OPERATOR`S MANUAL
Contents
1. OPERATOR S MANUAL LED LOW OR ULTRA LOW SULFUR FUEL ONLY Yor Emi ns27703 AME As of January 2008 U S EPA regulations require the application of a permanently applied label near the fuel tank fill port for diesel driven equipment This label is to state LOW OR ULTRA LOW SULFUR FUEL ONLY Northern Lights is providing this label for application to the fuel inlet of the fuel supply tank for each engine or generator set This is to be applied by the installer of the engine or gen set or by the manufacturer of the equipment that the engine or gen set is installed in The location of the label must be in clear site of personnel that refill the supply tank Note Starting in 2011 the label will state ULTRA LOW SULFUR ONLY A CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constitu ents are known to the State of California to cause cancer birth defects and other reproductive harm Northern Lights 4420 14th Avenue N W Seattle WA 98107 Tel 206 789 3880 Fax 206 782 5455 Copyright 2013 Northern Lights Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Northern Lights Inc Printed in U S A PART NO ONL773LW4 11 13 ES NORTHERN LIGHTS OPERATOR S MANUAL for Model NL773LW4 and NL773LW4E Read this operator s manual thoroughly before starting to operate your equipment This manual contains informat2. 4 D and higher number fuels 5 Biodiesel Biodiesel involves the transesterification of vegetable oils Coe gt or animal fats It can involve animal fats yellow greases used greases cotton seed sunflower seed coconut oil or sesame seed but mainly in the US soybean methyl ester is used SME In Europe mainly rapeseed canola methyl ester is made RME and in Asia palm methyl ester PME is made 100 biodiesel B100 is made in compliance with ASTM D6751 or EN14214 EU specifications Biodiesel may be used in a 5 blend 5 biodiesel 95 diesel from a BQ 9000 accredited producer 20 biodie sel blends 20 biodiesel 80 diesel can only be used if they meet ASTM D6751 or EN14214 EU specifications A 2 reduction in power and a 3 reduction in fuel economy can be expected if a 2096 blend is used With a 20 biodiesel blend an approved fuel conditioner is recommended The petroleum part of the biodiesel blend must meet ASTM D975 or EN590 EU specifications Biodiesel blends must be used within 90 days of their manufacture When biodiesel blends are used the oil level must be checked daily and storage leaking possible microbial growth plugging and components degradation must all be checked more frequently Note Using raw pressed or partially refined vegetable oils or recycled greases as fuel which have not been through transesterification could cause engine failure Request a certificate of analysis from an
3. N Figure 10 Remove return line ONL773LW4 11 13 18 revised 11 8 13 Servicing SP11 INJECTOR SERVICE 1 Injectors should be checked every 1000 hours Check should be made by a Northern Lights dealer or local injection repair station A CAUTION Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury f injured by escaping diesel fuel see a doctor at once 2 Injector removal a f Clean loose dirt from around the injectors and the fuel lines Relieve high pressure in the fuel lines by loosening the delivery line flare nuts at each injector Figure 8 Remove delivery lines by disconnecting from injectors and injection pump Figure 9 Remove all lines as an assembly do not remove the spacers Cover the ends of the lines the injector inlets and injection pump outlets to keep dirt out Remove the return line retaining bolts Figure 10 Remove the return line Figure 11 Unscrew and remove the injectors Figure 12 NOTE Do not use pry bars to remove injectors from cylinder head After removing the injectors discard the copper sealing washers from the injector hole in the head Figure 13 Cover holes to prevent dirt and debris from entering the cylinders 3 Injector installation a Install a new copper sealing washer in each injector hole Figure 13 Screw in injector and tighten to 43 or 50 ft Ibs 6
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5. ONL773LWA 11 13 22 added 11 26 13 Troubleshooting Lamp Flashing Pattern when Error has Occurred Before starting the engine 1 Check all connections before powering the Engine ECU on 2 When the Engine ECU is powered on assuming no failures the lamp will flash one time and then off 3 If an Engine ECU failure 15 detected the lamp will flash one of the codes below 4 To resolve an Engine ECU failure turn power off check and connect wiring connections and power on again Figure 16 Lamp Codes Lamp Code Reason For Error Error Dectection After Error Detection 13 Oil pressure SW failure or wire disconnected Engine ECU Power ON EG Start Enable Go to Low Power Mode 22 Pressure Sensor failure or wire disconnected Engine ECU Power ON EG Start Enable to Low Power Mode Engine running Go to Low Power Mode 33 Pressure Sensor failure or wire disconnected Engine ECU Power ON EG Start Enable to Low Power Mode Engine running Go to Low Power Mode 15 Speed Sensor Failure or wire disconnected Cranking Engine doesn t start Engine Running Go to Low Power Mode 04 Actuator drive wire disconnected Engine ECU Power ON Lamp action only Cranking Engine doesn t start Lamp Code Analysis Lamp Code specifies the pattern of long and short flashes the ECU uses to indicate a particular problem The lamp will continue flashing as shown below until the error is resolved Case 1 Error Only Code 13 Long Short Short Short Long Sho
6. W I baaria ln D amo ICi EH m MP bre I li A CIE RU aie Y T Fl HI a ots Me et OM SEL DEA iur 3 L Tar U hi Y LOU 23 195 B Hc m eH UD Te Te SH er Te HHA TS biR h ee A abe RIL SUA BALLAD MAATA OAL I T Lr ZH OUI Dei PR CH H LY oe zm De CH A Ci ca DT4 3 AA ismi HH l IA ibA F IE 1 m Tee LI zr 4 Lua MOM G da Tunt L n pow T Cam de 5 S Ir AT SMARTS ean T 5 hited HI E te As amp i B ui Ait i aE oe E dm HA Hl e us Fe DPI uz aa Es m de l sem s Xd ROM E r Thal A l r4 E i F at Eh r 7 0 MELO n mM a ee ee d Tem Li 1 L j CE I je s W ki s Ka G _ 7 7 wR 1 27 a s iini aL nu ried E Bf 4 RUe 7 7 723 ir c L HH ze scape ae Lowe TL eA E ae Uae AX ri Jia i dae Fo A LH eco E E 44 dla in anm jt 144 NSW INAS ONL773LW4 11 13 32 4420 14th Ave NW Seattle WA 98107 Tel 206 789 3880 1 80
7. 20 Period 11 21 Before Starting 11 Booster Battertes 21 11 Battery eae 21 auc M 11 Winterizing Out of Service 21 11 Shutdowns and Alarms 12 TROUBLESHOOTING Spare PariS ee ene ee one 12 i 22 Lamp CodeS RT ET 23 SERVICING SCHEDULE CHART 13 EHI A 24 26 WIRING DIAGRAMS 27 32 Proprietary Information This publication is the property of Northern Lights Inc It may not be reproduced in whole or in part without the written permission of Northern Lights Inc Northern Lights Inc All rights reserved Litho U S A Publication number ONL773LW4 11 13 ONL773LW4 11 13 1 Introduction Servicing of industrial engines and generator sets presents unique problems Generator sets cannot be compared to the servicing of automobiles trucks or even farm equipment Failures often occur in remote areas far from competent assistance Industrial engines are often taxed far more severely than auto or truck engines therefore maintenance schedules must be adhered to more strictly Failures begin with minor problems that are overlooked and become amplified when not corrected duri
