ONL498-2 - Northern Lights
Contents
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4. OPERATOR S MANUAL Publication ONL498 2 for Models NL498K2 and NL498D2 TDOW N ND PR BYPASS EHEAT NORTHERN LIGHTS CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Northern Lights 4420 14th Avenue N W Seattle WA 98107 Tel 206 789 3880 Fax 206 782 5455 Copyright 2006 Alaska Diesel Electric Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Alaska Diesel Electric Inc Printed in U S A PART NO ONL498 2 03 06 OPERATOR S MANUAL for Models NL498K2 and NL498D2 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 INTRODUCTION en 2 W Belts M 12 Model Included sss 2 Valve Clearances sse 12 Model Number veto 2 Retightening Cylinder Head Bolts 13 Serial Numbers sse 2 Fuels General as xin inan ne nk m lklek dl 13 Fuel Filters ecrire 13 WARRANTY erret rettet tenente 3 Bleeding the Fuel System 14 Injector Service ei s l m eerte 14 15 SAFETY RULES esee 3 Injection PUMP inn 15 Cooling System General 15 COMPONENT LOCATION Checking Coolan
5. In many cases the generator sets cannot equipment and its proper maintenance This is not a be moved to a repair facility Failures often occur comprehensive technical service manual Nor will it in remote areas far from competent assistance make the reader into an expert mechanic Its aim is therefore maintenance schedules must be adhered to aid you in maintaining your unit properly to more strictly Failures begin with minor problems that are overlooked and become amplified when not corrected during routine maintenance Unit Identification MODELS INCLUDED This manual covers the operating instructions for NL498K2 and NL498D2 industrial generator sets Model Numbers Model numbers give the unit s application block model aspiration and RPM NL 498 K2 amp D2 NL Northern Lights industrial generator set E of Bare block K2 Taiyo Generator End y D2 Stamford Generator End 4 98 mm NL498K2 Northern Lights industrial generator NL498D2 Northern Lights industrial generator set with Leere set with a 498 engine and a NE498D2 a 498 engine and a UCI224C16 generator end PX 332K generator ena Tier II Tier II 4 valve Serial Numbers Your set has three serial numbers an engine number stamped on a plate attached to the valve cover a generator end serial Serial No number and a generator set serial number Model No NORTHERN LIGHTS Northern Lights NOTE Always use the ge
6. oil 5 Never put additives or flushing oil in crankcase 6 SP1 CHECKING OIL LEVEL 1 Check the oil level in the crankcase with the dipstick Change the lube oil filter every 250 hours Use a filter wrench to remove old filter Dispose of filter in approved manner Make sure the gasket from the old filter is removed and discarded Clean mount face 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 Using hands only no wrench tighten filter one half turn farther Overtightening can do damage to filter housing 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 Oil filter part number is 24 07301 daily The oil level must be between the high and SP4 AIR CLEANER low marks on the stick Fill with the recommended oil and fill only to the high mark on the dipstick 1 Follow the lubrication recommendations above SP2 OIL CHANGES 2 1 The set is delivered with special break in oil 3 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 the above diagram After this change oil and filter every 250 hours 3 During intermittent cold weather operation change oil every 100 hours or six week
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8. 8 Secondary Fuel Filter 13 Lube Oil Filter Ts E Me ANO 4 AVR Fuse 8 Rocker Arm Cover 14 Fuel Return Manifold 19 Oil Pan 5 Air Cleaner 10 Fuel Injection Pump 15 Lube Oil Dipstick 20 Flywheel Housing 21 Starter ONL498 2 03 06 6 Control Panels 1 SHUTDOWN BYPASS PREHEAT SWITCH There are two functions built into this switch GENERATOR preheating the engine and bypassing the engine safety d m y 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 2 ENGINE CONTROL SWITCH To start the engine hold this switch in the START position 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 Di NOTE The rocker switch is used on Series I panels only and has a light that glows when the set is running 3 HOUR METER Y i Keeps track of engine running time MUN 4 OIL PRESSURE GAUGE TEB Shows the oil pressure in the engine lubricating system 5 WATER TEMPERATURE GAUGE Registers the temperature of the cooling water 6 D C VOLTMETER OR AMMETER When the engine is
