operator’s manual - northern lights · 2018-10-18 · operator’s manual uses three different...

OPERATOR’S MANUALOPERATOR’S MANUAL

OM773LW3For Model: M773LW3 and M773LW3G

www.northern-lights.com

Breathing Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.* Always start and operate the engine in a well-ventilated area.* If in an enclosed area, vent the exhaust to the outside.* Do not modify or tamper with the exhaust system.* Do not idle the engine except as necessary.For more information, go to www.P65warnings.ca.gov/diesel.

— CALIFORNIA —Proposition 65 Warning:

Northern Lights4420 14th Avenue NWSeattle, WA 98107Tel: (206) 789-3880Fax: (206) 782-5455

Copyright ©2018 Northern Lights, Inc.All rights reserved. Northern Lights™, andthe Northern Lights logo are trademarks ofNorthern Lights, Inc.

Printed in U.S.A.PART NO.: OM773LW3 10/18

OM773LW3 10/18

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Read this operator's manual thoroughly before starting to operate your equipment.This manual contains information you will need to run and service your new unit.

OPERATOR'S MANUALfor Model

M773LW3 and M773LW3G

INTRODUCTION ..................................................2 Models Included .................................................2 UnitIdentification ...............................................2 SerialNumbers ...................................................2

WARRANTY ...........................................................3

SAFETY RULES ..............................................3 - 7

LOCK OUT / TAG OUT PROCEDURES .......... 8

COMPONENT LOCATIONS M773LW3GMarineGenerators ...................... 10 M773LW3MarineGenerators ..........................11

CONTROL PANELS Series 1-B ......................................................... 12 Series 3 ............................................................. 12 Series 4 ............................................................. 13

OPERATING PROCEDURES Break-inPeriod ................................................ 14 BeforeStarting ................................................. 14 Starting ............................................................. 14 Operating ......................................................... 14 Stopping ........................................................... 14 ShutdownsandAlarms .................................... 15 SpareParts ....................................................... 15

SERVICING SCHEDULE CHART ................. 16

SERVICING RECORD NOTES ....................... 17

SERVICING Lubrication-General ....................................... 18 CheckingOil .................................................... 18 OilChanges ..................................................... 18 ChangingOilFilter .......................................... 18 AirFilter .......................................................... 19 V-Belts ............................................................. 19 ValveClearances .............................................. 19 Fuels-General ................................................. 20 FuelFilters ....................................................... 20 BleedingtheFuelSystem ................................ 21 InjectorService ........................................ 22 - 23 InjectionPump ................................................. 24 CoolingSystem-General ................................ 24 CoolingSystemFlushing ................................. 25 HeatExchanger ............................................... 25 RawWaterPump ............................................. 25 GeneratorEnds ................................................ 25 ElectricalSystem-General ............................. 25 GlowPlugs ....................................................... 25 BoosterBatteries .............................................. 26 BatteryCare ..................................................... 26 Winterizing/Out-of-Service ........................... 26

TROUBLESHOOTING Electrical .......................................................... 27 Engine ...................................................... 28 - 30

WIRING DIAGRAMS ACElectrical ........................................... 31 - 32 DCElectrical ........................................... 33 - 40 PanelDiagrams ........................................ 41 - 49

Proprietary InformationThispublicationisthepropertyofNorthernLights,Inc.

ItmaynotbereproducedinwholeorinpartwithoutthewrittenpermissionofNorthernLights,Inc.©NorthernLights,Inc.Allrightsreserved.LithoU.S.A.PublicationnumberOM773LW310/18

Table of Contents

OM773LW3 10/18

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Servicingofmarineenginesandgeneratorsetspresentsuniqueproblems.Inmanycasesboatscannotbemovedtoarepairfacility.Marineenginescannotbecomparedtotheservicingofautomobiles,trucksorevenfarmequipment.Failuresoftenoccurinremoteareasfarfromcompetentassistance.Marineenginesaretaxedfarmoreseverelythanautoortruckengines;therefore,maintenancesched-ulesmustbeadheredtomorestrictly.

Failuresbeginwithminorproblemsthatareover-lookedandbecomeamplifiedwhennotcorrectedduringroutinemaintenance.

Asoperator,itisyourobligationtolearnaboutyourequipmentanditspropermaintenance.Thisisnotacomprehensivetechnicalservicemanual.Norwillitmakethereaderintoanexpertmechanic.Itsaimistoaidyouinmaintainingyourunitproperly.

Introduction

L, W, G, 3

M - Northern Lights marine generator set

Model number of engine block Bore Cylinders 77 mm 3

MODELS INCLUDEDThismanualcoverstheoperatinginstructionsfor: M773LW3 and M77LW3G marine generator setsthe

unit'application,blockmodel,aspiration,andRPM:

L - Long strokeW - Auxiliary Winding in Generator EndG - GEM series base frame3 - US EPA Tier III compliant

+ +

Northern Lights marine generator set with a 773 engine, PX-309K2 generator end, AVR, US EPA Tier III.

M 773

M773LW3 =

Yoursethasthreeserialnumbers:1anenginenumberstampedontheblock,2 ageneratorplate,and3ageneratorsetplate.

Usetheserialnumberonthegeneratorsetplatewhenorderingpartsorincorrespondence.ThegeneratorsetplateisfoundontheservicesideofthegeneratorandresemblesthedrawinginFigure 1.

Unit Identification

Serial Numbers

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

Northern Lights marine diesel generator set with a 773 engine, PX-309K2 generator end, GEM series, US EPA Tier III.

M773LW3G =

Updated 7-6-18

OM773LW3 10/18

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Awarrantyregistrationcertificateissuppliedwithyourset.Itentitlestheoriginalpurchaserofourequipmenttoawarrantycoveringmaterialorassemblyfaults.TheextentofcoverageisdescribedintheLimitedWarrantyStatement.Werecommendthatyoustudythestatementcarefully.NOTE:Ifthewarrantyistoapply,theservicinginstructionsoutlinedinthismanualmustbefollowed.Iffurtherinformationisneeded,pleasecontactanauthorizeddealerorthefactory.

Safety Rules

Warranty

Updated 4-12-17

NOTICE: Accident reports show that careless use of engines causes a high percentage of accidents. You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.

IMPORTANTSAFETYINSTRUCTIONS.Electromagneticequipment,includinggeneratorsetsandtheiraccessories,cancausebodilyharmandlifethreateninginjurieswhenimproperlyinstalled,operatedormaintained.Topreventaccidentsbeawareofpotentialdangersandactsafely.

READANDFOLLOWALLSAFETYINSTRUCTIONSINTHISMANUAL,PRIORTOTHEINSTALLATIONOFANYGENERATORSETORACCESSORY.KEEPTHESEINSTRUCTIONSFORFUTUREREFERENCE.

Recognize Safety Symbols and InstructionsInadditiontotheinformationfoundinthissection,thisoperator’smanualusesthreedifferentsignalwordstooutlinepotentialdangersofaspecificnature.

Follow All Safety InstructionsCarefullyreadandunderstandallsafetymessagesinthismanualandonyourmachine’ssafetysigns.Keepsignsingoodandcleancondition.Replacemissingordamagedsigns.Besurenewequipmentcomponentsand

repairpartsincludethecurrentsafetysigns.Forreplacementsigns,properplacementofsafetysignsorclarificationonanysafetyissue,consultyourNorthernLightsdealerorthefactory.Therecanbeadditionalsafetyinformationcontainedonpartsandcomponentsfromoutsidesuppliersthatisnotreproducedinthismanual.Consultthesuppliersforadditionalsafetyinformation.

Learnhowtooperatethemachineandhowtousethecontrolsproperly.Onlytrainedpersonnelshouldoperatemachines,orworkonoraroundthem.

Keepyoumachineinproperworkingcondition.UNAUTHORIZEDMODIFICATIONSTOTHEMACHINERYMAYIMPAIRITSFUNCTIONANDSAFETYPARAMETERS.

Prevent Bypass and Accidental Starting

! WARNINGDonotstartenginebyshortingacrossstartterminal.Enginewillstartifnormalcircuitryisbypassed,creatingahazardbyrunawaymachinery.

Startengineonlyfromoperator’sstation.

! DANGER! WARNING! CAUTION

DANGERindicatesahazardoussituationwhich,ifnotavoided,willresultindeathorseriousinjury.

WARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresultindeathorseriousinjury.

CAUTIONindicatesahazardoussituationwhich,ifnotavoided,couldresultinminorormoderateinjury.

DANGER: Northern Lights generator sets and /or any other diesel powered equipment provided by NLI is not provided with spark arresting or explosion proof components, and therefore is not to be installed in the presence of combustible gases having a flash point of 43.3 Degrees C (110 Degrees F) or lower, such as Gasoline, Propane, Natural Gas or other similar fuel sources.