8. Clogged secondary fuel filter element Water or dirt in the fuel system Dirty or faulty injection nozzles Air in fuel system e Remove and check thermostat Clean or replace filter element Replace secondary filter element Drain flush fill and bleed system Have your dealer check injection nozzles nspect clamps and hoses on suction side of fuel pump for air leak Improper type of fuel Consult fuel supplier and use proper type of fuel for operating condition Lack of Engine Power Intake air restriction Service air cleaner check proper ventilation Clogged primary Clean or replace filter element fuel filter element Clogged secondary fuel filter element Injection pump not getting fuel Improper type of fuel ONL773LWA 11 13 24 Replace filter element Have injection pump checked Consult fuel supplier and use proper type of fuel for operating conditions ENGINE PROBLEM Lack of Engine Power continued Troubleshooting POSSIBLE CAUSE Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Poor cylinder compression pressure RECOMMENDATION S Consult fuel supplier and use proper type of fuel for operating conditions e See Engine Overheats in next category Remove and check thermostat Reset valves Best done by dealer Replace injectors Best done by dealer e See your
9. USING BOLT LOCK WASHER AND NUT WRAPPING WITH ELECTRICAL TAPE ll ISOLATE BY mi CO lt L1 N GND L2 N GND SEE NOTES 4 5 amp 6 c SEE NOTES 4 5 amp 6 L 4 WIRE SINGLE PHASE 100 200 115 230VAC 19 50 HZ 100 200 120 240VAC 19 60 HZ 4 WIRE SINGLE PHASE 200 230VAC 19 50 HZ A C VOLTAGE REGULATOR DST 100 2FAK REM VAR STAB u F 50 60 U X1 FROM ADJ GAIN KNEE SEE p 2 GEN le e amp d ne VR3 VR2 VR4 FREQ CPR 2 AMP SEE NOTE 1 VOLTS MARINE GENSETS ARE GROUNDED BY CUSTOMER AT CUSTOMER S DISCRETION INDUSTRIAL GENSETS ARE TO BE GROUNDED IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE AND ANY APPLICABLE LOCAL CODES HIDDEN DASHED LINES INDICATE CUSTOMER SUPPLIED AND CONNECTED MAIN OUTPUT CONDUCTORS SIZING TO BE DETERMINED PER INSTALLATION AVR INPUT SENSING SWITCH SW1 IS TO BE SET TO THE 200V POSITION FOR ALL VOLTAGES EXCEPT 100 120VAC APPLICATIONS SEE NOTE 7 VOLT ADJ AC Engine Wiring Diagram For Northern Lights NL773LW4 Drawing B 9724C Wiring diagrams are subject to change without notice ONL773LWA 11 13 30 Added 2 1 12 iagrams D iring W eoiou jnouim eBueuo o JOalgns aie v 246 gs Duiweiq VAVIELL IN 50517 u424140N JOA weibeig ov O e 2 m m z 3 N39 G 33S ZH OS OL O Z S
10. adjust the clearance on both valves for this cylinder 4 Loosen the lock nut and adjust the clearance between the rocker arm and valve guide of both the intake and exhaust valves with the adjustment screw Figure 5 Clearance on both intake and exhaust valves should be 0 008 in 0 2 mm 5 Repeat steps 3 and 4 for each cylinder Each set of valves must be adjusted individually 6 Replace the rocker arm cover Tighten cover nuts to 5 8 ft Ibs 0 8 2 3 kg m Cylinder No 1 2 3 Valve Arrangement Intake Exh Intake Exh Intake Exh When No 1 Cylinder is at TDC in O O Compression Stroke With the Crankshaft turned by 360 in normal direction from O O C above Valve Sequence ONL773LW4 11 13 15 Servicing FUELS GENERAL 1 Use only clean high quality fuels of the following specifications as defined by ASTM designation D975 for diesel fuels a Use grade no 2 diesel at ambient temperatures above freezing 32 F 0 C b Use grade no at ambient temperatures below freezing and for all temperatures at an altitude of above 5 500 ft 1500 meters 2 Use fuel having less that 1 sulphur preferably less that 0 5 3 The cetane number should be a minimum of 45 4 DONOT use these unsuitable grades of fuel a Domestic heating oils all types Class B engine Class D domestic fuels Class E F G or H industrial or marine fuels ASTM D975 60T No
11. damage to filter housing 6 Fill engine with recommended oil Start engine and check for leakage Stop engine wait 3 minutes and check oil level Add additional oil if necessary 7 The oil filter part number is 31224 02001 ONL773LWA 11 13 Servicing SP4 AIR CLEANER 1 Inspect air cleaner every 200 hours In dusty conditions check more often 2 Industrial sets the element cannot be cleaned Replace it when necessary Part numbers are NL773LW3 24 27301 4 NOTE Make absolutely sure no impurities enter the engine while changing the element Do NOT run the engine with the air cleaner removed SP5 V BELTS 1 Check the tension and wear on the V belt daily 2 Use your thumb to press on the belt at the midpoint between the crankshaft and alternator pulleys The tension is correct if the belt can be depressed about 3 16 in 5 mm a Adjustment Screw 4 SS d Rocker Arm 0 008 0 200 mm Figure 5 Valve Adjustment SP6 VALVE CLEARANCES 1 Adjust valve clearance after 1000 hours of operation or as needed 2 Valve adjustments should be done after the cylinder head bolts have been re tightened Engine should be cold and NOT running 3 Watch the valves while turning the engine over by hand Turn until the inlet valve starts to open and the exhaust valve starts to close the valves are rocking Then turn the crankshaft one more full turn and
12. local dealer Check bore for wear or check alignment of nozzle holder Re adjust valve clearance Engine Overheats Low coolant level Air cleaner element clogged Cooling system interior dirty Defective thermostat Defective temperature gauge Water pump impeller worn broken V belts slipping Fill tank or radiator to proper level with proper mixture of coolant Check hoses for loose connections and leaks Clean or replace Flush cooling system e Remove and check thermostat Check water temperature with thermometer and replace gauge if necessary Check impeller and replace if necessary Fix belts to proper tension Engine Knocks Insufficient oil Injection pump timing off Below normal engine temperature Engine overheating Call your dealer Call your dealer Check your thermostats Check water temperature to see if temperature gauge is working properly See Engine Overheating section High Fuel Consumption Improper type of fuel Clogged or dirty air cleaner Improper valve clearance Injection nozzles dirty Injection pump timing off Engine not at proper temperature Use correct fuel for temperature Service air cleaner e See your dealer e See your dealer e See your dealer Check your thermostats Check water temperature with thermometer and replace gauge if necessary If you cannot correct problems with these procedures see you
