Northern Lights NL753W2 Parts Manual

P753-2

For Models: M753W2 and NL753W2

PARTS MANUAL

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.

www.northern-lights.com

4420 14th Ave. NW., Seattle WA 98107

Tel: (206) 789-3880 • 1-800-762-0165

• Fax: (206) 782-5455

Northern Lights and Lugger are registered

trademarks of Alaska Diesel Electric, Inc.

PARTS CATALOG

for Models

M753w2 and NL753w2

Please read thoroughly before aempting to use this manual:

Table of Contents ........................................................................................................................................... 1

Model Designation & Serial Numbers .............................................................................................................. 2

Reading a Parts Page ...................................................................................................................................... 3

Table of Contents

GROUP 1 - ENGINE

Cylinder Block Assembly .......................... 0 - 1

Crankshaft Assembly ................................2 - 3

Camshaft & Oil Pump ............................... 4 - 5

Cylinder Head ..........................................6 - 7

Rocker Arm Cover & Assembly ............... 8 - 11

GROUP 2 - INTAKE & EXHAUST SYSTEM

Air Filter & Housing ................................. 0 - 1

Mufer ......................................................... 2

GROUP 3 - COOLING

Heat Exchanger & Exhaust Manifold ......... 0 - 1

Coolant Pump ......................................... 2 - 4

Raw Water Pump & Mounting ........................ 5

Raw Water Pump Assembly ............................ 6

Coolant Recovery Tank .................................. 7

Radiator & Guard ..................................... 8 - 9

GROUP 4 - FUEL SYSTEM

Injection Pump & Lines ...........................0 - 1

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

Fuel Filter & Piping .................................4 - 5

Fuel Line Connection .................................... 6

Fuel Injector .................................................. 7

Fuel Feed Pump ............................................ 8

GROUP 5 - ELECTRICAL SYSTEM

12 Volt Engine, Marine .................................. 0

Starter & Alternator ....................................... 1

12 Volt Engine, Industrial ............................... 2

Starter, Alternator, & Flywheel Housing .......... 3

Alternator Assembly ................................. 4 - 5

Starting Motor Assembly ........................... 6 - 8

Control Panels ........................................ 9 - 12

Belt Guard Assembly ................................... 13

GROUP 6 - GASKET SETS

Gasket Sets ..........................................................0

GROUP 7 - GEAR AND ADAPTER SETS Not available at this time.

GROUP 8 - FRAME & MOUNTING

Base Frame Assembly ............................... 1 - 2

GROUP 9 - ACCESSORIES

GROUP 9 - & OPTIONAL EQUIPMENT

Oil Drain Kit ................................................. 1

Keel Cooling Conversion Kit ..................... 2 - 3

Proprietary Information

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

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

P753-2 10/05

I

Model Designation

MODELS INCLUDED

This manual covers the operating instructions for:

M753W2 and NL753W2.

Model Numbers

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

M - NL 753 W 2

M - Northern Lights Marine generator set NL - Northern Lights Industrial generator set

M753W2

Northern Lights marine diesel generator set

= =

with an 753 engine and a PX-308K2 generator with a new winding, Tier II.

Model number of engine block Bore Cylinders 75 mm 3

NL753W2

Designates a

new winding in

the generator.

Northern Lights industrial diesel generator set with an 753 engine and a PX-308K2 generator with a new winding, Tier II.

Designates

Tier II

compliant.

Serial Numbers

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 drawings below.

P753-2 10/05

II

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 - NL753

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

23

13

11

P753 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ts.

3. Title and description of assembly. 10. Assembly or kit designated by •• or •.

4. Drawing numbers that correspond to key 11. Grouping index number.

 columnnumbersforpartsidentication. 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: 4 Arrows always point toward the front of the engine.

