operator’s manual - northern lights · 2018-10-18 · operator’s manual uses three different...
TRANSCRIPT
OPERATOR’S MANUALOPERATOR’S MANUAL
OM773LW3For Model: M773LW3 and M773LW3G
www.northern-lights.com
Breathing Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.* Always start and operate the engine in a well-ventilated area.* If in an enclosed area, vent the exhaust to the outside.* Do not modify or tamper with the exhaust system.* Do not idle the engine except as necessary.For more information, go to www.P65warnings.ca.gov/diesel.
— CALIFORNIA —Proposition 65 Warning:
Northern Lights4420 14th Avenue NWSeattle, WA 98107Tel: (206) 789-3880Fax: (206) 782-5455
Copyright ©2018 Northern Lights, Inc.All rights reserved. Northern Lights™, andthe Northern Lights logo are trademarks ofNorthern Lights, Inc.
Printed in U.S.A.PART NO.: OM773LW3 10/18
OM773LW3 10/18
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Read this operator's manual thoroughly before starting to operate your equipment.This manual contains information you will need to run and service your new unit.
OPERATOR'S MANUALfor Model
M773LW3 and M773LW3G
INTRODUCTION ..................................................2 Models Included .................................................2 UnitIdentification ...............................................2 SerialNumbers ...................................................2
WARRANTY ...........................................................3
SAFETY RULES ..............................................3 - 7
LOCK OUT / TAG OUT PROCEDURES .......... 8
COMPONENT LOCATIONS M773LW3GMarineGenerators ...................... 10 M773LW3MarineGenerators ..........................11
CONTROL PANELS Series 1-B ......................................................... 12 Series 3 ............................................................. 12 Series 4 ............................................................. 13
OPERATING PROCEDURES Break-inPeriod ................................................ 14 BeforeStarting ................................................. 14 Starting ............................................................. 14 Operating ......................................................... 14 Stopping ........................................................... 14 ShutdownsandAlarms .................................... 15 SpareParts ....................................................... 15
SERVICING SCHEDULE CHART ................. 16
SERVICING RECORD NOTES ....................... 17
SERVICING Lubrication-General ....................................... 18 CheckingOil .................................................... 18 OilChanges ..................................................... 18 ChangingOilFilter .......................................... 18 AirFilter .......................................................... 19 V-Belts ............................................................. 19 ValveClearances .............................................. 19 Fuels-General ................................................. 20 FuelFilters ....................................................... 20 BleedingtheFuelSystem ................................ 21 InjectorService ........................................ 22 - 23 InjectionPump ................................................. 24 CoolingSystem-General ................................ 24 CoolingSystemFlushing ................................. 25 HeatExchanger ............................................... 25 RawWaterPump ............................................. 25 GeneratorEnds ................................................ 25 ElectricalSystem-General ............................. 25 GlowPlugs ....................................................... 25 BoosterBatteries .............................................. 26 BatteryCare ..................................................... 26 Winterizing/Out-of-Service ........................... 26
TROUBLESHOOTING Electrical .......................................................... 27 Engine ...................................................... 28 - 30
WIRING DIAGRAMS ACElectrical ........................................... 31 - 32 DCElectrical ........................................... 33 - 40 PanelDiagrams ........................................ 41 - 49
Proprietary InformationThispublicationisthepropertyofNorthernLights,Inc.
ItmaynotbereproducedinwholeorinpartwithoutthewrittenpermissionofNorthernLights,Inc.©NorthernLights,Inc.Allrightsreserved.LithoU.S.A.PublicationnumberOM773LW310/18
Table of Contents
OM773LW3 10/18
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Servicingofmarineenginesandgeneratorsetspresentsuniqueproblems.Inmanycasesboatscannotbemovedtoarepairfacility.Marineenginescannotbecomparedtotheservicingofautomobiles,trucksorevenfarmequipment.Failuresoftenoccurinremoteareasfarfromcompetentassistance.Marineenginesaretaxedfarmoreseverelythanautoortruckengines;therefore,maintenancesched-ulesmustbeadheredtomorestrictly.
Failuresbeginwithminorproblemsthatareover-lookedandbecomeamplifiedwhennotcorrectedduringroutinemaintenance.
Asoperator,itisyourobligationtolearnaboutyourequipmentanditspropermaintenance.Thisisnotacomprehensivetechnicalservicemanual.Norwillitmakethereaderintoanexpertmechanic.Itsaimistoaidyouinmaintainingyourunitproperly.
Introduction
L, W, G, 3
M - Northern Lights marine generator set
Model number of engine block Bore Cylinders 77 mm 3
MODELS INCLUDEDThismanualcoverstheoperatinginstructionsfor: M773LW3 and M77LW3G marine generator setsthe
unit'application,blockmodel,aspiration,andRPM:
L - Long strokeW - Auxiliary Winding in Generator EndG - GEM series base frame3 - US EPA Tier III compliant
+ +
Northern Lights marine generator set with a 773 engine, PX-309K2 generator end, AVR, US EPA Tier III.
M 773
M773LW3 =
Yoursethasthreeserialnumbers:1anenginenumberstampedontheblock,2 ageneratorplate,and3ageneratorsetplate.
Usetheserialnumberonthegeneratorsetplatewhenorderingpartsorincorrespondence.ThegeneratorsetplateisfoundontheservicesideofthegeneratorandresemblesthedrawinginFigure 1.
Unit Identification
Serial Numbers
Model numbers give the unit’s application, block model, aspiration, and RPM
Northern Lights marine diesel generator set with a 773 engine, PX-309K2 generator end, GEM series, US EPA Tier III.
M773LW3G =
Updated 7-6-18
OM773LW3 10/18
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Awarrantyregistrationcertificateissuppliedwithyourset.Itentitlestheoriginalpurchaserofourequipmenttoawarrantycoveringmaterialorassemblyfaults.TheextentofcoverageisdescribedintheLimitedWarrantyStatement.Werecommendthatyoustudythestatementcarefully.NOTE:Ifthewarrantyistoapply,theservicinginstructionsoutlinedinthismanualmustbefollowed.Iffurtherinformationisneeded,pleasecontactanauthorizeddealerorthefactory.
Safety Rules
Warranty
Updated 4-12-17
NOTICE: Accident reports show that careless use of engines causes a high percentage of accidents. You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.
IMPORTANTSAFETYINSTRUCTIONS.Electromagneticequipment,includinggeneratorsetsandtheiraccessories,cancausebodilyharmandlifethreateninginjurieswhenimproperlyinstalled,operatedormaintained.Topreventaccidentsbeawareofpotentialdangersandactsafely.
READANDFOLLOWALLSAFETYINSTRUCTIONSINTHISMANUAL,PRIORTOTHEINSTALLATIONOFANYGENERATORSETORACCESSORY.KEEPTHESEINSTRUCTIONSFORFUTUREREFERENCE.
Recognize Safety Symbols and InstructionsInadditiontotheinformationfoundinthissection,thisoperator’smanualusesthreedifferentsignalwordstooutlinepotentialdangersofaspecificnature.
Follow All Safety InstructionsCarefullyreadandunderstandallsafetymessagesinthismanualandonyourmachine’ssafetysigns.Keepsignsingoodandcleancondition.Replacemissingordamagedsigns.Besurenewequipmentcomponentsand
repairpartsincludethecurrentsafetysigns.Forreplacementsigns,properplacementofsafetysignsorclarificationonanysafetyissue,consultyourNorthernLightsdealerorthefactory.Therecanbeadditionalsafetyinformationcontainedonpartsandcomponentsfromoutsidesuppliersthatisnotreproducedinthismanual.Consultthesuppliersforadditionalsafetyinformation.
Learnhowtooperatethemachineandhowtousethecontrolsproperly.Onlytrainedpersonnelshouldoperatemachines,orworkonoraroundthem.
Keepyoumachineinproperworkingcondition.UNAUTHORIZEDMODIFICATIONSTOTHEMACHINERYMAYIMPAIRITSFUNCTIONANDSAFETYPARAMETERS.
Prevent Bypass and Accidental Starting
! WARNINGDonotstartenginebyshortingacrossstartterminal.Enginewillstartifnormalcircuitryisbypassed,creatingahazardbyrunawaymachinery.
Startengineonlyfromoperator’sstation.
! DANGER! WARNING! CAUTION
DANGERindicatesahazardoussituationwhich,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationwhich,ifnotavoided,couldresultinminorormoderateinjury.
DANGER: Northern Lights generator sets and /or any other diesel powered equipment provided by NLI is not provided with spark arresting or explosion proof components, and therefore is not to be installed in the presence of combustible gases having a flash point of 43.3 Degrees C (110 Degrees F) or lower, such as Gasoline, Propane, Natural Gas or other similar fuel sources.
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Safety Rules (Continued)
Updated 4-12-17
Wear Protective Clothing
! WARNINGTopreventcatchinganythinginmovingmachinery,alwayswearclosefittingclothesandsafetyequipmentappropriatetothejob.Prolongedexposuretoloudnoisecancausehearinglossorimpairment.Wearsuitableauthorizedhearingprotection,suchasearmuffsorplugstoprotectagainstloudnoises.