13. 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 QUALITY 1 Distilled deionized soft water is preferred for use in cooling systems Bottled distilled water from a food store or water supplier is recommended Tap water often has a high mineral content Tap water should NEVER be put in a cooling system unless first tested by a water quality laboratory Do not use water made by the reverse osmosis method unless it has been PH neutralized ONL773LW4 11 13 19 revised 11 8 13 Servicing 2 Here are acceptable water quality specifications Parts Grains per Gallon Contaminates per Million 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 3 If chlorides sulfates or total dissolved solids are higher than the above given specification the water must be distilled demineralized or deionized before it is used in a cooling system 4 If total hardness is higher than 170 ppm and all other parameters are within the given specifications the water must be softened before it is used to make coolant solution SP13 CHECK THE COOLANT LEVEL 1 Check the coolant level each day before starting the engine Check the water level by removing the pres sure cap from the radiator In order to give the c
14. stopped Y3 before making any adjustments connections or performing A any other type of service to the engine or other driven equipment ONL773LW4 11 13 4 Revised 3 12 12 Safety Rules Continued Install all Safety Guards Direct contact with rotating fans belts pulley and drives can cause serious injury Keep all guards in place at all times during engine operation Wear close fitting clothes Stop the engine and be sure all fans belts pulleys and drives are stopped before making adjustments connections or cleaning near fans and their components Do not allow anything on your person to dangle into or come in contact with a moving fan belt pulley or drive Fans can act as vacuums and pull materials up from below so avoid that area as well while in service Safe Battery Handling Prevent Battery Explosions Battery gas is highly flammable Battery explosions can cause severe injury or death To help prevent battery explosions keep sparks lighted matches and open flame away from the top of battery When checking battery electrolyte level use a flashlight Never check battery charge by contacting the posts with a metal object Use a volt meter or hydrometer Frozen batteries may explode if charged Never charge a battery that has not been allowed to warm to at least 16 C 60 F Always remove grounded battery clamp first and replace ground clamp last Sulfuric acid in battery elect
15. to 7 kgm Figure 14 NOTE Overtightening can damage injector Install return line using new copper sealing above and below each connection Tighten return line retaining bolts to 22 30 ft Ibs Install delivery lines Leave loose at injectors for bleeding Pump hand level on fuel pump to fill lines Tighten lines at injectors Start engine and check for leaks using a piece of paper or cardboard DO NOT use hand to check for leaks SP12 INJECTION PUMP Since operating conditions may vary considerably it is difficult to give a definite interval for checking the injection pump But as a rule pump settings maximum speed idle speed and exhaust smoke should be checked after every 2500 hours of operation Service of the fuel injection pump should only be done if checks indicate pump malfunction Black smoke can be an indication of pump malfunction Before servicing the pump check other possible causes a Check cleanliness of air filter b Check valve clearances c Clean and check injectors Any repair which involves disassembly of the injection pump must be carried out by specially trained mechanics with the proper tools and test equipment NOTE All warranties on the engine become null and void if the injection pump seals are broken by unauthorized persons COOLING SYSTEM GENERAL A CAUTION The cooling water in the engine reaches extremely high temperatures You must use extreme caution when working
16. until the engine is running After the engine starts release the switch and it will return to RUN position To stop the engine hold the switch in the STOP position NOTE The rocker switch has a light that glows when the set is running HOUR METER Keeps track of engine running time ONL773LW4 11 13 10 Updated 1 10 13 Operating Procedures BREAK IN PERIOD 1 The first 100 hours on a new or reconditioned engine are critical to its life and performance 2 Operate the engine under various conditions particularly heavy loades with minimal idling to help seat engine components properly 3 Constantly check the engine temperature and oil pressure 4 Oil consumption is greater during break in as piston rings take time to seat 5 Break In Oil Changes Change engine oil and filter at 50 hours Change oil and filter again at 250 hours consult Lubricants section for oil recommendation BEFORE STARTING Check the water level by removing the pressure cap from the expansion tank or radiator In order to give the cooling water an opportunity to expand the level should be about 1 in 2 5 cm below the filler cap sealing surface when the engine is cold CAUTION Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns 2 Check the oil level in the crankcase with the A dipstick The oil level must be in the waffled area on the stick Never allow the level to go below this a
17. 0 762 0165 www northern lights com Northern Lights and Lugger are registered trademarks of Northern Lights Inc NORTHERN LIGHTS 2013 All rights reserved Litho USA
18. ECTRICAL SYSTEM PROBLEM POSSIBLE CAUSE RECOMMENDATION S Battery Will Not Charge Loose or corroded connections Clean and tighten battery connections Sulfated or worn out batteries Check specific gravity of each battery Check electrolyte level of each battery Loose or defective alternator belt Adjust belt tension Replace belt Starter Inoperative Check DC circuit breaker f the breaker is tripped reset it Loose or corroded connections Clean and tighten loose battery and harness plug connection Low battery output Check specific gravity of each battery Check electrolyte level of each battery Defective electrical system Repair or replace ground wire Starter Cranks Slowly Low battery output Battery is too small Battery cables are too small Check specific gravity Replace battery if necessary of each battery Check electrolyte level f low fill cells with distilled water of each battery Crankcase oil too heavy Fill with oil of appropriate viscosity Loose or corroded connections Clean and tighten loose connections Entire Electrical System Check DC circuit breaker If breaker is tripped reset it Does Not Function Faulty connection e Clean and tighten battery and harness plug connections Sulfated or worn out batteries Check specific gravity and electrolyte level of each battery If you cannot correct problems with these procedures see your Northern Lights dealer
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21. NSTRUCTIONS FOR FUTURE REFERENCE Prevent Bypass and Accidental Starting Recognize Safety Symbols and Instructions In addition to the information found in this section this 1 WARNING operator s manual uses three different signal words to outline potential dangers of a specific nature Do not start engine by shorting across start terminal Engine will DANGER indicates a hazardous situation which if start if nor mal circuitr y 1S bypassed A DAN G E not avoided will result in death or serious injury cre ating haz ard by runaway WARNING indicates a hazardous situation which if machiner y not avoided could result in death or serious injury CAUTION indicates a hazardous situation which Start engine only from operator s station A C AUTION if not avoided could result in minor or moderate injury Follow All Safety Instructions Handle Fuel Safely Avoid Flames Carefully read and understand ae all safety messages in this u 1 WARNING manual and on your machine s ond safety signs Keep signs in good and clean condition Replace missing or damaged signs Be sure new equipment components and repair parts include the current safety signs For replacement signs ALWAYS STOP ENGINE proper placement of safety signs or clarificationon any BEFORE FUELING safety issue consult your Northern Lights dealer or the MACHINE Always fill factory portable fuel tank outdoors There can be additional safety information contain