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Safety Rules (Continued)

Updated 4-12-17

Wear Protective Clothing

! WARNINGTopreventcatchinganythinginmovingmachinery,alwayswearclosefittingclothesandsafetyequipmentappropriatetothejob.Prolongedexposuretoloudnoisecancausehearinglossorimpairment.Wearsuitableauthorizedhearingprotection,suchasearmuffsorplugstoprotectagainstloudnoises.

Operatingequipmentrequiresthefullattentionoftheoperator.Donotuseradioormusicheadphoneswhileoperatingmachinery.Practice Safe Maintenance

! CAUTIONUnderstandallserviceproceduresbeforestartingwork.Keepareacleananddry.Neverlubricate,service,oradjustmachinewhileitisinoperation.

Keephands,feetandclothingawayfrompower-drivenequipment.Whenshuttingdownanengine,disengageallpowerandoperatorcontrols.Allowtheenginetocoolcompletelybeforebeginninganyservicework.

Securely support any machinery elements that must be raised for service work with support or lifting machinery specifically intended for that purpose.

Keepallpartsingoodconditionsandproperlyinstalled.Fixdamageimmediately.Replaceanywornorbrokenparts.Removeanybuildupofgrease,oilordebris.

Disconnectbatterygroundcable(-)beforemakinganyadjustmentsorservicework.

Handle Fuel Safely - Avoid Flames

! WARNINGDieselishighlyflammableandshouldbetreatedwithcareatalltimes.Dodonotrefuelwhilesmokingorwhennearsparksoropenflame.

ALWAYSSTOPENGINEBEFOREFUELINGMACHINE.Alwaysfillportablefueltankoutdoors.Neverfuelahotengine.Preventaccidentaldischargeofstartingfluidsbystoringallcansinacool,safeplace,awayfromsparksoropenflame.Storewithcapsecurelyoncontainer.Neverincinerateorpunctureafuelcontainer.

Preventfiresbykeepingmachinecleanofaccumulatedtrash,greaseanddebris.Alwayscleananyspilledfuelasswiftlyaspossible.Donotstoreoilyrags,whichcanigniteandburnspontaneously.

Bepreparedifafirestarts.Keepafirstaidkitandfireextinguisherhandy.Keepemergencycontactnumbersforfiredepartment,doctors,ambulanceandhospitalnearthetelephone.

Service Machines Safely

! DANGERDonotwearanecktie,scarf,necklace,ringsorotherjewelry,oranylooseclothingwhenworkingnearmovingparts.Tielonghairbehindyourhead.Ifanyoftheseitemsgetcaughtinmovingmachinery,severeinjuryordeathcouldresult.

Checkforanylooseelectricalconnectionsorfaultywiring. Lookcompletelyaroundenginetomakesurethateverythingisclearbeforestarting.

OM773LW3 10/18

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Stay Clear of Rotating Drivelines

! DANGEREntanglementinrotatingdrivelinescancauseseriousinjuryordeath.Keepshieldsinplaceatalltimes.Makesurethatrotatingshieldsturnfreelyinpacewiththedrivelines.

Donotwearloosefittingequipmentaroundrotatingdrivelines.Stoptheengineandmakesurethatallmovingpartshavestoppedbeforemakinganyadjustments,connections,orperforminganyothertypeofservicetotheengineorotherdrivenequipment. Install all Safety Guards

! WARNINGDirectcontactwithrotatingfans,belts,pulleyanddrivescancauseseriousinjury.

Keepallguardsinplaceatalltimesduringengineoperation.

Wearclose-fittingclothes.Stoptheengineandbesureallfans,belts,pulleysanddrivesarestoppedbeforemakingadjustments,connections,orcleaningnearfansandtheircomponents.

Donotallowanythingonyourpersontodangleintoorcomeincontactwithamovingfan,belt,pulleyordrive.Fanscanactasvacuumsandpullmaterialsupfrombelow,soavoidthatareaaswellwhileinservice.

Safe Battery Handling

! WARNINGPrevent Battery Explosions Batterygasishighlyflammable.Batteryexplosionscancausesevereinjuryordeath.Tohelppreventbatteryexplosions,keepsparks,lightedmatchesandopenflameawayfromthetopofbattery.Whencheckingbatteryelectrolytelevel,useaflashlight.


Updated 4-12-17

Nevercheckbatterychargebycontactingthepostswithametalobject.Useavolt-meterorhydrometer.

Frozenbatteriesmayexplodeifcharged.Neverchargeabatterythathasnotbeenallowedtowarmtoatleast16oC(60oF).Alwaysremovegrounded(-)batteryclampfirstandreplacegroundclamplast.

Sulfuricacidinbatteryelectrolyteispoisonousandstrongenoughtoburnskin,eatholesintoclothingandothermaterials,andcauseblindnessifsplashedintoeyes.

To Avoid Hazards:•Fillbatteriesonlyinwell-ventilatedareas.•Wearappropriateeyeprotectionandrubbergloves.•Neveruseairpressuretocleanbatteries.•Wearappropriateventilationequipmenttoavoidinhalingfumeswhenaddingelectrolyte.•Donotspillordripelectrolyte.•Usecorrectjump-startprocedureifrequired.

If acid is spilled on skin or in eyes:1.Flushskinwithwater.2.Applybakingsodaorlimetohelpneutralizeacid.3.Flusheyeswithwaterfor15-30minutes.4.Getmedicalattentionimmediately.Ifacidisswallowed:1.DONOTinducevomiting.2.Drinklargeamountsofwaterormilk,withoutexceeding2liters(2quarts)3.Getmedicalattentionimmediately

Batteryposts,terminals,andrelatedaccessoriescancontainleadandleadcompounds,chemicalsknowntotheStateofCaliforniatocausecancerandreproductiveharm.Washhandsafterhandling.

! WARNING

OM773LW3 10/18

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Updated 4-12-17

Donotuseachlorinatedsolventinanareawhereweldingwilloccur.Workonlyinareasthatarewellventilated.Disposeofpaintandsolventproperly.

Service Cooling System Safely

! WARNINGOpeningapressurizedcoolingsystemcanreleaseexplosivefluidsandcausingseriousburns.Beforeopeninganypressurizedcoolingsystem,makesuretheenginehasbeenshutoff.Donotremoveafillercapunlessitiscoolenoughtocomfortablygripwithbarehands.Slowlyloosencaptorelievepressurebeforeopeningfully.

Avoid High Pressure Fluids

! WARNINGRelievepressurepriortodisconnectingpressurizedlines.Escapingfluidunderpressurecanpenetratetheskincausingseriousinjury.Alwaysrelievepressurebeforedisconnectinghydraulicorotherpressurizedlines.Tightenallconnectionsfirmlybeforere-applyingpressure.

Ifsearchingforleaks,useapieceofcardboard.Alwaysprotectyourhandsandotherbodypartsfromhigh-pressurefluids.

Ifanaccidentoccurs,seeadoctorimmediately.Anyhighpressuresprayinjectedintotheskinmustberemovedwithinafewhourstopreventtheriskofgangreneorotherinfection.

Avoid Heating Near Pressurized Fluid Lines

! WARNINGFlammablespraycanbegeneratedbyheatingnearpressurizedfluidlines,resultinginsevereburnsandbodilyinjury.Pressurizedlinescanrupturewhenheatgoesbeyondtheimmediateflamearea.Donotweld,solderoruseatorchoropenflamenearpressurizedlinesorotherflammablefluids.

Handle Chemical Products Safely

! WARNINGDirectexposuretohazardouschemicalscancauseseriousinjury.AmongthepotentiallyhazardouschemicalsthatmaybeusedwithNorthernLightsproductsarelubricants,coolants,paintsandadhesives.

AllpotentiallyhazardouschemicalscomewithaMaterialDataSafetySheet(MSDS).TheMSDSprovidesspecificdetailsonchemicalproducts,includingphysicalhazards,safetyproceduresandemergencyresponsetechniques

ReadandunderstandtheMSDSforeachchemicalbeforeyoustartanyjobthatincludesit.Followtheproceduresanduseappropriateequipmentexactlyasrecommended.

ContactyourNorthernLightsdealerorNorthernLightsfactoryforMSDS’susedonNorthernLightsproducts.

Work in Well Ventilated Areas

! CAUTIONExhaustfumesfromenginescontaincarbonmonoxideandcancausesicknessordeath.Workinwellventilatedareastoavoidprolongedexposuretoenginefumes.Ifitisnecessarytorunanengineinanenclosedarea,routetheexhaustfumesoutoftheareawithanapproved,leakproofexhaustpipeextension.

Remove Paint Before Welding or Heating

! WARNINGHazardousfumescanbegeneratedwhenpaintisheatedbywelding,solderingorusingatorch.Toavoidpotentiallytoxicfumesanddust,removepaintbeforeheating.• Removepaintaminimumof100mm(4in.)fromtheareathatwillbeaffectedbyheat.• Ifpaintcannotberemoved,wearanapprovedrespirator.•Ifyousandorgrindpaint,useanapprovedrespirator.•Ifyouusesolventorpaintstripper,removestripperwithsoapandwaterbeforewelding.Removesolventorpaintstrippercontainersfromthearea.•Allowatleast15minutesforfumestodispersebeforeweldingorheating.