Operatingequipmentrequiresthefullattentionoftheoperator.Donotuseradioormusicheadphoneswhileoperatingmachinery.Practice Safe Maintenance
! CAUTIONUnderstandallserviceproceduresbeforestartingwork.Keepareacleananddry.Neverlubricate,service,oradjustmachinewhileitisinoperation.
Keephands,feetandclothingawayfrompower-drivenequipment.Whenshuttingdownanengine,disengageallpowerandoperatorcontrols.Allowtheenginetocoolcompletelybeforebeginninganyservicework.
Securely support any machinery elements that must be raised for service work with support or lifting machinery specifically intended for that purpose.
Keepallpartsingoodconditionsandproperlyinstalled.Fixdamageimmediately.Replaceanywornorbrokenparts.Removeanybuildupofgrease,oilordebris.
Disconnectbatterygroundcable(-)beforemakinganyadjustmentsorservicework.
Handle Fuel Safely - Avoid Flames
! WARNINGDieselishighlyflammableandshouldbetreatedwithcareatalltimes.Dodonotrefuelwhilesmokingorwhennearsparksoropenflame.
ALWAYSSTOPENGINEBEFOREFUELINGMACHINE.Alwaysfillportablefueltankoutdoors.Neverfuelahotengine.Preventaccidentaldischargeofstartingfluidsbystoringallcansinacool,safeplace,awayfromsparksoropenflame.Storewithcapsecurelyoncontainer.Neverincinerateorpunctureafuelcontainer.
Preventfiresbykeepingmachinecleanofaccumulatedtrash,greaseanddebris.Alwayscleananyspilledfuelasswiftlyaspossible.Donotstoreoilyrags,whichcanigniteandburnspontaneously.
Bepreparedifafirestarts.Keepafirstaidkitandfireextinguisherhandy.Keepemergencycontactnumbersforfiredepartment,doctors,ambulanceandhospitalnearthetelephone.
Service Machines Safely
! DANGERDonotwearanecktie,scarf,necklace,ringsorotherjewelry,oranylooseclothingwhenworkingnearmovingparts.Tielonghairbehindyourhead.Ifanyoftheseitemsgetcaughtinmovingmachinery,severeinjuryordeathcouldresult.
Checkforanylooseelectricalconnectionsorfaultywiring. Lookcompletelyaroundenginetomakesurethateverythingisclearbeforestarting.
OM773LW3 10/18
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Stay Clear of Rotating Drivelines
! DANGEREntanglementinrotatingdrivelinescancauseseriousinjuryordeath.Keepshieldsinplaceatalltimes.Makesurethatrotatingshieldsturnfreelyinpacewiththedrivelines.
Donotwearloosefittingequipmentaroundrotatingdrivelines.Stoptheengineandmakesurethatallmovingpartshavestoppedbeforemakinganyadjustments,connections,orperforminganyothertypeofservicetotheengineorotherdrivenequipment. Install all Safety Guards
! WARNINGDirectcontactwithrotatingfans,belts,pulleyanddrivescancauseseriousinjury.
Keepallguardsinplaceatalltimesduringengineoperation.
Wearclose-fittingclothes.Stoptheengineandbesureallfans,belts,pulleysanddrivesarestoppedbeforemakingadjustments,connections,orcleaningnearfansandtheircomponents.
Donotallowanythingonyourpersontodangleintoorcomeincontactwithamovingfan,belt,pulleyordrive.Fanscanactasvacuumsandpullmaterialsupfrombelow,soavoidthatareaaswellwhileinservice.
Safe Battery Handling
! WARNINGPrevent Battery Explosions Batterygasishighlyflammable.Batteryexplosionscancausesevereinjuryordeath.Tohelppreventbatteryexplosions,keepsparks,lightedmatchesandopenflameawayfromthetopofbattery.Whencheckingbatteryelectrolytelevel,useaflashlight.
Safety Rules (Continued)
Updated 4-12-17
Nevercheckbatterychargebycontactingthepostswithametalobject.Useavolt-meterorhydrometer.
Frozenbatteriesmayexplodeifcharged.Neverchargeabatterythathasnotbeenallowedtowarmtoatleast16oC(60oF).Alwaysremovegrounded(-)batteryclampfirstandreplacegroundclamplast.
Sulfuricacidinbatteryelectrolyteispoisonousandstrongenoughtoburnskin,eatholesintoclothingandothermaterials,andcauseblindnessifsplashedintoeyes.
To Avoid Hazards:•Fillbatteriesonlyinwell-ventilatedareas.•Wearappropriateeyeprotectionandrubbergloves.•Neveruseairpressuretocleanbatteries.•Wearappropriateventilationequipmenttoavoidinhalingfumeswhenaddingelectrolyte.•Donotspillordripelectrolyte.•Usecorrectjump-startprocedureifrequired.
If acid is spilled on skin or in eyes:1.Flushskinwithwater.2.Applybakingsodaorlimetohelpneutralizeacid.3.Flusheyeswithwaterfor15-30minutes.4.Getmedicalattentionimmediately.Ifacidisswallowed:1.DONOTinducevomiting.2.Drinklargeamountsofwaterormilk,withoutexceeding2liters(2quarts)3.Getmedicalattentionimmediately
Batteryposts,terminals,andrelatedaccessoriescancontainleadandleadcompounds,chemicalsknowntotheStateofCaliforniatocausecancerandreproductiveharm.Washhandsafterhandling.
! WARNING
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Safety Rules (Continued)
Updated 4-12-17
Donotuseachlorinatedsolventinanareawhereweldingwilloccur.Workonlyinareasthatarewellventilated.Disposeofpaintandsolventproperly.
Service Cooling System Safely
! WARNINGOpeningapressurizedcoolingsystemcanreleaseexplosivefluidsandcausingseriousburns.Beforeopeninganypressurizedcoolingsystem,makesuretheenginehasbeenshutoff.Donotremoveafillercapunlessitiscoolenoughtocomfortablygripwithbarehands.Slowlyloosencaptorelievepressurebeforeopeningfully.
Avoid High Pressure Fluids
! WARNINGRelievepressurepriortodisconnectingpressurizedlines.Escapingfluidunderpressurecanpenetratetheskincausingseriousinjury.Alwaysrelievepressurebeforedisconnectinghydraulicorotherpressurizedlines.Tightenallconnectionsfirmlybeforere-applyingpressure.
Ifsearchingforleaks,useapieceofcardboard.Alwaysprotectyourhandsandotherbodypartsfromhigh-pressurefluids.
Ifanaccidentoccurs,seeadoctorimmediately.Anyhighpressuresprayinjectedintotheskinmustberemovedwithinafewhourstopreventtheriskofgangreneorotherinfection.
Avoid Heating Near Pressurized Fluid Lines
! WARNINGFlammablespraycanbegeneratedbyheatingnearpressurizedfluidlines,resultinginsevereburnsandbodilyinjury.Pressurizedlinescanrupturewhenheatgoesbeyondtheimmediateflamearea.Donotweld,solderoruseatorchoropenflamenearpressurizedlinesorotherflammablefluids.
Handle Chemical Products Safely
! WARNINGDirectexposuretohazardouschemicalscancauseseriousinjury.AmongthepotentiallyhazardouschemicalsthatmaybeusedwithNorthernLightsproductsarelubricants,coolants,paintsandadhesives.
AllpotentiallyhazardouschemicalscomewithaMaterialDataSafetySheet(MSDS).TheMSDSprovidesspecificdetailsonchemicalproducts,includingphysicalhazards,safetyproceduresandemergencyresponsetechniques
ReadandunderstandtheMSDSforeachchemicalbeforeyoustartanyjobthatincludesit.Followtheproceduresanduseappropriateequipmentexactlyasrecommended.
ContactyourNorthernLightsdealerorNorthernLightsfactoryforMSDS’susedonNorthernLightsproducts.
Work in Well Ventilated Areas
! CAUTIONExhaustfumesfromenginescontaincarbonmonoxideandcancausesicknessordeath.Workinwellventilatedareastoavoidprolongedexposuretoenginefumes.Ifitisnecessarytorunanengineinanenclosedarea,routetheexhaustfumesoutoftheareawithanapproved,leakproofexhaustpipeextension.
Remove Paint Before Welding or Heating
! WARNINGHazardousfumescanbegeneratedwhenpaintisheatedbywelding,solderingorusingatorch.Toavoidpotentiallytoxicfumesanddust,removepaintbeforeheating.• Removepaintaminimumof100mm(4in.)fromtheareathatwillbeaffectedbyheat.• Ifpaintcannotberemoved,wearanapprovedrespirator.•Ifyousandorgrindpaint,useanapprovedrespirator.•Ifyouusesolventorpaintstripper,removestripperwithsoapandwaterbeforewelding.Removesolventorpaintstrippercontainersfromthearea.•Allowatleast15minutesforfumestodispersebeforeweldingorheating.