22. NV SYOLONGNOD NOILVTIVISNI TY 1 21 31ON NYL 18 lt s den aor S 16 ST y 338s 99 58 ss Sd ss do lt 3 IN3W3T3 dIONIS SPA BE L TWNOLWLAO AVI3M 1V3H3Md ET le a ogon f v 09 450 9g cg as 6 N qup e 2 1 yg vZ so Ly A zs jJ O 0 8 a eL D lt c yds T a lt d L e 310N 33S Sg 98 m yas b noe lt Av134 NMOQGLIRHS 480 T3NVd J0OMINOO T OL xd dH 017 58 ge lt 8 OF Z obo i AVI3S LAVIS yg 01 old Ed azo V ENVENI SSANYVH 9 3NVd ONL773LW4 11 13 2 Added 2 1 12 Wiring Diagrams PREHEAT f SHUTDOWN RUN INDICATOR LIGHT PURPLE NE PURPLE HOURMETER WHITE BYPASS SWITCH A A B F section AA MOLED PIN PLUG BLACK 12 Volt DC Standard Ground Engine Wiring Diagram For Northern Lights NL773LW4 with S 1B Drawing A 31 70 Wiring diagrams are subject to change without notice ONL773LW4 11 13 28 Added 2 1 12 iagrams D iring W y y w V Rey 9019 SS3N3VH TANVd o 9 Os amp dsb 1 joe qns sweibelp deZscIvst O S WIM YATELLTN 50977 u421140N 104 weibei
23. Not Open High Pressure Fuel System Many Northern Lights engines use high pressure fuel injection High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt any repair of fuel lines sensors or other ONL773LWA 11 13 6 Revised 3 12 12 Safety Rules Continued components between the high pressure fuel pump material containing asbestos Keep all bystanders and nozzles on engines with high pressure fuel away from any area where asbestos dust may be systems generated ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH Use Proper Lifting Equipment and Techniques PRESSURE FUEL INJECTION SYSTEMS 1 WARNING Avoid Hot Exhaust Say Lifting heavy components incorrectly 1 WARNING can cause severe injury or damage loads Do not use lifting eyes Lift the XB s to machinery Avoid unbalanced Avoid exposure to and physical generator set using lifting bars inserted contact with hot exhaust through the lifting holes on the skid gases Exhaust parts and streams can reach high Follow all recommended removal and installation temperatures during operation leading to burns or procedures in this and associated Northern Lights other serious injury manuals Cleaning exhaust filters can also lead to exposure to hot exhaust gas and the injury risk associated with Use Proper Tools it Avoid exposure to and physical contact with hot exhaust gases when cleaning exhaust fil
24. approved biodiesel fuel distributor to make sure the biodiesel blend meets specifications 6 Storing fuel a Keep dirt scale water and other foreign matter out of fuel b Avoid storing fuel for long periods of time c Hill the fuel tank at the end of each day s operation This will reduce condensation SP7 9 FUEL FILTERS 1 Your generator set should have a primary fuel filter installed We recommend the Racor brand of fuel filter water separators a Check the primary fuel filter daily as recommended by the filter manufacturer Empty the collection bowl as necessary b Change the element as often as necessary or every 200 hours c If the bowl fills with water change the primary and secondary element immediately 2 Change secondary fuel filter every 250 hours a Remove the spin on filter by turning it counterclockwise with a filter wrench Fill the new cartridge with fuel and install it after applying engine oil to gasket surface Screw on until the gasket surface comes into contact with sealing surface of filter base Then tighten it two thirds of a turn by hand Do not overtighten b The fuel filter part number is TI3LW3 24 52020 ONL773LWA 11 13 16 l Servicing SP10 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 connect
25. ding physical hazards safety procedures and emergency response techniques ONL773LWA 11 13 Revised 3 12 12 Safety Rules Continued Read and understand the MSDS for each chemical before you start any job that includes it Follow the procedures and use appropriate equipment exactly as recommended Contact your Northern Lights dealer or Northern Lights factory for MSDS s used on Northern Lights products Work in Well Ventilated Areas Exhaust fumes from engines contain carbon monoxide and can cause sickness or death Work in well ventilated areas to avoid prolonged exposure to engine fumes If it is necessary to run an engine in an enclosed area route the exhaust fumes out of the area with an approved leak proof exhaust pipe extension Remove Paint Before Welding or Heating Hazardous fumes can be generated zz when paint is heated by welding soldering or using a torch To avoid 52 potentially toxic fumes and dust remove paint before heating e Remove paint a minimum of 100 mm 4 in from the area that will be affected by heat f paint cannot be removed wear an approved respirator f you sand or grind paint use an approved respirator f you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers from the area Allow at least 15 minutes for fumes to disperse before welding or heating Do not use a chlorinated solvent in an area
26. ed Never fuel a hot engine Diesel is highly flammable and should be treated with care at all times Do not refuel while smoking or when near sparks or open flame ONL773LW4 11 13 3 Revised 3 12 12 Safety Rules Continued Prevent accidental discharge of starting fluids by Operating equipment requires the full attention of storing all cans in a cool safe place away from sparks the operator Do not use radio or music headphones or open flame Store with cap securely on container while operating machinery Never incinerate or puncture a fuel container Prevent fires by keeping machine clean of accumulated Practice Safe Maintenance trash grease and debris Always clean any spilled fuel as swiftly as possible Do not store oily rags which CAUTION can ignite and burn spontaneously A CAUTION Understand all service procedures Be prepared if a fire starts Keep a first aid kit and fire before starting work Keep area clean and dry extinguisher handy Keep emergency contact numbers Never lubricate service or adjust machine while it is for fire department doctors ambulance and hospital in Operation near the telephone Keep hands feet and clothing away from power driven equipment When shutting down an engine Service Machines Safely disengage all power and operator controls Allow the engine to cool completely before beginning any service work Do not wear a necktie scarf necklace