P753-2 10/05

III

GROUP 1 – ENGINE

Cylinder Block Assembly

P753-2 10/05

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753W2cylblock

GROUP 1 – ENGINE

Cylinder Block Assembly

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 110107461 1 Cylinder Block Assembly - Marine (includes keys #2- 21) 110107451 1 Cylinder Block Assembly - Industrial 2 198466050 1 Expansion Plug 3 064210025 1 Expansion Plug, 25 mm 4 064210035 2 Expansion Plug, 35 mm 5 064210015 1 Expansion Plug, 15 mm 6 064210040 2 Expansion Plug, 40 mm 7 198466010 4 Expansion Plug 8 198466030 4 Expansion Plug 9 165296142 1 Idle Gear Shaft 10 198466060 1 Plug 11 198517081 1 Bushing, Standard 198517085 1 Bushing, Undersize 0.25 mm 198517088 1 Bushing, Undersize 0.50 mm 12 040306203 1 Bearing 13 064100045 1 Expansion Plug, 45 mm 14 042303015 1 Needle Bearing 15 036509005 1 Snap Ring 16 030500512 2 Dowel Pin 17 030500616 2 Dowel Pin 18 030501025 2 Dowel Pin 19 030309005 2 Spring Pin 20 012110620 2 Stud Bolt 21 012110635 1 Stud Bolt 22 012110660 1 Stud Bolt 23 110996800 1 Gasket 24 198636080 1 Oil Seal 25 198736050 1 Drain Cock 26 140546020 1 Filter Joint 27 24-02001 1 Oil Filter 28 120116100 6 Tappet 29 120456201 6 Push Rod Set 30 140036220 1 Relief Valve Assembly 31 052109078 1 O-ring 32 068115200 1 Tube 33 198486770 1 Bushing 34 110708620 1 Oil Pan 110707820 1 Oil Pan

(Marine) - (Industrial) -

35 010109235 20 Bolt 36 18-72004 1 Oil Drain Hose 37 21-00003 1 Cap 38 198416270 1 Dipstick 39 011310612 1 Bolt 40 110756490 1 Dipstick Tube 110756070 1 Dipstick Tube

(Marine) - (Industrial) -

41 052109113 2 O-ring 42 010411212 2 Plug 43 025100012 2 Seal Washer

(Industrial only) -

44 23-78601 1 Bracket 45 15-00302 1 Lock Washer 3/8 46 12-00311 1 Capscrew, Hex Head 3/8-16 x 3/4" -

(includes keys #2- 21) -

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GROUP 1 – ENGINE

Crankshaft Assembly

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753W2crankshaft

GROUP 1 – ENGINE

Crankshaft Assembly

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 115256600 1 Crankshaft Assembly (includes keys #2 - 5) 2 115276180 1 Gear 3 034100508 1 Key 4 030509020 1 Dowel Pin 5 030300816 1 Spring Pin 6 110156111 1 Bearing Holder Assembly 7 110156121 1 Bearing Holder Assembly 8 110156330 1 Bearing Holder Assembly 9 030500612 6 Dowel Pin 10 198517112 3 Bearing, Standard 198517116 3 Bearing, Undersize 0.25 mm 198517119 3 Bearing, Undersize 0.50 mm 11 198517103 3 Bearing, Standard 198517107 3 Bearing, Undersize 0.25 mm 198517630 3 Bearing, Undersize 0.50 mm 12 010810840 6 Bolt 14 011510850 2 Bolt 15 010700845 2 Bolt 16 115107201 3 Piston Ring Kit, Standard 17 115017590 3 Piston Kit, Standard 18 115326231 3 Piston Pin 19 036500021 6 Snap Ring 20 115026191 3 Connecting Rod Assembly 21 198517125 3 Bush 22 115176150 6 Connecting Rod Bolt 23 020109075 6 Nut 24 198517132 6 Rod Bearing, Standard 198517136 6 Rod Bearing, Undersize 0.25 198517139 6 Rod Bearing, Undersize 0.50 25 115356720 1 Flywheel Assembly 26 115376130 1 Ring Gear (96 Teeth) 27 010109340 6 Bolt 28 115396650 1 Pulley 115396552 1 Pulley