OM773LW3 10/18
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Safety Rules (Continued)
Updated 4-12-17
Avoidcreatingdust.Neverusecompressedairforcleaning.Avoidbrushingorgrindingmaterialscontainingasbestos.Whenservicing,wearanapprovedrespirator.Aspecialvacuumcleanerisrecommendedtocleanasbestos.Ifthisvacuumisnotavailable,applyamistofoilorwateronthematerialcontainingasbestos.Keepallbystandersawayfromanyareawhereasbestosdustmaybegenerated.
Use Proper Lifting Equipment and Techniques
! WARNINGLiftingheavycomponentsincorrectlycancausesevereinjuryordamagetomachinery.Avoidunbalancedloads.Donotuseliftingeyes.Liftthegeneratorsetusingliftingbarsinsertedthroughtheliftingholesontheskid.FollowallrecommendedremovalandinstallationproceduresinthisandassociatedNorthernLightsmanuals.
Use Proper Tools
! CAUTIONMakeshifttoolsandprocedurescancreatesafetyhazards.Alwaysuseappropriatetoolsforthejob.
Usepowertoolsonlytoloosenthreadedpartsandfasteners.Forlooseningandtighteninghardware,alwaysusethecorrectsizedtools.
DonotuseUSmeasurementtoolsonmetricfasteners,orviceversa.UseonlyservicepartsthatmeetNorthernLightsspecifications.
Dispose of Waste Properly
! CAUTIONDisposingofwasteimproperlycanthreatentheenvironmentandleadtounsafeworkingconditions.PotentiallyharmfulwasteusedinNorthernLightsequipmentcanincludeoil,fuel,coolant,filtersandbatteries.
Useleakproofcontainerstodrainfluid.Donotusefoodorbeveragecontainersthatmaymisleadsomeoneintodrinkingfromthem.
Donotpourwasteontotheground,downadrainorintoanywatersource.
Do Not Open High-Pressure Fuel System
! DANGERManyNorthernLightsenginesusehigh-pressurefuelinjection.High-pressurefluidremaininginfuellinescancauseseriousinjury.Donotdisconnectorattemptanyrepairoffuellines,sensors,orother
componentsbetweenthehigh-pressurefuelpumpandnozzlesonengineswithhighpressurefuelsystems.
ONLYAUTHORIZEDTECHNICIANSCANPERFORMREPAIRSONANHIGHPRESSUREFUELINJECTIONSYSTEMS.
Avoid Hot Exhaust
! WARNINGAvoidexposuretoandphysicalcontactwithhotexhaustgases.Exhaustpartsandstreamscanreachhightemperaturesduringoperation,leadingtoburnsorotherseriousinjury.
Cleaningexhaustfilterscanalsoleadtoexposuretohotexhaustgasandtheinjuryriskassociatedwithit.Avoidexposuretoandphysicalcontactwithhotexhaustgaseswhencleaningexhaustfilters.
Duringautoormanual/stationaryexhaustfiltercleaningoperations,theenginewillrunatelevatedtemperaturesforanextendedperiodoftime.Exhaustpartsandstreamscanreachhightemperaturesduringoperation,leadingtoburnsorotherseriousinjury.
Avoid Harmful Asbestos Dust
! WARNINGInhalingasbestosfibersmaycauselungcancer.Avoidbreathinganydustthatmaybegeneratedwhenhandlingcomponentscontainingasbestosfibers,includingsomegaskets.
Theasbestosusedinthesecomponentsisusuallyfoundinaresinorotherwisesealed.Normalhandlingofthesecomponentsisnotdangerous,aslongasairbornedustcontainingasbestosisnotgenerated.
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General Policy
To avoid dangerous or hazardous situations, refrain from any of the following:• Removing or bypassing a guard or other safety device• Placing any part of your body in a position where you could be caught by moving machinery.• Cleaning or oiling machinery when in operation.• Adjusting circuits, chillers, pumps, air handlers, valves, circuit breakers or fans while in operation.• Working on piping or high pressure systems.
Lock Out/Tag Out Instructions - Electrical Equipment
Be sure the equipment’s ON/OFF switch is in the OFF position and is unplugged from any electrical source before attempting to perform any type of work on the equipment. Obtain an electrical plug cap cover with a lockset. Secure the plug terminal end using the electrical plug lockout cap. Lock the cap and retain the key.
If the equipment is directly wired into an electrical box with a shut off switch, obtain a lock pad and/or the appropriate colored tags and place the lock and tag through the shut off lever. Retain the key until the repair is completed and the machine is safe to start. Be certain the shut off lever is in the OFF position before restarting. NEVER give a lock out key to unauthorized personnel.
If the equipment is directly wired into an electrical box without a shut off switch and lock out capability, then a circuit breaker lock out will be required. Obtain a circuit lock and tag set. Install the lock onto the circuit breaker box. Ensure the unit ON/OFF switch is in the OFF position before restarting.
Lock Out/Tag Out Instructions - Pneumatic and Hydraulic Equipment
For servicing pneumatic and hydraulic equipment, the following additional procedures must be implemented, following completion of lock out/tag out procedures for the unit to be serviced:
Shut off air, water or supply valves at the equipment to be serviced.
Check the local bleed-off point for completed release of pressurized air, water or oil.
If shutting off of air, water or other material cannot be achieved at the local supply valve, shut off valves further back in the system and re-check the bleed-off point until complete shut-off is achieved.
Affix a DO NOT OPERATE tag to each valve handle that requires shut off. Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment.
Lock Out/Tag Out Instructions - Air Hose Connected Pneumatic Equipment
Equipment connected to the compressed air system through an air hose with a detachable fitting must be shutdown and unplugged. Excess air must be bled prior to removing the air hose, prior to any maintenance or repair activities.
Affix a DO NOT OPERATE tag to the air hose near the detachable fitting. Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment. Check that the equipment cannot be operated by activating the ON switch.
Stored Energy
Immediately after applying Lock Out or Tag Out devices, ensure that all potentially hazardous stored or residual energy is relieved, disconnected, restrained and otherwise rendered safe.
Verification of Isolation
Verify the machinery or equipment is actually isolated and de-energized prior to beginning work on a machine or on equipment that has been locked out.
Restarting Procedures
Follow the procedures below prior to restoring energy:• Ensure that all machinery or equipment is properly reassembled. Inspect the machinery or equipment to verify non-essential items have been removed.• Ensure that all personnel are safely outside danger zones. Notify personnel that lock out/tag out devices have been removed and energy will be reapplied.• Only authorized personnel may remove lock out/tag out devices or notices.
ScopeDuring maintenance, repairs or retooling of a Northern Lights generator set, simply turning the machine off or unplugging it while it is being worked on does not give enough protection to others who are not performing the maintenance or repair. Many serious accidents happen when someone thought the machine was turned off, or all of its energy was safely blocked or released.
! CAUTION
! WARNING
! WARNING
! WARNING
! WARNING
! CAUTION
! CAUTION
Lock Out / Tag Out Procedures
Updated 4-12-17
OM773LW3 10/18
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Notes
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Figure 1 (right): Service side M773LW3G (S/N: 7732-54637 and above)
17
2 43 5
6
7 8
109
11
12
1314
1516
18
19
Marine Generator Component Locations
Figure 2 (left): Non-service side M773LW3G (S/N: 7732-54367 and above)
20 2021 2223
25
26
1. Generator control box2. Coolant recovery bottle3. Fuel filter4. Air filter housing5. Fuel lift pump6. Fuel injector7. Lube oil fill, top
8. Coolant fill 9. Injection pump10. Stop solenoid11. Lube oil fill, side12. Sea water pump13. Oil dipstick
14. Fuel filter15. Fuel inlet and return16. Lube oil drain17. Control panel plug18. AC circuit breaker for AVR19. DC circuit breaker
20. Heat exchanger end caps21. Expansion tank22. Starter23. Exhaust elbow24. Vibration mount25. Alternator26. Belt guard
24
1
Updated 3-13-18
OM773LW3 10/18
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Marine Generator Component Locations
Updated 9-16-10
17
13
4 56
7
8
109
11
12
1415
1316
18
19
2
1. Generator control box2. Coolant recovery bottle3. Fuel filter4. Air filter housing5. Fuel lift pump6. Fuel injector7. Lube oil fill, top
8. Coolant fill 9. Injection pump10. Stop solenoid11. Lube oil fill, side12. Sea water pump13. Fuel inlet and return
14. Oil dipstick15. Fuel filter16. Lube oil drain17. Control panel plug18. AC circuit breaker for AVR19. DC circuit breaker
20. Heat exchanger end caps21. Expansion tank22. Starter23. Exhaust elbow24. Vibration mount25. Alternator26. Belt guard
Figure 3 (right): Service side M773LW3 (up to S/N: 7732-54636)
20 2021 2223
25
26
24
Figure 4 (left): Non-service side M773LW3 (up to S/N: 7732-54636)
OM773LW3 10/18
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Figure 6-a: Series 3 Generator Control Panel
Control Panels
Figure 5: Series 1-B Generator Control Panel
1. SHUTDOWN BYPASS-PREHEAT SWITCH Therearetwofunctionsbuiltintothisswitch: 1.Preheatsthefuelbeforebeginningthestarting process.Pressswitch10-20secondsbefore attemptingstart-up. 2.Bypassesthesafetyshutdownfeatureduring
startingprocess.Keepswitchengagedwhilestartingengineandfor2to3secondsafterwards,allowingoilpressuretobuildbeyondshutdownsetpoint.
2. ENGINE CONTROL SWITCH Tostarttheengine,holdthisswitchintheSTART positionuntiltheengineisrunning. NOTE: Excessive cranking of marine sets equipped with water lift muffler systems can cause engine
damage. See page 8. Aftertheenginestarts,releasetheswitchanditwill
returntoRUNposition.Tostoptheengine,holdtheswitchintheSTOPposition.
NOTE: The rocker switch is used on Series 1 panels only, and has a light that glows when the set is running.
3. HOUR METER Keepstrackofenginerunningtime.
4. OIL PRESSURE GAUGE Showstheoilpressureintheenginelubricatingsystem.
5. WATER TEMPERATURE GAUGE Registersthetemperatureofthecoolingwater.
6. D.C. VOLTMETER OR AMMETER Whentheengineisstopped,thevoltmeterindicatesthe
conditionofthebattery.Whentheengineisrunning,thevoltmeterindicatesthevoltageoutputofthe
alternator.
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Control Panels
Figure 6-b: Series 4 Generator Control Panel
For Series 4 Control Panels Only:
7. A.C. VOLTMETER Showsthegeneratoroutputvoltage.
8. FREQUENCY METER (Hertz) Thefrequencymeterindicatesenginespeed:1200or
1800RPM(60Hz),or1500RPM(50Hz).
9. AMMETER SELECTOR SWITCH Usedtocheckeachphaseforloadcondition. NOTE: Always leave this switch in the ON position
while the unit is running.
10. A.C. AMMETER Showsthegeneratorloadoneachphase.Thephaseis
selectedwiththeAmmeterSelectorswitch(Item 9).
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BREAK-IN PERIOD
1. Thefirst100hoursonaneworreconditioned enginearecriticaltoitslifeandperformance.2. Operatetheengineundervariousconditions,
particularlyheavyloadeswithminimalidling,tohelpseatenginecomponentsproperly.
3. Constantlychecktheenginetemperatureandoilpressuregauges(setswithSeries3or4panels).
4. Oilconsumptionisgreaterduringbreak-inas pistonringstaketimetoseat.5. Break-InOilChanges:Changeengineoiland filterat50hours.Changeoilandfilteragainat 100hours,thenatevery250hours(consult Lubricantssectionforoilrecommendation).
BEFORE STARTING
1. Checkthewaterlevelbyremovingthepressure capfromtheexpansiontank.Inordertogivethe
coolingwateranopportunitytoexpand,thelevelshouldbeabout1in.(2.5cm)belowthefillercapsealingsurfacewhentheengineiscold.
CAUTION: Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns.
2. Checktheoillevelinthecrankcasewiththedipstick.Theoillevelmustbeinthewaffledareabetweenmaximumandminimumlevelonthestick.Neverallowtheleveltogobelowthisarea.Alwaysaddthesameviscosityofoilasisalreadyinthecrankcase.
3. Checkthefueltanklevelandopenanyfuelvalves.4. Closethesea-cock,checkandcleantheseastrainer
andreopenthesea-cock.5. PlacethebatteryswitchintheONposition.6. NOTE: The battery switch must always be kept ON while the engine is running. If the switch is
turned OFF while the engine is running, the battery charging regulator could be ruined.
STARTING
1. HoldtheShutdownBypass-PreheatswitchintheONpositionfor10to20secondsbeforestartingacoldengine.Holdingtheswitchtoolongcanburnouttheglowplugs.Thisstepisnotnecessaryiftheengineisalreadywarm.
2. WhileholdingtheShutdownBypass-PreheatswitchintheONposition,pushtheEngineControlswitchtotheSTARTposition.
3. Assoonastheenginestarts,releasebothswitches.Donotcrankthestarterformorethan10seconds
consecutively.Iftheenginefailstostartwiththefirstattempt,besurethatithasstoppedcompletelyforatleast30secondsbeforere-engaging.
6. NOTE: Excessive cranking of the starter on Marine sets equipped with a water lift muffler can cause engine damage. If the engine does not start after three 10-second cranks, remove the impeller from the raw water pump. This will prevent the muffler from filling with water and backfilling the exhaust line and engine. Once the engine starts, shut it off
immediately and re-install the impeller. Re-start the engine and check the exhaust overboard outlet for gushes of water.
OPERATING
1. UnitswithSeries3andSeries4ControlPanels: checkgaugesoften.Oilpressuremustbeabove15
PSI.TheD.C.voltmetershouldreadbetween11and15voltsat80°F(25°C)ambienttemperature.Thecoolanttemperaturegaugemustbebetween167°Fand194°F(75°Cto90°C).ChecktheA.C.voltageandfrequencymeters(Series4panel).Ifthegaugesdeviatefromnormallevels,shutdownthegeneratorsetandinvestigate.
2. Lettheunitrununloadedforathreetofiveminutewarm-upperiod.
3. Addelectricalload.
STOPPING
1. Removeelectricalloadfromthegeneratorset.2. MovetheEngineControlswitchtotheSTOP positionmomentarily.3. Shutofftheseacock,fuelvalve,andbattery
switch.
Operating Procedures
Updated 1-9-13
OM773LW3 10/18
15
SHUTDOWNS AND ALARMS
1. Generatorsetshaveshutdownsystemstostoptheengineintheeventofhighwatertemperatureorlowoil pressure.
a. Otheralarmsandshutdownsareavailableas optionalequipment. NOTE: Do not rely on your shutdown to the exclu-
sion of careful gauge monitoring. Watching your gauges can prevent damage to the unit and danger-ous power losses.
2. Dothefollowingwhenyourwarningorshutdownsystemisactivated:
a. Engagethepreheatswitchtocheckthe temperaturegauge. b. Ifabove205°F(96°C),UsetheTroubleShoot
ingGuideonpage22toisolatethecauseofthe overheat.
CAUTION: Do not remove the water fill cap of an overheated engine. Escaping high temperature steam can cause severe burns. Allow the engine to cool and then remove the cap slowly using protective clothing.
c. Makerepairs.Restartyourgeneratorsetafterthe temperaturegaugeregistersbelow200°F(94°C). d. Watchthetemperaturegaugeregularlyand turnofftheunitifthetemperaturerisesabove 205°F(96°C)onMarineunits.Repeattrouble-
shooting.3. Ifshutdownisactivatedandthetemperaturegauge
showstemperaturewithinnormaltemperaturerange: a. Thisshutdowncouldhavehappenedbecauseof
atoohighexhausttemperature.Thiscouldhave beencausedbyadamagedimpellerorapartially blockedseawaterstrainer.Checktheseawater strainerfirst.Ifitisclear,thencheckthe
conditionoftheseawaterpumpimpeller. b. Checktheenginecrankcaseoillevel. c. Iftheoillevelislow,fillwithrecommended lubricatingoilandrestart.Watchtheoilpressure gaugecarefullyandshutofftheengineifitdoes notshowanormalreading(20-60PSI)aftera fewsecondsofoperation. d. Iftheoillevelisnormal,DONOTrestartthe engine.Callyourdealerforassistance.
SPARE PARTS
1. NorthernLightsrecommendsthatyoukeepthefollowingsparepartsonhandforfieldservice.ThepartsareavailablefromyourlocalNorthernLightsdealer.Marinemodelshaveoptional“On-Board-Kits,”ahandyboxthatcontainsthemostcommonpartsyouwillneed.
2. Allownersshouldhavethefollowing: a. Primaryandsecondaryfuelfilterelements b. Oilfilters c. Airfilter d. Alternatorbelt e. Thermostatandgaskets f. Seawaterpumpimpeller&gaskets g. Glowplug h. Injectorandwasher3. Ifyoursetisoperatingalongdistancefroma servicingdealer,addthefollowing: a. Completesetofinjectors b. Copperwashersforinjectorchange c. Completesetofglowplugs d. Fuelliftpump
Operating Procedures
Updated 8-27-09
OM773LW3 10/18
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SERVICE 50 200 250 500 1000 2500 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours Hours
ENGINE: SP1 18 Check oil level • SP2 18 Change engine oil 1) 5) • • SP3 18 Change lube oil filters 1) 5) • • SP4 19 Check air cleaner, change element @ 1000 hrs. 1) 4) 5 •
SP5 19 Check V-belt tension • SP6 19 Check valve clearances 1) 2) • FUEL SYSTEM: SP7 20 Check primary filter (Racor) 2) 3) • SP8 20 Change primary filter element (Racor) 2) 3) • SP9 20 Change secondary fuel filter 1) 3) • SP10 21 Bleed the fuel system 3) SP11 22 Check injectors 1) 3) 6) 7) • SP12 22 Check fuel injection pump 7) • COOLING SYSTEM: SP13 24 Check coolant level • SP14 24 Check and flush cooling system • SP15 25 Check and clean heat exchanger • SP16 25 Change impeller in raw water pump 1) 3) • SP20 Inspect condition of exhaust elbow 1) 3) • ELECTRICAL SYSTEM: SP17 26 Check electrolyte level in batteries • SP18 26 Check condition of batteries with hydrometer 1) 4) • OUT OF SERVICE: SP19 26 Winterizing or out-of-service 3)
TheServicingScheduleChartbelowshowstheserviceschedulerequiredforpropermaintenanceofyourgeneratorset.MoredetailedcoverageofeachServicePoint(SP)islistedonthepagenotedinthe‘page’column.
DAILY: SP1 Checkoillevelinengine SP5 CheckV-belttension SP7 Checkprimaryfuelfilter SP13 Checkcoolantlevel Checkseastrainer SP17 Checkelectrolyteinbatteries
AFTER FIRST 50 HOURS: SP2/3 Changeengineoilandfilter SP6 Adjustvalves
AFTER FIRST 100 HOURS: SP2/3 Changeengineoilandfilter
EVERY 200 HOURS: SP2/3 Changeengineoilandfilter
EVERY 250 HOURS: SP4 Checkaircleaner SP18 Checkstateofchargeofbatteries
EVERY 500 HOURS: SP8 Changeprimaryfuelfilterelement SP9 Changesecondaryfuelfilter SP20 Inspectconditionofexhaustelbow
EVERY 1000 HOURS: SP4 Replaceaircleanerelement SP6 Checkvalveclearances SP11 Checkinjectors SP16 Changeimpeller
EVERY 2500 HOURS: SP12 Checkfuelinjectionpump SP14 Checkandflushcoolingsystem SP15 Checkandcleanheatexchanger
1) Perform all maintenance once a year even if hour level has not been reached.2) Consult manufacturer's maintenance schedule, note on chart.3) Whenever necessary.4) More often if necessary.5) After first 50 hours, then at 100 hrs., then every 200 hrs.
6) Clean injection nozzles every 1500 hours.7) For EPA emission standards fuel nozzle needs to be
cleaned every 1500 hours, the fuel nozzle and fuel pump need to be cleaned, adjusted, or repaired every 3000 hours, and the quality guarantee for these parts is 1500 hours or 2 years.
Servicing Schedule Chart
Updated 10-18-18
OM773LW3 10/18
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Service Record Notes
OM773LW3 10/18
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Servicing
LUBRICATION - GENERAL
1. Useonlyclean,highqualitylubricantsstoredincleancontainersinaprotectedarea.
2. Theselubricantsareacceptable: a.APIServiceCC/CD/CEsingleviscosityoils. b.APIServiceCC/CD/CFmulti-viscosityoils.3. Usetheproperweightoilforyouraverageoperation
temperature.
Figure 8: Lube Oils
4. SomeincreaseinoilconsumptionmaybeexpectedwhenSAE5WandSAE5-20Woilsareused.Checkoillevelfrequently.
5. Neverputadditivesorflushingoilincrankcase.
SP-1. CHECKING OIL LEVEL
1. Checktheoillevelinthecrankcasewiththedipstick.Theoillevelmustbeinthewaffledarea
onthestick.Neverallowtheleveltogobelowthisarea.Followthelubricationrecommendationsabove.
SP-2. OIL CHANGES
1. Thesetisdeliveredwithspecialbreak-inoil. Changetheengineoilandoilfilterafter50hours ofoperation.UseServiceCC30weightoilduring
thefirst100hours.2. Changetheoilandfilteragainat100hoursusingthe
oilrecommendedinFigure8.Afterthis,changeoilandfilterevery200hours.
3. Duringintermittentcoldweatheroperation,changeoilevery100hoursorsixweeks,whichevercomesfirst.
4. Changeoilatanyseasonalchangeintemperaturewhenanewviscosityofoilisrequired.
5. Changeoilwhenengineiswarm.6. Disposeofwasteoilinanapprovedmanner.7. Neveruseaflushingoil.8. Loosentheclampontheoilchangetube.Remove
cap.Drainoil.Replacethecapandtube.9. Refillenginewithrecommendedoil.10.Enginecapacitywithnewoilfilteris: M773LW3(G) - 4.75 quarts (4.9 liters)
SP-3. CHANGING LUBE OIL FILTER
1. Changethelubeoilfilterevery200hours.2. Useafilterwrenchtoremoveoldfilter.Disposeof
filterinapprovedmanner.3. Makesurethegasketfromtheoldfilterisremoved
anddiscarded.Cleanmountface.4. Spreadathinfilmofengineoilontherubbergasket
onthenewfilterandscrewitonnippleuntilgasketmeetsthesealingsurface.
5. Usinghandsonly–nowrench–tightenfilter one-halfturnfarther.Overtighteningcando damagetofilterhousing.6. Fillenginewithrecommendedoil.Startengineand
checkforleakage.Stopengine,wait3minutes,andcheckoillevel.Addadditionaloilifnecessary.
7. Oilfilterpartnumbersare: M773LW3(G) - #24-02002
Air Single Multi- Temperature Viscosity Viscosity
Above 32°F SAE 30W SAE 15-40W (0°C)
-10 to 32°F SAE 10W SAE 10-30W (-23 to 0°C)
Below -10°F SAE 5W SAE 5-20W (-23°C)
Updated 12/18/12
OM773LW3 10/18
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SP-4. AIR CLEANER
1. Inspectaircleanerevery250hours.Industycondi-tions,checkmoreoften.
2. Ifdirty,washelementinsoapywater.Rinseanddrythoroughlybeforere-installing.
Replaceifnecessary.Partnumbersare: M773LW3 – #24-28602 3. NOTE: Make absolutely sure no impurities enter
the engine while changing the element. Do NOT run the engine with the air cleaner removed.
SP-5. V-BELTS
1. CheckthetensionandwearontheV-beltdaily.
2. Useyourthumbtopressonthebeltatthemidpointbetweenthecrankshaftandalternatorpulleys.Thetensioniscorrectifthebeltcanbedepressedabout3/16in.(5mm).
Servicing
Figure 9: Valve Adjustment
SP-6. VALVE CLEARANCES
1. Adjustvalveclearanceafter1000hoursorasneeded.
2. Valveadjustmentsshouldbedoneafterthecylinderheadboltshavebeenre-tightened.EngineshouldbecoldandNOTrunning.
3. TobringtheNo.1cylindertotopdeadcenterinthecompressionstroke,alignthetimingmark;thetopmarkofthecrankpulleywiththatofthetiminggearcase.Removetherockerarmcoverandturnthecrankshaftfowardandbackward.IftheinletandexhaustvalvesoftheNo.1cylinderdonotmoveitisintopdeadcenterposition.Whenthevalvesmove,orrock,turnthecrankshaftonefullturnandalignthetopmarkofthecrankpulleywiththetopmarkofthetiminggearcase.
4. Loosenthelocknutandadjusttheclearancebetweentherockerarmandvalveguideofboththeintakeandexhaustvalveswiththeadjustmentscrew(Figure 9).Clearanceonbothintakeandexhaustvalvesshouldbe0.008in.(0.2mm).
5. Repeatsteps3and4foreachcylinder.Eachsetofvalvesmustbeadjustedindividually.
6. Replacetherockerarmcover.Tightencovernutsto5-8ft/lbs(0.8-2.3kg/m).
Figure 10: Timing Mark
Cylinder No. 1 2 3
Valve Arrangement Int. Exh. Int. Exh. Int. Exh.
When No.1 cylinderis at Top Dead Centerin the compressionstroke
With the crankshaftturned 3600 innormal direction fromabove
Valve Arrangement
OM773LW3 10/18
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Servicing
FUELS - GENERAL
1. Useonlyclean,highqualityfuelsofthefollowingspecifications,asdefinedbyASTMdesignationD975fordieselfuels:
a. Usegradeno.2dieselatambienttemperatures abovefreezing32°F(0°C). b. Usegradeno.1atambienttemperaturesbelow freezingandforalltemperaturesatanaltitudeof above5,500ft.(1500meters).2. Usefuelhavinglessthat1%sulphur(preferablyless
that0.5%).3. Thecetanenumbershouldbeaminimumof45.4. DONOTusetheseunsuitablegradesoffuel: a. Domesticheatingoils,alltypes. b. ClassBengine. c. ClassDdomesticfuels. d. ClassE,F,GorHindustrialormarinefuels. e. ASTM-D975-60TNo.4-Dandhighernumber fuels.5. Storingfuel: a. Keepdirt,scale,water,andotherforeignmatter out of fuel. b. Avoidstoringfuelforlongperiodsoftime. c. Fillthefueltankattheendofeachday’s operation.Thiswillreducecondensation.
FUEL FILTERS
1. Yourgeneratorsetshouldhaveaprimaryfuelfilterinstalled.WerecommendtheRacorbrandoffuelfilter-waterseparators.
SP-7. PRIMARY FUEL FILTER a. Checktheprimaryfuelfilterdailyas recommendedbythefiltermanufacturer. Emptythecollectionbowlasnecessary.SP-8. PRIMARY FUEL FILTER ELEMENT b. Changetheelementasoftenasnecessaryor every500hours. c. Ifthebowlfillswithwater,changetheprimary andsecondaryelementimmediately.
SP-9. SECONDARY FUEL FILTER2. Changesecondaryfuelfilterevery500hoursoras
necessary. a. Removethespin-onfilterbyturningit counterclockwisewithafilterwrench.Fillthe newcartridgewithfuelandinstallitafter applyingengineoiltogasketsurface.Screwon untilthegasketsurfacecomesintocontactwith sealingsurfaceoffilterbase.Then,tightenit two-thirdsofaturnbyhand.Donotovertighten. b. Fuelfilterpartnumberis:
M773LW3(G): #24-52020
OM773LW3 10/18
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Servicing
SP-10. BLEEDING THE FUEL SYSTEM
CAUTION: Escaping diesel fuel under pressure can penetrate skin causing serious personal injury. Before disconnecting lines be sure to relieve all pressure. Before applying pressure, be sure all connections are tight and lines, pipes and hoses aren't damaged. Fuel escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks. If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if proper medical treatment isn't administered immediately.
Figure 11: Fuel System.
1. Thefuelsystemisself-bleeding.However,anysystemmayneedmanualbleedingwhen:
a. Anewfuelfilterisinstalled; b. Theenginehasrunoutoffuel; c. Thefuellines,injectionpumporanyotherfuel systemcomponenthasbeenremovedand installed.2. Loosenbleedbolt“A”(Figure 11)ontopofthe
filter.Pumphandprimer“B”onfuelliftpumpuntilpurefuel(nobubbles)escapesfrombleedbolt“A”.Tightenbleedscrew“A”.
3. Loosenbleedscrew“C”.Pumphandprimer“B”untilpurefuel(nobubbles)escapes.Thentightenbleedscrew“C”.
4. Iftheenginedoesnotstartaftertheabovebleed-ingprocess,loosenafuellineattheinjectorwhilecrankingtheenginewiththestartermotoruntilpurefuelescapes.Thentightentheconnection.Doeachline one-at-a-time.
5. Aftertheenginehasstarted,useapieceofcardboardtolookforfuelleaks.
OM773LW3 10/18
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Servicing
SP-11. INJECTOR SERVICE
1. Injectorsshouldbecheckedevery1000hours,orwhenevernecessary.CheckshouldbemadebyaNorthernLightsdealerorlocalinjectionrepair
station.
CAUTION: Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury. If injured by escaping diesel fuel, see a doctor at once.
2. Injector removal: a. Cleanloosedirtfromaroundtheinjectorsand the fuel lines. b. Relievehighpressureinthefuellinesby looseningthedeliverylineflarenutsateach injector(Figure 12). c. Removedeliverylinesbydisconnectingfrom injectorsandinjectionpump(Figure 13).Remove alllinesasanassembly;donotremovethe spacers.Covertheendsofthelines,theinjector inletsandinjectionpumpoutletstokeepdirtout. d. Removethereturnlineretainingbolts(Figure 14). Removethereturnline(Figure 15). e. Unscrewandremovetheinjectors(Figure 16). NOTE: Do not use pry bars to remove injectors from cylinder head. f. Afterremovingtheinjectors,discardthecopper sealingwashersfromtheinjectorholeinthehead (Figure 17).Coverholestopreventdirtanddebris fromenteringthecylinders.
3. Injector installation: a. Installanewcoppersealingwasherineach injectorhole(Figure 17). b. Screwininjectorandtightento43or50ft/lbs (6to7kgm)(Figure 18). NOTE: Overtightening can damage injector. c. Installreturnlineusingnewcoppersealingabove andbeloweachconnection.Tightenreturnline retainingboltsto22-30ft/lbs. d. Installdeliverylines.Leavelooseatinjectorsfor bleeding. e. Pumphandlevelonfuelpumptofilllines. Tightenlinesatinjectors.Startengineandcheck forleaksusingapieceofpaperorcardboard. DO NOT use hand to check for leaks.
SP-12. INJECTION PUMP
1. Sinceoperatingconditionsmayvaryconsiderably,itisdifficulttogiveadefiniteintervalforcheckingtheinjectionpump.Butasarule,pumpsettings,
maximumspeed,idlespeedandexhaustsmokeshouldbecheckedafterevery2500hoursof
operation.Serviceofthefuelinjectionpumpshouldonlybedoneifchecksindicatepumpmalfunction.
2. Blacksmokecanbeanindicationofpump malfunction.Beforeservicingthepump,checkother
possiblecauses: a. Checkcleanlinessofairfilter. b. Checkvalveclearances. c. Cleanandcheckinjectors.3. Anyrepairwhichinvolvesdisassemblyoftheinjec-
tionpumpmustbecarriedoutbyspeciallytrainedmechanicswiththepropertoolsandtestequipment.
NOTE: All warranties on the engine become null and void if the injection pump seals are broken by unauthorized persons.
OM773LW3 10/18
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Servicing
Figure 15: Remove return line.
Figure 12: Remove delivery line flare nuts.
Figure 13: Remove delivery lines.
Figure 14: Remove return line nuts.
Figure 16: Unscrew injector.
Figure 17: Remove and replace copper sealing washer.
Figure 18: Reinstall injector. Torque to proper tightness.
Updated 11-8-13
OM773LW3 10/18
24
COOLING SYSTEM - GENERAL
NOTE: Be sure to close the sea-cock before working on the engine cooling system.
CAUTION: The cooling water in the engine reaches extremely high temperatures. You must use extreme caution when working on hot engines to avoid burns. Allow the engine to cool before working on the cooling system. Open the filler cap carefully, using protective clothing when the engine is warm.
WATER QUALITY1. Distilled,deionized,softwaterispreferredforusein
coolingsystems.Bottleddistilledwaterfromafoodstoreorwatersupplierisrecommended.Tapwateroftenhasahighmineralcontent.TapwatershouldNEVER beputinacoolingsystemunlessfirsttestedbyawaterqualitylaboratory.Do notusewatermadebythereverseosmosismethodunlessithasbeenPHneutralized.
2.Hereareacceptablewaterqualityspecifications:
3. Ifchlorides,sulfatesortotaldissolvedsolidsarehigherthantheabovegivenspecification,thewatermustbedistilled,demineralized,or
deionizedbeforeitisusedinacoolingsystem.4. Iftotalhardnessishigherthan170ppmandallother
parametersarewithinthegiven specifications,thewatermustbesoftenedbeforeitis
usedtomakecoolantsolution.
SP-13. CHECK THE COOLANT LEVEL
1. Checkthecoolantleveleachdaybeforestartingtheengine.Checkthewaterlevelbyremovingthepressurecapfromtheexpansiontankorradiator.
Inordertogivethecoolingwateranopportunitytoexpand,thelevelshouldbeabout1in.(2.5cm)belowthefillercapsealingsurfacewhentheengineiscold.
2. Thepressurevalveinthefillercapreleaseswhenthepressureisapproximately7PSI(0.5bar).Useacappressuretestertocheckcapifyoususpectitisfaulty
.SP-14. COOLING SYSTEM FLUSHING
1. Flushthecoolingsystemevery2500hoursorevery12months,whichevercomesfirst.
a. Removeexpansiontankcapanddrainengine block. b. Openblockdraincock. Removepluginlowerleft sideofheatexchangertank. c. Pourcleanwaterintoexpansiontankuntilwater comingfromdrainsisfreeofdiscolorationand sediment.Letwaterdraincompletely.Close drainsandrefillwithrecommendedmixture.2. CoolantSpecifications: Use50%water/50%ethyleneglycolantifreezemix.
Antifreezemixtureisrecommendedasagoodyear-roundcoolant,butnotmethylalcoholbasedantifreezebecauseofit’seffectonnon-metallic
componentsandit’slowboilingpoint.Also,antifreezewithhighsilicateshouldnotbeusedasitcouldcasesilicagelationproblems.
3. Checkhosesandconnectionsandrepairanyleakage.
Servicing
Parts GrainsContaminates per Million per Gallon
Maximum Chlorides 40 2.5
Maximum Sulfates 100 5.9
Maximum Dissolved Solids 340 20.0
Maximum Total Hardness 170 10.0
PH Level 5.5 to 9.0
Updated 11-8-13
OM773LW3 10/18
25
ELECTRICAL SYSTEM - GENERAL
1. Neverswitchbatteryswitchofforbreakthecircuitbetweenthealternatorandbatterieswhiletheengineisrunning.Regulatordamagecanresult.
2. DoNOTreversethepolarityofbatterycableswheninstallingthebattery.
3. Whenweldingontheunit,disconnecttheregulatorandbattery.Isolatetheleads.
4. DisconnectthebatterycableswhenservicingtheD.C.alternator.
5. Nevertestwithascrewdriver,etc.,againstanyter-minaltoseeifitemitssparks.
6. Donotpolarizethealternatororregulator.7. AD.C.circuitbreakerprotectsyourcontrolpanel
andwiringharness.Itislocatedinthesideofthegeneratorjunctionbox.
GLOW PLUGS
1. Eachcylinderissuppliedwithaglowplugwhichservestoheatthecombustionchamber.
2. Tochecktheglowplugs,loosenthecurrent carryingflatwirebetweentheplus-polesofthe glowplugs(Figure 19).ConnectaD.C.testbulb
betweentheplus-poleofthebatteryandthe plus-poleoftheglowplug.Ifthebulblightsup, theglowplugisfunctioningproperly.3. Checkallglowplugsandreplaceanythatarefaulty.
Figure 19: Glow plugs.
SP-15. HEAT EXCHANGER
1. Cleantheheatexchangercoreonceayearorafter2500hoursofoperation.
2. Drainexpansiontankandheatexchanger.3. Removeheatexchangerendcoversandremove
core.4. Cleantheinsideofexchangercoretubesusing ametalrod.Flush,inspectandcleanagainif necessary.5. Reassemble.Fillthecoolingsystem,starttheengine
andcheckforleaks.
SP-16. RAW WATER PUMP
1. Changetheseawaterpumpimpellerevery1000hours,orasneeded.
2. Removethepumpendcover.Pryouttheimpellerusingneedle-nosepliersortwoscrewdrivers.
Besureyouremoveallpiecesoffailedimpeller. NOTE: Place some kind of protection under the
screwdrivers in order not to damage the pump housing.3. Cleantheinsideofthehousing.4. Pressinthenewimpellerandplacethesealing
washersintheouterendoftheimpellercenterifthishasnotalreadybeendone.
5. Replacethecoverusinganewgasket. NOTE: Make sure that there is always an extra
impeller and cover gasket in reserve on board.
GENERATOR ENDS
ThemaintenanceandoperationrecommendationsforthegeneratorendareinaseparateOwner’sManual.Ifyoudonothaveoneofthesemanuals,contactyourlocalNorthernLightsdealer.
Servicing
Updated 11-8-13
OM773LW3 10/18
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BOOSTER BATTERIES
CAUTION: Battery gas can explode. Keep all flames and sparks away from batteries.Battery electrolyte is sulfuric acid diluted, which can burn or stain body or clothes.
1. Beforechangingorusingboosterbatteries,checkbat-teryelectrolytelevel.Adddistilledwaterifnecessary.
2. Boosterandmainbatteriesmusthavethesamevolt-agerating.
3. First,connectpositive(+)terminalofboosterbat-terytopositive(+)terminalofmainbattery.Then,connectnegative(-)terminalofboosterbatterytogroundontheengineblock(see Figure 20).
4. Removeboosterbatteryafterstartingengine.5. Sealedbatteries:Seemanufacturerchargingand
boosterinstructions.
BATTERY CARESP-18. CHECK ELECTROLYTE LEVELS 1. Checkelectrolyteleveldaily.Adddistilledwaterto
manufacturer’srecommendedlevel.SP-19. CHECK CABLES AND TERMINALS 2. Batteries,cablesandcableterminalsshould becheckedandcleanedevery100hours. Cleancorrosionwithawaterandbakingsoda solution.Flushwithcleanwater.Tightenterminals
andgreasethemtoinhibitcorrosion.3. Checkthebatteryconditionwithahydrometerevery
250hours.
Updated 10/18/18
Servicing
Figure 20:Battery connections.
SP-20. WINTERIZING / OUT-OF-SERVICE
Ifthegeneratorsetwillnotbeusedformorethan3monthsthefollowingpreparationsshouldbetakenforlongtermstorage.• Changeengineoilandfilter,usingAPICJorCK-4,
15W-40oil.• Runtheengineuptoatleast140oFfromasmall,
cleansourceoffueldosedwitheither“Stab-il”brandfuelsystemstabilizer(dieselengineformula),orStanadynePerformancefuelsystemconditioner.Ifneitherofthesefueltreatmentsisavailable,youmayalsouseJohnDeerefuelsystemconditioner.
• Completelydrain,flush,andfillthecoolingsystemwithpre-mixed,50/50,conventionalethylene-glycolheavy-dutydieselenginecoolant(withSCAs).
• Loosenalternatordrivebelt.• Completelysealoffintakeandexhaustopenings
withheavyplasticbagsandducttape.• Coverentireengineinlargeplasticbagandtape
closedatbottomofbag-placeseveralmoistureabsorbingdesiccantpacksinsideplasticbagStoreengineinoriginalshippingcrate,ifpossible,orothersuitablestoragecrate.
• Storeengineinsideabuilding(preferablyclimatecontrolled)topreventcorrosion.
ToRemoveGeneratorSetfromLong-TermStorage:1. Takeoffallprotectivecoveringsandunsealallthe
openingsthatwerecoveredup.2. Installbatteriesthatarefullychargedandconnect
theterminals.3. Installthefanandalternatorbeltsiftheyhadbeen
removed.4. Fillthefueltank.5. Performallpre-startchecks.6. Cranktheenginefor20secondswiththestarter,
withoutlettingtheenginestart.Wait2minutesandcranktheengineanadditional20secondstomakesureallbearingsurfacesarewellcoated.
7. Starttheengineandrunatnoloadinalowidleforseveralminutes.Makesuretheengineiswarmedupandcheckgaugesbeforegoingunderload.
8. Checkallgaugesandcheckforleaks.
OM773LW3 10/18
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Troubleshooting
Ifyoucannotcorrectproblemswiththeseprocedures,seeyourNorthern Lights dealer.
DC ELECTRICAL SYSTEM PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)
Battery Will Not Charge Looseorcorrodedconnections •Cleanandtightenbatteryconnections.
Sulfatedorwornoutbatteries •Checkspecificgravityofeachbattery. •Checkelectrolytelevelofeachbattery.
Looseordefectivealternatorbelt •Adjustbelttension. •Replacebelt.
Starter Inoperative CheckDCcircuitbreaker •Ifthebreakeristripped,resetit.
Looseorcorrodedconnections •Cleanandtightenloosebatteryand harnessplugconnection.
Lowbatteryoutput •Checkspecificgravityofeachbattery. •Checkelectrolytelevelofeachbattery.
Defectiveelectricalsystem •Repairorreplace. groundwire:
Starter Cranks Slowly Lowbatteryoutput •Batteryistoosmall. •Batterycablesaretoosmall.
Checkspecificgravity •Replacebatteryifnecessary. ofeachbattery
Checkelectrolytelevel •Iflow,fillcellswithdistilledwater. ofeachbattery
Crankcaseoiltooheavy •Fillwithoilofappropriateviscosity.
Looseorcorrodedconnections •Cleanandtightenlooseconnections.
Entire Electrical System CheckDCcircuitbreaker •Ifbreakeristripped,resetit.Does Not Function Faultyconnection •Cleanandtightenbatteryandharness plugconnections.
Sulfatedorwornoutbatteries •Checkspecificgravityandelectrolyte levelofeachbattery.
OM773LW3 10/18
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Troubleshooting
ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)
Engine Hard to Start Improperstartingprocedure •Seestartingsectionofthismanual.Takeor Will Not Start specialnoteofBypassSwitchoperation.
Nofuel •Checkleveloffuelinfueltank.
Lowbatteryoutput •Checkelectrolytelevelandcondition.
Excessiveresistance •Cleanandtightenallbatteryconnections. instartingcircuit
Crankcaseoiltooheavy •Useoilofproperviscosity.
Impropertypeoffuel •Consultfuelsupplierandusepropertype offuelforoperatingcondition.
Water,dirtorairinfuelsystem •Drain,flush,fillandbleedsystem.
Cloggedprimary •Cleanorreplacefilterelement. fuelfilterelement
Cloggedsecondary •Replacefilterelement. fuelfilterelement
Dirtyorfaultyinjectionnozzles •Haveyourdealercheckinjectionnozzles. Fuelinjectedbutnoignition •Glowplugmalfunction •Injectiontimingnotcorrect •Lowcylindercompressionpressure
Engine Runs Irregularly Belownormalenginetemperature •Removeandcheckthermostat.or Stalls Frequently Cloggedprimary •Cleanorreplacefilterelement. fuelfilterelement
Cloggedsecondary •Replacesecondaryfilterelement. fuelfilterelement
Waterordirtinthefuelsystem •Drain,flush,fillandbleedsystem.
Dirtyorfaultyinjectionnozzles •Haveyourdealercheckinjectionnozzles.
Airinfuelsystem •Inspectclampsandhosesonsuctionside offuelpumpforairleak.
Impropertypeoffuel •Consultfuelsupplierandusepropertype offuelforoperatingcondition.
Lowidle,notstable •Unevencylindercompression
Lack of Engine Power Intakeairrestriction •Serviceaircleaner.
Cloggedprimaryorsecondary •Cleanorreplacefilterelement. fuelfilterelement
Impropertypeoffuel •Consultfuelsupplierandusepropertypeof fuelforoperatingconditions.
Overheatedengine •See“EngineOverheats”innextcategory.
OM773LW3 10/18
29
Troubleshooting
ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)
Lack of Engine Power,continued Belownormalenginetemperature •Removeandcheckthermostat. Injectionpumpfuelsupply •Airmixingininjectionpump. insufficient •Fuelfilterclogged.
Impropervalveclearance •Resetvalves.Bestdonebydealer.
Dirtyorfaultyinjectionnozzles •Replaceinjectors.Bestdonebydealer.
Cylindercompressionpressure •Adjustvalveclearance low,cylindercompressionpressure •Adjustnozzleholderalignment leakage •Checkcylinderborewear
Engine Overheats Lowcoolantlevelorcooling •Filltankorradiatortoproperlevel. systemdefective •Checkhosesforlooseconnections andleaks. •Fanbeltslippng
Keelcoolingtubes •Removepaintfromtubes. havebeenpainted
Coolingsystemneedsflushing •Flushcoolingsystem.
Defectivethermostat •Removeandcheckthermostat.
Defectivetemperaturegauge •Checkwatertemperaturewiththermometer andreplacegaugeifnecessary.
Waterpumpimpellerworn/broken •Checkimpellerandreplaceifnecessary.
Engine Knocks Insufficientoil •Callyourdealer.
Injectionpumpoutoftime •Callyourdealer.
Belownormalenginetemperature •Checkyourthermostats. •Checkwatertemperaturetoseeif temperaturegaugeisworkingproperly.
Engineoverheating •See“EngineOverheating”section.
High Fuel Consumption Impropertypeoffuel,orfuel •Usecorrectfuelfortemperature. leaking •Checkinstallationortightening. Cloggedordirtyaircleaner •Serviceaircleaner.
Impropervalveclearance •Seeyourdealer.
Injectionnozzlesdirty •Seeyourdealer.
Injectionpumpoutoftime •Seeyourdealer.
Engineoverloaded •Checkloadusage.
Enginenotatpropertemperature •Checkyourthermostats. •Checkwatertemperaturewiththermometer andreplacegaugeifnecessary.
Ifyoucannotcorrectproblemswiththeseprocedures,seeyourNorthern Lights dealer.
OM773LW3 10/18
30
Troubleshooting
ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)
Below Normal EngineTemperature Thermostatsnotworkingproperly •Checkthermostats.
Temperaturegauge •Checkwatertemperaturewiththermometer. notworkingproperly
Low Oil Pressure Lowoillevel •Fillcrankcasetoproperlevel.
Cloggedfilterandstraineror •Repairorreplace wornbearingsandoilpump
Impropertypeofoil •Drainandfillcrankcasewithcorrectoil.
Partiallypluggedoilfilter •Replacefilter.
High Oil Consumption Break-inperiod •Oilconsumptiondecreasesafterbreakin.
Crankcaseoiltoolight •Useproperviscosityoil.
Oilleaks •Checkforleaksinlinesaroundgaskets anddrainplug.
Engine Emits Black Cloggedordirtyaircleaner •Serviceaircleaner.or Gray Exhaust Smoke Defectivemuffler •Havedealercheckbackpressure. (backpressuretoohigh)
Improperfuel •Usecorrectfuelfortemperature.
Injectionnozzlesdirty •Seeyourdealer.
Enginetimingoff •Seeyourdealer.
Engine Emits Improperfuel •Usecorrectfuelfortemperature.White Smoke Coldengine •Warmupenginetonormaloperating temperature.
Defectivethermostat •Removeandcheckthermostat.
Enginetimingoff •Seeyourdealer.
Ifyoucannotcorrectproblemswiththeseprocedures,seeyourNorthern Lights dealer.
OM773LW3 10/18
31
AC Wiring Diagrams
AC
Eng
ine
Wiri
ng D
iagr
am T
aiyo
Px3
00K2
4 L
ead
Gen
erat
or
w/ D
ST-1
00-2
FAK
AVR
B-9
724E
Updated 1-16-18
OM773LW3 10/18
32
AC Wiring Diagrams
AC
Eng
ine
Wiri
ng D
iagr
amTa
iyo
PX30
0K2
12 L
ead
Gen
erat
or
w/ D
ST-1
00-2
FAK
AVR
B-9
723D
Updated 6-5-17
OM773LW3 10/18
33
DC Wiring Diagrams
DC
Wiri
ng D
iagr
am M
/NL
773L
W 1
2 VD
C
Stan
dard
Gro
und
B+ C
ontro
l B
-107
67A
Updated 6-5-17
OM773LW3 10/18
34
NO
RT
HE
RN
LIG
HT
S
DC Wiring Diagrams
DC
Wiri
ng D
iagr
am M
773L
W 2
4 VD
C Is
olat
ed G
roun
d B+
Onl
y B
-108
80
Updated 6-5-17
OM773LW3 10/18
35
DC Wiring Diagrams
DC
Wiri
ng D
iagr
amM
773
24
VDC
Sta
ndar
d G
roun
d B
+ on
lyB
-108
34
Updated 6-5-17
OM773LW3 10/18
36
DC Wiring Diagrams
DC
Wiri
ng D
iagr
am M
773L
W 1
2 VD
C Is
olat
ed G
roun
d B
-108
35
Updated 6-5-17
OM773LW3 10/18
37
DC Wiring Diagrams
DC
Eng
ine
Wiri
ng D
iagr
amM
773L
W3
12
Volt
Stan
dard
Gro
und
B-9
852A
Updated 3-13-12
OM773LW3 10/18
38
DC
Eng
ine
Wiri
ng D
iagr
amM
773L
W3
12 V
olt I
sola
ted
Gro
und
B-1
0130
B
DC Wiring Diagrams
Updated 7-9-12
OM773LW3 10/18
39
DC Wiring Diagrams
DC
Eng
ine
Wiri
ng D
iagr
amM
773L
W3
24
VDC
Sta
ndar
d G
roun
dB
-B-9
908
Updated 3-13-12
OM773LW3 10/18
40
DC
Eng
ine
Wiri
ng D
iagr
amM
773L
W3
24
Volt
Isol
ated
Gro
und
B-8
662C
DC Wiring Diagrams
OM773LW3 10/18
41
Panel Wiring Diagrams
Pane
l Wiri
ng D
iagr
am S
-1 P
anel
, B+
Deu
tsch
A-1
2798
Updated 6-5-17
OM773LW3 10/18
42
Panel Wiring Diagrams
Pane
l Wiri
ng D
iagr
am S
-1B
Pane
l, B+
A
-127
91B
Updated 6-5-17
OM773LW3 10/18
43
Panel Wiring Diagrams
Pane
l Wiri
ng D
iagr
am S
-3B
Pane
l, Vi
ewlin
e B+
A-1
2799
A
Updated 6-5-17
OM773LW3 10/18
44
Panel Wiring Diagrams
Pane
l Wiri
ng D
iagr
am S
-3C
Pan
el, V
iew
line
B+
A-1
2790
A
Updated 6-5-17
OM773LW3 10/18
45
Panel Wiring Diagrams
Pane
l Wiri
ng D
iagr
amS-
3C
View
line
Pane
ls 1
2VD
raw
ing
A-12
645A
Updated 7-9-12
OM773LW3 10/18
46
Panel Wiring Diagrams
Pane
l Wiri
ng D
iagr
am M
773L
W3,
Con
trol P
anel
S-3
C, 1
2 V
A-1
2572
B
Updated 3-13-12
OM773LW3 10/18
47
Panel Wiring Diagrams
Pane
l Wiri
ng D
iagr
am M
773L
W3,
Con
trol P
anel
S-3
C, V
iew
line
A-1
2645
B
Updated 7-9-12
OM773LW3 10/18
48
Panel Wiring Diagrams
Pane
l W
iring
Dia
gram
M77
3LW
3, C
ontro
l Pan
el S
-1B
24V
A-4
792
Updated 3-13-12
OM773LW3 10/18
49
Panel Wiring Diagrams
Pane
l Wiri
ng D
iagr
am M
773L
W3,
Con
trol P
anel
S-3
C, 2
4VA
-125
94B
Updated 3-13-12
4420 14th Ave. NW., Seattle WA 98107 Tel: (206) 789-3880 • 1-800-762-0165 • www.northern-lights.comNorthern Lights and Lugger are registered trademarks of Northern Lights, Inc. © 2018 All rights reserved. Litho USA.