27. emperature gauge shows temperature within normal temperature range a Check the engine crankcase oil level b If the oil level 1s low fill with recommended lubricating oil and restart Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading 20 60 PSI after a few seconds of operation c If the oil level is normal DO NOT restart the engine Call your dealer for assistance 4 If the ECU is indicating a trouble code a Record the code and shut off the engine b Refer to Figure 16 on page 23 and the DC wiring diagram to determine the problem c Repair the problem and restart the engine SPARE PARTS 1 Northern Lights recommends that you the following spare parts on hand for field service The parts are available from your local Northern Lights dealer All owners should have the following Primary and secondary fuel filter elements Oil filters Air filter Alternator belt Thermostat and gaskets Glow plug Injector and washer com oa fo E If your set is operating a long distance from a servicing dealer add the following a Complete set of injectors b Copper washers for injector change c Complete set of glow plugs d Fuel lift pump ONL773LWA 11 13 12 Servicing Schedule Chart The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your generator set More detailed coverage of each Service Poi
28. f battery cables when installing the battery 3 When welding on the unit disconnect the regulator and battery Isolate the leads 4 Disconnect the battery cables when servicing the D C alternator 5 Never test with a screwdriver etc against any terminal to see if it emits sparks 6 Do not polarize the alternator or regulator 7 AD C circuit breaker protects your control panel and wiring harness It is located in the side of the generator junction box ONL773LWA 11 13 Servicing GLOW PLUGS SP 18 19 BATTERY CARE 1 Each cylinder is supplied with a glow plug which 1 Check electrolyte level every 50 hours or once per serves to heat the combustion chamber month Add distilled water to manufacturer s 2 check the glow plugs loosen the current recommended level carrying flat wire between the plus poles of the 2 Batteries cables and cable terminals should glow plugs Figure 14 Connect a D C test bulb be checked and cleaned every 100 hours between the plus pole of the battery and the Clean corrosion with a water and baking soda plus pole of the glow plug If the bulb lights up solution Flush with clean water Tighten terminals the glow plug is functioning properly and grease them to inhibit corrosion 3 Check all glow plugs and replace any faulty ones 3 Check the battery condition with a hydrometer every 250 hours SP20 WINTERIZING OUT OF SERVICE 1 Industrial sets a Drain and flush the radiator and c
29. fled area on the stick Never allow the level to go below this area Follow the lubrication recommendations above SP2 OIL CHANGES 1 The set is delivered with special break in oil Change the engine oil and oil filter after 50 hours of operation Use Service CC 30 weight oil during the first 100 hours 2 Change the oil and filter again at 100 hours using the oil recommended in Figure 4 After this change oil and filter every 200 hours 3 During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes first 4 Change oil at any seasonal change in temperature when a new viscosity of oil is required Change oil when engine is warm Dispose of waste oil in an approved manner Never use a flushing oil Loosen the clamp on the oil change tube Remove cap Drain oil Replace the cap and tube 9 Refill engine with recommended oil 10 Engine capacity with new oil filter is 4 8 quarts 4 5 liters ue Lo EM SP3 CHANGING LUBE OIL FILTER 1 Change the lube oil filter every 200 hours 2 Usea filter wrench to remove old filter Dispose of filter in approved manner 3 Make sure the gasket from the old filter is removed and discarded Clean mount face 4 Spread a thin film of engine oil on the rubber gasket on the new filter and screw it on nipple until gasket meets the sealing surface 5 Using hands only no wrench tighten filter one half turn farther Overtightening can do
30. g Hum S8ui Bb5ug puno HOA ZL 90 6 MNOISIS3H 6 SWHO OZv 38 OL SI NOISIS3M 90786 cc6 ldNVd NO 15 051 0 38 OL SI 39nv5 3esensSs3sd 10 c G310N SV L1d39X3 Q3QNVMIS 2 601 9 MLN vl 9MV 38 OL 1 5 NOILVTIVLSNI TV L e lt NYL N3339 e e e Q OVI8 xX2v18 lg yovld xov1i8 31n18 qa4 31n18 J1dMfid U OZ M313AL10A 3 0S 0 e 2 i H ame 6 310N 33S e ISd 08 0 vcf 39155304 110 yvig dnd yovid AA 31dund SIHOI1 39nv9 lt SIH O q33 HOLIMS SSVdA8 NMOGLNHS a lt dna lt PERD dois OV 18 O LYVLS HOLIMS JOMINOO lt Q34 MOTT3A V lt 55 1 UBI 3NVd IOMINOO ONL773LW4 11 13 29 Revised 2 1 12 SEE NOTES 4 5 amp 6 4 WIRE SINGLE PHASE 100 115VAC 19 50 HZ 100 120VAC 19 60 HZ iagrams iring W NOTES SET SW2 FOR CURRENT APPLICATION 50 OR 60 HZ 2 SET SW3 PER APPLICATION IF REMOTE VOLTAGE ADJUST RHEOSTAT IS USED 5 FOR REMOTE VOLTAGE ADJUST RHEOSTAT CUT JUMPER AND SPLICE INTO PURPLE LEADS 4 TERMIAL BLOCKS WILL NOT ACCOMMODATE LARGER GAUGE CONDUCTORS IF REQURIED REMOVE AFFECTED LEADS FROM TERMINAL BLOCK S AND MAKE CONNECTIONS
31. iming off Service air cleaner e Have dealer check back pressure Use correct fuel for temperature e See your dealer e See your dealer Engine Emits White Smoke Improper fuel Cold engine Defective thermostat Engine injectors timing off Use correct fuel for temperature Warm up engine to normal operating temperature e Remove and check thermostat See your dealer If you cannot correct problems with these procedures see your Northern Lights dealer ONL773LWA 11 13 26 Revised 2 1 12 iagrams D iring W 1 60 32018 3NI9N3 xovig auHw Si V auHM 1 A399 AINO 3NIMVW HOLIMS dN3L 1SnvHX3 WIYLSNGNI 3 0 6 3NINVIN 3 20 QN9 3SVO L HOLIM 39018 3NION3 D _ dN31 D V 10 Ag S33H SIOVINOO 3S3VHOSIQ 33d YSHSINONILX4S 33 gay uns nans 19008 45 aand OE o 32018 aN 8 4YOLO3NNOO 9 OL VLG ATL YOLVNYSLIV LN _ _ nouum 59 qns swesbelp 986 9 Duiweiq Hum 8ui B5ug punoas 5g FONVOHOLIMS ZO 918 Q33 NMO38 3 3 INV 1009 rey N WNOILdO ies NOILLO3NNOO ON x WoD 3LIHM z E ISd 92 099 X7 3UHM 30m8 PSY WIMISDONI 4 01Z ANISVW 4 002 JYNSS3Yd 10 a WV IV 33d 4 Woo 9n1d SSINYYH ON _ WNOI
32. ion you will need to run and service your new unit INTRODUCTION 2 SERVICING Models Included 2 Lubrication General 14 Model Numbers 2 C Tlieckins Qilu 14 Serial NuUniDETS vin 2 OTLC DADOS uu as wanawakeyguwankuqhasqiiwaukaaquspaquads 14 Changing Oil Fier u aa 14 WARRANTY 3 PA RETRO RE PE 15 bel E E 15 SAFETY RULES 3 7 Valye CISaraliGe Suae ua 15 Fuels eC lt gt 16 LOCK OUT TAG OUT PROCEDURES 8 Ue E REESE NER T 16 Bleeding the Fuel System 17 COMPONENT LOCATIONS 18 19 Industrial Generator 9 Injection Pump 19 Cooling System 19 CONTROL PANEL Cooling System Flushing 20 S 1B Control Panel 10 Cl an RAI OP Ju a aaa 20 Generator Ent uuu aaa 20 OPERATING PROCEDURES Electrical System General
33. ions 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 6 The Fuel System the NL773LW4 varies slightly from this depiction The fuel system is self bleeding However any system may need manual bleeding when a A new fuel filter 1s installed b The engine has run out of fuel c The fuel lines injection pump or any other fuel system component has been removed and installed Loosen bleed bolt A Figure 6 on top of the filter Pump hand primer B on fuel lift pump until pure fuel no bubbles escapes from bleed bolt Tighten bleed screw 3 Loosen bleed screw C Pump hand primer B until pure fuel no bubbles escapes Then tighten bleed screw 4 If the engine does not start after the above bleed ing process loosen a fuel line at the injector while cranking the engine with the starter motor until pure fuel escapes Then tighten the connection Do each line one at a time 5 After the engine has started use a piece of cardboard to look for fuel leaks ONL773LWA 11 13 17 Servicing For illustration purposes the NL773LW4 may look a little different