(Marine) - (Industrial) -

29 020800018 1 Nut -

(includes keys #9-12) - (includes keys #9-12) - (includes keys #9-12) -

Lower -

Lower - Lower -

Upper -

Upper - Upper -

(includes key #16) -

(includes keys #21-23) -

(includes key #26) -

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GROUP 1 – ENGINE

Camshaft and Oil Pump

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1 - 4

753W2camshaft,oilpump

GROUP 1 – ENGINE

Camshaft and Oil Pump

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 120026830 1 Camshaft Assembly (includes keys #2 - 6) 2 120016021 1 Cam Gear 3 034100508 1 Key 4 120736081 1 Gear 5 199216230 3 Spacer 6 040109059 1 Bearing 7 125256120 1 Slider Assembly 8 199566651 1 Plate 9 010700610 1 Bolt 10 011310612 1 Bolt 11 165026100 1 Idle Gear Assembly 12 199266180 1 Thrust Washer 13 198216821 1 Spring 14 140166130 1 Rotor 15 140116140 1 Oil Pump Cover 16 199286150 1 Shim, t=0.10 199286160 1 Shim, t=0.15 199286170 1 Shim, t=0.20 199286180 1 Shim, t=0.50 17 198216720 1 Spring 18 199236540 1 Collar 19 036800010 1 Snap Ring 20 165166240 1 Front Plate 165166191 1 Front Plate

(Marine) - (Industrial) -

21 165996520 1 Gasket 22 011310612 3 Bolt 23 140986830 1 Oil Hose 140986480 1 Oil Hose 24 140406500 1 Oil Pick-up 140406270 1 Oil Pick-up

(Marine) - (Industrial) -

25 011310612 2 Bolt 26 052109076 1 O-ring -

(includes key #13) -

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GROUP 1 – ENGINE

Cylinder Head

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753W2cylhead

GROUP 1 – ENGINE

Cylinder Head

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 111010690 1 Cylinder Head Assembly (Marine, includes keys #2 -3, 6-13, & 19) 111010730 1 Cylinder Head Assembly 2 064210018 8 Expansion Plug 3 064210030 2 Expansion Plug 4 199236680 1 Collar 5 011510830 1 Bolt

(Marine) -

6 120166360 3 Intake Valve 7 120176250 3 Exhaust Valve 8 120406070 3 Valve Guide Seal - Intake 9 198216700 6 Spring 10 120186080 6 Retainer 11 120226070 12 Cotter 12 120406050 3 Valve Guide Seal - Exhaust 13 120216040 6 Cap 14 111147630 1 Head Gasket, t=1.2 mm 111147640 1 Head Gasket, t=1.3 mm 15 111136440 11 Head Bolt 16 111136450 3 Head Bolt 17 195816650 2 Lifting Eye 195816540 1 Lifting Eye 18 011510820 1 Bolt 011510816 1 Bolt

(Marine) -

(Industrial) - (Marine) - (Industrial) -

19 110136300 3 Valve Seat -

(Industrial, includes keys #2 -3, 6-13, & 19) -

P753-2 10/05

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GROUP 1 – ENGINE

Rocker Arm Assembly

P753-2 10/05

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753W2rockerarm

GROUP 1 – ENGINE

Rocker Arm Assembly

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 120037130 1 Rocker Arm Assembly (Marine, includes keys #2-7, 16, 17, 19, 20) 120037170 1 Rocker Arm Assembly 2 120356200 3 Rocker Arm - Intake 3 120356210 3 Rocker Arm - Exhaust 4 199486220 6 Screw 5 020109076 6 Nut 6 120316300 1 Rocker Arm Shaft 7 198216780 2 Spring 8 011310625 2 Bolt 9 012109177 3 Stud Bolt 10 023100008 3 Nut 11 185246011 1 Oil Pressure Switch 12 140607400 1 Oil Pipe 13 140996260 4 Gasket 14 198486780 1 Banjo Bolt 15 120996150 1 Gasket 16 052100120 1 O-ring 17 199280280 4 Shim 18 198487590 1 Banjo Bolt 19 198436150 1 Plug 20 015100410 1 Screw -