OM773LW3 10/18

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Updated 4-12-17

Avoidcreatingdust.Neverusecompressedairforcleaning.Avoidbrushingorgrindingmaterialscontainingasbestos.Whenservicing,wearanapprovedrespirator.Aspecialvacuumcleanerisrecommendedtocleanasbestos.Ifthisvacuumisnotavailable,applyamistofoilorwateronthematerialcontainingasbestos.Keepallbystandersawayfromanyareawhereasbestosdustmaybegenerated.

Use Proper Lifting Equipment and Techniques

! WARNINGLiftingheavycomponentsincorrectlycancausesevereinjuryordamagetomachinery.Avoidunbalancedloads.Donotuseliftingeyes.Liftthegeneratorsetusingliftingbarsinsertedthroughtheliftingholesontheskid.FollowallrecommendedremovalandinstallationproceduresinthisandassociatedNorthernLightsmanuals.

Use Proper Tools

! CAUTIONMakeshifttoolsandprocedurescancreatesafetyhazards.Alwaysuseappropriatetoolsforthejob.

Usepowertoolsonlytoloosenthreadedpartsandfasteners.Forlooseningandtighteninghardware,alwaysusethecorrectsizedtools.

DonotuseUSmeasurementtoolsonmetricfasteners,orviceversa.UseonlyservicepartsthatmeetNorthernLightsspecifications.

Dispose of Waste Properly

! CAUTIONDisposingofwasteimproperlycanthreatentheenvironmentandleadtounsafeworkingconditions.PotentiallyharmfulwasteusedinNorthernLightsequipmentcanincludeoil,fuel,coolant,filtersandbatteries.

Useleakproofcontainerstodrainfluid.Donotusefoodorbeveragecontainersthatmaymisleadsomeoneintodrinkingfromthem.

Donotpourwasteontotheground,downadrainorintoanywatersource.

Do Not Open High-Pressure Fuel System

! DANGERManyNorthernLightsenginesusehigh-pressurefuelinjection.High-pressurefluidremaininginfuellinescancauseseriousinjury.Donotdisconnectorattemptanyrepairoffuellines,sensors,orother

componentsbetweenthehigh-pressurefuelpumpandnozzlesonengineswithhighpressurefuelsystems.

ONLYAUTHORIZEDTECHNICIANSCANPERFORMREPAIRSONANHIGHPRESSUREFUELINJECTIONSYSTEMS.

Avoid Hot Exhaust

! WARNINGAvoidexposuretoandphysicalcontactwithhotexhaustgases.Exhaustpartsandstreamscanreachhightemperaturesduringoperation,leadingtoburnsorotherseriousinjury.

Cleaningexhaustfilterscanalsoleadtoexposuretohotexhaustgasandtheinjuryriskassociatedwithit.Avoidexposuretoandphysicalcontactwithhotexhaustgaseswhencleaningexhaustfilters.

Duringautoormanual/stationaryexhaustfiltercleaningoperations,theenginewillrunatelevatedtemperaturesforanextendedperiodoftime.Exhaustpartsandstreamscanreachhightemperaturesduringoperation,leadingtoburnsorotherseriousinjury.

Avoid Harmful Asbestos Dust

! WARNINGInhalingasbestosfibersmaycauselungcancer.Avoidbreathinganydustthatmaybegeneratedwhenhandlingcomponentscontainingasbestosfibers,includingsomegaskets.

Theasbestosusedinthesecomponentsisusuallyfoundinaresinorotherwisesealed.Normalhandlingofthesecomponentsisnotdangerous,aslongasairbornedustcontainingasbestosisnotgenerated.

OM773LW3 10/18

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General Policy

To avoid dangerous or hazardous situations, refrain from any of the following:• Removing or bypassing a guard or other safety device• Placing any part of your body in a position where you could be caught by moving machinery.• Cleaning or oiling machinery when in operation.• Adjusting circuits, chillers, pumps, air handlers, valves, circuit breakers or fans while in operation.• Working on piping or high pressure systems.

Lock Out/Tag Out Instructions - Electrical Equipment

Be sure the equipment’s ON/OFF switch is in the OFF position and is unplugged from any electrical source before attempting to perform any type of work on the equipment. Obtain an electrical plug cap cover with a lockset. Secure the plug terminal end using the electrical plug lockout cap. Lock the cap and retain the key.

If the equipment is directly wired into an electrical box with a shut off switch, obtain a lock pad and/or the appropriate colored tags and place the lock and tag through the shut off lever. Retain the key until the repair is completed and the machine is safe to start. Be certain the shut off lever is in the OFF position before restarting. NEVER give a lock out key to unauthorized personnel.

If the equipment is directly wired into an electrical box without a shut off switch and lock out capability, then a circuit breaker lock out will be required. Obtain a circuit lock and tag set. Install the lock onto the circuit breaker box. Ensure the unit ON/OFF switch is in the OFF position before restarting.

Lock Out/Tag Out Instructions - Pneumatic and Hydraulic Equipment

For servicing pneumatic and hydraulic equipment, the following additional procedures must be implemented, following completion of lock out/tag out procedures for the unit to be serviced:

Shut off air, water or supply valves at the equipment to be serviced.

Check the local bleed-off point for completed release of pressurized air, water or oil.

If shutting off of air, water or other material cannot be achieved at the local supply valve, shut off valves further back in the system and re-check the bleed-off point until complete shut-off is achieved.

Affix a DO NOT OPERATE tag to each valve handle that requires shut off. Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment.

Lock Out/Tag Out Instructions - Air Hose Connected Pneumatic Equipment

Equipment connected to the compressed air system through an air hose with a detachable fitting must be shutdown and unplugged. Excess air must be bled prior to removing the air hose, prior to any maintenance or repair activities.

Affix a DO NOT OPERATE tag to the air hose near the detachable fitting. Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment. Check that the equipment cannot be operated by activating the ON switch.

Stored Energy

Immediately after applying Lock Out or Tag Out devices, ensure that all potentially hazardous stored or residual energy is relieved, disconnected, restrained and otherwise rendered safe.

Verification of Isolation

Verify the machinery or equipment is actually isolated and de-energized prior to beginning work on a machine or on equipment that has been locked out.

Restarting Procedures

Follow the procedures below prior to restoring energy:• Ensure that all machinery or equipment is properly reassembled. Inspect the machinery or equipment to verify non-essential items have been removed.• Ensure that all personnel are safely outside danger zones. Notify personnel that lock out/tag out devices have been removed and energy will be reapplied.• Only authorized personnel may remove lock out/tag out devices or notices.

ScopeDuring maintenance, repairs or retooling of a Northern Lights generator set, simply turning the machine off or unplugging it while it is being worked on does not give enough protection to others who are not performing the maintenance or repair. Many serious accidents happen when someone thought the machine was turned off, or all of its energy was safely blocked or released.

! CAUTION

! WARNING

! WARNING

! WARNING

! WARNING

! CAUTION

! CAUTION

Lock Out / Tag Out Procedures

Updated 4-12-17

OM773LW3 10/18

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Notes

OM773LW3 10/18

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Figure 1 (right): Service side M773LW3G (S/N: 7732-54637 and above)

17

2 43 5

6

7 8

109

11

12

1314

1516

18

19

Marine Generator Component Locations

Figure 2 (left): Non-service side M773LW3G (S/N: 7732-54367 and above)

20 2021 2223

25

26

1. Generator control box2. Coolant recovery bottle3. Fuel filter4. Air filter housing5. Fuel lift pump6. Fuel injector7. Lube oil fill, top

8. Coolant fill 9. Injection pump10. Stop solenoid11. Lube oil fill, side12. Sea water pump13. Oil dipstick

14. Fuel filter15. Fuel inlet and return16. Lube oil drain17. Control panel plug18. AC circuit breaker for AVR19. DC circuit breaker

20. Heat exchanger end caps21. Expansion tank22. Starter23. Exhaust elbow24. Vibration mount25. Alternator26. Belt guard

24

1

Updated 3-13-18

OM773LW3 10/18

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Marine Generator Component Locations

Updated 9-16-10

17

13

4 56

7

8

109

11

12

1415

1316

18

19

2

1. Generator control box2. Coolant recovery bottle3. Fuel filter4. Air filter housing5. Fuel lift pump6. Fuel injector7. Lube oil fill, top

8. Coolant fill 9. Injection pump10. Stop solenoid11. Lube oil fill, side12. Sea water pump13. Fuel inlet and return

14. Oil dipstick15. Fuel filter16. Lube oil drain17. Control panel plug18. AC circuit breaker for AVR19. DC circuit breaker

20. Heat exchanger end caps21. Expansion tank22. Starter23. Exhaust elbow24. Vibration mount25. Alternator26. Belt guard

Figure 3 (right): Service side M773LW3 (up to S/N: 7732-54636)

20 2021 2223

25

26

24

Figure 4 (left): Non-service side M773LW3 (up to S/N: 7732-54636)

OM773LW3 10/18

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Figure 6-a: Series 3 Generator Control Panel

Control Panels

Figure 5: Series 1-B Generator Control Panel

1. SHUTDOWN BYPASS-PREHEAT SWITCH Therearetwofunctionsbuiltintothisswitch: 1.Preheatsthefuelbeforebeginningthestarting process.Pressswitch10-20secondsbefore attemptingstart-up. 2.Bypassesthesafetyshutdownfeatureduring

startingprocess.Keepswitchengagedwhilestartingengineandfor2to3secondsafterwards,allowingoilpressuretobuildbeyondshutdownsetpoint.

