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Northern Lights M50C13 Operator's Manual

For models: m50c13, m80c13, m65c13, m99c13, m120c13 and m150c13
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OPERATOR'S MANUAL
OPERATOR'S MANUAL
OM-C3
For Models: M50C13, M80C13, M65C13,
M99C13, M120C13 and M150C13
www.northern-lights.com

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  • Page 1 OPERATOR’S MANUAL OPERATOR’S MANUAL OM-C3 For Models: M50C13, M80C13, M65C13, M99C13, M120C13 and M150C13 www.northern-lights.com...
  • Page 2 4420 14th Avenue N.W. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455 Copyright ©2013 Northern Lights, Inc. All rights reserved. Northern Lights™, and the Northern Lights logo are trademarks of Northern Lights, Inc. Printed in U.S.A. PART NO.: OM-C3 11/21...

  • Page 3: Table Of Contents

    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 OM-C3 11/21...

  • Page 4: Introduction

    ® Powertech Tier III 6068 engine block and an electronically controlled fuel system. Serial Numberss When referencing Northern Lights equipment by serial number, please refer only to the number stamped on the Northern Lights serial number plate. ® OM-C3 11/21...

  • Page 5: Warranty

    For replacement signs, ALWAYS STOP ENGINE proper placement of safety signs or clarification on any BEFORE FUELING safety issue, consult your Northern Lights dealer or the MACHINE. Always fill factory. portable fuel tank outdoors. There can be additional safety information contained Never fuel a hot engine.
  • Page 6 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.
  • Page 7 Among the potentially hazardous with a metal object. Use a volt-meter or hydrometer. chemicals that may be used with Northern Lights Frozen batteries may explode if charged. Never products are lubricants, charge a battery that has not been allowed to warm to at least 16 o C (60 o F).
  • Page 8 Slowly loosen cap to relieve pressure before and use appropriate equipment exactly as recommended. opening fully. Contact your Northern Lights dealer or Northern Lights factory for MSDS’s used on Northern Lights products. Avoid High Pressure Fluids WARNING...
  • Page 9 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...

  • Page 10: Lockout / 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.
  • Page 11 Notes OM-C3 11/21...

  • Page 12: Component Locations

    Component Locations Figures 1 & 2: M65C13 1. Junction Box 6. Alternator 11. Turbocharger 2. Air Cleaner 7. Belt Guard 12. Fuel Injection Pump 3. Fuel Filter 8. Starter 13. Exhaust Elbow 4. Lube Oil Fill 9. Lube Oil Dipstick 14.

  • Page 13: M99C13

    Component Locations (Shown with optional PTO) Figure 3 & 4: M99C13 1. Junction Box 6. Lube Oil Dipstick 11. Starter 2. Air Cleaner 7. Lube Oil Filter 12. Thermostat Cover 3. Coolant Fill 8. Lube Oil Fill 13. Expansion Tank 4.

  • Page 14: S-3B Control Panel (Optional)

    SB Control Panel (Optional) 1. SHUTDOWN BYPASS SWITCH Bypasses the safety shutdown feature during the starting process. 2. ENGINE CONTROL SWITCH To start engine: hold Engine Control 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.

  • Page 15: Engine Operation

    Engine Operation NORMAL ENGINE OPERATION Observe engine coolant temperature and engine oil pressure. Temperatures and pressures will vary between engines and with changing operating conditions , temperatures, and loads. See GENERAL ENGINE SPECIFICATIONS on pages 74-75 of this manual for temperature and pressure specifications for your engine.

  • Page 16: Break-In Procedure

    BREAK-IN OIL IMPORTANT: Lightly Loaded Applications Post The engine is factory filled with Northern Lights Diesel Break-In - Engine break-in will not compensate for the Engine Break-In Oil. This is a special formulation of oil observable conditions of a lightly loaded engine such that is designated to aid with the proper break-in of engine as black fuel oil residue in the exhaust system.

