Northern Lights NL673D Parts Manual

PARTS

CATALOG

for Models M673 and NL673

P673

— 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. P.O. Box 70543 Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455

Printed in U.S.A. PART NO.: P673 12/02

PARTS CATALOG

for Models M673 & NL673

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 Assembly ............................0 - 1

Crankshaft & Piston .....................................2 - 3

Oil Pump & Strainer.......................................... 4

Camshaft............................................................ 5

Cylinder Head & Rocker Arm Assembly ....6 - 7

Rocker Arm Cover ............................................ 8

GROUP 2 - AIR INTAKE SYSTEM

Air Intake & Rocker Arm Cover....................... 1

Air Filter ............................................................ 2

Muffler .............................................................. 3

GROUP 3 - COOLING SYSTEM & EXHAUST

Exhaust Manifold / Expansion Tank ............0 - 2

Coolant Pump .................................................... 3

Raw Water Pump .........................................4 - 5

Radiator & Mounting ...................................6 - 7

GROUP 4 - FUEL SYSTEM

General Arrangement ............................... 0 - 1

Governor & Timing Gear Case ....................2 - 3

Fuel Filter & Mounting............................. 4 - 5

Injection Pump Assembly ................................. 6

Injector Assembly ............................................. 7

Fuel Lift Pump .................................................. 8

GROUP 5 - ELECTRICAL SYSTEM

12 Volt Engine .............................................0 - 1

Flywheel Housing & Starter Assembly............. 2

Alternator & Mounting...................................... 3

Alternator Assembly ......................................... 4

Starter Motor Assembly .................................... 5

Series 1 & 1B Control Panels............................ 6

Series 1 Start/Stop Control Panel ...................... 7

Series 1B Start/Stop Control Panel ................... 8

Belt Guard ......................................................... 9

GROUP 6 - GASKET SETS

Gasket Sets ...................................................0 - 1

GROUP 7 - GENERATOR

Generator Components.................................0 - 7

GROUP 8 - FRAME & MOUNTING

Base Frame Assemblies ...............................0 - 3

GROUP 9 - ACCESSORIES

GROUP 9 - & OPTIONAL EQUIPMENT

Standard Line - Series 3C, Flush Mount, 12 V .... 0

Standard Line - Series 3B, Control Panel, 12 V.. 1

Oil Drain Kit...................................................... 2

Remote Expansion Tank ................................... 3

Sound Enclosure Assembly..........................4 - 7

Coolant Recovery Tank..................................... 8

It may not be reproduced in whole or part without the expressed written permission of Alaska Diesel Electric, Inc.

This publication is the sole property of Alaska Diesel Electric, Inc.

Proprietary Information

P673 12/02

Model Designation

MODELS INCLUDED

This manual covers the operating instructions for:

M673 and NL673, which both use the 673 engine.

Model Numbers

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

M - NL 673

M - Northern Lights marine generator set

NL - Northern Lights industrial generator set

M 673

NL 673

Northern Lights marine diesel generator set with a 673 engine.

Northern Lights industrial diesel generator set with a 673 engine.

Model number of engine block

Bore Cylinders

67 mm 3

Serial Numbers

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

P673 12/02

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 - NL844

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 -

8 9

P844 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.

P673 12/02

III

GROUP 1 – ENGINE

Cylinder Block Assembly

P673: 1-0

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 110107821 1 Cylinder Block - Industrial Application -

110107831 1 Cylinder Block - Marine Application 2 064200015 1 Expansion Plug 15 mm 3 064200018 2 Expansion Plug 18 mm 4 064200035 4 Expansion Plug 35 mm 5 198466070 5 Blank Plug 6 198466050 1 Blank Plug 7 19-00010 1 Hose Clamp #10

(Marine application only) -

P673 12/02

(formerly #110107830) -

1 - 0

GROUP 1 – ENGINE

Cylinder Block Assembly

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

8 198466010 4 Blank Plug -

9 165296160 1 Idle Gear Shaft 10 198466060 1 Sealing Cap 11 198517301 1 Bushing, Standard