9. the load to help seat the rings BEFORE STARTING 1 Check the water level by removing the pressure cap from the 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 dipstick The oil level must be between high and low marks on the stick Never allow the level to go below this area Always add the same viscosity of oil as is already in the crankcase 3 Check the fuel tank level and open any fuel valves on the tank and at the secondary fuel filter 4 Turn on any optional battery switch that may have been installed 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 heater elements This step is not necessary if the engine is 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 Units with Series 3 and Serie
10. 1 cylinder to the compression TDC and adjust the clearance of the mark of the above table Then turn the flywheel once and adjust the clearance of the mark When adjusting the 4 valve cylinder head push the bridge head so that a valve bridge and two valve stem heads contact uniformly and adjust the adjusting bolt so that the gap of the valve stem head becomes 0 Tighten a locknut after the valve bridge is fixed with a wrench Apply oil to the contact surface between adjusting screw and push rod ONL498 2 03 06 14 d Class E F G or H industrial or marine fuels e ASTM D975 60T No 4 D and higher number fuels Disassembly Camshaft side Fan side 5 Storing fuel a Keep dirt scale water and other foreign matter out of fuel Head bolt disassembly order j b Avoid storing fuel for long periods of time 4 cylinder head c Fill the fuel tank at the end of each day s Camshaft side operation This will reduce condensation B 0 O O OS Assembly SP8 10 FUEL FILTERS Fan side 1 Your generator set should have a primary fuel filter Head bolt tightning order installed We recommend the Northern Lights brand 4 cylinder head of fuel filter water separators Figure 9 Cylinder Head Bolt Torque Sequence 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 2
11. 50 hours c If the bowl fills with water change the primary and secondary element immediately 2 Change secondary fuel filter every 250 hours NOTE The fuel filter on the engine is considered the secondary fuel filter The engine will be fitted with an element or cannister type secondary fuel filter a Element Retightening Cylinder Head Bolts 1 Tighten bolts when the engine is cold 2 Loosen the nuts and remove rocker arm cover 3 Tighten head bolts with a torque wrench in the order shown in figure 9 Tighten bolts evenly in 2 or 3 passes ending at the specified torque in final pass 4 Replace rocker arm cover Tightening Torque specifications First Step 49 0 58 8 Nem 5 0 6 0 kgfem Second Step 103 1 112 9 Nem 10 5 11 5 kgfem Turn off the fuel valve Remove the bowl retaining ring by hand Dispose of fuel and contaminants from bowl and wipe clean Put in new element Fill bowl with fuel and replace by tightening retaining ring Open fuel valve b Spin on type filter Turn off the fuel valve 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 the sealing surface of the filter base Then follow instructions on FUELS GENERAL 1 Use only clean high quality fuels of the following specifications as defined by ASTM des
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15. El NM 11 Sqva1 LNdLNO YOLVIINI9 SAYIT LNGANO YOLVYINIS SOOT LndinO YOLVVINID Ol 7 8 4 SALON 335 Ol Y 8 Z S3ION 33S ONL498 2 03 06 23 29104 INOYJIM 28upi2 0 192 QNS su p 8n p EWM 9 04S 9 HAV O9vXS s o e eues pee y z weber Duuu OV Zd8671N qa3sn va ANII S31V9IONI EERO LAN 39M V HO 3dVl TWOINLOATA 9NISn XIS Qv31 31Vv1OSI 0O9gvXS 3HL NO 1H9I3 ONY N3 A3S SIVNINS3L OL 1H913 ONY N3A3S SQV31 193NNOO y gauino3s JON SI 39VL IOA N 1 31 NOLLO3NNOO IVMIn3N 313130 Z 3009 1v2IH123 13 NOIL332SIQ S JINOLSNO LV ATNO YSWOLSND AG Q3QN 039 38 Ol 38NV SL3SN3O 3NINVN TWNOILVN 3HL JO 8 SlZ VOlNV HLM 39NVQNOOOV NI LN3S3ud SI IVALNIN N3A383HM 39NVHO 343VAW 38 Ol SI 931 HOIH 9 3002 1v201 31BvOllddv ANY ANY 3009 1V231M159313 1VNOLLVN 3HL HLIM H Man NM Rn JONVOYODDV NI 38 OL SI SNIGNMOYD AINO SI 3SN39 IWINLSNGNI Z NOILVTIVISNI 3d O3NIA3130 NIZIS SNOLONGNOD LNdNO NIVIN 03193NNOO ANY AJLON SY 1d30X3 OVAGOS ONVMISILTIN GaNddNS SINOLSNI SLVSIGNI SINNT GSHSVG N3GGIH e D SOL MLW 3dAL pL SMV 38 Ol SYOLONGNOD NOILVTIVLSNI TIV 1
16. P6 amp 7 Check valve clearances retighten cyl head bolts 4 FUEL SYSTEM SP8 Check primary filter SP9 Change primary filter element SP10 Change secondary fuel filter SP11 Bleed the fuel system SP12 Check injectors SP20 Check fuel injection nozzle pressure SP13 Check fuel injection pump e COOLING SYSTEM SP14 Check cooling water level SP15 Check and flush cooling system e SP16 Check and clean radiator fins ELECTRICAL SYSTEM SP17 Check electrolyte level in batteries SP18 Check condition of batteries with hydrometer OUT OF SERVICE SP19 16 Winterizing or out of service 3 Perform all maintenance once a year even if hour level has not been reached 1 2 Consult manufacturer s maintenance schedule note on chart 3 Whenever necessary 4 More often if necessary 5 After first 50 hours 6 Adjust at first 100 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 3000 hours or 5 years ONL498 2 03 06 11 Service Point OPERATION HOURS DATE 50 HOURS SP5 Check V belt tension SP17 Check electrolyte in batteries 250 HOURS SP2 Change engine oil SP3 Change lubricating oil filters SP4 Check air cleaner SP9 Change primary filter element SP10 Change secondary fuel f