  • Page 17: Break-In Service

    100 hour break-in period is recommended using a new II engine oil will not allow a new or overhauled engine to change of Northern Lights Engine Break-In Oil and a new properly seat during the break-in period. Northern Lights oil filter.
  • Page 18 Engine Operation DO NOT fill above the crosshatch pattern (A) or the 6. Watch coolant temperature gauge (A) closely. If coolant FULL mark, whichever is present. Oil levels anywhere temperature rises above maximum coolant temperature within the crosshatch are considered in the acceptable (see GENERAL ENGINE SPECIFICATIONS in operating range.

  • Page 19: Generator Power Set Units

    Engine Operation GENERATOR SET POWER UNITS To assure that your engine will deliver efficient generator operation when needed, start engine and run at rated speed (with 50%—70% load) for 30 minutes every 2 weeks. DO NOT allow engine to run extended period of time with no load.

  • Page 20: Starting The Engine

    Engine Operation STARTING THE ENGINE COLD WEATHER OPERATION CAUTION Additional information on cold weather operation is available from your authorized servicing dealer. Before starting engine in a confined engine room, install proper outlet exhaust ventilation equipment. Always use Some engines are equipped with an air intake heater safety approved fuel storage and piping.

  • Page 21: Electronic Control Unit Connections

    3. Control units are not repairable. 4. Since control units are the components LEAST likely to fail, isolate failure before replacing by completing a diagnostic procedure. (See your Northern Lights dealer.) 5. The wiring harness terminals and connectors for electronic control units are repairable.

  • Page 22: Lubrication

    Sulfur Content for Tier 3 and Stage III A Engines Consult your Northern Lights servicing dealer for • Use of diesel fuel with sulfur content less than 1000 recommended fuels, lubricants, and coolant. Also...

  • Page 23: Supplemental Diesel Fuel Additives

    To further aid in maintaining performance and reliability Keep all storage tanks as full as practicable to minimize of the engine’s fuel system,Northern Lights has developed condensation. a family of fuel additive products for most global markets. The primary products include Fuel-Protect Diesel Fuel...

  • Page 24: Biodiesel Fuel

    Expect a 2% reduction in power and a 3% reduction in fuel economy when using B20. • Possible fuel leakage through seals and hoses (primarily These Northern Lights engines can operate on biodiesel an issue with older engines) blends above B20 (up to 100% biodiesel). Operate at levels above B20 ONLY if the biodiesel is permitted by •...
  • Page 25 Lubrication Consult your Northern Lights dealer for approved fuel Contact your Northern Lights dealer for more information conditioners to improve storage and performance with on diesel fuel analysis. biodiesel fuels. Fuel Filters The following must also be considered if using biodiesel...

  • Page 26: Oil And Filter Service Intervals

    Some Northern Lights brand coolants and Oil types in the table include: lubricants may not be available in your location. Consult • Northern Lights Plus-50 II and John Deere Plus-oils. your Northern Lights dealer to obtain information and recommendations. Synthetic lubricants may be used if •...

  • Page 27: Coolant

    The following engine coolant is also recommended: Total dissolved I hardness <170 mg/L 5.5 - 9.0 • Northern Lights COOL-GARD II Concentrate in a 40-60% mixture of concentrate with quality water. IMPORTANT: Do not use bottled drinking water because IMPORTANT: When mixing coolant concentrate with it often contains higher concentrations of total dissolved solids.

  • Page 28: Freeze Protection

    Coolant FREEZE PROTECTION The relative concentrations of glycol and water in the engine coolant determine its freeze protection limit. Ethylene Glycol Freeze protection limit C (-12 C (-34 C (-62 Propylene Glycol Freeze protection limit C (-6 C (-27 C (-56 DO NOT use a coolant-water mixture greater than 60% ethylene glycol or 60% propylene glycol.

  • Page 29: Service And Maintenance Chart

    Service and Maintenance Chart The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your marine generator set. More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’ column. 2000 SERVICE PAGE...