34. materials use food or beverage containers that may mislead containing asbestos When servicing wear an someone into drinking from them approved respirator A special vacuum cleaner is recommended to clean asbestos If this vacuum is Do not pour waste onto the ground down a drain or not available apply a mist of oil or water on the into any water source ONL773LW4 11 13 7 Added 3 12 12 Lock Out Tag Out Procedures Scope During 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 General Policy 44 CAUTION x To avoid dangerous or hazardous situations refrain from any of the following e 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 attempti
35. ng routine maintenance As operator it is your obligation to learn about your equipment and its proper maintenance This is not a comprehensive technical service manual Nor will it make the reader into an expert mechanic Its aim is to aid you in maintaining your unit properly Unit Identification MODELS INCLUDED This manual covers the operating instructions for NL773LW4 amp NL773LWAE industrial generator sets Model Numbers Model numbers give the unit s application block model aspiration and RPM NL NL Northern Lights industrial generator set NL773LW4 Model number of engine block Bore 77mm 3 Northern Lights industrial generator set with a 773 engine and PX 309K2 generator end Tier IV 773 W new winding within Cylinders generator set E Electronic Northern Lights industrial generator set with a 773 engine and PX 309K2 generator end Electronic Tier IV NL773LW4 Serial Numbers NORTHERN LIGHTS Serial No Model No Northern Lights 4420 14th Ave NW Seattle WA 98107 Figure 1 Generator set serial number plate Your set has three serial numbers an engine number stamped on the block a generator plate and a generator set plate Use the serial number on the generator set plate when ordering parts or in correspondence The generator set plate is found on the service side of the generator and resembles the drawing in Figure 1 ONL773LW4 11 13 Re
36. ng 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 sy
37. nt SP is listed on the page noted in the page column DAILY EVERY 500 HOURS SP1 Check oil level in engine SP2 3 Change engine oil and filter SP5 Check V belt tension SP8 Change primary fuel filter element SP7 Check primary fuel filter SP9 Change secondary fuel filter SP13 Check coolant level SP18 Check electrolyte in batteries EVERY 1000 HOURS SP4 Change air cleaner element AFTER FIRST 50 HOURS SP6 Check valve clearances SP2 3 Change engine oil and filter SP11 Check injectors SP6 Adjust valves EVERY 2500 HOURS AFTER FIRST 100 HOURS SP12 Check fuel injection pump SP2 3 Change engine oil and filter SP14 Check and flush cooling system EVERY 250 HOURS SP2 3 Change engine oil and filter SP4 Check air cleaner SP16 Check and clean radiator SP19 Check state of charge of batteries SERVICE 250 500 1000 POINT OPERATION DAILY Hours Hours Hours ENGINE Check oil level Change engine oil Change lube oil filters 5 Check air cleaner 4 Check V belt tension Check valve clearances FUEL SYSTEM Check primary filter Racor 14 Change primary filter element Racor 14 Change secondary fuel filter 15 Bleed the fuel system 17 Check injectors 17 Check fuel injection pump T EEE SP13 8 amp 17 Check coolant level SP14 18 Check and flush cooling system SP16 18 Check and clean radiator fins ELECTRICAL SYSTEM SP18 19 Check electrolyte level in batteries SP19 19 Check condition of batteries with hydrometer OUT OF SERVICE SP20 19 Winteri
38. o stop the engine in the event of high water temperature or low oil pressure Other alarms and shutdowns are available as optional equipment NOTE Do not rely on your shutdown to the exclusion of careful gauge monitoring Watching your gauges can prevent damage to the unit and dangerous power losses ONL773LW4 11 13 updated 11 26 13 Operating Procedures 2 Electronically controlled generator sets will run at reduced capacity when the Engine Control Unit ECU detects a problem with one of its sensors These problems are indicated by a flashing trouble code on the ECU warning light For the NL676L4E see Figure 16 on page 23 for the meaning of different codes Do the following when your warning or shutdown system is activated a Check the temperature gauge Industrial sets If above 230 F 110 C shut off the engine immediately b Use the Trouble Shooting Guide on page 21 to isolate the cause of the 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 Make repairs Restart your Industrial set after the temperature gauge registers below 225 F 107 C d Watch the temperature gauge regularly and turn off the unit if the temperature rises above 230 F 110 C on Industrial sets Repeat trouble shooting If shutdown is activated and the t
39. ooling system Leave dry or refill with antifreeze water mixture If refilling start the engine and run to circulate the antifreeze b Fill the fuel tank or add biocide as per Figure 14 Glow plugs manufacturer s instructions c Seal the air cleaner inlet exhaust opening BOOSTER BATTERIES crankcase breather pipe and fuel tank vent with plastic bags and tape CAUTION Battery gas can explode d Store the set in a dry protected place If unit must Keep all flames and sparks away from batteries be stored outside be sure it is well protected with a cover 1 Before changing or using booster batteries check bat e Change the crankcase oil and filter tery electrolyte level Add distilled water if necessary f Loosen the alternator belt 2 Booster and main batteries must have the same g Disconnect and clean battery Remove to warm voltage rating storage place if possible 3 First connect positive terminal of booster h Clean outside of unit Paint any scratched or battery to positive terminal of main battery chipped surfaces Put corrosion preventative on Then connect negative terminal of booster all exposed metal surfaces battery to ground on the engine block see Figure 15 4 Remove booster battery after starting engine 5 Sealed batteries See manufacturer charging and booster instructions Figure 15 Battery connections Battery Booster Battery ONL773LW4 11 13 21 Troubleshooting DC EL