17. an opportunity to expand the level should be bracket and nuts Tighten nuts evenly to 18 20 about in 2 5 cm below the filler cap sealing ft Ibs 2 5 2 9 kgf m surface when the engine is cold b Install fuel lines b The pressure valve in the filler cap releases c Install return lines and clamps when the pressure is approximately 12 PSI d Install delivery lines Leave loose at injectors for 0 9 kgm cm Use a cap pressure tester to check bleeding cap if you suspect it is faulty e Pump hand lever on fuel pump to fill lines Tighten lines at injectors Start engine and check SP15 COOLING SYSTEM FLUSHING for leaks using a piece of paper or cardboard DO NOT use hand to check for leaks 1 Flush the cooling system every 2000 hours or every 12 months whichever comes first SP13 INJECTION PUMP 2 Remove radiator cap and open drains on radiator and engine block The radiator drain is a rubber cap on the bottom of the radiator Loosen the hose clamp and remove the clamp and cap The hex headed engine block drain is on the service side of the engine below the intake manifold next to the flywheel housing 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 drains and drain the engine and radiator completely Close drains and refill the radiator with recommended coolant mixture Use 5096 water 5096
18. ature with thermometer not working properly Low Oil Pressure Low oil level Fill crankcase to proper level Improper type of oil Drain and fill crankcase with correct oil Partially plugged oil filter Replace filter High Oil Consumption Break in period Oil consumption decreases after break in Crankcase oil too light Use proper viscosity oil Oil leaks Check for leaks in lines around gaskets and drain plug If you cannot correct problems with these procedures see your Northern Lights dealer ONL498 2 03 06 21 ENGINE PROBLEM Engine Emits Engine Emits White Smoke or Gray Exhaust Smoke POSSIBLE CAUSE Black Clogged or dirty air cleaner Defective muffler back pressure too high V belt loose Improper fuel Injection nozzles dirty Engine out of time Leak in intake line Intake and exhaust valve timing not set properly Improper fuel Cold engine Defective thermostat Engine out of time Fuel injection not spraying correctly Intake and exhaust valve timing not set properly Troubleshooting RECOMMENDATION S Service air cleaner Have dealer check back pressure Adjust the belt see page 12 Use correct fuel for temperature See your dealer See your dealer Repair or replace Adjust valve clearance see page 12 Use correct fuel for temperature Warm up engine to normal operating temperature Remove and check thermostat See your deal
19. by dealer Replace injectors Best done by dealer See your local dealer ONL498 2 03 06 20 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION S Engine Overheats Low coolant level Fill tank or radiator to proper level Check hoses for loose connections and leaks Cooling system needs flushing Flush cooling system Defective thermostat Remove and check thermostat Defective temperature gauge Check water temperature with thermometer and replace gauge if necessary Fan belt loose Adjust belt tension see page 12 Engine Knocks Insufficient oil Call your dealer Injection pump out of time Call your dealer Below normal engine temperature Check your thermostats Check water temperature to see if temperature gauge is working properly Engine overheating See Engine Overheating section Connecting rod bolt loose Tighten to torque 44 1 to 49 0 Nem 4 5 kgf m to 5 0 kgf m High Fuel Consumption Improper type of fuel Use correct fuel for temperature Clogged or dirty air cleaner Service air cleaner Improper valve clearance See your dealer Injection nozzles dirty See your dealer Injection pump out of time See your dealer Engine not at proper temperature Check your thermostats Check water temperature with thermometer and replace gauge if necessary Below Normal Thermostats not working properly Check thermostats Engine Temperature Temperature gauge Check water temper