  • Page 30: Service And Maintenance - Daily

    In addition, oil may be added at rocker arm filler cap (C). SP1. Check engine oil level Left side dipstick - M50C13, M65C13, M99C13 Check engine oil level on dipstick (A). Add as required, using seasonal viscosity grade oil. (See DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant Section for oil specifications.)
  • Page 31 Service and Maintenance - Daily SP2. Check coolant level 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.
  • Page 32 Service and Maintenance - Daily SP5. Drain Water From Fuel Filter SP6. Visually inspect the entire generator set IMPORTANT: When using BIODIESEL blends, monitor Make a thorough inspection of the engine room. Look for water quantity more closely in the fuel filter element. oil or coolant leaks, worn drive belts, loose connections Water in the filter separator may need to be drained more and trash build-up.

  • Page 33: Service And Maintenance - 250 Hrs

    SP 7. Change engine oil and replace oil filter lubrication. Always change filter regularly. Use filter meeting Northern Lights performance specifications. NOTE: Change engine oil and filter for the first time 5. Apply clean engine oil to the new filter at the inner (B) before 100 hours maximum of operation, then every 250 and outer (C) seals and to filter threads.
  • Page 34 Service and Maintenance - 250 Hour 9. Fill engine crankcase with correct engine oil through rocker arm cover opening (A, below). (See DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant Section for determining correct engine oil.) To determine the correct oil fill quantity for your engine, see ENGINE CRANKCASE OIL FILL QUANTITIES in the Specifications Section of this manual.
  • Page 35 Service and Maintenance - 250 Hour SP9. Service Battery 3. Keep battery fully charged, especially during cold weather. If a battery charger is used, turn charger off before connecting charger to battery(ies). Attach WARNING POSITIVE (+) battery charger lead to POSITIVE (+) battery post.
  • Page 36 Northern Lights dealer. 4. If tensioner has been removed, tighten tensioner mounting cap screw (B) to 70 N·m (52 lb-ft). Location of zinc plugs (A) and end cap (B)- M50C13, M65C13, M99C13 5. Install belt guard. Location of zinc plugs (A) and end cap (B)- M150C13...
  • Page 37 Service and Maintenance - 250 Hour SP12. Replace Crankcase Vent Filter 1. Remove screws (A) and remove the crankcase vent lid. 2. Remove old filter and discard. 3. Install new filter into crankcase vent housing and snap into place. 4. Install lid and lock down screws. Location of hoses on crankcase.

  • Page 38: Service And Maintenance - 500 Hrs

    3. Loosen drain plug and air vent screw. Drain fuel into Page 63) suitable container. Location of drain (A), filter/filter housing (B) and filter base Location of drain (A), filter/filter housing (B) and filter base (C)- M50C13, M65C13, M99C13 (C) - M150C13 OM-C3 11/21...
  • Page 39 6. Inspect filter mounting base for cleanliness. Clean as required. Location of electrical connector (A),drain (B), filter base (C), Location of electrical connector (A),drain (B), filter base (C), filter/water separator (D) - M50C13, M65C13, M99C13 filter/water separator (D) - M150C13 OM-C3 11/21...
  • Page 40 Service and Maintenance - 500 Hour SP 16. Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner) Belt drive systems equipped with automatic (spring) belt tensioners cannot be adjusted or repaired. The automatic belt tensioner is designed to maintain proper belt tension over the life of the belt.
  • Page 41 If pulleys or bearings need tensioner mounting base (b) replacement, contact your Northern Lights dealer. 2. Release tension on tension arm and remove drive tool. 3. Put a mark (A, right) on swing arm of tensioner as shown.
  • Page 42 Service and Maintenance - 500 Hour SP 18. Checking Cooling System Maintaining the correct coolant conditioner concentration (SCAs) and freeze point is essential in your cooling CAUTION system to protect against rust, liner pitting and corrosion, and freeze-ups due to incorrect coolant dilution. Explosive release of fluids from pressurized cooling system can DO NOT mix one brand of SCA with a different brand.
  • Page 43 Service and Maintenance - 500 Hour SP 20. Remove, Inspect and Clean Engine Heat NOTE: The heat exchanger core may be removed from Exchanger Core housing when either end cap is removed. It is strongly recommended that both end caps be removed for cleaning IMPORTANT: Initially remove and inspect the engine when cleaning the heat exchanger core.
  • Page 44 Service and Maintenance - 500 Hour Install Heat Exchanger Core 1. Install rear end cap, install cap screws and evenly tighten until end cap (B) is about 6.4 mm (0.25 in.) Thoroughly inspect condition of end cap sealing O-rings from housing (C). Index end cap in same position as (A, below).
  • Page 45 Service and Maintenance - 500 Hour Remove, Inspect and Clean Engine Aftercooler Core IMPORTANT: Initially remove and inspect the aftercooler core at 250 hour or three month service interval on a new engine. Then, remove and clean at every 500 hour or 12 month interval thereafter.
  • Page 46 Service and Maintenance - 500 Hour SP 21. Pressure Testing Cooling System CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
  • Page 47 Service and Maintenance - 500 Hour SP 22. Flushing and Refilling Cooling System 7. Close all drain valves after coolant has drained. CAUTION CAUTION Explosive release of fluids from Do not run engine longer than 10 minutes. Doing so pressurized cooling system can may cause engine to overheat, causing burns when cause serious burns.

  • Page 48: Service And Maintenance - 2000 Hrs

    Service and Maintenance - 2000 Hour SP24. Checking and Adjusting Engine Valve Clearance 4. Adjust valves to specifications below using the valve clearance adjustment procedure in the following blocks. Loosen the jam nut on rocker arm adjusting screw. Turn CAUTION adjusting screw until feeler gauge slips with a slight drag.
  • Page 49 Adjust valve clearance on No. 2 and 4 exhaust valves and No. 3 and 4 intake valves. 4 cylinder valve adjustment (M50C13, M65C13, M99C13) - Front of engine (A), No. 1 piston at TDC compression stroke (B), No. 4 piston at TDC compression stroke (C), exhaust valve (E),...
  • Page 50 Service and Maintenance - 2000 Hour SP 25. Checking Crankshaft Vibration Damper (M150C13 Only) 1. Remove belts (shown removed). 2. Grasp vibration damper with both hands and attempt to turn it in both directions. If rotation is felt, damper is defective and should be replaced.
  • Page 51 Service and Maintenance - 2000 Hour SP 26: Remove Thermostats CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
  • Page 52 Service and Maintenance - 2000 Hour Inspecting Thermostats and Testing Opening Temperature 1. Remove thermostats. (page 49.) 2. Visually inspect thermostats for corrosion or damage. Replace thermostats as a matched set as necessary. 3. Inspect thermostat with wiggle wire in vent notch. If wire movement is restricted, replace thermostat if cleaning does not free movement.
  • Page 53 Service and Maintenance - 2000 Hour SP 27. Inspect and Repair Sea Water Pump (M50C13, M65C13, M99C13) • Inspect pump housing for seal leakage 1. Inspect the sea water pump housing weep hole, if equipped, for evidence of water or oil indicating seal leakage.
  • Page 54 Service and Maintenance - 2000 Hour SP 27. Inspect and Repair Sea Water Pump Remove cover (M150C13) plate (A) • Inspect pump housing for seal leakage 1. Inspect the sea water pump housing weep hole, if equipped, for evidence of water or oil indicating seal leakage.

