ONL843N2SATS - Northern Lights
Contents
1. 9 WIRING DIAGRAMS 9 AC BIectEIcal icono cu eei o au uns sas DC Electrical SERVICING SCHEDULE CHART 10 SERVICING Lubrication General 12 12 OIL Chan Ges cp uuu a ss 12 Ghanging OI Filter rue ars vache 12 TALES 13 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 O Northern Lights Inc All rights reserved Litho U S A Publication number ONL843NSATS 10 09 ONL843NSATS 10 09 3 Introduction Servicing of generator sets presents unique problems As operator it is your obligation to learn about your Failures often occur in remote areas far from competent equipment and its proper maintenance This is not a assistance Generators are taxed far more severely than comprehensive technical service manual Nor will it auto or truck engines therefore maintenance schedules make the reader into an expert mechanic Its aim 1s to must be adhered to more strictly aid you in maintaining your unit properly Failures can begin with minor problems that are over looked and become amplified when not corrected during routine maintenance Unit Identification MODELS INCLUDED This manual covers the operating Instructions for NL843N2 NL843NW2 and NL843NW3 industrial generator sets Fill in the mo2. 33GN3S T3A31N o 1313 Jidund Le q33 MOTI3A XO8 hl YOLVYANAD LOL 8 A349 66 ce NIMIM LOANNOOYSLNI NV SS3NMVH TIV19Id AIVIN3NON NOLLNSHSNd NOLLWALLOV 39nvd 1303 YALINYNOH 6 BION 335 AINUL 1V3H33d M 20166 93 TINTON JVISOLNV st vt L ARDS 66 G3u MOTIA z HOLIMS HOLIMS NR LAS NMOGLNHS 7OMLINOO 3NION3 ic SM3H1O A8 SNOLLO3NNOO GNV 9NLLNnONW 310N 33S SnO3NVTI3OSIN VL S AJYNSOIONA 13SN3O ONL843NSATS 10 09 2f
3. ONL843NSATS For Models NL843N2 NL843NW2 and NL843N3 OPERATOR S MANUAL LUGGER NORTHERN LIGHTS Marine Generators Marine Diesel Engines Land Based Generators LOW OR ULTRA LOW SULFUR VIn FUEL ONLY R527703 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 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 2009 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 ONL843NSATS 10 09 LIGHTS
4. OPERATOR S MANUAL for Models NL843N2 NL843NW2 and NL843NW3 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 Table of Contents INTRODUCTION 4 SERVICING continued Models Included 4 xV P e rm 4 Valve Serial Num BETS uu uu uay un u nka a 4 Fuels General edat paires WARRANTY avian 5 Bleeding the Fuel System InjectotSet VICE rera sss SAFETY RULES 5 Injection Pump uuu Cooling System General COMPONENT LOCATIONS Cooling System Flushing NL843NW2 Industrial Generator 6 Generator Ends oue au uyana Qasa Electrical System General CONTROL PANELS GOW PINGS D Northern Lights Generator Sets 7 Booster Batf rl Suy Battery Cane usd a etudes OPERATING PROCEDURES Winterizing Out of Service Break in Period 8 Betore Starine L uya unu uu ss 8 TROUBLESHOOTING SUATCITIB e Baa ad ss ae 8 Electrical eite Esp asco Dhu sensu uuu aus sss tasa 8 J IS li o unuy To pad tam ce curs SLOP DIS u uuu uuu UM CHA MUN 8 Shutdowns and Alarms
5. Faulty connection Sulfated or worn out batteries RECOMMENDATION S Clean and tighten battery connections Check specific gravity of each battery Check electrolyte level of each battery Adjust belt tension Replace belt If 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 f low fill cells with distilled water Fill with oil of appropriate viscosity Clean and tighten loose connections If breaker 15 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 ONL843NSATS 10 09 20 ENGINE POSSIBLE CAUSE Troubleshooting Engine Hard to Start or Will Not Start Engine Runs Irregularly or Stalls Frequently Lack of Engine Power 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 Below normal engine temp