20. e bulb lights up the heater is functioning properly If not the heater isn t functioning and the heater elements need replacing BOOSTER BATTERIES CAUTION Battery gas can explode Keep all flames and sparks away from batteries 1 Before changing or using booster batteries check battery electrolyte level Add distilled water if necessary 2 Booster and main batteries must have the same voltage rating 3 First connect positive terminal of booster battery to positive terminal of main battery Then connect negative terminal of booster battery to ground on the engine block see Figure 11 Battery Booster Battery Figure 11 Battery Connections 4 3 Remove booster battery after starting engine Sealed batteries See manufacturer charging and booster instructions SP 17 18 BATTERY CARE ll Check electrolyte level every 50 hours or once per month Add distilled water to manufacturer s recommended level Batteries cables and cable terminals should be checked and cleaned every 100 hours Be sure to not connect battery cables backwards the and ends confused as this could cause damage to the stator coil and the alternator diode Clean corrosion with a water and baking soda solution Flush with clean water Tighten terminals and grease them to inhibit corrosion Check the battery condition with a hydrometer every 500 hours SP19 WINTERIZING OUT OF SERVICE 1 Drain a
21. ed screw ig Drain cock Water separator TI gt Fuel filter Figure 10 Bleeding Fuel System The fuel system is self bleeding However any system may need manual bleeding when a A new fuel filter is 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 screw on top of the fuel filter Figure 10 Pump hand primer on fuel lift pump until pure fuel no bubbles escapes from bleed screw Tighten bleed screw Loosen bleed screw on the injection pump Pump hand primer until pure fuel no bubbles escapes Tighten bleed screw SP11 BLEEDING THE FUEL SYSTEM 4 Tf the engine does not start after this bleeding 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 SP12 INJECTOR SERVICE 1 Injectors should be checked every 500 hours Check should be made by a Northern Lights dealer or local injection repair station CAUTION Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury If injured by escaping fuel see a doctor at once 2 Injector removal a Clean loose dirt from around the injectors and the fuel lines b Relieve high pressure in the f
22. er See your dealer for repair Adjust valve clearance see page 12 If you cannot correct problems with these procedures see your Northern Lights dealer ONL498 2 03 06 22 20110u INOYJIM 28UDYI 0 P lqns SUIDASDIP EWM 3861 49 HAV A30 19 1SO s o e eueo pee 9 ZL weiber Duuu OV 24867 TN jdvl 7791919313 HLIM 9NIddVMM AG 31V OS LON ONY N3HSVM 3201 1108 9NISQ SNOLLO23NNOO 3 IVIN ONY S 420 8 IVNINY3L WOH3 SQv3l 03190343Y 3AOW3H 039INDIY 3i SIOLINANOD 39nv9 Y3DYV1 31VQOWWOOOV LON TIM SADO18 WNIAWH3L SONILWY MA 39Y170A L3SN39 N3HLO O ONIZIS JOLINONOD YOY ONIYJIINIDNI 3 0 V LINSNOD _ 30VLIOA Q31Sl1 153M01 JHL IN SUNA MAJEE YOY Q3ZIS S IOLININOS WYLAAN 6 OL ATNO SNOIVONMdaV IVAOZI 00L LHOIVYLS YO4 001 TWNINYSL XAY OL Q3193NNOO SI 3 QV31 ONISNAS 9 3009 391919313 1VNOIVN 3H1 30 8 SIZ ZOU HLIM 3INVOYODOV NI 1N3S3Md SI WYLAIN N3HM 39NV3O O3AYVN 38 Ol 931 HOIH INO INN S 9 ES a D S oO lt
23. ethylene glycol antifreeze mix Antifreeze mixture is recommended as a good year round coolant 1 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 2000 hours of operation Service of the fuel injection pump should 3 only be done if checks indicate pump malfunction 2 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 4 c Clean and check injectors 3 Any repair which involves disassembly of the injection pump must be carried out by specially 5 Check hoses and connections and repair any leakage trained mechanics with the proper tools and test 6 Start the engine and check for leaks Run the engine equipment for five minutes then shut it down Let engine cool NOTE All warranties on the engine become null and then check the coolant level in the radiator Add and void if the injection pump seals are broken by unauthorized persons coolant as needed SP16 CLEAN RADIATOR COOLING SYSTEM GENERAL 1 Remove debris from radiator fins daily 2 In very dusty applications clean the radiator with compressed air or steam cleaner every 100 hours CAUTION The cooling water in the engine Clean in the reverse direction of the airflo
24. ignation 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 c International fuel specifications ISO 8217 DMA BS 2869 Part 1 Class Al BS za Pat ios filter regarding additional tightening Do not 2 Use fuel having less that 1 sulphur preferably less overtighten Open fuel valve than 0 5 c Fuel filter part numbers are Model Part Number NLA498 824 57304 Final Fuel Filter 119802 55700 Primary Fuel Filter 3 The cetane number should be a minimum of 45 DO NOT use these unsuitable grades of fuel a Domestic heating oils all types b Class B engine c Class D domestic fuels ONL498 2 03 06 15 l Y 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 Fuel filter 8 Fuel return hose Fuel priming pump Air ble