2. ENGINE CONTROL SWITCH Tostarttheengine,holdthisswitchintheSTART positionuntiltheengineisrunning. NOTE: Excessive cranking of marine sets equipped with water lift muffler systems can cause engine

damage. See page 8. Aftertheenginestarts,releasetheswitchanditwill

returntoRUNposition.Tostoptheengine,holdtheswitchintheSTOPposition.

NOTE: The rocker switch is used on Series 1 panels only, and has a light that glows when the set is running.

3. HOUR METER Keepstrackofenginerunningtime.

4. OIL PRESSURE GAUGE Showstheoilpressureintheenginelubricatingsystem.

5. WATER TEMPERATURE GAUGE Registersthetemperatureofthecoolingwater.

6. D.C. VOLTMETER OR AMMETER Whentheengineisstopped,thevoltmeterindicatesthe

conditionofthebattery.Whentheengineisrunning,thevoltmeterindicatesthevoltageoutputofthe

alternator.

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Control Panels

Figure 6-b: Series 4 Generator Control Panel

For Series 4 Control Panels Only:

7. A.C. VOLTMETER Showsthegeneratoroutputvoltage.

8. FREQUENCY METER (Hertz) Thefrequencymeterindicatesenginespeed:1200or

1800RPM(60Hz),or1500RPM(50Hz).

9. AMMETER SELECTOR SWITCH Usedtocheckeachphaseforloadcondition. NOTE: Always leave this switch in the ON position

while the unit is running.

10. A.C. AMMETER Showsthegeneratorloadoneachphase.Thephaseis

selectedwiththeAmmeterSelectorswitch(Item 9).

OM773LW3 10/18

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BREAK-IN PERIOD

1. Thefirst100hoursonaneworreconditioned enginearecriticaltoitslifeandperformance.2. Operatetheengineundervariousconditions,

particularlyheavyloadeswithminimalidling,tohelpseatenginecomponentsproperly.

3. Constantlychecktheenginetemperatureandoilpressuregauges(setswithSeries3or4panels).

4. Oilconsumptionisgreaterduringbreak-inas pistonringstaketimetoseat.5. Break-InOilChanges:Changeengineoiland filterat50hours.Changeoilandfilteragainat 100hours,thenatevery250hours(consult Lubricantssectionforoilrecommendation).

BEFORE STARTING

1. Checkthewaterlevelbyremovingthepressure capfromtheexpansiontank.Inordertogivethe

coolingwateranopportunitytoexpand,thelevelshouldbeabout1in.(2.5cm)belowthefillercapsealingsurfacewhentheengineiscold.

CAUTION: Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns.

2. Checktheoillevelinthecrankcasewiththedipstick.Theoillevelmustbeinthewaffledareabetweenmaximumandminimumlevelonthestick.Neverallowtheleveltogobelowthisarea.Alwaysaddthesameviscosityofoilasisalreadyinthecrankcase.

3. Checkthefueltanklevelandopenanyfuelvalves.4. Closethesea-cock,checkandcleantheseastrainer

andreopenthesea-cock.5. PlacethebatteryswitchintheONposition.6. NOTE: The battery switch must always be kept ON while the engine is running. If the switch is

turned OFF while the engine is running, the battery charging regulator could be ruined.

STARTING

1. HoldtheShutdownBypass-PreheatswitchintheONpositionfor10to20secondsbeforestartingacoldengine.Holdingtheswitchtoolongcanburnouttheglowplugs.Thisstepisnotnecessaryiftheengineisalreadywarm.

2. WhileholdingtheShutdownBypass-PreheatswitchintheONposition,pushtheEngineControlswitchtotheSTARTposition.

3. Assoonastheenginestarts,releasebothswitches.Donotcrankthestarterformorethan10seconds

consecutively.Iftheenginefailstostartwiththefirstattempt,besurethatithasstoppedcompletelyforatleast30secondsbeforere-engaging.

6. NOTE: Excessive cranking of the starter on Marine sets equipped with a water lift muffler can cause engine damage. If the engine does not start after three 10-second cranks, remove the impeller from the raw water pump. This will prevent the muffler from filling with water and backfilling the exhaust line and engine. Once the engine starts, shut it off

immediately and re-install the impeller. Re-start the engine and check the exhaust overboard outlet for gushes of water.

OPERATING

1. UnitswithSeries3andSeries4ControlPanels: checkgaugesoften.Oilpressuremustbeabove15

PSI.TheD.C.voltmetershouldreadbetween11and15voltsat80°F(25°C)ambienttemperature.Thecoolanttemperaturegaugemustbebetween167°Fand194°F(75°Cto90°C).ChecktheA.C.voltageandfrequencymeters(Series4panel).Ifthegaugesdeviatefromnormallevels,shutdownthegeneratorsetandinvestigate.

2. Lettheunitrununloadedforathreetofiveminutewarm-upperiod.

3. Addelectricalload.

STOPPING

1. Removeelectricalloadfromthegeneratorset.2. MovetheEngineControlswitchtotheSTOP positionmomentarily.3. Shutofftheseacock,fuelvalve,andbattery

switch.

Operating Procedures

Updated 1-9-13

OM773LW3 10/18

15

SHUTDOWNS AND ALARMS

1. Generatorsetshaveshutdownsystemstostoptheengineintheeventofhighwatertemperatureorlowoil pressure.

a. Otheralarmsandshutdownsareavailableas optionalequipment. NOTE: Do not rely on your shutdown to the exclu-

sion of careful gauge monitoring. Watching your gauges can prevent damage to the unit and danger-ous power losses.

2. Dothefollowingwhenyourwarningorshutdownsystemisactivated:

a. Engagethepreheatswitchtocheckthe temperaturegauge. b. Ifabove205°F(96°C),UsetheTroubleShoot

ingGuideonpage22toisolatethecauseofthe overheat.

CAUTION: Do not remove the water fill cap of an overheated engine. Escaping high temperature steam can cause severe burns. Allow the engine to cool and then remove the cap slowly using protective clothing.

c. Makerepairs.Restartyourgeneratorsetafterthe temperaturegaugeregistersbelow200°F(94°C). d. Watchthetemperaturegaugeregularlyand turnofftheunitifthetemperaturerisesabove 205°F(96°C)onMarineunits.Repeattrouble-

shooting.3. Ifshutdownisactivatedandthetemperaturegauge

showstemperaturewithinnormaltemperaturerange: a. Thisshutdowncouldhavehappenedbecauseof

atoohighexhausttemperature.Thiscouldhave beencausedbyadamagedimpellerorapartially blockedseawaterstrainer.Checktheseawater strainerfirst.Ifitisclear,thencheckthe

conditionoftheseawaterpumpimpeller. b. Checktheenginecrankcaseoillevel. c. Iftheoillevelislow,fillwithrecommended lubricatingoilandrestart.Watchtheoilpressure gaugecarefullyandshutofftheengineifitdoes notshowanormalreading(20-60PSI)aftera fewsecondsofoperation. d. Iftheoillevelisnormal,DONOTrestartthe engine.Callyourdealerforassistance.

SPARE PARTS

1. NorthernLightsrecommendsthatyoukeepthefollowingsparepartsonhandforfieldservice.ThepartsareavailablefromyourlocalNorthernLightsdealer.Marinemodelshaveoptional“On-Board-Kits,”ahandyboxthatcontainsthemostcommonpartsyouwillneed.