198517305 1 Bushing, Undersize 0.25 mm

198517308 1 Bushing, Undersize 0.50 mm 12 040106203 1 Bearing 13 064100045 1 Expansion Plug 14 042303015 1 Bearing 15 030500512 1 Dowel Pin 16 030500616 2 Dowel Pin 17 030500820 2 Dowel Pin 18 030309005 2 Lock Pin 19 012110620 2 Stud M6 x 1.0 x 20 mm 20 012100635 1 Stud M6 x 1.0 x 35 mm 21 012100660 1 Stud M6 x 1.0 x 60 mm 22 036509005 1 Retaining Ring 23 110996590 1 Gasket 24 011500860 1 Bolt

(Marine application only) -

25 140976040 1 Bracket (Marine application only) 26 140606710 1 Drain Hose 27 054109013 1 Gasket

(Marine application only) -

28 198636080 1 Oil Seal 29 398430560 1 Cap

(Marine application only – formerly #398430080) -

30 110706770 1 Oil Pan - Marine Application -

110706691 1 Oil Pan - Industrial Application 31 010109235 18 Capscrew, Hex Head Phillips M6 x 1.0 x 14 mm 33 198736050 1 Drain Cock 34 140546020 1 Adapter 35 24-02001 1 Oil Filter 36 110756070 1 Dipstick Tube 37 052100100 2 O-Ring 38 011300612 1 Capscrew, Hex Head with Washer M6 x 1.0 x 12 mm 39 198416350 1 Dipstick 40 120116100 Tappet * -

120116180 Tappet #1 Cylinder, Exhaust Only 41 120456240 6 Push Rod 42 140036220 1 Relief Valve Assembly 43 152100150 1 O-Ring 46 068115200 1 Hose 47 15-00701 1 Flat Washer M8 48 15-00702 1 Lock Washer M8 49 14-00711 1 Nut M8 x 1.25 50 010401212 ** Plug, Hex Head M12x1.25 51 025100012 ** Sealing Washer -

(formerly #198517300) -

(formerly #198517305) - (formerly #198517308) -

(Marine application only) -

* -

(formerly #140036120) -

*Note: Camshaft 120026171 requires 6 ea. of Tappet 120116100.

Replacement Camshaft requires 5 ea. Tappet 120116100 and 1 ea.

120116180.

**As required

P673 12/02

1 - 1

GROUP 1 – ENGINE

Crankshaft and Pistons

P673 12/02

1 - 2

P673: 1-2

GROUP 1 – ENGINE

Crankshaft and Pistons

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 115256570 1 Crankshaft 2 115276210 1 Crankshaft Gear 3 030509020 1 Dowel Pin 5 110156220 1 Bearing Holder Assembly 6 010810840 6 Bolt 7 030500612 6 Dowel Pin 8 110156230 1 Bearing Holder Assembly 9 110156240 1 Bearing Holder Assembly

10 198517331 2 Bearing, standard

198517335 2 Bearing, undersize 0.25 mm

198517338 2 Bearing, undersize 0.50 mm 11 198517341 2 Bearing, standard

198517345 2 Bearing, undersize 0.25 mm

198517348 2 Bearing, undersize 0.50 mm 12 198517102 1 Bearing, standard

198517106 1 Bearing, undersize 0.25 mm

198517109 1 Bearing, undersize 0.50 mm 13 198517111 1 Bearing, standard

198517115 1 Bearing, undersize 0.25 mm

198517118 1 Bearing, undersize 0.50 mm 14 011510850 2 Bolt 15 010700845 3 Bolt 16 115107400 3 Ring Kit, standard -

115107410 3 Ring Kit, oversize 0.50 mm 17 115016960 3 Piston, standard

115016970 3 Piston, oversize 0.50 mm 18 115326260 3 Piston Pin 19 036500019 6 Snap Ring 20 115026240 3 Connecting Rod Assembly 21 198517325 3 Bushing 22 115176130 6 Connecting Rod Bolt 23 020109103 6 Nut 24 198517311 6 Bearing, standard

198517315 6 Bearing, undersize 0.25 mm

198517318 6 Bearing, undersize 0.50 mm 25 115356930 1 Flywheel, Complete 26 115376040 1 Ring Gear 27 010109330 4 Bolt 28 020800018 1 Nut 29 115396780 1 Crankshaft Pulley 30 40-02002 1 Drive Belt 31 026200018 1 Washer 32 034100508 1 Key 33 012111025 4 Stud M10 x 1.5 x 25 mm -