25. ilter SP16 Check and clean radiator 500 HOURS SP12 Check injectors SP18 Check condition of batteries with hydrometer 1000 HOURS SP7 Check valve clearances Check fuel injection nozzle pressure 2000 HOURS SP13 Check fuel injection pump SP15 Check and flush cooling system Service Notes ONL498 2 03 06 12 LUBRICATION GENERAL 1 Use only clean high quality lubricants stored in 4 clean containers in a protected area 2 These lubricants are acceptable a API Service CD CF single viscosity oils b SAE viscocity 10W 30 or 15W 40 oils 3 Use the proper weight oil for your average operation temperature W BEQ d Change oil at any seasonal change in temperature when a new viscosity of oil is required Change oil when engine is warm but not hot Dispose of waste oil in an approved manner Never use a flushing oil Loosen plug in oil pan and drain oil into basin Refill engine with recommended oil 10 Engine capacity with new oil filter is Air Single Multi Temperature Viscosity Viscosity 498 11 1 quarts 10 5 liters A Zi SAE 15 40W SP3 CHANGING LUBE OIL FILTER 10 to 32 F o 1 23 to 0 C SAE 10W SAE 10 30W s Below 10 F 23 C SAE 5W SAE 5 20W 5 Figure 5 Lube Oils 4 4 Some increase in oil consumption may be expected when SAE 5W and SAE 5 20W oils are used Check 5 oil level frequently and do not mix different types of
26. kin Use a piece of cardboard or wood not your hands to search for leaks Avoid wearing loose clothing without a belt when working around engines Donotoil or grease engine while it is running Use caution in handling fuel Never refuel a hot or running engine Do not smoke while filling fuel tank or servicing fuel system Keep your hands feet hair and clothing away from power driven parts Check for any loose electrical connections or faulty wiring Engines should be operated only by knowledgeable qualified personnel Look completely around engine to make sure that everything is clear before starting e Do not operate an engine that isn t in proper working order If an unsafe operating condition is noted tag the set and control panel so others will also know about the problem Provide first aid kits this book to alert you to possible danger areas CAUTION This symbol is used throughout Please take special notice of these sections CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ONL498 2 03 06 Industrial Generator Component Locations i Si i Figure 2A amp B NL498D2 6 Exh st Elbow 11 Lube Oil Fill 16 Primary Fuel Filter 2 Generator Junction Box 7 Muffler 12 Radiator Shroud ees 3 DC Circuit Breaker
27. nctions ALARM LAMP TEST AND RESET BUTTON Press UP to test the indicator lights and press DOWN to reset the alarm A C VOLTAGE ADJUSTMENT RHEOSTAT Voltage has been set at the factory and should only be adjusted by factory trained personnel AMMETER SELECTOR SWITCH Used to check each phase for load condition NOTE Always leave this switch in the ON position while the unit is running FREQUENCY METER HERTZ The frequency meter indicates alternator current frequency 60 Hz 1200 or 1800 RPM or 50 Hz 1500 RPM A C VOLTMETER Shows the generator output voltage A C AMMETER Shows the generator load on each phase The phase is selected with the Ammeter Selector switch Item 9 ONL498 2 03 06 8 Operating Procedures BREAK IN PERIOD 1 The first 100 hours on a new or reconditioned engine are critical to its life and performance 2 Constantly check the engine temperature and oil pressure gauges 3 Oil consumption is greater during break in as piston rings take time to seat 4 Break In Oil Changes Change engine oil and filter at 50 hours Change oil and filter again at 100 hours consult Lubricants section for oil recommendation then every 250 hours 5 Retighten head bolts at 50 hours Operating Instructions Maintain at least a 75 load on your generator set for the first 100 hours If this is not possible maintain no less than a 50 load to ensure proper seating of the piston rings Vary
28. nd flush the radiator and cooling system Leave dry or refill with antifreeze water mixture If refilling start the engine and run to circulate the antifreeze Fill the fuel tank or add biocide as per manufacturer s instructions Seal the air cleaner inlet exhaust opening crankcase breather pipe and fuel tank vent with plastic bags and tape Change the crankcase oil and filter Loosen the alternator belt Disconnect and clean battery Remove to warm storage place if possible Clean outside of unit Paint any scratched or chipped surfaces Put corrosion preventative on all exposed metal surfaces Store the set in a dry protected place If unit must be stored outside be sure it is well protected with a cover ONL498 2 03 06 18 Troubleshooting DC ELECTRICAL SYSTEM PROBLEM Battery Will Not Charge POSSIBLE CAUSE Loose or corroded connections Sulfated or worn out batteries Loose or defective alternator belt Starter Inoperative Check DC circuit breaker Loose or corroded connections Low battery output Defective electrical system ground wire Starter Cranks Slowly Low battery output Check specific gravity of each battery Check electrolyte level of each battery Crankcase oil too heavy Loose or corroded connections Entire Electrical System Check DC circuit breaker Does Not Function Faulty connection Sulfated or worn out batteries RECOMMENDATION S Clean and tighten batte