6. GENERAL SP2 OIL CHANGES 1 Use only clean high quality lubricants stored in 1 The set is delivered with special break in oil clean containers in a protected area Change the engine oil and oil filter after 50 hours 2 These lubricants are acceptable of operation Use Service CC 30 weight oil during a API Service CC CD CE single viscosity oils the first 100 hours b API Service CC CD SF multi viscosity oils 2 Change the oil and filter again at 100 hours using the 3 Use the proper weight oil for your average opera oil recommended in the above diagram After this tion temperature change oil and filter every 250 hours 3 During intermittent cold weather operation change Air Single Multi oil every 100 hours or six weeks whichever comes Temperature Viscosity Viscosity first 4 Change oil at the end of each season and the O sor SAE30W SAE 15 40W beginning of each 0 C eginning of each season Change oil when engine is warm 10 to 32 F 23 to 0 C SAE 10W SAE 10 30W Below 10 F 23 C SAE 5W SAE 5 20W Dispose of waste oil in an approved manner Never use a flushing oil EC eu Loosen the clamp on the oil change tube Remove cap Drain oil Replace the cap and tube 9 Refill engine with recommended oil for the season Figure 4 Lube Oils 10 Engine capacity with new oil filter 1s NL843NW2 and NL843N2 1 6 gallons 4 Some increase in oil consumption may be 6 liters expected when SAE 5W and SAE 5 20W
7. JYNSO TONS LINN N asss 27 3OLv 10933 S JOVLIOA NOILONNP YOLVYANAD ONL843NSATS 10 09 25 iring W GEEL6 G piepue S OdA rv ZNEPSIN BuurM OG 031V2IONI QN3 LY ONNOYD QANI IV Q3ONRnOND 38 01 SI Q 3IHS 3IVd O3ISIML S 0310ON SV ONY 030131 5 Q31SIML Ld3OX3 OvAQO9 QNvVHISIUTQN 9 601 MLN 9 SMV 38 OL SHOLILOnONOO SS3NUVH Vj S 71 v 3535 SI HOLIMS SIHL N3HM AT3IVIO3NWI 18VIS33 TIM 13SN39 NOILISOd 413938 330 3 1 NI LON SI HOLIMS 10N1NO2 3NION3 JHL JI NOLLAVI 78 SMV NIN JION 33S XOG f YOLVYANAD quen I dW3LIV 9NDINVSO SONOQ3S O XINI 35155359 10 CZH S69 POOL INN all 0334S83 0 2 806 Wa y 006 u 133NNO2SIO SQNO23S 0 31942 ANVYJ fS9NILL3S JTNGOW LYVISOLNY Z 0310ON SV ONY 030131 5 Q31SIML L1d39X3 2vAQOS H Es g g he 1135358 01 Tind 13SN39 NMOGLAHS OL HS d MOMMS 9015 AON39N3N3 ONVYLSILINN 2 801 3dAL vj OMY 38 OL SHOIOnONOO NOLVTIVISNI TIY J N o To 9g SS3NuVH S3LON A a 306 ISa 6 i a SESHIU 5 Y30N3S T3431 134 ims N SHTHIO 78 TINS We NIS o Gannanon 3n18 B NOLLn BHShd IS d ZY NOIIVAIL3V QNnOND 35v2 lt 39nv9 1303 N3
8. current carrying flat wire between the plus poles of the glow plugs Figure 18 Connect a D C test bulb between the plus pole of the battery and the plus pole of the glow plug If the bulb lights up the glow plug is functioning properly 3 Check all glow plugs and replace any faulty ones 4 Figure 18 Glow plugs ONL843NSATS 10 09 18 BOOSTER BATTERIES CAUTION Battery gas can explode Keep all flames and sparks away from batteries Before changing or using booster batteries check battery electrolyte level Add distilled water if necessary Booster and main batteries must have the same voltage rating 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 19 Remove booster battery after starting engine Sealed batteries See manufacturer charging and booster instructions Battery Booster Battery Figure 19 Battery connections Servicing SP 18 19 BATTERY CARE 1 Check electrolyte level daily Add distilled water to manufacturer s recommended level 2 Batteries cables and cable terminals should be checked and cleaned every 100 hours Clean corrosion with a water and baking soda solution Flush with clean water Tighten terminals and grease them to inhibit corrosion 3 Check the battery condition with a hydrometer every
9. day s operation This will reduce condensation and possible biological contamination d If biological contamination is detected or suspected contact your dealer for assistance SP7 9 FUEL FILTERS Primary Fuel Filter Part Numbers Complete Unit 24 50002 Element 24 50012 Figure 8 Primary Fuel Filter if provided by Northern Lights 1 Your generator set may 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 500 hours c If the bowl fills with water change the primary and secondary element immediately 2 Change secondary fuel filter every 500 hours NOTE The fuel filter on the engine is considered the secondary fuel filter 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 Secondary fuel filter cartridge part number 1s NL843N2 amp NW2 24 52020 ONL843NSATS 10 09 14 SP10 BLEEDING THE FUEL SYSTEM Servicing Before disconnecting lines be sure to relieve all pressure Before applying