40. ooling water an opportunity to expand the level should be about 1 in 2 5 cm below the filler cap sealing surface when the engine is cold 2 The pressure valve in the filler cap releases when the pressure is approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it is faulty SP14 COOLING SYSTEM FLUSHING Flush the cooling system every 2500 hours or every 12 months whichever comes first 2 Industrial sets Remove radiator cap and open drain cocks on radiator and engine block Pour clean water into radiator until water coming from radiator is clear of discoloration Close the radiator drain and continue flushing until water from engine drain is clear Open all drain cocks and drain completely Close drain cock and refill with recommended coolant mixture Clean fins on radiator 3 Coolant Specifications Use 50 water 50 ethylene glycol antifreeze mix Antifreeze mixture is recommended as a good year round coolant 4 Check hoses and connections and repair any leakage SP16 CLEAN RADIATOR 1 Remove debris from radiator fins daily 2 In very dusty applications clean the radiator with compressed air or steam cleaner every 100 hours Clean in the reverse direction of the airflow ELECTRICAL SYSTEM GENERAL 1 Never switch battery switch off or break the circuit between the alternator and batteries while the engine is running Regulator damage can result 2 Do NOT reverse the polarity o
41. r Northern Lights dealer ONL773LW4 11 13 25 ENGINE PROBLEM High Fu Consumption continue Troubleshooting POSSIBLE CAUSE Fuel leakage Excessive load on engine RECOMMENDATION S Improper installation or tightening e Check loads Below Normal Engine Temperature Engine Malfunctions at High Output Range Thermostat not working properly Temperature gauge not working properly Fuel supply insufficient Fuel injection amount between plungers uneven e Check thermostat Check water temperature with thermometer Air in fuel system or clogged fuel filter element Check fuel injectors Valve clearance adjusted incorrectly Re adjust valve clearances Valve spring broken Governor spring broken Replace valve spring Replace governor spring Low Oil Pressure Low oil level Improper type of oil Partially plugged oil filter Fill crankcase to proper level Drain and fill crankcase with correct oil Replace filter Check bearings oil pump and relief valve for wear High Oil Consumption Break in period Crankcase oil too light Oil leaks Oil consumption decreases after break in Use proper viscosity oil Check for leaks in lines around gaskets and drain plug Engine Emits Black or Gray Exhaust Smoke Clogged or dirty air cleaner Defective muffler back pressure too high Improper fuel Injection nozzles dirty Engine injectors t
42. re 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 ONL773LWA 11 13 8 Industrial Generator Component Locations Figures 2 A and B NL773LW4 Junction Air Filter Crankcase Vent Lube Oil Fill Coolant Fill Injection Pump O ON Fuel Lift Pump Dipstick Fuel Inlet and Return Oil Filter 11 12 Block Water Drain Secondary Fuel Filter ONL773LWA 11 13 9 13 14 15 16 1 7 Hourmeter Control Panel Starter Alternator Radiator Shroud Control Panel La PREHEAT amp SHUT GENERATOR GENERATOR DOWN BYPASS HOURS a Hobbs o o owe TOTAL NOVIS d Figure 3 Series 1 B Generator Control Panel SHUTDOWN BYPASS PREHEAT SWITCH There are two functions built into this switch preheating the engine and bypassing the engine safety shutdown circuit enabling a quicker start Hold the switch in the ON position for approximately 10 to 20 seconds before starting a cold engine Holding the switch ON for too long can burn out the glow plugs NOTE Three position Engine Control switches must be in the RUN position during preheating Preheat switch must be held in ON position during starting ENGINE CONTROL SWITCH To start the engine hold this switch in the START position
43. rea Always add the same viscosity of oil as is already in the crankcase 3 Check the fuel tank level and open any fuel valves 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 Hold the Shutdown Bypass Preheat switch in the ON position for 10 to 20 seconds before starting a cold engine Holding the switch too long can burn out the glow plugs This step is not necessary if the engine 15 already warm 2 While holding the Shutdown Bypass Preheat switch in the ON position push the Engine Control switch to the START position 3 As soon as the engine starts release both switches Do not crank the starter for more than 20 seconds consecutively If the engine fails to start with the first attempt be sure that it has stopped completely before re engaging OPERATING 1 Check oil pressure often Oil pressure must be above 15 PSI The water temperature must be below 225 F 107 C Check the AC voltage and frequency If these deviate from normal levels shut down the generator set and investigate 1 Let the unit run unloaded for a three to five minute warm up period 2 Add electrical load STOPPING 1 Remove electrical load from the generator set 2 Move the Engine Control switch to the STOP position momentarily SHUTDOWNS AND ALARMS 1 Generator sets have shutdown systems t
44. rings or other jewelry or any loose clothing when working near moving parts Tie long hair behind your head If any of these Keep all parts in good conditions and properly items get caught in moving machinery severe injury or installed Fix damage immediately Replace any death could result worn or broken parts Remove any build up of grease oil or debris Securely support any machinery elements that must be raised for service work with support or lifting machinery specifically intended for that purpose Check for any loose electrical connections or faulty wiring Disconnect battery ground cable before making any adjustments or service work Look completely around engine to make sure that everything is clear before starting Stay Clear of Rotating Drivelines Wear Protective Clothing R 1 WARNING Entanglement in rotating drivelines can cause serious injury or death Keep shields in place at all times To prevent catching anything in moving machinery Make sure that rotating shields turn freely in pace always wear close fitting clothes and safety equipment with the drivelines appropriate to the job Prolonged exposure to loud noise can cause hearing Do not wear loose fitting equipment around rotating loss or impairment Wear suitable authorized CD hearing protection such FA as earmuffs or plugs to Y protect against loud noises drivelines Stop the engine and make sure that all AD moving parts have
45. rolyte is poisonous and strong enough to burn skin eat holes into clothing and other materials and cause blindness if splashed into eyes To Avoid Hazards Fill batteries only in well ventilated areas Wear appropriate eye protection and rubber gloves Never use air pressure to clean batteries Wear appropriate ventilation equipment to avoid inhaling fumes when adding electrolyte Do not spill or drip electrolyte Use correct jump start procedure if required If acid is spilled on skin or in eyes 1 Flush skin with water 2 Apply baking soda or lime to help neutralize acid 3 Flush eyes with water for 15 30 minutes 4 Get medical attention immediately If acid is swallowed 1 DO NOT induce vomiting 2 Drink large amounts of water or milk without exceeding 2 liters 2 quarts 3 Get medical attention Battery posts terminals and related accessories can contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling chemicals can cause serious injury Among the potentially hazardous chemicals that may be used with Northern Lights products are lubricants coolants paints and adhesives Handle Chemical Products Safely Direct exposure to hazardous All potentially hazardous chemicals come with a Material Data Safety Sheet MSDS The MSDS provides specific details on chemical products inclu