29. nerator set serial number when ordering Seattle WA 98107 parts or in correspondence The generator set serial number plate is found on the service side of the generator and resembles the drawing in Figure 1 Figure 1 Generator set serial number plate ONL498 2 03 06 4 A warranty registration certificate is supplied with your set It entitles the original purchaser of our equipment to a warranty covering material or assembly faults The extent of coverage is described in the Limited Warranty Statement We recommend that you study the statement carefully Warranty NOTE If the warranty is to apply the servicing instructions outlined in this manual must be followed If further information is needed please contact an authorized dealer or the factory Safety Rules CAUTION 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 Never leave engine without proper security Turn the coolant tank cap slowly to relieve pressure before removing Add coolant only when the engine is stopped and cool Mount a fire extinguisher near engine Always disconnect the battery ground strap before making adjustments Operate engines in properly ventilated areas e Keep trash and other objects away from engine Escaping fluids under pressure can penetrate your s
30. njection nozzles Air in fuel system Improper type of fuel Lack of Engine Power Intake air restriction Clogged primary fuel filter element Clogged secondary fuel filter element Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Troubleshooting 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 Replace filter element Have your dealer check injection nozzles 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 Inspect clamps and hoses on suction side of fuel pump for air leak Consult fuel supplier and use proper type of fuel for operating condition Service air cleaner Clean or replace filter element Replace filter element Consult fuel supplier and use proper type of fuel for operating conditions See Engine Overheats in next category Remove and check thermostat Reset valves Best done
31. oting Guide on page 19 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 and restart after the temperature gauge registers below 210 F 99 C d Watch the temperature gauge regularly and turn off the unit if the temperature rises above 220 F 105 C Repeat troubleshooting 3 If shutdown is activated and the temperature gauge shows temperature within normal temperature range a Check the engine crankcase oil level b If the oil level is 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 Operating Procedures SPARE PARTS 1 ADE recommends that you keep the following spare parts on hand for field service The parts are available from your local Northern Lights dealer Primary and secondary fuel filter elements Oil filters Air filter elements Alternator belt Thermostat and gaskets Heater element moods p g Injector and washer 2 If your set is operating a long distance from a servicing dealer add the following a Complete set of injectors b Fuel lift
32. piston of the No 1 nd cylinder to top dead center the position where the Time intake and exhaust valves are both closed Also see that the crankshaft pulley top mark is positioned at zero on the timing scale To adjust insert a thickness gauge in between the rocker arm and valve bridge and record the valve clearance Then loosen the lock nut and adjusting screw of the rocker arm Be careful that excessive tension is not applied to the valve bridge by fixing it with a wrench so that the bridge does not rotate and a valve will not lean Figures 7 and 8 Clearance on intake and exhaust valves should be 0 006 01 in 0 15 0 25 mm SP5 V BELTS Figure 7 Valve Adjustment Valve clearance Rocker arm Valve clearance 4 valve head Figure 8 Valve Clearance 4 valve 6 Then turn the crankshaft 180 and make adjustments for the No 3 cylinder Then No 4 and No 2 cylinders in that order The first cylinder to be adjusted does not have to be the No 1 cylinder just select and adjust the cylinder where the piston is nearest to the top dead center after turning Then make adjustments for the other cylinders in the order of ignition by turning the crankshaft 180 each time Oylinder 1 2 3 4 Valve Intake Exh Intake Exh Intake Exh Intake Exh No 1 Compres TDC No 4 Compres TDC OO O O Ignition Order of 4 cylinder engines 1 3 4 2 Set the No