10. oils are used Check oil level frequently SP3 CHANGING LUBE OIL FILTER 5 Never put additives or flushing oil in crankcase 1 Change the lube oil filter every 250 hours SP1 CHECKING OIL LEVEL 2 Use a filter wrench to remove old filter Dispose of filter in approved manner 1 Check the oil level in the crankcase with the dip 3 Make sure the gasket from the old filter Is removed stick The oil level must be in the waffled area and discarded Clean mount face on the stick Never allow the level to go below 4 Spreada thin film of engine oil on the rubber gasket this area Follow the lubrication recommendations on the new filter and screw it on nipple until gasket above meets the sealing surface 5 Using hands only no wrench tighten filter one half turn farther Overtightening can do 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 Oil filter part number is NL843N2 amp NW2 71224 03100 ONL843NSATS 10 09 12 SP4 AIR CLEANER 1 Inspect air cleaner every 250 hours In dusty conditions check more often 2 Replace if necessary Part number is NL843NW2 amp N2 ELEMENT ONLY 27224 27302 3 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
11. parts are available from your local Northern Lights dealer 2 All owners should have the following spares Primary and secondary fuel filter elements Oil filters Air filter Alternator belt Thermostat and gaskets Glow plug Injector and washer mond gt Operating Procedures 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 ONL843NSATS 10 09 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 SP5 Check V belt tension SP7 Check primary fuel filter SP13 Check coolant level EVERY 500 HOURS SP8 Change primary fuel filter element SP9 Change secondary fuel filter SP22 Inspect condition of exhaust system SP18 Check electrolyte in batteries EVERY 1000 HOURS AFTER FIRST 50 HOURS SP6 Check valve clearances I a SP11 Check injectors SP2 3 Change engine oil and filter SP6 Adjust valves EVERY 2500 HOURS AFTER FIRST 100 HOURS SP12 Check fuel injection pump SP2 3 Change eneine oil and filer SP14 Check and flush cooling system EVERY 250 HOURS SP2 3 Change engine oil and filter SP4 Check air cleaner SP15 Check and clean rad
12. pressure be sure all connec CAUTION Escaping diesel fuel under pressure can penetrate skin causing serious personal injury tions are tight and lines pipes and hoses are not 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 is not administered immediately Figure 9 NLS43NW2 Fuel System for illustration purposes 1 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 2 Loosen bleed bolt A Figure 9 on top of the filter Pump hand primer B on fuel lift pump until pure fuel no bubbles escapes from bleed bolt A Tighten bleed screw A 3 Loosen bleed screw C Pump hand primer B until pure fuel no bubbles escapes Then tighten bleed screw C If the engine does not start after the above 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 After the engine has started use a piece of cardboard to look for fuel leaks ONL84
13. the warranty 15 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 high percentage of accidents 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 Keep trash and other objects away from engine Escaping fluids under pressure can penetrate your skin 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 Do not oil or grease engine while it is running e Use caution in handling fuel Never refuel a hot or running engine Do not smoke while filling fuel tank or servicing fuel system You can avoid accidents by observing these safety rules Study these rules carefully and enforce them on the job 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 t