2. Allownersshouldhavethefollowing: a. Primaryandsecondaryfuelfilterelements b. Oilfilters c. Airfilter d. Alternatorbelt e. Thermostatandgaskets f. Seawaterpumpimpeller&gaskets g. Glowplug h. Injectorandwasher3. Ifyoursetisoperatingalongdistancefroma servicingdealer,addthefollowing: a. Completesetofinjectors b. Copperwashersforinjectorchange c. Completesetofglowplugs d. Fuelliftpump

Operating Procedures

Updated 8-27-09

OM773LW3 10/18

16

SERVICE 50 200 250 500 1000 2500 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours Hours

ENGINE: SP1 18 Check oil level • SP2 18 Change engine oil 1) 5) • • SP3 18 Change lube oil filters 1) 5) • • SP4 19 Check air cleaner, change element @ 1000 hrs. 1) 4) 5 •

SP5 19 Check V-belt tension • SP6 19 Check valve clearances 1) 2) • FUEL SYSTEM: SP7 20 Check primary filter (Racor) 2) 3) • SP8 20 Change primary filter element (Racor) 2) 3) • SP9 20 Change secondary fuel filter 1) 3) • SP10 21 Bleed the fuel system 3) SP11 22 Check injectors 1) 3) 6) 7) • SP12 22 Check fuel injection pump 7) • COOLING SYSTEM: SP13 24 Check coolant level • SP14 24 Check and flush cooling system • SP15 25 Check and clean heat exchanger • SP16 25 Change impeller in raw water pump 1) 3) • SP20 Inspect condition of exhaust elbow 1) 3) • ELECTRICAL SYSTEM: SP17 26 Check electrolyte level in batteries • SP18 26 Check condition of batteries with hydrometer 1) 4) • OUT OF SERVICE: SP19 26 Winterizing or out-of-service 3)

TheServicingScheduleChartbelowshowstheserviceschedulerequiredforpropermaintenanceofyourgeneratorset.MoredetailedcoverageofeachServicePoint(SP)islistedonthepagenotedinthe‘page’column.

DAILY: SP1 Checkoillevelinengine SP5 CheckV-belttension SP7 Checkprimaryfuelfilter SP13 Checkcoolantlevel Checkseastrainer SP17 Checkelectrolyteinbatteries

AFTER FIRST 50 HOURS: SP2/3 Changeengineoilandfilter SP6 Adjustvalves

AFTER FIRST 100 HOURS: SP2/3 Changeengineoilandfilter

EVERY 200 HOURS: SP2/3 Changeengineoilandfilter

EVERY 250 HOURS: SP4 Checkaircleaner SP18 Checkstateofchargeofbatteries

EVERY 500 HOURS: SP8 Changeprimaryfuelfilterelement SP9 Changesecondaryfuelfilter SP20 Inspectconditionofexhaustelbow

EVERY 1000 HOURS: SP4 Replaceaircleanerelement SP6 Checkvalveclearances SP11 Checkinjectors SP16 Changeimpeller

EVERY 2500 HOURS: SP12 Checkfuelinjectionpump SP14 Checkandflushcoolingsystem SP15 Checkandcleanheatexchanger

1) Perform all maintenance once a year even if hour level has not been reached.2) Consult manufacturer's maintenance schedule, note on chart.3) Whenever necessary.4) More often if necessary.5) After first 50 hours, then at 100 hrs., then every 200 hrs.

6) Clean injection nozzles every 1500 hours.7) For EPA emission standards fuel nozzle needs to be

cleaned every 1500 hours, the fuel nozzle and fuel pump need to be cleaned, adjusted, or repaired every 3000 hours, and the quality guarantee for these parts is 1500 hours or 2 years.

Servicing Schedule Chart

Updated 10-18-18

OM773LW3 10/18

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Service Record Notes

OM773LW3 10/18

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Servicing

LUBRICATION - GENERAL

1. Useonlyclean,highqualitylubricantsstoredincleancontainersinaprotectedarea.

2. Theselubricantsareacceptable: a.APIServiceCC/CD/CEsingleviscosityoils. b.APIServiceCC/CD/CFmulti-viscosityoils.3. Usetheproperweightoilforyouraverageoperation

temperature.

Figure 8: Lube Oils

4. SomeincreaseinoilconsumptionmaybeexpectedwhenSAE5WandSAE5-20Woilsareused.Checkoillevelfrequently.

5. Neverputadditivesorflushingoilincrankcase.

SP-1. CHECKING OIL LEVEL

1. Checktheoillevelinthecrankcasewiththedipstick.Theoillevelmustbeinthewaffledarea

onthestick.Neverallowtheleveltogobelowthisarea.Followthelubricationrecommendationsabove.

SP-2. OIL CHANGES

1. Thesetisdeliveredwithspecialbreak-inoil. Changetheengineoilandoilfilterafter50hours ofoperation.UseServiceCC30weightoilduring

thefirst100hours.2. Changetheoilandfilteragainat100hoursusingthe

oilrecommendedinFigure8.Afterthis,changeoilandfilterevery200hours.

3. Duringintermittentcoldweatheroperation,changeoilevery100hoursorsixweeks,whichevercomesfirst.

4. Changeoilatanyseasonalchangeintemperaturewhenanewviscosityofoilisrequired.

5. Changeoilwhenengineiswarm.6. Disposeofwasteoilinanapprovedmanner.7. Neveruseaflushingoil.8. Loosentheclampontheoilchangetube.Remove

cap.Drainoil.Replacethecapandtube.9. Refillenginewithrecommendedoil.10.Enginecapacitywithnewoilfilteris: M773LW3(G) - 4.75 quarts (4.9 liters)

SP-3. CHANGING LUBE OIL FILTER

1. Changethelubeoilfilterevery200hours.2. Useafilterwrenchtoremoveoldfilter.Disposeof

filterinapprovedmanner.3. Makesurethegasketfromtheoldfilterisremoved

anddiscarded.Cleanmountface.4. Spreadathinfilmofengineoilontherubbergasket

onthenewfilterandscrewitonnippleuntilgasketmeetsthesealingsurface.

5. Usinghandsonly–nowrench–tightenfilter one-halfturnfarther.Overtighteningcando damagetofilterhousing.6. Fillenginewithrecommendedoil.Startengineand

checkforleakage.Stopengine,wait3minutes,andcheckoillevel.Addadditionaloilifnecessary.

7. Oilfilterpartnumbersare: M773LW3(G) - #24-02002

Air Single Multi- Temperature Viscosity Viscosity

Above 32°F SAE 30W SAE 15-40W (0°C)

-10 to 32°F SAE 10W SAE 10-30W (-23 to 0°C)

Below -10°F SAE 5W SAE 5-20W (-23°C)

Updated 12/18/12

OM773LW3 10/18

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SP-4. AIR CLEANER

1. Inspectaircleanerevery250hours.Industycondi-tions,checkmoreoften.

2. Ifdirty,washelementinsoapywater.Rinseanddrythoroughlybeforere-installing.

Replaceifnecessary.Partnumbersare: M773LW3 – #24-28602 3. NOTE: Make absolutely sure no impurities enter

the engine while changing the element. Do NOT run the engine with the air cleaner removed.

SP-5. V-BELTS

1. CheckthetensionandwearontheV-beltdaily.

2. Useyourthumbtopressonthebeltatthemidpointbetweenthecrankshaftandalternatorpulleys.Thetensioniscorrectifthebeltcanbedepressedabout3/16in.(5mm).

Servicing

Figure 9: Valve Adjustment

SP-6. VALVE CLEARANCES

1. Adjustvalveclearanceafter1000hoursorasneeded.

2. Valveadjustmentsshouldbedoneafterthecylinderheadboltshavebeenre-tightened.EngineshouldbecoldandNOTrunning.

3. TobringtheNo.1cylindertotopdeadcenterinthecompressionstroke,alignthetimingmark;thetopmarkofthecrankpulleywiththatofthetiminggearcase.Removetherockerarmcoverandturnthecrankshaftfowardandbackward.IftheinletandexhaustvalvesoftheNo.1cylinderdonotmoveitisintopdeadcenterposition.Whenthevalvesmove,orrock,turnthecrankshaftonefullturnandalignthetopmarkofthecrankpulleywiththetopmarkofthetiminggearcase.

4. Loosenthelocknutandadjusttheclearancebetweentherockerarmandvalveguideofboththeintakeandexhaustvalveswiththeadjustmentscrew(Figure 9).Clearanceonbothintakeandexhaustvalvesshouldbe0.008in.(0.2mm).

5. Repeatsteps3and4foreachcylinder.Eachsetofvalvesmustbeadjustedindividually.

6. Replacetherockerarmcover.Tightencovernutsto5-8ft/lbs(0.8-2.3kg/m).

Figure 10: Timing Mark

Cylinder No. 1 2 3

Valve Arrangement Int. Exh. Int. Exh. Int. Exh.

When No.1 cylinderis at Top Dead Centerin the compressionstroke

With the crankshaftturned 3600 innormal direction fromabove

Valve Arrangement

OM773LW3 10/18

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Servicing

FUELS - GENERAL

1. Useonlyclean,highqualityfuelsofthefollowingspecifications,asdefinedbyASTMdesignationD975fordieselfuels:

a. Usegradeno.2dieselatambienttemperatures abovefreezing32°F(0°C). b. Usegradeno.1atambienttemperaturesbelow freezingandforalltemperaturesatanaltitudeof above5,500ft.(1500meters).2. Usefuelhavinglessthat1%sulphur(preferablyless

that0.5%).3. Thecetanenumbershouldbeaminimumof45.4. DONOTusetheseunsuitablegradesoffuel: a. Domesticheatingoils,alltypes. b. ClassBengine. c. ClassDdomesticfuels. d. ClassE,F,GorHindustrialormarinefuels. e. ASTM-D975-60TNo.4-Dandhighernumber fuels.5. Storingfuel: a. Keepdirt,scale,water,andotherforeignmatter out of fuel. b. Avoidstoringfuelforlongperiodsoftime. c. Fillthefueltankattheendofeachday’s operation.Thiswillreducecondensation.