(includes keys #2, #3, #32) -

(includes keys #6 & #7) -

(includes keys #6 & #7) - (includes keys #6 & #7) -

(formerly #198517330) -

(formerly #198517334) - (formerly #198517337) -

(formerly #198517340) -

(formerly #198517344) - (formerly #198517347) -

(formerly #198517301) -

(formerly #198517305) - (formerly #198517308) -

(formerly #198517310) -

(formerly #198517314) - (formerly #198517317) -

(includes key #16) -

(includes keys #21 - #23) -

(formerly #198517310) -

(formerly #198517314) - (formerly #198517317) -

(includes key #26) -

(formerly #080109048) -

P673 12/02

1 - 3

GROUP 1 – ENGINE

Oil Pump and Strainer

P673: 1-4

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 198216821 1 Spring 2 199266180 1 Thrust Washer 3 165026110 1 Idle Gear Assembly 4 140166130 1 Rotor 5 140116140 1 Oil Pump Cover 6 199286150 1 Shim: Thickness = 0.10 mm -

199286160 1 Shim: Thickness = 0.15 mm 199286170 1 Shim: Thickness = 0.20 mm -

199286180 1 Shim: Thickness = 0.50 mm 7 199216720 1 Spring 8 199236540 1 Collar 9 036800010 1 Snap Ring -

13 052109076 1 O-Ring 14 140986590 1 Oil Pipe 15 140406310 1 Suction Filter 16 011310612 2 Capscrew, Hex Head with Washer M6 x 1.0 x 12 mm 17 165166280 1 Front Plate 18 165996400 1 Gasket 19 011300612 3 Capscrew, Hex Head Phillips M6 x 1.0 x 12 mm -

P673 12/02

1 - 4

GROUP 1 – ENGINE

Camshaft

P673: 1-5

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 120026172 1 Camshaft Assembly

120026171) * -

(includes keys #1 - #10 – formerly #120026170 & from xxxx-29623

2 120016060 1 Cam Gear 3 034100508 1 Key 4 120736081 1 Gear 5 199261230 3 Spacer 6 040109048 1 Bearing 7 125256120 1 Slider 8 199566651 1 Plate 9 011310612 1 Bolt -

10 010700610 1 Bolt -

Note: Requires new Tappets - see Cylinder Block

P673 12/02

1 - 5

GROUP 1 – ENGINE

Cylinder Head and Rocker Arm Assembly

P673 12/02

1 - 6

P673cylhead

GROUP 1 – ENGINE

Cylinder Head and Rocker Arm Assembly

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 111016951 1 Cylinder Head Assembly 2 064200018 2 Expansion Plug, 18 mm 4 064200022 6 Expansion Plug, 22 mm 5 198466070 4 Blank Plug 6 120166280 3 Intake Valve 7 120176290 3 Exhaust Valve 8 120406080 6 Valve Guide Seal -

9 198217070 6 Spring 10 120186100 6 Retainer 11 120226080 12 Valve Keeper 12 012100650 1 Stud, M6 x 1.0 x 50 mm 14 110136290 3 Intake Valve Seat 15 111147400 1 Head Gasket, Thickness = 0.5 mm 16 111136460 11 Head Bolt, 10 mm Hex 17 111136470 3 Head Bolt, 10 mm Hex 18 012109177 3 Stud Bolt 19 120036330 1 Rocker Arm Assembly – Early Production

120036700 1 Rocker Arm Assembly – Late Production -

(includes Keys #20 - #32; requires Valve Cap #62)

20 120356110 3 Rocker Arm - intake with swivel tip – Early Production -

120356200 3 Rocker Arm - intake – Late Production

21 120356120 3 Rocker Arm - exhaust with swivel tip – Early Production -

120356210 3 Rocker Arm - exhaust – Late Production 22 199486220 6 Screw 23 020109076 6 Nut 24 120346170 3 Rocker Arm Bracket 25 120316190 1 Rocker Arm Shaft 26 198217080 2 Spring 27 064609006 2 Plug 28 030300325 1 Spring Pin 29 199280280 4 Shim 32 14-00711 3 Hex Nut M8 x 1.25 33 198516340 1 Lifting Eye 34 011310816 1 Bolt 39 198996060 7 Gasket 44 068122560 1 Vinyl Tube 46 011300650 2 Capscrew, Hex Head M6 x 1.0 x 50 mm with Washer 47 145996440 1 Gasket 48 198217410 1 Spring 49 145206062 1 Thermostat 50 145216171 1 Thermostat Housing 51 195816550 1 Lifting Eye 52 011510820 1 Bolt 53 140606680 1 Oil Pipe 54 198486780 2 Bolt 55 185246011 1 Oil Pressure Switch 56 15-01132 8 Lock Washer M6 57 14-01131 3 Hex Nut M6 x 1.0 59 21-00139 1 Adapter 1/8 BSPT x 1/8 NPT