14. 1000 hours SP21 WINTERIZING OUT OF SERVICE 1 Industrial sets a Drain flush the radiator and cooling system Refill with antifreeze water mixture Start the engine and run to circulate the antifreeze Fill the fuel tank or add biocide as per the manufacturer s instructions Change the crankcase oil and filter Seal the air cleaner inlet exhaust opening crankcase breather pipe and fuel tank vent with plastic bags and tape 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 the unit must be stored outside be sure it is well protected with a cover ONL843NSATS 10 09 19 Troubleshooting DC ELECTRICAL SYSTEM PROBLEM Battery Will Not Charge Starter Inoperative Starter Cranks Slowly Entire Electrical System Does Not Function POSSIBLE CAUSE Loose or corroded connections Sulfated or worn out batteries Loose or defective alternator belt Check DC circuit breaker Loose or corroded connections Low battery output Defective electrical system ground wire Low battery output Check specific gravity of each battery Check electrolyte level of each battery Crankcase oil too heavy Loose or corroded connections Check DC circuit breaker
15. 33O0 JHL NI LON SI HOLMS 1OMINOO 3NION3 JHL 31 13S3M OL TINd L3SN39 NMOGLAHS Ol HSNd dOLS AON39M3W3 iring W gum SIdN3LIV SNDINYNO SQNOO3S OL M3WIL SYNSS3Yd ZH S69 Wd 06 did Q33dSH3AO ZH 806 Wd 4 008777777777 LOANNOOSIG SQNOO3S 0OL 7 7310A9 ONVHO SONILL3S 310qON LYVLSOLNV Z Q310N SV ANY GSCTSIHS Q31SIML 1d39X3 OvAOO9 GNVYLSILINW 0 601 MLN L SMV 38 OL SYOLONGNOD NOLVTIVISNI TV L 2 TS d Z L _ TNS annoys asyo SZ rwn Ta penk1 ir 4 3 118 HOLMS QNnOND 3SVO C_ 4 122 L Less f 3unSS33d 10 gt J gt wits A rm x eE 1 I HOLIMS wQG2 i s3onvo GAN uni dal 3NISN3 gory mn N d Mand NOLIVIS wel M XS 1 min 3V39 SNI3 a uam WEEE 8 owed X cs zs UM ple Se sae ee Im a dol SH3HIO A8 M3I3MYOH OL Sum NOIdO 39nvo N3ONSS TANT __ 3UHM ZL qas oif QION3 IOS ovs Tan QNnOM9 35v9 VOY NYZ qa4 13A 01 gh 0e HOLIMS 193NNOOSIQ ig 039 01 AMALLVE VSZL 7 9 L V X y 2S YOLOW NILYVIS OQAvZC L OL HION3 XVN J1 8vO SMV NIN MOLO3NNOO OLWN 39018 9N3 un 2 3 O L8 O AV133 Nf vel us P e r AVIY LMVIS 3333318 L 3LON 33S 9018 SSINYVH SMd_SS3INYVH 3015 3NI9N3 3015 T3NVd
16. 389 HOLIMS ONNOYD 3SVO 3 ZZ A PON 3unSS3Nd 10 Oc A 9 HOLIMS q 1550 HOLIMS dW3L 3NION3 30144340 NMOGLNHS iwi owows 08 sawas gt K lt 1 gt JUHM 3 L3NYNOH e XB 983 9 Cie v FIT Tidd pa ar 9g SB QION3105 A ind C xvi 1303 AV138 3 00080 35v 1V3H 3 id e U dA 2 MOTI3A 98 5 OQ E X39 86 a TRONS re v3 ana 8 E O UND 3Sy5 5 91 79 T N vol Ea HLS omo po omo x 4 See FE andiya gt AVI38 LNVIS E odwz 172412 SH3HIO AB NOIIINNOO 43015 HIVI 70 038 HON 335 TaS 3NDN3 OL HI9N31 XVN HOLIMS HJLIMS 1 15 NMOOINHS AON392383NW3 7TIOMINOO 3NION3 j v JION 33S SY3HIO AB SNOILJ3NNOO ONV 9NIINDON SnO3NvVTI3D2SIN M VJ S FJYNSOIONA 135339 IMIM LOSNNODYIIN NV SSINYWH TIVLDId ONL843NSATS 10 09 26 ACElLE G punoJc psepuejs OCA vc EMN ZMNETS TN Wesbeiq G3LVOIGNI GNNOYS NO QN3 Q3QNnON9 38 OL SI GT3IHS Hivd Q3lSIML S Q310N SV GSCTSIHS Q31SIML 1d39X3 OvAOO9 GNVYLSILINW 5 5601 MLN 3dAL 9L 38 OL SYOLONGNOD SS3NMVH VL S TW v 13S3M SI HOLIMS SIHL N3HM A T31VIQ3AWI 1MVIS3M I3SN39 3HL NOLISOd 13S33
17. 3NSATS 10 09 15 Servicing Figures 10 17 For illustrative purposes only may not be exact model Figure I1 Remove delivery lines Figure 15 Unscrew injector Figure 13 Remove return line nuts Figure 17 Reinstall injector Torque to proper tightness ONL843NSATS 10 09 16 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 2 Injector removal a Clean loose dirt from around the InJectors and CAUTION Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury If injured by escaping diesel fuel see a doctor at once the fuel lines b Relieve high pressure in the fuel lines by loosening the delivery line flare nuts at each injector Figure 10 c Remove delivery lines by disconnecting from injectors and injection pump Figure 11 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 Figure 12 d Remove the return line retaining bolts Figure 13 Remove the return line Figure 14 e Unscrew and remove the injectors Figure 15 NOTE Do not use pry bars to remove injectors from cylinder head f After removing the injectors discard the copper sealing washers from the injector hole in the head Figure 16 Cover holes to prevent dirt
