, PXK, BCI, and PSL generators
P498K 12/99
II
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INTRODUCTION |
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READING A PARTS PAGE |
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IMPORTANT: |
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Before selecting parts, be sure that you are choosing parts from the correct page. |
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Check the model designation at the page top. |
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Do not use this illustration for parts purchasing. |
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1 |
ELECTRICAL SYSTEM |
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ALTERNATOR ASSEMBLY: M - NL844 |
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4 |
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3 |
2 |
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6 |
7 |
8 |
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9 |
5 |
KEY |
PART NUMBER |
QTY. |
DESCRIPTION |
SERIALNUMBER |
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0 |
185046210 |
1 |
Alternator Assembly |
10 |
- |
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1 |
185446219 |
1 |
Flywheel, complete |
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- |
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2 |
185446217 |
1 |
Plate, complete |
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- |
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3 |
185716200 |
1 |
Plate |
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- |
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4 |
185446218 |
1 |
Stator, complete |
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- |
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5 |
040126210 |
2 |
Bearing |
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- |
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6 |
020210010 |
1 |
Nut |
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- |
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7 |
027100010 |
1 |
Spring washer |
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- |
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8 |
026100010 |
1 |
Washer |
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- |
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9 |
185446220 |
1 |
Clamp |
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- |
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10 |
015140408 |
1 |
Screw |
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- |
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11 |
015140425 |
2 |
Screw |
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- |
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12 |
199236510 |
1 |
Collar |
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- |
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13 |
P844 06/96 |
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14 |
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11 |
5-2 |
12 |
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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.
P498K 12/99
III
GROUP 1 – ENGINE
Cylinder Block
Figure 1
P498K 12/99
1 - 0
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GROUP 1 – ENGINE |
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Cylinder Block |
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KEY |
PART NUMBER |
QTY |
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DESCRIPTION |
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SERIAL NUMBER |
1 |
729902-01560 |
1 |
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Cylinder Block Assembly (Includes Keys #2 - #12) |
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2 |
23871-030000 |
1 |
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Plug, 3/8 BSPT |
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3 |
171051-01921 |
1 |
Plug |
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- |
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4 |
129900-02020 |
10 |
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Main Cap Bolt |
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5 |
129900-02410 |
1 |
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Camshaft Bush |
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6 |
22351-060012 |
2 |
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Spring Pin |
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7 |
23871-030000 |
1 |
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Plug, 3/8 BSPT |
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8 |
27231-550000 |
1 |
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Expansion Plug, 55 mm |
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9 |
23871-030000 |
1 |
Plug |
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10 |
27241-300000 |
8 |
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Expansion Plug, 30 mm |
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11 |
129900-02800 |
5 |
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Main Bearing, Standard |
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129900-02340 |
5 |
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Main Bearing, Under-sized 0.25 mm |
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12 |
129900-02930 |
2 |
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Thrust Bearing, Standard |
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129900-02940 |
2 |
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Thrust Bearing, Over-sized 0.25 mm |
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13 |
129900-01200 |
18 |
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Head Bolt |
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14 |
129902-01330 |
1 |
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Head Gasket |
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- |
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P498K 12/99
1 - 1
GROUP 1 – ENGINE
Flywheel Housing and Oil Sump
Figure 2
P498K 12/99
1 - 2
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GROUP 1 – ENGINE |
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Flywheel Housing and Oil Sump |
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KEY |
PART NUMBER |
QTY |
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DESCRIPTION |
SERIAL NUMBER |
1 |
129955-01600 |
1 |
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Flywheel Housing |
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2 |
129100-01580 |
2 |
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Parallel Pin |
- |
3 |
119620-01750 |
1 |
Plug |
- |
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4 |
26206-100702 |
3 |
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Bolt, M10 x 70 Plated |
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5 |
26206-100352 |
9 |
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Bolt, M10 x 35 Plated |
- |
6 |
124411-01780 |
1 |
Seal |
- |
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7 |
129902-01710 |
1 |
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Oil Sump Assembly |
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8 |
119640-01640 |
1 |
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Drain Plug, M22 x 1.5 |
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36-77300 |
1 |
Oil Drain Valve with 5/8" Hose Barb (optional - not shown) |
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9 |
22190-220002 |
1 |
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Seal Washer |
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10 |
26106-080122 |
21 |
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Bolt, M8 x 12 Plated |
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11 |
977770-01212 |
1 |
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Liquid Gasket |
- |
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P498K 12/99
1 - 3
GROUP 1 – ENGINE
Crankshaft and Piston
Figure 3
P498K 12/99
1 - 4
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GROUP 1 – ENGINE |
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Crankshaft and Piston |
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KEY |
PART NUMBER |
QTY |
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DESCRIPTION |
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SERIAL NUMBER |
1 |
129902-21000 |
1 |
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Crankshaft Assembly (Includes Keys #2 - #5) |
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2 |
121850-21920 |
1 |
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Parallel Pin |
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3 |
129900-21200 |
1 |
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Crankshaft Gear |
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4 |
121850-21290 |
1 |
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Parallel Pin |
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5 |
22512-070140 |
1 |
Key |
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6 |
24341-000530 |
1 |
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O-Ring |
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7 |
129900-21670 |
1 |
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Crankshaft Pulley |
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8 |
129960-21640 |
1 |
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Washer |
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9 |