FUEL FILTERS

1. Yourgeneratorsetshouldhaveaprimaryfuelfilterinstalled.WerecommendtheRacorbrandoffuelfilter-waterseparators.

SP-7. PRIMARY FUEL FILTER a. Checktheprimaryfuelfilterdailyas recommendedbythefiltermanufacturer. Emptythecollectionbowlasnecessary.SP-8. PRIMARY FUEL FILTER ELEMENT b. Changetheelementasoftenasnecessaryor every500hours. c. Ifthebowlfillswithwater,changetheprimary andsecondaryelementimmediately.

SP-9. SECONDARY FUEL FILTER2. Changesecondaryfuelfilterevery500hoursoras

necessary. a. Removethespin-onfilterbyturningit counterclockwisewithafilterwrench.Fillthe newcartridgewithfuelandinstallitafter applyingengineoiltogasketsurface.Screwon untilthegasketsurfacecomesintocontactwith sealingsurfaceoffilterbase.Then,tightenit two-thirdsofaturnbyhand.Donotovertighten. b. Fuelfilterpartnumberis:

M773LW3(G): #24-52020

OM773LW3 10/18

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Servicing

SP-10. BLEEDING THE FUEL SYSTEM

CAUTION: Escaping diesel fuel under pressure can penetrate skin causing serious personal injury. Before disconnecting lines be sure to relieve all pressure. Before applying pressure, be sure all connections are tight and lines, pipes and hoses aren't damaged. Fuel escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks. If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if proper medical treatment isn't administered immediately.

Figure 11: Fuel System.

1. Thefuelsystemisself-bleeding.However,anysystemmayneedmanualbleedingwhen:

a. Anewfuelfilterisinstalled; b. Theenginehasrunoutoffuel; c. Thefuellines,injectionpumporanyotherfuel systemcomponenthasbeenremovedand installed.2. Loosenbleedbolt“A”(Figure 11)ontopofthe

filter.Pumphandprimer“B”onfuelliftpumpuntilpurefuel(nobubbles)escapesfrombleedbolt“A”.Tightenbleedscrew“A”.

3. Loosenbleedscrew“C”.Pumphandprimer“B”untilpurefuel(nobubbles)escapes.Thentightenbleedscrew“C”.

4. Iftheenginedoesnotstartaftertheabovebleed-ingprocess,loosenafuellineattheinjectorwhilecrankingtheenginewiththestartermotoruntilpurefuelescapes.Thentightentheconnection.Doeachline one-at-a-time.

5. Aftertheenginehasstarted,useapieceofcardboardtolookforfuelleaks.

OM773LW3 10/18

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Servicing

SP-11. INJECTOR SERVICE

1. Injectorsshouldbecheckedevery1000hours,orwhenevernecessary.CheckshouldbemadebyaNorthernLightsdealerorlocalinjectionrepair

station.

CAUTION: Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury. If injured by escaping diesel fuel, see a doctor at once.

2. Injector removal: a. Cleanloosedirtfromaroundtheinjectorsand the fuel lines. b. Relievehighpressureinthefuellinesby looseningthedeliverylineflarenutsateach injector(Figure 12). c. Removedeliverylinesbydisconnectingfrom injectorsandinjectionpump(Figure 13).Remove alllinesasanassembly;donotremovethe spacers.Covertheendsofthelines,theinjector inletsandinjectionpumpoutletstokeepdirtout. d. Removethereturnlineretainingbolts(Figure 14). Removethereturnline(Figure 15). e. Unscrewandremovetheinjectors(Figure 16). NOTE: Do not use pry bars to remove injectors from cylinder head. f. Afterremovingtheinjectors,discardthecopper sealingwashersfromtheinjectorholeinthehead (Figure 17).Coverholestopreventdirtanddebris fromenteringthecylinders.

3. Injector installation: a. Installanewcoppersealingwasherineach injectorhole(Figure 17). b. Screwininjectorandtightento43or50ft/lbs (6to7kgm)(Figure 18). NOTE: Overtightening can damage injector. c. Installreturnlineusingnewcoppersealingabove andbeloweachconnection.Tightenreturnline retainingboltsto22-30ft/lbs. d. Installdeliverylines.Leavelooseatinjectorsfor bleeding. e. Pumphandlevelonfuelpumptofilllines. Tightenlinesatinjectors.Startengineandcheck forleaksusingapieceofpaperorcardboard. DO NOT use hand to check for leaks.

SP-12. INJECTION PUMP

1. Sinceoperatingconditionsmayvaryconsiderably,itisdifficulttogiveadefiniteintervalforcheckingtheinjectionpump.Butasarule,pumpsettings,

maximumspeed,idlespeedandexhaustsmokeshouldbecheckedafterevery2500hoursof

operation.Serviceofthefuelinjectionpumpshouldonlybedoneifchecksindicatepumpmalfunction.

2. Blacksmokecanbeanindicationofpump malfunction.Beforeservicingthepump,checkother

possiblecauses: a. Checkcleanlinessofairfilter. b. Checkvalveclearances. c. Cleanandcheckinjectors.3. Anyrepairwhichinvolvesdisassemblyoftheinjec-

tionpumpmustbecarriedoutbyspeciallytrainedmechanicswiththepropertoolsandtestequipment.

NOTE: All warranties on the engine become null and void if the injection pump seals are broken by unauthorized persons.

OM773LW3 10/18

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Servicing

Figure 15: Remove return line.

Figure 12: Remove delivery line flare nuts.

Figure 13: Remove delivery lines.

Figure 14: Remove return line nuts.

Figure 16: Unscrew injector.

Figure 17: Remove and replace copper sealing washer.

Figure 18: Reinstall injector. Torque to proper tightness.

Updated 11-8-13

OM773LW3 10/18

24

COOLING SYSTEM - GENERAL

NOTE: Be sure to close the sea-cock before working on the engine cooling system.

CAUTION: The cooling water in the engine reaches extremely high temperatures. You must use extreme caution when working on hot engines to avoid burns. Allow the engine to cool before working on the cooling system. Open the filler cap carefully, using protective clothing when the engine is warm.

WATER QUALITY1. Distilled,deionized,softwaterispreferredforusein

coolingsystems.Bottleddistilledwaterfromafoodstoreorwatersupplierisrecommended.Tapwateroftenhasahighmineralcontent.TapwatershouldNEVER beputinacoolingsystemunlessfirsttestedbyawaterqualitylaboratory.Do notusewatermadebythereverseosmosismethodunlessithasbeenPHneutralized.

2.Hereareacceptablewaterqualityspecifications:

3. Ifchlorides,sulfatesortotaldissolvedsolidsarehigherthantheabovegivenspecification,thewatermustbedistilled,demineralized,or

deionizedbeforeitisusedinacoolingsystem.4. Iftotalhardnessishigherthan170ppmandallother

parametersarewithinthegiven specifications,thewatermustbesoftenedbeforeitis

usedtomakecoolantsolution.

SP-13. CHECK THE COOLANT LEVEL

1. Checkthecoolantleveleachdaybeforestartingtheengine.Checkthewaterlevelbyremovingthepressurecapfromtheexpansiontankorradiator.

Inordertogivethecoolingwateranopportunitytoexpand,thelevelshouldbeabout1in.(2.5cm)belowthefillercapsealingsurfacewhentheengineiscold.

2. Thepressurevalveinthefillercapreleaseswhenthepressureisapproximately7PSI(0.5bar).Useacappressuretestertocheckcapifyoususpectitisfaulty

.SP-14. COOLING SYSTEM FLUSHING

1. Flushthecoolingsystemevery2500hoursorevery12months,whichevercomesfirst.

a. Removeexpansiontankcapanddrainengine block. b. Openblockdraincock. Removepluginlowerleft sideofheatexchangertank. c. Pourcleanwaterintoexpansiontankuntilwater comingfromdrainsisfreeofdiscolorationand sediment.Letwaterdraincompletely.Close drainsandrefillwithrecommendedmixture.2. CoolantSpecifications: Use50%water/50%ethyleneglycolantifreezemix.

Antifreezemixtureisrecommendedasagoodyear-roundcoolant,butnotmethylalcoholbasedantifreezebecauseofit’seffectonnon-metallic

componentsandit’slowboilingpoint.Also,antifreezewithhighsilicateshouldnotbeusedasitcouldcasesilicagelationproblems.