18. E AWG 14 105 C MTW MULTISTRAND 600 VAC EXCEPT AS NOTED GENERATOR JUNCTION BOX SEE NOTE 3 TYPE 2 GROUNDING IS TO BE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE AND ANY APPLICABLE LOCAL CODES 3 REMOVE AND DISCARD UNUSED SENSING LEAD 6 ELECTRICAL TAPE OR A WIRE NUT 10 GREEN W2 GEN FRAME ENG BLOCK ONL843NSATS 10 09 24 OUTPUT TERMINAL BLOCK SSC L U 1 0606 DO V6 NPL D CN OM UG 120 208VAC 50 60 HZ KKK OOOO SY L RSS N 9 9 99 9 9 9 Q 2 INDICATES LINK USED 6 BLACK I L1 46 RED L2 6 BLUE LZ 6 ITE N 6 GREEN SEE NOTE 2 GND AC Wiring Diagram NL843N2 120 208 VAC 30 B 9183 D iring W v8L6 dg E OVA 80 01 CMNETSTN Wesbeiq BuulM OV NOLIVTIVISNI 33d QO3NIW33130 SNIZIS SYOLONGNOD INdLNO Q3ridans YIWNOLSND 31VOIQNI SINIT Q3HSvO N3QQlH Z AIBW3SSV 318v9 YOLONGNOD 3A 0 ANS ON JI ZL I Ol SILON x 6 g Z EA 0 S IVIVIP VIVIS 19078 T1VNIN331 BU M LNdLNO 32018 TVNIN 31 LNdLNO NIVN Al ily g 3n18 9j ZH 09 DVASOZ OZI aay 97 Z 310N 33S w 310N 33S pl es 2v18 40 O Iw l yovla 9 3 J3l13J NIVMIS JONVYO 033 NYL MO1V33N39 OVI A mous eae f MOTBA 4 AVIC O0 1SQ
19. Engine Overheating section Use correct fuel for temperature Service air cleaner See your dealer See your dealer See your dealer Check your thermostats Check water temperature with thermometer and replace gauge if necessary Check thermostat Check water temperature with thermometer Fill crankcase to proper level Drain and fill crankcase with correct oil Replace filter Oil consumption decreases after break in Use proper viscosity oil Check for leaks in lines around gaskets and drain plug If you cannot correct problems with these procedures see your Northern Lights dealer ONL843NSATS 10 09 22 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION S Engine Emits Black Clogged or dirty air cleaner Service atr cleaner or Gray Exhaust Smoke Improper fuel Use correct fuel for temperature Injection nozzles dirty See your dealer Engine timing off See your dealer Engine Emits Improper fuel Use correct fuel for temperature White Smoke Cold engine Warm up engine to normal operating temperature Defective thermostat Remove and check thermostat Engine timing off See your dealer If you cannot correct problems with these procedures see your Northern Lights dealer ONL843NSATS 10 09 23 Wiring Diagram A C VOLTAGE REGULATOR TS UF 60 VOLTS UFRO STABILITY NOTES 1 ALL INSTALLATION CONDUCTORS TO B
20. and debris from entering the cylinders 3 Injector installation a Install a new copper sealing washer in each injector hole Figure 16 b Screw in injector and tighten to 44 51 ft Ibs 6 to 7 kgm Figure 17 NOTE Overtightening can damage injector c Install return line using a new sealing washer below each connection Tighten return line retaining bolts to 22 30 ft Ibs d Install delivery lines Leave loose at injectors for bleeding e Crank engine to fill lines Tighten lines at injectors to 11 18 ft Ibs Start engine and check for leaks using a piece of paper or cardboard DO NOT use hand to check for leaks Servicing 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 injecti
21. between the rocker arm and valve guide of both the intake and exhaust valves with the adjustment screw Figure 6 Clearance on both intake and exhaust valves should be 0 008 in 0 2 mm Repeat steps 3 and 4 for each cylinder Each set of valves must be adjusted individually Replace the rocker arm cover Tighten cover nuts to 5 8 ft Ibs 0 8 2 3 kg m When No 1 cyl is at in compression stroke With the crankshaft turned by 360 in normal direction from Figure 7 843NW2 Valve sequence ONL843NSATS 10 09 13 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 b Use grade no 1 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 DO NOT 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 4 D and higher number fuels 5 Storing fuel a G a Keep dirt scale water and other foreign matter out of fuel b Avoid storing fuel for long periods of time c Fill the fuel tank at the end of each