121850-21680 |
1 |
Bolt |
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10 |
129955-21590 |
1 |
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Flywheel Assembly (Includes Key #11) |
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11 |
129900-21600 |
1 |
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Ring Gear |
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12 |
121850-21130 |
6 |
Bolt |
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13 |
129902-22080 |
4 |
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Piston with Rings, Standard |
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129902-22900 |
4 |
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Piston with Rings, Over-sized 0.25 mm |
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14 |
129903-22050 |
4 |
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Piston Ring Set, Standard |
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129903-22950 |
4 |
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Piston Ring Set, Over-sized 0.25 mm |
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15 |
120130-22301 |
4 |
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Piston Pin |
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16 |
22252-000300 |
8 |
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Snap Ring |
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17 |
129900-23000 |
4 |
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Connecting Rod Assembly (Includes Keys #18 - #20) |
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18 |
129900-23910 |
4 |
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Piston Pin Bush |
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19 |
129900-23200 |
8 |
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Connecting Rod Bolt |
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20 |
129900-23600 |
4 |
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Bearing, Standard |
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- |
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129900-23610 |
4 |
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Bearing, Under-sized 0.25 mm |
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- |
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P498K 12/99
1 - 5
GROUP 1 – ENGINE
Camshaft and Driving Gear
Figure 4
P498K 12/99
1 - 6
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GROUP 1 – ENGINE |
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Camshaft and Driving Gear |
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KEY |
PART NUMBER |
QTY |
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DESCRIPTION |
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SERIAL NUMBER |
1 |
129900-14580 |
1 |
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Camshaft Assembly (Includes Keys #2 - #4) |
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2 |
129150-02450 |
1 |
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Thrust Plate |
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3 |
129900-14100 |
1 |
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Camshaft Gear |
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4 |
22512-070140 |
1 |
Key |
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- |
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5 |
129150-14200 |
8 |
Tappet |
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- |
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6 |
129900-14400 |
8 |
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Push Rod |
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7 |
26106-080162 |
2 |
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Bolt, M8 x 16 Plated |
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8 |
129900-25060 |
1 |
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Idler Shaft |
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9 |
129900-25100 |
1 |
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Idle Gear Assembly (Includes Key #10) |
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10 |
129150-25920 |
1 |
Bushing |
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- |
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11 |
26106-080552 |
2 |
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Bolt, M8 x 55 Plated |
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12 |
129900-25900 |
1 |
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Injection Pump Drive Gear |
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13 |
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1 |
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Lock Washer |
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- |
14 |
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1 |
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Hex Nut |
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15 |
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1 |
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O-Ring |
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- |
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P498K 12/99
1 - 7
GROUP 1 – ENGINE
Timing Gear Housing
Figure 5
P498K 12/99
1 - 8
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GROUP 1 – ENGINE |
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Timing Gear Housing |
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KEY |
PART NUMBER |
QTY |
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DESCRIPTION |
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SERIAL NUMBER |
1 |
729900-01570 |
1 |
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Timing Cover Assembly (Includes Key #2) |
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2 |
129900-01780 |
1 |
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Oil Seal |
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- |
3 |
24341-000240 |
1 |
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O-Ring |
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- |
4 |
129900-01740 |
1 |
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Cover |
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5 |
26106-060162 |
2 |
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Bolt, M6 x 16 Plated |
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6 |
129900-01820 |
1 |
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Timing Gear Housing Assembly (Includes Keys #8 - #9) |
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7 |
24311-000320 |
1 |
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O-Ring |
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- |
8 |
129900-32000 |
1 |
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Oil Pump Assembly (Parts not available separately) |
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9 |
26216-100302 |
4 |
Stud |
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- |
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10 |
129900-32030 |
1 |
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O-Ring |
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11 |
129900-32040 |
1 |
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O-Ring |
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12 |
22312-080160 |
4 |
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Parallel Pin |
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- |
13 |
26366-100002 |
4 |
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Nut, M10 |
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14 |
26106-080162 |
1 |
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Bolt, M8 x 16 Plated |
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15 |
26106-080202 |
3 |
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Bolt, M8 x 20 Plated |
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16 |
26106-080302 |
1 |
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Bolt, M8 x 30 Plated |
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17 |
26106-080402 |
5 |
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Bolt, M8 x 40 Plated |
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18 |
26106-080402 |
5 |
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Bolt, M8 x 40 Plated |
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19 |
26106-080452 |
3 |
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Bolt, M8 x 45 Plated |
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20 |
129001-91810 |
6 |
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Bolt, M8 x 70 Plated |
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21 |
129001-91810 |
1 |
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Bolt, M8 x 70 Plated |
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- |
22 |
124160-01751 |
1 |
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Oil Filler Cap |
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- |
23 |
24311-000070 |
1 |
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O-Ring |
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- |
24 |
121023-01550 |
1 |
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Cover |
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- |
25 |
977770-01212 |
1 |
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Liquid Gasket |
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- |
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P498K 12/99
1 - 9
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