33. pump ONL498 2 03 06 10 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 Point SP is listed on the page noted in the page column DAILY SP1 Check oil level in engine SP4 Check air cleaner dust trap replace element 250 hrs or when needed SP8 Check primary fuel filter SP14 Check cooling water level AFTER FIRST 50 HOURS SP2 3 Change engine oil and filter SP5 Check V belt tension SP6 Retighten cylinder head bolts EVERY 50 HOURS SP5 Check V belt tension SP11 Bleed the fuel system SP17 Check electrolyte in batteries EVERY 250 HOURS SP2 3 Change engine oil and filter SP5 Check V belt tension SP9 Change primary fuel filter element SP10 Change secondary fuel filter SP11 Bleed the fuel system SP16 Check and clean radiator EVERY 500 HOURS SP12 Check injectors SP18 Check state of charge of batteries EVERY 1000 HOURS SP7 Check valve clearances SP20 Check fuel injection nozzle pressure EVERY 2000 HOURS SP13 Check fuel injection pump SP15 Check and flush cooling system SERVICE 50 250 500 1000 2000 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours ENGINE SP1 Check oil level SP2 Change engine oil 1 SP3 Change lube oil filters 1 SP4 Check air cleaner replace element 1 4 SP5 Check V belt tension 1 S
34. ry connections Check specific gravity of each battery Check electrolyte level of each battery Adjust belt tension Replace belt f the breaker is tripped reset it Clean and tighten loose battery and harness plug connection Check specific gravity of each battery Check electrolyte level of each battery Repair or replace Battery is too small Battery cables are too small Replace battery if necessary If low fill cells with distilled water Fill with oil of appropriate viscosity Clean and tighten loose connections f breaker is tripped reset it Clean and tighten battery and harness plug connections Check specific gravity and electrolyte level of each battery If you cannot correct problems with these procedures see your Northern Lights dealer ONL498 2 03 06 19 ENGINE PROBLEM Engine Hard to Start or Will Not Start POSSIBLE CAUSE Improper starting procedure 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 Clogged secondary fuel filter element Dirty or faulty injection nozzles Engine Runs Irregularly or Stalls Frequently Below normal engine temperature Clogged primary fuel filter element Clogged secondary fuel filter element Water or dirt in the fuel system Dirty or faulty i
35. s whichever comes first Check dust trap on bottom of air cleaner daily Squeezing the lips of the rubber cap allows dirt to fall out Visually inspect air cleaner every 250 hours In dusty conditions check more often An element cannot be cleaned Replace dirty elements when necessary Part numbers are 24 28503 Outer 24 28504 Inner NOTE Make absolutely sure no impurities enter the engine while changing the element and do not run the engine with the air cleaner removed ONL498 2 03 06 13 1 Check the tension and wear on the V belt after every 50 hours 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 10 14 mm at point A 7 10 mm at point B and 9 to 13 mm at point C for a belt used on a running engine for more than 5 minutes Fig 6 Radiator fan Set bolt Figure 6 Alternator Drive Belt V belt Adjustment To adjust the belt tension loosen bolt in the tensioning arm and move the alternator to tighten the belt If the belt has to be replaced adjust it and then run the engine for 5 minutes and re adjust if needed SP7 VALVE CLEARANCES Adjust valve clearance every 1000 hours or once a year Valve adjustments should be done when the engine is cold and NOT running Remove the rocker arm cover 1st Turn the crankshaft clockwise as seen from the Time radiator side and bring the
36. s 7 Control Panels check gauges often Oil pressure must be above 15 PSI The D C voltmeter should read between 11 and 15 volts at 80 F 25 C ambient temperature The water temperature gauge must be below 200 F 94 C Check the A C voltage and frequency meters Series 7 panel If the gauges deviate from normal levels shut down the generator set and investigate 2 Let the unit run unloaded for a three to five minute warm up period 3 Add electrical load STOPPING 1 Remove electrical load from the generator set 2 Run the engine for a three to five minute cool down period 3 Move the Engine Control switch to the STOP position until the engine stops completely 4 Shut off fuel valve at the tank ONL498 2 03 06 9 SHUTDOWNS AND ALARMS 1 Your unit is fitted with a system to protect it from high water temperature or low oil pressure a Generator sets have shutdown systems to stop the engine They have no warning horns b Other alarms and shutdowns are available as optional equipment NOTE If your unit is equipped with optional shutdowns and alarms do not rely on your warning or shutdown system to the exclusion of careful gauge monitoring Watching your gauges can prevent damage to the unit and dangerous power losses 2 Do the following when your warning or shutdown system is activated Depress the shutdown bypass switch and check the temperature gauge If above 230 F 110 C use the Trouble Sho