22. del number of your unit in the blank space provided This will give you a reference whenever service or maintenance is required My Northern Lights generator set MODEL number is Model Numbers Model numbers give the unit s application block model aspiration and RPM NL 843 N W Northern Lights industrial generator set Model number of engine block 8 N N engine Bore Cylinders W New winding 84 mm 3 NL843NW2 bius o Sel NL843N2 Northern Lights industrial diesel generator Wil ass P engine and qi Pas set with an 843N engine and a BCI 164 generator end generator end Serial Numbers NORTHERN LIGHTS Your set has three serial numbers 1 an engine number stamped on the block 2 a generator plate and 3 a generator set plate Serial No Use the serial number on the generator set plate when ordering parts Model or In correspondence The generator set plate Is found on the service Northern Lights side of the generator and resembles the drawing in Figure 1 4420 14th Ave NW Seattle WA 98107 Figure 1 Generator set serial number plate ONL843NSATS 10 09 4 A warranty registration certificate 15 supplied with your set It entitles the original purchaser of our equipment to a warranty covering material or assembly faults The extent of coverage 15 described in the Limited Warranty Statement We recommend that you study the statement carefully Warranty NOTE If
23. e maintain no less than a 50 load to ensure proper seating of the piston rings Vary the load to help seat the rings BEFORE STARTING 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 in 2 5 cm below the filler cap sealing surface when the engine is cold CAUTION Use protective clothing and open 2 4 the filler cap carefully when the engine is warm to prevent burns Check the oil level in the crankcase with the dipstick The oil level must be in the waffled area on the stick Never allow the level to go below this area Always add the same viscosity of oil as 1s already in the crankcase 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 Turn the toggle switch to Start Run position The engine will take 15 to 20 seconds to start cranking with glow plugs 2 Ifthe unit automatically shuts down and the problem fixed the toggle switch has to be placed in the Off Reset position before starting again OPERATING 1 Ifthe generator shuts down automatically investigate possible reasons high temperature low oil pressure etc then reset and restart 2 Let the unit run unloaded for a three to five m
24. erature Clogged primary fuel filter element Clogged secondary fuel filter element Water or dirt in the fuel system Dirty or faulty injection nozzles Air in fuel system Improper type of fuel 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 ONL843NSATS 10 09 21 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 nspect 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 fue
25. iator SP19 Check state of charge of batteries SERVICE 250 500 1000 POINT PAGE OPERATION DAILY Hours Hours Hours ENGINE Check oil level Change engine oil Change lube oil filters 1 5 Check air cleaner change element 1000 hrs 1 4 Check V belt tension Check valve clearances 1 2 FUEL SYSTEM Check primary filter Racor 2 3 Change primary filter element Racor 2 3 Change secondary fuel filter 1 3 Bleed the fuel system 3 Check injectors 1 3 6 7 Check fuel injection pump COOLING SYSTEM Check coolant level Check and flush cooling system Check and clean radiator ELECTRICAL SYSTEM Check electrolyte level in batteries Check condition of batteries with hydrometer OUT OF SERVICE Winterizing or out of service 6 Clean injection nozzles every 1500 hours 7 For EPA emission standards fuel nozzle needs to be cleaned every 1500 hours the fuel nozzle and fuel pump need to be cleaned adjusted or repaired every 3000 hours and the quality guarantee for these parts is 1500 hours or 2 years 1 Perform all maintenance once a year even if hour level has not been reached 2 Consult manufacturer s maintenance schedule note on chart 3 Whenever necessary 4 More often if necessary 5 After first 50 hours then after 100 hours then at every 250 hours ONL843NSATS 10 09 10 Service Record Notes ONL843NSATS 10 09 11 Servicing LUBRICATION
26. inute warm up period 3 Apply electrical load STOPPING 1 Remove electrical load from the generator set 2 Run the engine for a 3 to 5 minute cool down period 3 Turn the Engine Control switch to the Off Reset position SHUTDOWNS 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 2 Do the following when your warning or shutdown system 1s activated a Use the Trouble Shooting Guide on page 20 to isolate the cause of the overheat ONL843NSATS 10 09 8 CAUTION Do not remove the water fill A 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 d Make repairs Repeat troubleshooting 3 Ifshutdown is activated and the temperature does not appear to be outside the 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 SPARE PARTS 1 Northern Lights recommends that you keep the following spare parts on hand for field service The
27. l 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 See your local dealer Troubleshooting ENGINE PROBLEM Engine Overheats Engine Knocks High Fuel Consumption Below Normal Engine Temperature Low Oil Pressure High Oil Consumption POSSIBLE CAUSE Low coolant level Keel cooling tubes have been painted marine Cooling system needs flushine Defective thermostat Defective temperature gauge Insufficient oil Injection pump out of time Below normal engine temperature Engine overheating Improper type of fuel Clogged or dirty air cleaner Improper valve clearance Injection nozzles dirty Injection pump out of time Engine not at proper temperature Thermostat not working properly Temperature gauge not working properly Low oil level Improper type of oil Partially plugged oil filter Break in period Crankcase oil too light Oil leaks RECOMMENDATION S Fill tank or radiator to proper level Check hoses for loose connections and leaks Remove paint from tubes Flush cooling system Remove and check thermostat Check water temperature with thermometer and replace gauge if necessary Call your dealer Call your dealer Check your thermostats Check water temperature to see if temperature gauge is working properly See
28. o make sure that everything is clear before starting Do not operate an engine that isn t in proper working order If an unsafe operating condition 15 noted tag the set and control panel so others will also know about the problem Provide first aid kits CAUTION This symbol is used throughout this book to alert you to possible danger areas Please take special notice of these sections ONL843NSATS 10 09 5 Industrial Generator Component Locations OFO Figure 2A and 2B NL843NW2 Control Panel Plug in Generator Plate Generator Junction Box DC Circuit Breaker 5 Air Filter 6 Air Filter Pre cleaner RON 7 8 9 10 11 12 Cil Fill Fuel Injector Oil Pressure Switch Coolant Fill Injection Pump Shutdown Solenoid 13 Fuel Filter Water Separator 14 Fuel Inlet Line 15 Fuel Return Line 16 Oil Dipstick 17 Block Drain 18 Oil Drain Valve ONL843NSATS 10 09 6 Oil Filter Fuel Lift Pump Magnetic Pick up Secondary Fuel Filter Coolant Temp Switch Exhaust Outlet 25 26 27 28 29 Starter DC Alternator Detachable Supply amp Return Valves Fuel Filter Neck Fuel Gauge Sender Figure 3 a S IA Control Panel Figure 3 b Auxiliary DC Power Supply NATO Connector S 1A Control Panel AUTOSTARTI STOP MODULE Automatically pre heats starts and monitors the engine for overcrank overspeed high coolant temperature and low