(tapped 1/8 NPT) -

(Marine, includes keys #2-7, 16, 17, 19, 20) -

(see Electrical) -

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GROUP 1 – ENGINE

Rocker Arm Cover

Marine

753W2rockerarmcover

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 111217960 1 Rocker Arm Cover 2 111996420 1 Gasket -

 3 110666220 1 Bafe -

4 110666060 1 Breather Element 5 015600406 4 Screw 6 140996260 3 Gasket 7 024600008 3 Cap Nut 8 198436010 1 Cap 9 052100400 1 O-ring 10 110566080 1 Valve, Breather 11 011100408 4 Bolt 12 011310680 3 Bolt 13 011310625 2 Bolt 14 135566610 1 Air Intake 15 135996750 1 Gasket 16 011310620 2 Bolt -

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GROUP 1 – ENGINE

Rocker Arm Cover

Industrial

753W2rockerarmcover

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 111210140 1 Rocker Arm Cover 2 111996420 1 Gasket -

 3 110666220 1 Bafe -

4 110666060 1 Breather Element 5 015600406 4 Screw 6 140996260 3 Gasket 7 024600008 3 Cap Nut 8 198436010 1 Cap 9 052100400 1 O-ring 10 110566080 1 Valve, Breather 11 011100408 4 Bolt 12 011310680 3 Bolt 13 011310625 2 Bolt 14 135566630 1 Air Intake 15 135996750 1 Gasket 16 011310620 2 Bolt -

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GROUP 2 – INTAKE & EXHAUST SYSTEM

Air Filter and Housing

Marine

A-10836A / C-5742

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

•• 24-28200 1 Air Filter Assembly (includes keys #1-18) 1 10-28202 1 Air Filter Housing 2 18-28201 1 Hose 1- 5/8” ID x 1- 3/4” 3 Ply Silicone 3 19-00024 2 Hose Clamp #24 4 28-28601 1 Intake Silencer Plate 5 10-28603 1 Cover, Lower Air Intake 6 12-01124 4 Capscrew, Hex Head M6 x 1.0 x 50 mm 7 15-00008 8 Flat Washer M6 8 24-28601 1 Screen 9 24-28602 1 Air Filter Element 10 10-28602 1 Cover, Air Filter Housing 11 12-01131 4 Capscrew, Hex Head M6 x 1.0 x 20 mm 12 18-28601 1 Hose, Air Intake 13 19-70022 1 Cushion Clamp #22 14 12-09751 1 Capscrew, Hex Head M8 x 1.25 x 16 mm S/S 15 15-00706 1 Flat Washer M8 S/S 16 12-00712 4 Capscrew, Hex Head M8 x 1.25 x 25 mm 17 15-00702 4 Lock Washer, Helical M8 18 15-00701 2 Flat Washer M8 -

P753-2 10/05

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GROUP 2 – INTAKE & EXHAUST SYSTEM

Air Filter and Housing

Industrial

753W2aircleaner

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 135016310 1 Air Cleaner Assembly (includes keys #9-12) 2 198756130 2 Hose Band 3 135597900 1 Hose 4 135976610 1 Bracket 5 199236730 1 Collar 6 011510825 2 Bolt 7 011510820 2 Bolt 8 131976050 1 Bracket 9 135326200 1 Filter Housing 10 24-27301 1 Element 11 135326201 1 Cover 12 314531163 1 Valve -

P753-2 10/05

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Northern Lights NL753W2 Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual