OPERATOR`S MANUAL
Contents
1. 14 li ole la Za 14 SAR UME 14 ODES D 14 STOPP NE eas secreta druide rU 14 Shutdowns and Alarms 15 Spare Pals uuu uu aya ieee 15 SERVICING SCHEDULE CHART 16 SERVICING RECORD NOTES 17 SERVICING Lubrication General 18 Checking 1 EEUU 18 COL BITS RERO 18 Changing Oil Filter 18 L eost E A 19 E ens 19 NValye C16 ANC SS 19 Fuels General secessione 20 uuu u 20 Bleeding the Fuel System 21 Injector S e VIO 22 23 Injection 23 Cooling System 23 Cooling System Flushing 24 Heat Exe hanter s scenes t vor Het 24 24 Generator Ends 24 Electrical System General 25 Glow IPOS REDEEM 25 Booster BIRET u sn 25 Battery Care uu aaa iint Gies SenUEEUI koiras 25 Winterizing Out of Service 25 TROUBLESHOOTING gt ICAL 2 26 Ene E UE 27 29 WIRING DIAGRAMS AC Electrical L eerte eos 30 31 DC Electrical 32 39 Proprietary Information2. SILON 6 SLON 33S ll S 1 33S ZH OS l 11 001 ZH OG l O Z Si1 002 001 ZH 09 1 021 001 l ZH 09 61 OtZ OZLi 002 001 l 4 VITO TATE ZI M WZ 917 JHM ZL o 9 8 310N 33S 8 310N 33S 9 9 2 6 i 26982244 Z9ILSG OLY m m G SION 33S jION 33S ZH OS OZz2 2Vi 061L 011 ZH OS 9 gt 08 0 ZH 09 Ov2 6 1 061 011 ZH 09 0o8v 2 089 02C CL JAM H9SIH cl sf 8 31ON 33S 8 67 8 m Oke LLLOL N3349 01 OM773LW3 11 13 31 UPdated page 3 13 12 iagrams D iring W 86 9 PUNOJE PIEPUE S OA WT1 ZZIN weibeig DuuiM 53g Fa G4TWWISNI 38 LSNW Su3gN3S _ZOQVOHOLIMS ETN E Q33 NMOU8 NOlVIS 0350 ST3NYd Q39nv9 OML dl 9 IA n _ CSLVOIGNI LNIOd 1Y ANNONS ANO QN3 IV 69 G3QNNOND 2018 3NI9N3 38 OL 34V SGT3IHS Hivd G3ISIML S ON i ZH SZ Wdy v 0Z2 7c di ML HOLMS Q33dSM3AO ZH 09 03 XH _ ZH 21 2 WdH eg ees dIML HOLMS Q33dSM3AO ZH OS pore ISd Sc 88 STANVd I3N3AVM MO 00r 2S9 S 00 2S9 S HILIM a on C7 3uHW 3ma L 2 NISN N3HM NMOHS SV MOS AVISY NMOGLAHS 3AOW3M 9 WIMLSNGNI 4 OLZ __ LNIOd
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6. normal direction from above Valve Arrangement OM773LW3 11 13 19 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 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 DO NOT use these unsuitable grades of fuel a O 0 C 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 Keep dirt scale water and other foreign matter out of fuel b Avoid storing fuel for long periods of time 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 Change the element as often as necessary or every 500 hours If the bowl fills
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8. 2 ENGINE CONTROL SWITCH To start the engine hold this switch in the START position until the engine is running NOTE Excessive cranking of marine sets equipped with water lift muffler systems can cause engine damage See page 6 After the engine starts release the switch and it will NT T tae return to RUN position To stop the engine hold the to n switch the STOP position 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 Keeps track of engine running time 4 OIL PRESSURE GAUGE 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 stopped the voltmeter indicates the condition of the battery When the engine is running the voltmeter indicates the voltage output of the alternator QUARTZ For Series 4 Control Panels Only 7 A C VOLTMETER Series 4 tor Set Control Panel Shows the generator output voltage 8 FREQUENCY METER Hertz The frequency meter indicates engine speed 1200 or 1800 RPM 60 Hz or 1500 RPM 50 Hz Ard Preheal Snitch a CMM ich Es 9 AMMETER SELECTOR SWITCH k Used to check each phase for load condition NOTE Always leave this switch in the ON position while the unit is running 10 A C AMMETER Shows the generator load on each phase The phase is selected
9. OPERATOR 5 MANUAL 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 M and the Northern Lights logo are trademarks of Northern Lights Inc Printed in U S A PART NO OM773LW3 11 13 NORTHERN LIGHTS OPERATOR S MANUAL for Model M773LW5s 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 2 Models InClUdEd gt L U petu daisies 2 Model NUmDerS aaa qua 2 Serial Numbers a 2 WARRANTY _ SAFETY RULES 3 7 LOCK OUT TAG OUT PROCEDURES 8 COMPONENT LOCATIONS M773LW Marine Generators 10 M773LW3 Marine Generators 11 PANELS Northern Lights Generator Sets 12 13 OPERATING PROCEDURES Break in Period
10. Figure 13 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 14 Remove the return line Figure 15 Unscrew and remove the injectors Figure 16 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 17 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 17 Screw in injector and tighten to 43 or 50 ft Ibs 6 to 7 kgm Figure 18 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 Se
11. Generator End 3 Tier Ill _ Northern Lights marine generator set with a M773LW3 773 engine PX 309K2 generator end AVR Tier Ill Serial Numbers Your set has three serial numbers 1 an engine number stamped on the block 2 a generator plate and 3 a generator set plate NORTHERN LIGHTS 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 Serial No Model No Northern Lights 4420 14th Ave NW Seattle WA 98107 Figure 1 Generator set serial number plate OM773LW3 11 13 2 updated 7 10 13 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 A warranty registration certificate is supplied with your set The extent of coverage is described in the Limited Warranty Statement We recommend that you study the statement carefully 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 Electromagnetic equipment including generator sets and their accessories can cause bodily harm and life threatening injuries when
12. 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 OM773LW3 11 13 OM773LW3 11 13 1 Introduction Servicing of marine engines and generator sets presents unique problems In many cases boats cannot be moved to a repair facility Marine engines cannot be compared to the servicing of automobiles trucks or even farm equipment Failures often occur in remote areas far from competent assistance Marine engines are taxed far more severely than auto or truck engines therefore maintenance sched ules must be adhered to more strictly Failures begin with minor problems that are over looked and become amplified when not corrected during 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 M773LWS marine generator set Model numbers give the unit s application block model aspiration and RPM M 773 L W 3 M Northern Lights marine generator set Model number of engine block L Long stroke e Bore Cylinders W New Winding in 77 3
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14. dealer Check your thermostats Check water temperature to see if temperature gauge is working properly See Engine Overheating section Use correct fuel for temperature Check installation or tightening Service air cleaner See your dealer See your dealer e See your dealer Check load usage Check your thermostats Check water temperature with thermometer and replace gauge if necessary see your Northern Lights dealer Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION S Below Normal Engine Temperature Thermostats not working properly Check thermostats Temperature gauge Check water temperature with thermometer not working properly Low Oil Pressure Low oil level Fill crankcase to proper level Clogged filter and strainer or Repair or replace worn bearings and oil pump 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 Engine Emits Black Clogged or dirty air cleaner Service air cleaner or Gray Exhaust Smoke Defective muffler e Have dealer check back pressure back pressure too high Improper fuel Use correct fuel for temperature Injection nozzles dirty e See your dealer Engine timin
15. for a three to five minute warm up period 3 Add electrical load STOPPING 1 Remove electrical load from the generator set 2 Move the Engine Control switch to the STOP position momentarily 3 Shut off the seacock fuel valve and battery switch OM773LW3 11 13 updated page 8 27 09 Operating Procedures SHUTDOWNS AND ALARMS 1 Generator sets have shutdown systems to stop the engine in the event of high water temperature or low oil pressure a Other alarms and shutdowns are available as optional equipment NOTE Do not rely on your shutdown to the exclu sion of careful gauge monitoring Watching your gauges can prevent damage to the unit and danger ous power losses Do the following when your warning or shutdown system is activated a Engage the preheat switch to check the temperature gauge b If above 205 F 96 C Use the Trouble Shoot ing Guide on page 22 to isolate the cause of the overheat CAUTION Do not remove the water fill 1 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 e Make repairs Restart your generator set after the temperature gauge registers below 200 F 94 C d Watch the temperature gauge regularly and turn off the unit if the temperature rises above 205 F 96 C on Marine units Repeat trouble shooting If shutdown is activate
16. improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL PRIOR TO THE INSTALLATION OF ANY GENERATOR SET OR ACCESSORY KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE Recognize Safety Symbols and Instructions In addition to the information found in this section this operator s manual uses three different signal words to outline potential dangers of a specific nature T D AN GER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a hazardous situation which A AUTION if not avoided could result in minor or moderate injury Follow All Safety Instructions Carefully read and understand v all safety messages in this CF manual and on your machine s 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 proper placement of safety signs or clarification on any safety issue consult your Northern Lights dealer or the factory There can be additional safety information contained parts components from outside suppliers that is not reproduced in this manual Consult the supplier
17. 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 A 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 A 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 Ensure that all personnel are safely outside danger zones Notify personnel that lock out tag out devices have been removed and energy will be reapplied Only authorized personnel may remove lock out tag out devices or notices OM773LW3 11 13 8 Notes OM773LW3 11 13 9 Marine Generator Component Locations Figure 1 amp 2 M773LW with PX 309K2 generator NOOR WD Generator Control Box Air Filter Fuel Filter Fuel Lift Pump Crankcase Vent Lube Oil Fill Top Coolant Fill 8 9 10 11 Fuel Injector Stop Solenoid Injection Pump Lube Oil Fill Side 12 13 14 Seawater Pump Lube Oil Drain Base frame 15 16 17 18 19 20 Block Drain Fuel Inlet and Return Oil Dipstick Lube Oil Filter Co
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19. with the Ammeter Selector switch Item 9 Figure 6 b Series 4 Generator Control Panel OM773LW3 11 13 12 Control Panels SHUTDOWN BYPASS SWITCH Manual Start Panels S 7 1 and S 7 3 Hold the switch in the START position until the sea A EY sas engine is running SERIES 7 NTROL maf Ow ON NOTE Excessive cranking may cause engine damage 5 After the engine starts release the switch and it will E return to the RUN position To stop the engine hold VJ e the switch in the STOP position Auto Start Panels S 7 0 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 FIGURE 7 A Series 7 0 through Series 7 6 Generator 3 HOUR METER Control Panels Keeps track of engine running time 4 ENGINE TEMPERATURE GAUGE Registers the temperature of the coolant 5 D C VOLTMETER STATUS INDICATORS When the engine is running the voltmeter indicates the Standard S 7 3 thru S 7 6 voltage output of the alternator svstem eaor Standard S 7 6 Standard S 7 6 6 STATUS INDICATOR PANEL Standard S 7 3 thru S 7 6 Engine monitoring alarms and lamps for monitoring engine functions KOELTE Standard S 7 3 thru S 7 6 EL IL Jl Standard 5 7 4 thru S 7 6 7 ALARM
20. 4 Ifthe engine does not start after the above bleed c The fuel lines injection pump or any other fuel ing process loosen a fuel line at the injector while system component has been removed and cranking the engine with the starter motor until pure installed fuel escapes Then tighten the connection Do each 2 Loosen bleed bolt A Figure 11 on top of the line one at a time filter Pump hand primer B on fuel lift pump until 5 After the engine has started use a piece of cardboard pure fuel no bubbles escapes from bleed bolt to look for fuel leaks Tighten bleed screw A OM773LW3 11 13 21 Servicing Figure 18 Reinstall injector Torque to proper tightness Figure 15 Remove return line OM773LW3 11 13 22 revised 11 8 13 Servicing SP11 INJECTOR SERVICE 1 Injectors should be checked every 1000 hours or whenever necessary 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 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 12 Remove delivery lines by disconnecting from injectors and injection pump
21. LAMP TEST AND RESET BUTTON Standard S 7 4 thru S 7 6 Press UP to test the indicator lights and press DOWN Standard S 7 3 thru S 7 6 to reset the alarm dude 2799272119576 s Ac VOLTAGE ADJUSTMENT RHEOSTAT Standard S 7 5 amp 576 Voltage has been set at the factory and should only be near E 1 M i ene ee adjusted by factory trained personnel ELI Standard S 7 5 amp S 7 6 SEI AME Standard S 7 6 9 AMMETER SELECTOR SWITCH coe Standard S 7 6 Used to check each phase for load condition NOTE Always leave this switch in the ON position 6 while the unit is running MANUAL START LAMP TEST 10 FREQUENCY METER HERTZ OFF A RESET a The frequency meter indicates alternator current ae ee da frequency 60 Hz 1200 or 1800 RPM or 50 Hz 1500 T 9 11 VOLTMETER n Shows the generator output voltage FIGURE 7 B Status Indicators for Series 7 0 through 12 A C AMMETER Series 7 6 Generator Control Panels Shows the generator load on each phase The phase is selected with the Ammeter Selector switch OM773LW3 11 13 13 updated page 1 9 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 engi
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24. NOILO3NNOO HOV3 LV ANINWW 4 002 J 3unssasd 110 x L8 M3MNVIAN ANIM AG O3IJILN3GI 38 1SNW A3N9 38 OL 33V SYOLONGNOD Q3TIVISNI TY 03000 30102 SSIINN Z oma NOLES JALON SV ONY SlYd Q3LSIML SSINYYH 3MIM dW3L 3NISN3 72 ANIONS JHL 1d32X3 GNVYLSILINW 2 601 9 MLW Wuviv dMd n 3dAL tL OMV 38 OL 3HV SYOLONGNOD NOWWTIVISNI TIY WNOILdO __ 1 94 OND 3SVO 4052 9 18 18 dil 3NI N3 3svo ama 08 ana 08 lt H ISd 08 0 SGN 9018 3NI9N3 34n S3Md 10 ES 9 LA Xovi8 LOL n 21 98 98 ALON 41 607 lt 1 ON L tv COY CC 0 0 lt E L quos 96 HMS addas 31IHA 8 x ode qua HOW B NMOS IN3W3T3 TIONIS 40018 3NION3 HOLIMS MO d cr WNOLLdO Aviat IV3H33d Ka T NAT gt v I xovi8 3uHM SLE 616 355 JONVYO ES L I am ft 9 ogon UNE Ld gt S ILON 33S A3 09 450 98 cg 4 ae non 3589 eee 728 NV39 ONIN pua SIS UMS T33HMA 14 pon ug SES De UE A S c L x3 L A389 2 ye HOLIMS isa TFL i Jas dal ANIONS m aaa L x xovig i HOLIMS MSHSINONILXS IVNOlLdO sts p duni ze i qaasi 39566 lt g Avi34 NMOGLAHS dlON310S x ESSEN P L8 ku T3NVd J0HLNO9 _35 9 2 8 OC E
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26. Temperature Viscosity Viscosity Above 32 SAE 30W SAE 15 40W 0 C 10 to 32 F 23 to 0 C SAE 10W SAE 10 30W Below 10 F 23 C SAE 5W SAE 5 20W Figure 8 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 Never put additives or flushing oil in crankcase SP1 CHECKING OIL LEVEL 1 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 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 8 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 15 TI3LW3 4 75 q
27. ZIZZ WdM Geol dll HOLIMS Q33dSHN3AO ZH OS ST3NVd 1 HILIM NISN N3HM NMOHS SV MOS AVIY NMOGLNHS 3AOW3M LL INIOd NOILO3NNOO LV M3MNVA 33IM Q3IJILN3OI 38 LSNW A349 38 OL 92 SMOIOnQNOO Q3TIVISNI TWV 03000 30109 SSIINN Z JALON SV ANY SWlVd Q3ISIML SS3NNVH IYIM ANIONS 3HL 1d30X3 GNVYLSILINW 0 601 OVAOO9 MIN pL OMY 38 OL 33V SHOLONGNOD NOLYTWISNI Ty 1S JLON NYL 18 lt 08 lt H 31IHM E Xovi8 LOL 9 11987 22 _ MAWIL 35109 16 1V3H33Md UD ne re JLON 33S 96 Ej rage 4m 3 L WNOILdO WEL 3IHA lt s NN amp Av13H IV3H3Md HM o 1f 05 00 v ASIA 09 950 99 cg 7 na t qup zz 1 x ovig NOM L vct so L 2 3 jg Og 0 8 MA t 2 e Ak U lt E yds Fdund 4 lt E e 310N 33S sg 98 quas 2359 66 lt a Avi34 NMOGLAHS 180 18 o ps iz Fo Gay 017 Sg 98 Ln lt 8 Q3H MOTI3A Z obo Avi3H luvis 01 VSI U old aay 201 lt V ENTENTE IANI TANVd OM773LW3 11 13 37 iagrams D iring W 9 998 9 PUNOJE P E OS HOA vo EMIEZZIN 5g onald 9 11d SS3JNUVH 3015 3015
28. all of its energy was safely blocked or released General Policy A 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 e 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 equipments ON OFF switch is in the OFF position and is unplugged from any electrical source before attempting to perform any type of work on the equipment Obtain an electrical plug cap cover with a lockset Secure the plug terminal end using the electrical plug lockout cap Lock the cap and retain the key If the equipment is directly wired into an electrical box with a shut off switch obtain a lock pad and or the appropriate colored tags and place the lock and tag through the shut off lever Retain the key until the repair is completed and the machine is safe to start Be certain the shut off lever is in the OFF position before restarting NEVER give a lock out key to unauthorized personnel If the equipment is directly wired into an electrical box without a shut off switch and lock out capability then a circuit breaker lock out will be required Obtain a circ
29. are acceptable water quality specifications Parts Grains Contaminates per Million per Gallon Maximum Chlorides 2 5 Maximum Sulfates 100 5 9 40 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 Check the coolant level each day before starting the engine Check the water level by removing the pres sure 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 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 1s faulty SP14 COOLING SYSTEM FLUSHING Flush the cooling system every 2500 hours or every 12 months whichever comes first a Remove expansion tank cap and drain engine block b Open block drain cock Remove plug in lower left side of heat exchanger tank c Pour clean water into expansion tank until water coming fr
30. 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 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 OM773LW3 11 13 6 Revised 3 13 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 A CAN PERFORM REPAIRS ON AN HIGH Use Proper Lifting Equipment and Techniques PRESSURE FUEL INJECTION SYSTEMS 1 WARNING Avoid Hot Exhaust Lifting heavy components incorrectly can cause severe injury or da
31. d and the temperature gauge shows temperature within normal temperature range a This shutdown could have happened because of a too high exhaust temperature This could have been caused by a damaged impeller or a partially blocked sea water strainer Check the sea water Strainer first If 1t 1s clear then check the condition of the sea water pump impeller b Check the engine crankcase oil level c 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 d If the oil level is normal DO NOT restart the engine Call your dealer for assistance SPARE PARTS l Northern Lights recommends that you keep the following spare parts on hand for field service The parts are available from your local Northern Lights dealer Marine models have optional On Board Kits a handy box that contains the most common parts you will need All owners should have the following a Primary and secondary fuel filter elements Oil filters Air filter Alternator belt Thermostat and gaskets Seawater pump impeller amp gaskets Glow plug Injector and washer If your set is operating a long distance from a servicing dealer add the following so 0 c a Complete set of injectors b Copper washers for injector change c Complete set of glow plugs d Fuel lift
32. e of fuel Low idle not stable Lack of Engine Power Intake air restriction Clogged primary or secondary fuel filter element Improper type of fuel Overheated engine OM773LW3 11 13 21 RECOMMENDATION S e 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 Glow plug malfunction njection timing not correct Low cylinder compression pressure 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 Consult fuel supplier and use proper type of fuel for operating condition Uneven cylinder compression e Service air cleaner Clean or replace filter element Consult fuel supplier and use proper type of fuel for operating conditions See Engine Overheats in next category Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE Lack of Engine Power continued Below normal engine t
33. emperature Injection pump fuel supply insufficient Improper valve clearance Dirty or faulty injection nozzles Cylinder compression pressure low cylinder compression pressure leakage Engine Overheats Low coolant level or cooling system defective Keel cooling tubes have been painted Cooling system needs flushing Defective thermostat Defective temperature gauge Water pump impeller worn broken Engine Knocks Insufficient oil Injection pump out of time Below normal engine temperature Engine overheating High Fuel Consumption Improper type of fuel or fuel leaking Clogged or dirty air cleaner Improper valve clearance Injection nozzles dirty Injection pump out of time Engine overloaded Engine not at proper temperature If you cannot correct problems with these procedures OM773LW3 11 13 28 RECOMMENDATION S Remove and check thermostat e Air mixing in injection pump Fuel filter clogged Reset valves Best done by dealer Replace injectors Best done by dealer Adjust valve clearance Adjust nozzle holder alignment Check cylinder bore wear Fill tank or radiator to proper level Check hoses for loose connections and leaks Fan belt slippng Remove paint from tubes Flush cooling system e Remove and check thermostat Check water temperature with thermometer and replace gauge if necessary Check impeller and replace if necessary Call your dealer Call your
34. er 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 OM773LW3 11 13 26 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 Clogged secondary fuel filter element Dirty or faulty injection nozzles Fuel injected but no ignition Engine Runs Irregularly Below normal engine temperature or Stalls Frequently 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 typ
35. filter element Racor Change secondary fuel filter Bleed the fuel system Check injectors Check fuel injection pump COOLING SYSTEM Check coolant level Check and flush cooling system Check and clean heat exchanger Change impeller in raw water pump Inspect condition of exhaust elbow ELECTRICAL SYSTEM Check electrolyte level in batteries Check condition of batteries with hydrometer OUT OF SERVICE 1 4 Winterizing or out of service Perform all maintenance once a year even if hour level has not been reached Consult manufacturer s maintenance schedule note on chart Whenever necessary More often if necessary After first 50 hours then at 100 hrs then every 200 hrs OM773LW3 16 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 11 13 Service Record Notes OM773LW3 11 13 17 updated 12 18 12 Servicing LUBRICATION GENERAL Use only clean high quality lubricants stored in clean containers in a protected area These lubricants are acceptable a API Service CC CD CE single viscosity oils b API Service CC CD SF multi viscosity oils Use the proper weight oil for your average operation temperature Air Single Multi
36. g drain cocks b Drain water supply lines and wet exhaust line O Loosen the seawater pump cover and drain pump d Fill the fuel tank or add biocide as per manufacturer s instructions e Seal the air cleaner inlet exhaust opening crankcase breather pipe and fuel tank vent with plastic bags and tape f Store the set in a dry protected place If unit must be stored outside be sure it is well protected with a cover g Change the crankcase oil and filter h Loosen the alternator belt 1 Disconnect and clean battery Remove to warm storage place if possible j Clean outside of unit Paint any scratched or chipped surfaces Put corrosion preventative on all exposed metal surfaces OM773LW3 11 13 Troubleshooting DC ELECTRICAL 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 Start
37. g off e 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 OM773LW3 11 13 29 updated page 3 13 12 iagrams D iring W 226 9 HAV MVACOOlL LSC JojejeueD pes 2400 Xd 0 1 weibeig bul 9V LYA san pas YA fav L10 ZL SALON 33S TRZ Z ado a CYA N39 WO za v32 001 1Sa YOLVINSAY 39VL1OA 0V SNOlIVOllddv OVAOCL OOL 1d3OX3 S39VLIIOA NOlLISOd AOOc 3HL OL 135 38 OL SI LMS HOLIMS SNISN3S 1 UAV NOLLVTTVISNI Mad Q3NIAWM3I3O 38 OL ONIZIS SYOLONGNOD LAdLNO Q3193NNOO 03119905 M3AOISQO JLVOIGNI SINN G3SHSVG N3QGIH 3000 1 001 d318vOllddv ANY ANY 3002 1VOIMIO3T3 IWNOILVN JHL HILIM JONVGYOOOV NI GSGNNONS 38 OL 33V 5135339 WIMLSNGNI NOLL3MOSIQ S M3WOISnO LV M3WOIShO Q3Q0NnON9 3HV SI3SN39 3NIMVWN AdVL 1VOIMIO313 9NIddV3M A8 31 1051 LAN M3HSVM 201 L104 ONISN SNOLLO3NNOO 3MVW S M2O18 IWWNINYSL WON4 SQv31 Qaaio344v 3AOW3M OalJno3s 3l SHOIORnQNOO 39nv9 M39MV1 31VQOWIANOOOV LON SM2018 VINYL SQv31 32145 M3dWnr
38. hat 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 electrolyte 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 e 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 am
39. k all glow plugs and replace any faulty ones Glow Plugs c HER Figure 19 Glow plugs BOOSTER BATTERIES CAUTION Battery gas can explode Keep all flames and sparks away from batteries Battery electrolyte is sulfuric acid diluted which can burn or stain body or clothes Before changing or using booster batteries check bat tery electrolyte level Add distilled water if necessary Booster and main batteries must have the same volt age rating 3 First connect positive terminal of booster bat tery to positive terminal of main battery Then connect negative terminal of booster battery to ground on the engine block see Figure 20 4 Remove booster battery after starting engine 5 Sealed batteries See manufacturer charging and booster instructions Figure 20 Battery connections Battery Booster Battery 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 250 hours SP20 WINTERIZING OUT OF SERVICE 1 Generator sets a Drain fresh water and seawater cooling systems completely Remember to shut off seacocks before openin
40. mage WARNING to machinery Avoid unbalanced DM loads Do not use lifting eyes Lift the AS generator set using lifting bars inserted Avoid exposure to and physical 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 filters A C AUTION During auto or manual stationary exhaust filter Makeshift tools and procedures cleaning operations 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 tha
41. ne temperature and oil pressure gauges sets with Series 3 or 4 panels 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 100 hours then at every 250 hours consult Lubricants section for oil recommendation BEFORE STARTING Check the water level by removing the pressure cap from the expansion tank 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 in the waffled area between maximum and minimum level 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 4 Close the sea cock check and clean the sea strainer and reopen the sea cock 5 Place the battery switch in the ON position 6 NOTE The battery switch must always be kept ON while the engine is running If the switch is turned OFF while the engine is running the battery charging regulator could be ruined STARTING Hold the Shutdown Bypass Preheat switch in the ON position for 10 to 20 seconds before star
42. nging the element Do NOT case Remove the rocker arm cover and turn the run the engine with the air cleaner removed crankshaft foward and backward If the inlet and exhaust valves of the No 1 cylinder do not move SP5 V BELTS it is in top dead center position When the valves move or rock turn the crankshaft one full turn and Check the tension and wear on the V belt daily align the top mark of the crank pulley with the top mark of the timing gear case 2 Use your thumb to press on the belt at the midpoint 4 Loosen the lock nut and adjust the clearance between between the crankshaft and alternator pulleys The the rocker arm and valve guide of both the intake tension is correct if the belt can be depressed about and exhaust valves with the adjustment screw Figure 3 16 in 5 mm 9 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 LV Valve Adjustment Screw Rocker Arm 4 0 008 in 3 t 0 200 mm Figure 9 Valve Adjustment Cylinder No 1 2 3 Valve Arrangement Int Exh Int Exh Int Exh When No 1 cylinder is at Top Dead Center Figure 10 Timing Mark in the compression O O Q stroke With the crankshaft turned 360 in C C C
43. ntrol Panel Plug Generator Data Plate OM773LW3 11 13 10 AC Circuit Breaker for AVR DC Circuit Breaker Expansion Tank Wet Exhaust Elbow Vibration Mount um di T 26 Starter 27 Alternator 28 HeatExchangerEnd Cap 29 Coolant Recovery Tank Figure 3 amp 4 M773LW3 with PX 309K2 O generator end Generator Control Box DC Circuit Breaker Coolant Recovery Tank Air Filter Fuel Filter Fuel Lift Pump Marine Generator Component Locations Fuel Injector Coolant Fill Lube Oil Fill Top Stop Solenoid Injection Pump Lube Oil Fill Side Updated 9 16 10 13 Seawater Pump 14 Fuel Inlet and Return 15 Oil Dipstick 16 Lube Oil Filter 17 Oil Drain 18 Generator Data Plate 19 Expansion Tank OM773LW3 11 13 11 20 21 Wet Exhaust Elbow 22 Vibration Mount 23 Starter 24 Alternator Control Panels OAT 8 e eae 1 SHUTDOWN BYPASS PREHEAT SWITCH BYPASS START LIBRES It Com domeca Cee your merce There are two functions built into this switch 1 Preheats the fuel before beginning the starting process Press switch 10 20 seconds before attempting start up 2 Bypasses the safety shutdown feature during starting process Keep switch engaged while starting engine and for 2 to 3 seconds afterwards allowing oil pressure to build beyond shutdown set point
44. om drains is free of discoloration and sediment Let water drain completely Close drains and refill with recommended mixture 2 Coolant Specifications Use 50 water 50 ethylene glycol antifreeze mix Antifreeze mixture is recommended as a good year round coolant but not methyl alcohol based antifreeze because of it s effect on non metallic components and it s low boiling point Also antifreeze with high silicate should not be used as it could case silica gelation problems 3 Check hoses and connections and repair any leakage SP15 HEAT EXCHANGER Clean the heat exchanger core once a year or after 2500 hours of operation Drain expansion tank and heat exchanger Remove heat exchanger end covers and remove core Clean the inside of exchanger core tubes using a metal rod Flush inspect and clean again if necessary Reassemble Fill the cooling system start the engine and check for leaks SP17 RAW WATER PUMP Change the seawater pump impeller every 1000 hours or as needed Remove the pump end cover Pry out the impeller using needle nose pliers or two screwdrivers Be sure you remove all pieces of failed impeller NOTE Place some kind of protection under the screwdrivers in order not to damage the pump housing Clean the inside of the housing Press in the new impeller and place the sealing wash ers in the outer end of the impeller center if this has not already been done Re
45. ounts of water or milk without exceeding 2 liters 2 quarts 3 Get medical attention immediately 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 Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injur Among the potentially hazardous chemicals that may be used with Northern Lights products are lubricants coolants paints and adhesives All potentially hazardous chemicals come with a Material Safety Data Sheet MSDS The MSDS provides specific details on chemical products including physical hazards safety procedures and emergency response techniques OM773LW3 11 13 Revised 3 13 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 Remo
46. place the cover using a new gasket NOTE Make sure that there is always an extra impeller and cover gasket in reserve on board 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 OM773LW3 11 13 24 revised 11 8 13 Servicing ELECTRICAL SYSTEM GENERAL Never switch battery switch off or break the circuit between the alternator and batteries while the engine is running Regulator damage can result Do NOT reverse the polarity of battery cables when installing the battery When welding on the unit disconnect the regulator and battery Isolate the leads Disconnect the battery cables when servicing the D C alternator Never test with a screwdriver etc against any ter minal to see if it emits sparks Do not polarize the alternator or regulator A D C circuit breaker protects your control panel and wiring harness It is located in the side of the generator junction box GLOW PLUGS Each cylinder is supplied with a glow plug which serves to heat the combustion chamber To check the glow plugs loosen the current carrying flat wire between the plus poles of the glow plugs Figure 19 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 Chec
47. pump OM773LW3 11 13 updated 12 18 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 Point SP is listed on the page noted in the page column DAILY SP1 SP5 SP7 SP13 Check oil level in engine Check V belt tension Check primary fuel filter Check coolant level Check sea strainer SP18 Check electrolyte in batteries AFTER FIRST 50 HOURS SP2 3 Change engine oil and filter SP6 Adjust valves AFTER FIRST 100 HOURS SP2 3 Change engine oil and filter EVERY 200 HOURS SP2 3 Change engine oil and filter SERVICE POINT OPERATION DAILY ENGINE Check oil level EVERY 250 HOURS SP4 Check air cleaner SP19 Check state of charge of batteries EVERY 500 HOURS SP8 Change primary fuel filter element SP9 Change secondary fuel filter SP21 Inspect condition of exhaust elbow EVERY 1000 HOURS SP4 Replace air cleaner element SP6 Check valve clearances SP11 Check injectors SP17 Change impeller EVERY 2500 HOURS SP12 Check fuel injection pump SP14 Check and flush cooling system SP15 Check and clean heat exchanger 250 Hours 500 Hours 1000 Hours Change engine oil Change lube oil filters Check air cleaner change element 1000 hrs 1 4 5 Check V belt tension Check valve clearances FUEL SYSTEM Check primary filter Racor Change primary
48. rn Lights Inc NORTHERN LIGHTS 2013 All rights reserved Litho USA
49. rotective Clothing A D AN G R 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 C drivelines Stop the engine and make sure that all Wear suitable authorized CD LO A moving parts have stopped Y3 before making any adjustments connections or performing A any other type of service to the engine or other driven equipment hearing protection such as earmuffs or plugs to 3 protect against loud noises OM773LW3 11 13 4 Revised 7 9 12 Safety Rules Continued Install all Safety Guards VS Z e 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 t
50. rvice 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 injec tion 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 NOTE Be sure to close the sea cock before working A on the engine cooling system CAUTION The cooling water in the engine reaches extremely high temperatures You must use extreme caution when working on hot engines to avoid burns Allow the engine to cool before working on the cooling system Open the filler cap carefully using protective clothing when the engine is warm WATER QUALITY 1 Distilled deionized soft water is preferred for use in cooling systems Bottled distilled water from a food store or water supplier 1s 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 OM773LW3 11 13 23 revised 11 8 13 Servicing 2 Here
51. s for additional safety information Learn how to operate the machine and how to use the controls properly Only trained personnel should Operate machines or work on or around them Keep you machine in proper working condition UNAUTHORIZED MODIFICATIONS TO THE MACHINERY MAY IMPAIR ITS FUNCTION AND SAFETY PARAMETERS Prevent Bypass and Accidental Starting Do not start engine by shorting across start terminal Engine will start if normal circuitry is bypassed creating a hazard by runaway machinery Start engine only from operator s station Handle Fuel Safely Avoid Flames 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 ALWAYS STOP ENGINE BEFORE FUELING MACHINE Always fill portable fuel tank outdoors Never fuel a hot engine OM773LW3 11 13 Revised 3 13 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 can igni
52. t may be generated when handling components containing bii asbestos fibers including some CAUTION CAUTION gaskets 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 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 OM773LW3 11 13 7 Added 2 24 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