064500010 1 Plug 1/8 BSPT

(without oil pressure sender) -

60 198486720 1 Female Tee, 1/8 BSPT 61 198486380 ** Hex Nipple, 1/8 BSPT 62 120216130 6 Valve Cap – Late Production -

(formerly #111136340, 12 mm Hex) - (formerly #111136350, 12 mm Hex) -

(includes keys #20 - #32) -

(requires Valve Cap #62) -

(see Electrical System) -

(with oil pressure sender) -

(**As required) -

P673 12/02

1 - 7

GROUP 1 – ENGINE

Rocker Arm Cover

Industrial Application

P673: 2-0A

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 010110690 2 Bolt 2 198436010 1 Cap 3 052100400 1 O-Ring 4 024500008 3 Nut 5 198996060 3 Gasket 6 111216610 1 Rocker Arm Cover 7 111996330 1 Gasket 8 111996060 1 Gasket -

9 110986500 1 Pipe 10 068122560 1 Vent Tube 11 110666120 1 Filter 12 110666110 1 Oil Stopper 13 011140612 2 Bolt -

P673 12/02

1 - 8

GROUP 2 – INTAKE & EXHAUST SYSTEM

Air Intake and Rocker Arm Cover

Marine Application

P673: 2-0B

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 111206270 1 Rocker Arm Cover/Air Intake 2 010110690 2 Bolt 3 135176030 1 Plate 4 135996560 1 Gaslet 5 198436010 1 Cap 6 052100400 1 O-Ring 7 110666090 2 Filter 8 064200030 1 Plug -

9 024500008 3 Nut 10 198996060 3 Gasket 11 010100810 1 Bolt 12 025100008 1 Sealing Washer 13 111996340 1 Gasket 14 011500812 5 Bolt 15 24-28300 1 Air Filter -

P673 12/02

(includes key #8) -

2 - 1

GROUP 2 – INTAKE & EXHAUST SYSTEM

Air Filter

Industrial Application

P673: 2-2

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 399480070 1 Screw 2 399610100 1 Pin 3 399610110 1 Pin 4 314630030 1 Clamp 5 398113190 2 Rubber 6 135597480 1 Air Intake Hose 7 067100056 2 Hose Clamp 8 408060010 1 Air Filter Assembly

9 198116380 1 Rubber 10 135976570 1 Bracket 11 011500820 2 Bolt 12 135976120 1 Bracket 13 135156100 1 Filter Housing 14 408620004 1 Valve 15 408620002 1 Element 16 408620005 1 Packing 17 408620006 1 Packing 18 014100620 1 Wing Bolt 19 135326060 1 Rain Cap with Clamp

(includes Keys 13-18) -

(not shown) -

P673 12/02

2 - 2

GROUP 2 – INTAKE & EXHAUST SYSTEM

Muffler

Industrial Application

P673: 2-3

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 135046100 1 Muffler Assembly 2 135996520 1 Gasket 3 135616551 1 Exhaust Manifold 4 011310640 3 Bolt 5 012110670 2 Stud 6 027100006 2 Spring Washer 7 020100006 2 Nut 8 011310670 1 Bolt -

9 135996530 1 Gasket 10 135406170 1 Muffler 11 011300612 10 Bolt 12 020100008 1 Nut 13 027100008 1 Spring Washer 14 026100008 2 Washer 15 010110860 1 Bolt 16 408330010 1 Clamp 17 135606150 1 Exhaust Adapter, 90° -