46. rt Short Short Long Short Short Short 1 Cycle 1 Cycle repeated Case 2 Error combination when 2 errors occur at the same time Code 13 13 means Long Short Short Short Code 04 04 means Short Short Short Short Long Short Short Short Short Short Short Short ed 1 Cycle ONL773LW4 11 13 23 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE Engine Hard to Start Improper starting procedure or Will Not Start No fuel Low battery output Excessive resistance in starting circuit Crankcase oil too heavy Improper type of fuel Water dirt or air in fuel system Clogged primary fuel filter element Lift pump malfunction Clogged secondary fuel filter element Dirty or faulty injection nozzles Uneven compression pressure between cylinders RECOMMENDATION S See starting section of this manual Take special note of Bypass Switch operation Check level of fuel in fuel tank Check electrolyte level and condition Clean and tighten all battery connections Use oil of proper viscosity Consult fuel supplier and use proper type of fuel for operating condition Drain flush fill and bleed system Clean or replace filter element Repair lift pump Replace filter element Have your dealer check injection nozzles Check cylinder compression pressure Engine Runs Irregularly Below normal engine temperature or Stalls Frequently Clogged primary fuel filter element
47. stem 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 CAUTION x 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 CAUTION x 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 Ensu
48. ters A C AUTION During auto or manual stationary exhaust filter Makeshift tools and procedures cleaning operations the engine will run at can create safety hazards elevated temperatures for an extended period of Always use appropriate tools for time Exhaust parts and streams can reach high the job temperatures during operation leading to burns or other serious injury Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware always use the correct sized tools Avoid Harmful Asbestos Dust Do not use US measurement tools on metric fasteners or vice versa Use only service parts that meet Northern Lights specifications Inhaling asbestos fibers may cause lung cancer Avoid breathing any dust that may be generated when handling components containing asbestos fibers including some gaskets A CAUTION Disposing of waste improperly can threaten the Dispose of Waste Properly The asbestos used in these components is usually environment and lead to unsafe working conditions found in a resin or otherwise sealed Normal Potentially harmful waste used in Northern Lights handling of these components is not dangerous equipment can include oil fuel coolant filters and as long as airborne dust containing asbestos is not batteries generated Avoid creating dust Never use compressed air for Use leakproof containers to drain fluid Do not cleaning Avoid brushing or grinding
49. vised 7 10 13 Warranty A warranty registration certificate is supplied NOTE If the warranty is to apply the servicing with your set The extent of coverage is described instructions outlined in this manual must be in the Limited Warranty Statement We followed If further information is needed please recommend that you study the statement carefully contact an authorized dealer or the factory Safety Rules A 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 IMPORTANT SAFETY INSTRUCTIONS on parts and components from outside suppliers Electromagnetic equipment including generator sets that is not reproduced in this manual Consult the and their accessories can cause bodily harm and suppliers for additional safety information life threatening injuries when improperly installed operated or maintained To prevent accidents be aware Learn how to operate the machine and how to use of potential dangers and act safely the controls properly Only trained personnel should operate machines or work on or around them READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL Keep you machine in proper working condition PRIOR TO THE INSTALLATION UNAUTHORIZED MODIFICATIONS TO THE OF ANY GENERATOR SET OR MACHINERY MAY IMPAIR ITS FUNCTION ACCESSORY KEEP THESE AND SAFETY PARAMETERS I
50. where welding Will occur Work only in areas that are well ventilated Dispose of paint and solvent properly Service Cooling System Safely Opening a pressurized cooling system can release explosive fluids and causing serious burns Before opening any pressurized cooling system make sure the engine has been shut off Do not remove a filler cap unless it is cool enough to comfortably grip with bare hands Slowly loosen cap to relieve pressure before opening fully Avoid High Pressure Fluids Relieve pressure prior to disconnecting pressurized lines Escaping fluid under pressure can penetrate the skin causing serious injury Always relieve pressure before disconnecting hydraulic or other pressurized lines Tighten all connections firmly before re applying pressure If searching for leaks use a piece of cardboard Always protect your hands and other body parts from high pressure fluids If an accident occurs see a doctor immediately Any high pressure spray injected into the skin must be removed within a few hours to prevent the risk of gangrene or other infection Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns and bodily injury Pressurized lines can rupture when heat goes beyond the immediate flame area Do not weld solder or use a torch or open flame near pressurized lines or other flammable fluids Do
51. zing or out of service 3 Perform all maintenance once a year even if hour level has not been reached 6 Clean injection nozzles every 1500 hours Consult manufacturer s maintenance schedule note on chart 7 For EPA emission standards fuel nozzle needs to be Whenever necessary cleaned every 1500 hours the fuel nozzle and fuel pump More often if necessary need to be cleaned adjusted or repaired every 3000 After first 50 hours then after 100 hours then at every 250 hours hours and the quality guarantee for these parts is 1500 hours or 2 years ONL773LWA 11 13 13 Updated 7 9 13 Servicing LUBRICATION GENERAL 1 Use only clean high quality lubricants stored in clean containers in a protected area 2 These lubricants are acceptable a API Service CC CD CE single viscosity oils b API Service CC CD SF multi viscosity oils 3 Use the proper weight oil for your average operation temperature Air Single Multi Temperature Viscosity pane i Mr SAE 30W 15 40 10 to 32 F 23 to 0 C SAE 10W SAE 10 30W Below 10 F 23 C SAE 5W SAE 5 20W Figure 4 Lube Oils 4 Some increase in oil consumption may be expected when SAE 5W and SAE 5 20W oils are used Check oil level frequently 5 Never put additives or flushing oil in crankcase SP1 CHECKING OIL LEVEL Check the oil level in the crankcase with the dip stick The oil level must be in the waf
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