37. stopped the voltmeter indicates the condition of the battery When the engine is running the voltmeter indicates the voltage output of the alternator ee 3 6 Figure 3 B Series 3 Generator Control Panel ONL498 2 03 06 7 Control Panels Figure 4 SHUTDOWN BYPASS SWITCH Manual Start Panels S 7 1 and S 7 3 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 Auto Start Panels S 7 2 S 7 4 S 7 5 and S 7 6 When the switch is placed in the AUTO START position the unit will automatically start when there is a drop in utility power OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system HOUR METER Keeps track of engine running time ENGINE TEMPERATURE GAUGE Registers the temperature of the coolant 10 11 12 Series 7 1 through Series 7 6 Generator Control Panels D C VOLTMETER When the engine is running the voltmeter indicates the voltage output of the alternator STATUS INDICATOR PANEL Engine monitoring alarms and lamps for monitoring engine fu
38. t Level nune 15 Industrial Generator 4 Cooling System Flushing 15 Clean Radiator eccentric eret 15 CONTROL PANELS Generator Ends us eet 16 Northern Lights Generator Sets 5 6 Electrical System General 16 Booster Batteries 1 tree 16 OPERATING PROCEDURES Battery Care ina Sek deet dee 16 Break in Period eroe akar coto 7 Winterizing Out of Service 16 Before Starting kunda daros 7 SIENTE C 7 TROUBLESHOOTING Operating contetuer et IEEE ERU 7 Electrical deis 17 ell 7 E 18 20 Shutdowns and Alarms sneseenseee esenee seerste 8 Spare Parts res 8 WIRING DIAGRAMS AC Electrical ones 21 22 SERVICING SCHEDULE CHART 9 10 DC Electrical gedet dd 23 24 SERVICING Lubrication General seserinis 11 Checking Ol 2 4 a seki y n seker kese yan res 11 COI CHAN SOS criticada 11 Changing Oil Eltere 11 Air EAE cce itte noce ree e eem Wes 11 Proprietary Information This publication is the property of Alaska Diesel Electric Inc It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric Inc Alaska Diesel Electric Inc All rights reserved Litho U S A Publication number ONL498 2 03 06 ONL498 2 03 06 3 Introduction The servicing of generator sets presents unique As operator it is your obligation to learn about your problems
39. uel lines by loosening the delivery line flare nuts at each injector c Remove delivery lines by disconnecting from injectors and injection pump 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 NOTE On some models it is necessary to remove the air filter housing to access the fuel injection lines d Remove the return line retaining clamps and remove the return lines e Remove the nuts on each side of the injector body Remove the hold down bracket with a 6 mm wrench or socket Pull the injector body from the hole NOTE Do not use pry bars to remove injectors from cylinder head f After removing the injectors discard the sleeves from the injector hole in the head Cover holes to prevent dirt and debris from entering the cylinders IMPORTANT Make sure you pull the sleeve out of the injector hole as it may not come out with the injector ONL498 2 03 06 3 Injector repair and cleaning SP14 CHECK THE COOLANT LEVEL a Take injectors to your Northern Lights dealer or local injection repair station for testing and service 1 Check the coolant level each day before starting the engine 4 Injector installation a Check the water level by removing the pressure a Place new sleeve in injector hole Slide injector cap from the radiator In order to give the cooling into hole or on the injector replace hold down water
40. w 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 ONL498 2 03 06 17 GENERATOR ENDS The maintenance and operation recommendations for the generator end are in a separate Owner s Manual If you do not have one of these manuals contact your local Northern Lights dealer ELECTRICAL SYSTEM GENERAL 1 Never turn an optional 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 of 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 A D C circuit breaker protects your control panel and wiring harness It is located in the side of the generator junction box INTAKE HEATER Model NL498 has an optional heater element in the end of the intake manifold To test the heater element remove the power wire from the terminal Connect D C test bulb between the positive pole of the battery and the terminal of the heater If th
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