3. Checkhosesandconnectionsandrepairanyleakage.

Servicing

Parts GrainsContaminates per Million per Gallon

Maximum Chlorides 40 2.5

Maximum Sulfates 100 5.9

Maximum Dissolved Solids 340 20.0

Maximum Total Hardness 170 10.0

PH Level 5.5 to 9.0

Updated 11-8-13

OM773LW3 10/18

25

ELECTRICAL SYSTEM - GENERAL

1. Neverswitchbatteryswitchofforbreakthecircuitbetweenthealternatorandbatterieswhiletheengineisrunning.Regulatordamagecanresult.

2. DoNOTreversethepolarityofbatterycableswheninstallingthebattery.

3. Whenweldingontheunit,disconnecttheregulatorandbattery.Isolatetheleads.

4. DisconnectthebatterycableswhenservicingtheD.C.alternator.

5. Nevertestwithascrewdriver,etc.,againstanyter-minaltoseeifitemitssparks.

6. Donotpolarizethealternatororregulator.7. AD.C.circuitbreakerprotectsyourcontrolpanel

andwiringharness.Itislocatedinthesideofthegeneratorjunctionbox.

GLOW PLUGS

1. Eachcylinderissuppliedwithaglowplugwhichservestoheatthecombustionchamber.

2. Tochecktheglowplugs,loosenthecurrent carryingflatwirebetweentheplus-polesofthe glowplugs(Figure 19).ConnectaD.C.testbulb

betweentheplus-poleofthebatteryandthe plus-poleoftheglowplug.Ifthebulblightsup, theglowplugisfunctioningproperly.3. Checkallglowplugsandreplaceanythatarefaulty.

Figure 19: Glow plugs.

SP-15. HEAT EXCHANGER

1. Cleantheheatexchangercoreonceayearorafter2500hoursofoperation.

2. Drainexpansiontankandheatexchanger.3. Removeheatexchangerendcoversandremove

core.4. Cleantheinsideofexchangercoretubesusing ametalrod.Flush,inspectandcleanagainif necessary.5. Reassemble.Fillthecoolingsystem,starttheengine

andcheckforleaks.

SP-16. RAW WATER PUMP

1. Changetheseawaterpumpimpellerevery1000hours,orasneeded.

2. Removethepumpendcover.Pryouttheimpellerusingneedle-nosepliersortwoscrewdrivers.

Besureyouremoveallpiecesoffailedimpeller. NOTE: Place some kind of protection under the

screwdrivers in order not to damage the pump housing.3. Cleantheinsideofthehousing.4. Pressinthenewimpellerandplacethesealing

washersintheouterendoftheimpellercenterifthishasnotalreadybeendone.

5. Replacethecoverusinganewgasket. NOTE: Make sure that there is always an extra

impeller and cover gasket in reserve on board.

GENERATOR ENDS

ThemaintenanceandoperationrecommendationsforthegeneratorendareinaseparateOwner’sManual.Ifyoudonothaveoneofthesemanuals,contactyourlocalNorthernLightsdealer.

Servicing

Updated 11-8-13

OM773LW3 10/18

26

BOOSTER BATTERIES

CAUTION: Battery gas can explode. Keep all flames and sparks away from batteries.Battery electrolyte is sulfuric acid diluted, which can burn or stain body or clothes.

1. Beforechangingorusingboosterbatteries,checkbat-teryelectrolytelevel.Adddistilledwaterifnecessary.

2. Boosterandmainbatteriesmusthavethesamevolt-agerating.

3. First,connectpositive(+)terminalofboosterbat-terytopositive(+)terminalofmainbattery.Then,connectnegative(-)terminalofboosterbatterytogroundontheengineblock(see Figure 20).

4. Removeboosterbatteryafterstartingengine.5. Sealedbatteries:Seemanufacturerchargingand

boosterinstructions.

BATTERY CARESP-18. CHECK ELECTROLYTE LEVELS 1. Checkelectrolyteleveldaily.Adddistilledwaterto

manufacturer’srecommendedlevel.SP-19. CHECK CABLES AND TERMINALS 2. Batteries,cablesandcableterminalsshould becheckedandcleanedevery100hours. Cleancorrosionwithawaterandbakingsoda solution.Flushwithcleanwater.Tightenterminals

andgreasethemtoinhibitcorrosion.3. Checkthebatteryconditionwithahydrometerevery

250hours.

Updated 10/18/18

Servicing

Figure 20:Battery connections.

SP-20. WINTERIZING / OUT-OF-SERVICE

Ifthegeneratorsetwillnotbeusedformorethan3monthsthefollowingpreparationsshouldbetakenforlongtermstorage.• Changeengineoilandfilter,usingAPICJorCK-4,

15W-40oil.• Runtheengineuptoatleast140oFfromasmall,

cleansourceoffueldosedwitheither“Stab-il”brandfuelsystemstabilizer(dieselengineformula),orStanadynePerformancefuelsystemconditioner.Ifneitherofthesefueltreatmentsisavailable,youmayalsouseJohnDeerefuelsystemconditioner.

• Completelydrain,flush,andfillthecoolingsystemwithpre-mixed,50/50,conventionalethylene-glycolheavy-dutydieselenginecoolant(withSCAs).

• Loosenalternatordrivebelt.• Completelysealoffintakeandexhaustopenings

withheavyplasticbagsandducttape.• Coverentireengineinlargeplasticbagandtape

closedatbottomofbag-placeseveralmoistureabsorbingdesiccantpacksinsideplasticbagStoreengineinoriginalshippingcrate,ifpossible,orothersuitablestoragecrate.

• Storeengineinsideabuilding(preferablyclimatecontrolled)topreventcorrosion.

ToRemoveGeneratorSetfromLong-TermStorage:1. Takeoffallprotectivecoveringsandunsealallthe

openingsthatwerecoveredup.2. Installbatteriesthatarefullychargedandconnect

theterminals.3. Installthefanandalternatorbeltsiftheyhadbeen

removed.4. Fillthefueltank.5. Performallpre-startchecks.6. Cranktheenginefor20secondswiththestarter,

withoutlettingtheenginestart.Wait2minutesandcranktheengineanadditional20secondstomakesureallbearingsurfacesarewellcoated.

7. Starttheengineandrunatnoloadinalowidleforseveralminutes.Makesuretheengineiswarmedupandcheckgaugesbeforegoingunderload.

8. Checkallgaugesandcheckforleaks.

OM773LW3 10/18

27

Troubleshooting

Ifyoucannotcorrectproblemswiththeseprocedures,seeyourNorthern Lights dealer.

DC ELECTRICAL SYSTEM PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)

Battery Will Not Charge Looseorcorrodedconnections •Cleanandtightenbatteryconnections.

Sulfatedorwornoutbatteries •Checkspecificgravityofeachbattery. •Checkelectrolytelevelofeachbattery.

Looseordefectivealternatorbelt •Adjustbelttension. •Replacebelt.

Starter Inoperative CheckDCcircuitbreaker •Ifthebreakeristripped,resetit.

Looseorcorrodedconnections •Cleanandtightenloosebatteryand harnessplugconnection.

Lowbatteryoutput •Checkspecificgravityofeachbattery. •Checkelectrolytelevelofeachbattery.

Defectiveelectricalsystem •Repairorreplace. groundwire:

Starter Cranks Slowly Lowbatteryoutput •Batteryistoosmall. •Batterycablesaretoosmall.

Checkspecificgravity •Replacebatteryifnecessary. ofeachbattery

Checkelectrolytelevel •Iflow,fillcellswithdistilledwater. ofeachbattery

Crankcaseoiltooheavy •Fillwithoilofappropriateviscosity.

Looseorcorrodedconnections •Cleanandtightenlooseconnections.

Entire Electrical System CheckDCcircuitbreaker •Ifbreakeristripped,resetit.Does Not Function Faultyconnection •Cleanandtightenbatteryandharness plugconnections.

Sulfatedorwornoutbatteries •Checkspecificgravityandelectrolyte levelofeachbattery.

OM773LW3 10/18

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Troubleshooting

ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)

Engine Hard to Start Improperstartingprocedure •Seestartingsectionofthismanual.Takeor Will Not Start specialnoteofBypassSwitchoperation.

Nofuel •Checkleveloffuelinfueltank.

Lowbatteryoutput •Checkelectrolytelevelandcondition.

Excessiveresistance •Cleanandtightenallbatteryconnections. instartingcircuit

Crankcaseoiltooheavy •Useoilofproperviscosity.

Impropertypeoffuel •Consultfuelsupplierandusepropertype offuelforoperatingcondition.

Water,dirtorairinfuelsystem •Drain,flush,fillandbleedsystem.

Cloggedprimary •Cleanorreplacefilterelement. fuelfilterelement

Cloggedsecondary •Replacefilterelement. fuelfilterelement

Dirtyorfaultyinjectionnozzles •Haveyourdealercheckinjectionnozzles. Fuelinjectedbutnoignition •Glowplugmalfunction •Injectiontimingnotcorrect •Lowcylindercompressionpressure

Engine Runs Irregularly Belownormalenginetemperature •Removeandcheckthermostat.or Stalls Frequently Cloggedprimary •Cleanorreplacefilterelement. fuelfilterelement

Cloggedsecondary •Replacesecondaryfilterelement. fuelfilterelement

Waterordirtinthefuelsystem •Drain,flush,fillandbleedsystem.