31-38300 1 Exhaust Adapter, straight 1-1/4 NPT -

18 27-38302 1 Stainless Steel Exhaust Flex 1-1/4 NPT x 18" -

(includes Keys #3, #9, #10, & #11) -

P673 12/02

2 - 3

GROUP 3 – COOLING SYSTEM

Exhaust Manifold / Expansion Tank

Heat Exchanger Cooling Components

P673: 3-0

P673: A-4177/C-2326

P673 12/02

3 - 0

GROUP 3 – COOLING SYSTEM

Exhaust Manifold / Expansion Tank

Heat Exchanger Cooling Components

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

2 14-00711 1 Hex Nut M8 x 1.25 -

3 15-00702 1 Lock Washer -

4 340460170 1 Gear -

5 052400400 1 O-ring -

6 25-18305 1 Raw Water Pump

25-12007 Raw Water Pump 7 19-00010 1 Hose Clamp #10 8 12-00717 3 Capscrew, Hex Head M8 x 1.25 x 60 mm -

12-00701 1 Capscrew, Hex Head M8 x 1.25 x 110 mm 9 140976040 1 Bracket -

17 21-12007 1 Filler Cap 18 145546430 1 Filler Neck 19 067200100 1 Clamp 20 068106500 1 Overflow Tube 21 052400330 1 O-ring 22 135606160 1 Exhaust Manifold/Expansion Tank 25 14-01131 4 Hex Nut M6 x 1.0 26 15-01132 12 Lock Washer M6 27 012110690 3 Stud M6 x 1.0 x 90 mm 28 12-01136 5 Capscrew, Hex Head M6 x 1.0 x 90 mm 29 20-12003 1 Heat Exchanger Element 30 19-00040 2 Hose Clamp #40 31 19-00036 2 Hose Clamp #36 32 145536440 2 End Cap 33 19-00012 5 Hose Clamp #12 34 145986170 1 Pipe 35 145536461 1 Hose 36 145536451 1 Hose 37 19-00016 2 Hose Clamp #16 38 145206062 1 Thermostat 39 198217410 1 Spring 40 135996730 1 Gasket 41 Zinc Anode 42 198436200 1 Plug 43 064200022 1 Plug 44 011510816 1 Bolt 45 195816340 1 Lifting Eye 46 012100620 1 Stud M6 x 1.0 x 20 mm 47 135996550 1 Gasket 48 011300620 3 Bolt 49 135616570 1 Wet Exhaust Elbow 49 27-38300 1 Dry Exhaust Elbow 50 00-08301 1 Decal “Northern Lights” 51 00-38301 1 Heat Shield -

(see parts detail) replaced by 25-12007 * up to S/N xxxx- (see parts detail) * from S/N xxxx-

(includes keys #18, #21 & #43) -

(no longer required) -

(not shown) -

* NOTE:

Raw water pumps may be identified by markings on pump

covers.

P673 12/02

3 - 1

GROUP 3 – COOLING SYSTEM

Exhaust Manifold / Expansion Tank

Keel Cooling Components

P673: 2-1

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 10-18301 2 End Cap 2 28-18300 1 Plate 3 27-38300 1 Dry Exhaust Elbow 1-1/4 4 00-38301 1 Heat Shield 5 12-00751 1 Cap Screw, Hex Head M8 x 1.25 x 16 mm 6 15-00702 1 Lock Washer M8 7 15-01132 4 Lock Washer M6 8 11-78301 1 Gasket 9 135996550 1 Gasket -

Note: See Heat Exchanger Cooling for parts not shown here.

P673 12/02

3 - 2

GROUP 3 – COOLING SYSTEM

Coolant Pump

P673: 3-2

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 145016860 1 Coolant Pump Assembly

(parts not available separately) -

2 145386520 1 Plate 3 1 Temperature Switch 4 145996630 1 Gasket

(formerly #145996420) -

(see Electrical System) -

5 145146290 1 Set Plate 6 145996640 1 Gasket

(formerly #145996430) -

7 011300635 3 Capscrew, Hex Head w/Washer M6 x 1.0 x 35 mm 8 011300655 3 Capscrew, Hex Head w/Washer M6 x 1.0 x 55 mm 9 14-00131 1 Hex Nut M6 x 1.0 -

10 15-01132 1 Lock Washer M6 11 145336490 1 Pulley 12 011310620 4 Capscrew, Hex Head w/Washer M6 x 1.0 x 20 mm 13 140976060 1 Bracket, Belt Guard Support

(see Electrical System) -

14 199116370 1 Clamp -

P673 12/02

3 - 3

+ 49 hidden pages