29. oil pressure Annunciates run and fault conditions via unit mounted LEDs Also monitors mag pick up signal If signal is lost the engine will shut down and the overcrank and over speed LEDs will turn on ENGINE CONTROL SWITCH Toggle switch turns engine off or on HOUR METER Keeps track of engine running time MASTER BATTERY SWITCH On off switch disconnects batteries from engine controls BATTLE SHORT SWITCH Bypasses safety shutdowns Does not bypass mag netic pick up shut down or prevent user from shut ting the engine down via the engine control switch 22 or the emergency stop switch 6 EMERGENCY STOP Easily accessible button to turn the engine off quickly SWITCH TO ACTIVATE FUEL GAUGE Activates fuel gauge when the engine is not running FUEL LEVEL GAUGE Shows fuel level AUXILIARY DC POWER SUPPLY Extra plug in for DC power ONL843NSATS 10 09 7 Operating Procedures BREAK IN PERIOD The first 100 hours on a new or reconditioned engine are critical to its life and performance Frequently check the engine temperature and oil pressure Oil consumption is greater during break in as piston rings take time to seat 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 Operating Instructions Maintain at least a 75 load on your generator set for the first 100 hours If this is not possibl
30. on 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 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 SP13 CHECK THE COOLANT LEVEL 1 Check the coolant level each day before starting the engine 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 1s cold 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 1s faulty ONL843NSATS 10 09 17 Servicing SP14 COOLING SYSTEM FLUSHING Flush the cooling system every 2500 hours or every 12 months whichever comes first Industrial sets a Remove radiator cap and drain engine block b Pour clean water into radiator until water coming from radiator 15 free of discoloration and sediment c Close the radiator drain and continue flushing until water from the engine drain is clear d Open all drain cocks and drain completely e Close drain cock and refill with recommended mixture f Clean leaves dust and other debris off
31. the radiator fins Coolant Specifications Use 50 distilled water 50 ethylene glycol anti freeze mix Antifreeze mixture is recommended as a good year round coolant Check hoses and connections and repair any leakage SP15 CLEAN RADIATOR 2 Remove debris from radiator fins daily In very dusty applications clean the radiator with compressed air or steam cleaner every 100 hours and check for leaks 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 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 of battery cables when installing the battery 3 If 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 ter minal 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 GLOW PLUGS 1 Each cylinder is supplied with a glow plug which serves to heat the combustion chamber 2 To check the glow plugs loosen the
32. the V belt daily with the engine shut off 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 Fan belt slackness should be about 3 16 in 5 mm 3 To adjust the belt tension loosen the alternator adjusting plate bolt and the alternator mounting bolt Pivot the alternator at the mounting bolt as needed 4 Tighten the mounting bolt and the adjusting bolt 5 Re start the engine and operate engine at low speed and recheck the belt tension after stopping the engine Figure 5 Timing mark LY lt Valve Adjustment Screw Servicing Rocker Arm 4 4 0 008 in ME t 0 200 mm A Figure 6 Valve Adjustment SP6 VALVE CLEARANCES Adjust valve clearance after first 50 hours of operation and every 1000 hours thereafter Valve adjustments should be done after the cylinder head bolts have been re tightened Engine should be cold and NOT running 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 adjust the clearance on both valves for this cylinder Align the top mark of the crank pulley with the TOP mark of the timing gear case Loosen the lock nut and adjust the clearance
Download Pdf Manuals
Related Search