53. te and burn spontaneously A CAUTION ai 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 A DANGER service work Do not wear a necktie scarf necklace 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 P
54. ting a cold engine Holding the switch too long can burn out the glow plugs This step is not necessary if the engine is already warm While holding the Shutdown Bypass Preheat switch in the ON position push the Engine Control switch to the START position As soon as the engine starts release both switches Do not crank the starter for more than 10 seconds consecutively If the engine fails to start with the first attempt be sure that it has stopped completely for at least 30 seconds before re engaging NOTE Excessive cranking of the starter on Marine sets equipped with a water lift muffler can cause engine damage If the engine does not start after three 10 second cranks remove the impeller from the raw water pump This will prevent the muffler from filling with water and backfilling the exhaust line and engine Once the engine starts shut it off immediately and re install the impeller Re start the engine and check the exhaust overboard outlet for gushes of water OPERATING l Units with Series 3 and Series 4 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 coolant temperature gauge must be between167 F and 194 F 75 C to 90 C Check the A C voltage and frequency meters Series 4 panel If the gauges deviate from normal levels shut down the generator set and investigate Let the unit run unloaded
55. uarts 4 9 liters SP3 CHANGING LUBE OIL FILTER Change the lube oil filter every 200 hours 2 Useafilter 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 Spreada 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 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 numbers are TI3LW3 24 02001 OM773LW3 11 13 18 Servicing SP4 AIR CLEANER SP6 VALVE CLEARANCES 1 Inspect air cleaner every 250 hours In dusty condi 1 Adjust valve clearance after 1000 hours or as tions check more often needed 2 Ifdirty wash element in soapy water Rinse and dry 2 Valve adjustments should be done after the cylinder thoroughly before re installing head bolts have been re tightened Engine should be Replace if necessary Part numbers are cold and NOT running M773LW3 24 28602 3 To bring the No 1 cylinder to top dead center in the compression stroke align the timing mark the top 3 NOTE Make absolutely sure no impurities enter mark of the crank pulley with that of the timing gear the engine while cha
56. uit lock and tag set Install the lock onto the circuit breaker box Ensure the unit ON OFF switch is in the OFF position before restarting Lock Out Tag Out Instructions Pneumatic and Hydraulic Equipment For servicing pneumatic and hydraulic equipment the following additional procedures must be implemented following completion of lock out tag out procedures for the unit to be serviced Shut off air water or supply valves at the equipment to be serviced Check the local bleed off point for completed release of pressurized air water or oil If shutting off of air water or other material cannot be achieved at the local supply valve shut off valves further back in the system and re check the bleed off point until complete shut off is achieved Affix a DO NOT OPERATE tag to each valve handle that requires shut off Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment Lock Out Tag Out Instructions Air Hose Connected Pneumatic Equipment Equipment connected to the compressed air system through an air hose with a detachable fitting must be shutdown and unplugged Excess air must be bled prior to removing the air hose prior to any maintenance or repair activities Affix a DO NOT OPERATE tag to the air hose near the detachable fitting Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment Check that the equipment cannot be
57. ve Paint Before Welding or Heating Hazardous fumes can be generated when paint is heated by welding i soldering or using a torch To avoid 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 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 f 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
58. with water change the primary and secondary element immediately Change secondary fuel filter every 500 hours or as necessary a OM773LW3 11 13 20 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 Fuel filter part number is 773LW3 24 52020 Servicing SP10 BLEEDING THE FUEL SYSTEM A CAUTION Escaping diesel fuel under pressure can penetrate skin causing serious personal injury Before disconnecting lines be sure to relieve all pressure Before applying pressure be sure all connections are tight and lines pipes and hoses aren t damaged Fuel escaping from a very small hole can be almost invisible Use a piece of cardboard or wood rather than hands to search for suspected leaks If injured by escaping fuel see a doctor at once Serious infection or reaction can develop if proper medical treatment isn t administered immediately Figure 11 Fuel System 1 The fuel system is self bleeding However any 3 Loosen bleed screw Pump hand primer B system may need manual bleeding when until pure fuel no bubbles escapes Then tighten a Anew fuel filter is installed bleed screw b The engine has run out of fuel
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