Dirtyorfaultyinjectionnozzles •Haveyourdealercheckinjectionnozzles.

Airinfuelsystem •Inspectclampsandhosesonsuctionside offuelpumpforairleak.

Impropertypeoffuel •Consultfuelsupplierandusepropertype offuelforoperatingcondition.

Lowidle,notstable •Unevencylindercompression

Lack of Engine Power Intakeairrestriction •Serviceaircleaner.

Cloggedprimaryorsecondary •Cleanorreplacefilterelement. fuelfilterelement

Impropertypeoffuel •Consultfuelsupplierandusepropertypeof fuelforoperatingconditions.

Overheatedengine •See“EngineOverheats”innextcategory.

OM773LW3 10/18

29

Troubleshooting


Lack of Engine Power,continued Belownormalenginetemperature •Removeandcheckthermostat. Injectionpumpfuelsupply •Airmixingininjectionpump. insufficient •Fuelfilterclogged.

Impropervalveclearance •Resetvalves.Bestdonebydealer.

Dirtyorfaultyinjectionnozzles •Replaceinjectors.Bestdonebydealer.

Cylindercompressionpressure •Adjustvalveclearance low,cylindercompressionpressure •Adjustnozzleholderalignment leakage •Checkcylinderborewear

Engine Overheats Lowcoolantlevelorcooling •Filltankorradiatortoproperlevel. systemdefective •Checkhosesforlooseconnections andleaks. •Fanbeltslippng

Keelcoolingtubes •Removepaintfromtubes. havebeenpainted

Coolingsystemneedsflushing •Flushcoolingsystem.

Defectivethermostat •Removeandcheckthermostat.

Defectivetemperaturegauge •Checkwatertemperaturewiththermometer andreplacegaugeifnecessary.

Waterpumpimpellerworn/broken •Checkimpellerandreplaceifnecessary.

Engine Knocks Insufficientoil •Callyourdealer.

Injectionpumpoutoftime •Callyourdealer.

Belownormalenginetemperature •Checkyourthermostats. •Checkwatertemperaturetoseeif temperaturegaugeisworkingproperly.

Engineoverheating •See“EngineOverheating”section.

High Fuel Consumption Impropertypeoffuel,orfuel •Usecorrectfuelfortemperature. leaking •Checkinstallationortightening. Cloggedordirtyaircleaner •Serviceaircleaner.

Impropervalveclearance •Seeyourdealer.

Injectionnozzlesdirty •Seeyourdealer.

Injectionpumpoutoftime •Seeyourdealer.

Engineoverloaded •Checkloadusage.

Enginenotatpropertemperature •Checkyourthermostats. •Checkwatertemperaturewiththermometer andreplacegaugeifnecessary.


OM773LW3 10/18

30

Troubleshooting


Below Normal EngineTemperature Thermostatsnotworkingproperly •Checkthermostats.

Temperaturegauge •Checkwatertemperaturewiththermometer. notworkingproperly

Low Oil Pressure Lowoillevel •Fillcrankcasetoproperlevel.

Cloggedfilterandstraineror •Repairorreplace wornbearingsandoilpump

Impropertypeofoil •Drainandfillcrankcasewithcorrectoil.

Partiallypluggedoilfilter •Replacefilter.

High Oil Consumption Break-inperiod •Oilconsumptiondecreasesafterbreakin.

Crankcaseoiltoolight •Useproperviscosityoil.

Oilleaks •Checkforleaksinlinesaroundgaskets anddrainplug.

Engine Emits Black Cloggedordirtyaircleaner •Serviceaircleaner.or Gray Exhaust Smoke Defectivemuffler •Havedealercheckbackpressure. (backpressuretoohigh)

Improperfuel •Usecorrectfuelfortemperature.

Injectionnozzlesdirty •Seeyourdealer.

Enginetimingoff •Seeyourdealer.

Engine Emits Improperfuel •Usecorrectfuelfortemperature.White Smoke Coldengine •Warmupenginetonormaloperating temperature.

Defectivethermostat •Removeandcheckthermostat.

Enginetimingoff •Seeyourdealer.


OM773LW3 10/18

31

AC Wiring Diagrams

AC

Eng

ine

Wiri

ng D

iagr

am T

aiyo

Px3

00K2

4 L

ead

Gen

erat

or

w/ D

ST-1

00-2

FAK

AVR

B-9

724E

Updated 1-16-18

OM773LW3 10/18

32

AC Wiring Diagrams

AC

Eng

ine

Wiri

ng D

iagr

amTa

iyo

PX30

0K2

12 L

ead

Gen

erat

or

w/ D

ST-1

00-2

FAK

AVR

B-9

723D

Updated 6-5-17

OM773LW3 10/18

33

DC Wiring Diagrams

DC

Wiri

ng D

iagr

am M

/NL

773L

W 1

2 VD

C

Stan

dard

Gro

und

B+ C

ontro

l B

-107

67A

Updated 6-5-17

OM773LW3 10/18

34

NO

RT

HE

RN

LIG

HT

S

DC Wiring Diagrams

DC

Wiri

ng D

iagr

am M

773L

W 2

4 VD

C Is

olat

ed G

roun

d B+

Onl

y B

-108

80

Updated 6-5-17

OM773LW3 10/18

35

DC Wiring Diagrams

DC

Wiri

ng D

iagr

amM

773

24

VDC

Sta

ndar

d G

roun

d B

+ on

lyB

-108

34

Updated 6-5-17

OM773LW3 10/18

36

DC Wiring Diagrams

DC

Wiri

ng D

iagr

am M

773L

W 1

2 VD

C Is

olat

ed G

roun

d B

-108

35

Updated 6-5-17

OM773LW3 10/18

37

DC Wiring Diagrams

DC

Eng

ine

Wiri

ng D

iagr

amM

773L

W3

12

Volt

Stan

dard

Gro

und

B-9

852A

Updated 3-13-12

OM773LW3 10/18

38

DC

Eng

ine

Wiri

ng D

iagr

amM

773L

W3

12 V

olt I

sola

ted

Gro

und

B-1

0130

B

DC Wiring Diagrams

Updated 7-9-12

OM773LW3 10/18

39

DC Wiring Diagrams

DC

Eng

ine

Wiri

ng D

iagr

amM

773L

W3

24

VDC

Sta

ndar

d G

roun

dB

-B-9

908

Updated 3-13-12

OM773LW3 10/18

40

DC

Eng

ine

Wiri

ng D

iagr

amM

773L

W3

24

Volt

Isol

ated

Gro

und

B-8

662C

DC Wiring Diagrams

OM773LW3 10/18

41

Panel Wiring Diagrams

Pane

l Wiri

ng D

iagr

am S

-1 P

anel

, B+

Deu

tsch

A-1

2798

Updated 6-5-17

OM773LW3 10/18

42


Pane

l Wiri

ng D

iagr

am S

-1B

Pane

l, B+

A

-127

91B

Updated 6-5-17

OM773LW3 10/18

43


Pane

l Wiri

ng D

iagr

am S

-3B

Pane

l, Vi

ewlin

e B+

A-1

2799

A

Updated 6-5-17

OM773LW3 10/18

44


Pane

l Wiri

ng D

iagr

am S

-3C

Pan

el, V

iew

line

B+

A-1

2790

A

Updated 6-5-17

OM773LW3 10/18

45


Pane

l Wiri

ng D

iagr

amS-

3C

View

line

Pane

ls 1

2VD

raw

ing

A-12

645A

Updated 7-9-12

OM773LW3 10/18

46


Pane

l Wiri

ng D

iagr

am M

773L

W3,

Con

trol P

anel

S-3

C, 1

2 V

A-1

2572

B

Updated 3-13-12

OM773LW3 10/18

47


Pane

l Wiri

ng D

iagr

am M

773L

W3,

Con

trol P

anel

S-3

C, V

iew

line

A-1

2645

B

Updated 7-9-12

OM773LW3 10/18

48


Pane

l W

iring

Dia

gram

M77

3LW

3, C

ontro

l Pan

el S

-1B

24V

A-4

792

Updated 3-13-12

OM773LW3 10/18

49


Pane

l Wiri

ng D

iagr

am M

773L

W3,

Con

trol P

anel

S-3

C, 2

4VA

-125

94B

Updated 3-13-12

4420 14th Ave. NW., Seattle WA 98107 Tel: (206) 789-3880 • 1-800-762-0165 • www.northern-lights.comNorthern Lights and Lugger are registered trademarks of Northern Lights, Inc. © 2018 All rights reserved. Litho USA.

operator’s manual - northern lights · 2018-10-18 · operator’s manual uses three different...

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