  • Page 55: Service And Maintenance - As Required

    Service and Maintenance - As Required Remove and Install Sea Water Pump (M50C13, M65C13, M99C13) NOTE: Sea water pump may have two more mounting cap screws than illustrated. Remove/install procedure is unchanged. • Remove Sea Water Pump: 1. Close sea cock and drain sea water system.
  • Page 56 Service and Maintenance - As Required Remove And Install Sea Water Pump 1. Close sea cock and drain sea water system. 2. Remove sea water outlet connection (A), remove sea water pump cap screws (B) and remove pump. 3. Clean all gasket material from both mating surfaces. 4.
  • Page 57 Service and Maintenance - As Required Remove and Install Sea Water Pump (M150C13) 1. Close sea cock and drain sea water system. 2. Remove sea water pump inlet connection. Loosen constant tension clamps (B) on formed hose (C) that is attached to the aftercooler inlet (A). 3.
  • Page 58 Service and Maintenance - As Required Install Impeller 1. Apply LOCTITE® 242 to curved side of cam plate near threaded hole and install cam plate into impeller housing bore, be sure holes in cam plate and housing are aligned. Apply LOCTITE® 242 to cam screw (B), install, and tighten.
  • Page 59 Also replace element if it is torn, or visibly dirty. pressurized cooling system can cause serious burns. NOTE: This procedure applies to Northern Lights air cleaner kits. Refer to manufacturers’ instructions for Shut off engine. Only remove filler servicing air cleaners not supplied by Northern Lights.
  • Page 60 Service and Maintenance - As Required Replacing Air Cleaner Filter Element Replace element if it is torn, or visibly dirty. NOTE: This procedure applies to Northern Lights air cleaner kits. Refer to manufacturers’ instructions for servicing air cleaners not supplied by Northern Lights.
  • Page 61 Service and Maintenance - As Required 5. Rinse filter with low pressure water, flushing opposite the direction of air flow (from clean side to dirty side). IMPORTANT: Let element dry at room temperature. Compressed air will damage filter media. Heat will shrink filter media and may damage rubber base or end cap.
  • Page 62 Service and Maintenance - As Required Replacing Air Cleaner Filter Element IMPORTANT: Replace the element after 10 cleanings. 1. Loosen clamp (A) and remove filter element. 2. Install new filter element and tighten clamp. Filter element Replacing Dry Air Cleaner Element IMPORTANT: ALWAYS REPLACE primary air cleaner element when air restriction indicator (A) shows vacuum of 625 mm (25 in.) H2O, or when reset button has popped...
  • Page 63 NOTE: While belt is removed, inspect pulleys and bearings. Rotate and feel for hard turning or any unusual sounds. If pulleys or bearings need replacement, see your Northern Lights dealer. 1. Remove cap screws (A) and carefully remove belt guard from engine.
  • Page 64 High Pressure Common Rail (HPCR) fuel system. Only technicians familiar with this type of system can perfo repairs. (See your Northern Lights dealer.) Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid hazards by relieving pressure before connecting hydraulic or other lines.

  • Page 65: Engine Layout

    Electronically Controlled Engine Layout 1— Engine Control Unit (ECU) 11— Low-Pressure Fuel Pump 22— Unterminated Ground 2— Auxiliary Power Connector Connector (Battery) 3— Coolant Temperature Sensor 12— Oil Pressure Sensor 23— Unterminated Power Connector Connector (Battery) 4— Fuel Injection Harness 13 —...

  • Page 66: Long Term Storage

    Engine Storage Guidelines petroleum diesel fuel. Filling the tank completely will 1. Northern Lights generator sets can be stored outside for ensure that water does not build up due to condensation. up to three (3) months with no long term preparation For storage of more than one year, use Northern Lights IF COVERED BY WATERPROOF COVERING.
  • Page 67 Long Term Storage 12. Clean the exterior of the engine with salt-free water 4. Perform all appropriate pre-starting checks. (See and touch up any scratched or chipped painted surfaces DAILY PRESTARTING CHECKS, pages 28-30.) with a good quality paint or corrosion inhibitor if not feasible to paint.

  • Page 68: Troubleshooting

    Troubleshooting NOTE: If using biodiesel blends above B20, the possibility of some of the symptoms listed below, such as power loss, could increase. NOTE: Before troubleshooting the engine, first retrieve any fault codes on the diagnostic gauge display and perform the corrective actions.
  • Page 69 Improper valve clearance Consult Authorized Dealer Dirty or faulty injection nozzles Consult Authorized Dealer Injector tip deposits Use Northern Lights approved biodiesel fuel conditioners containing deposits Injection pump out of time Consult Authorized Dealer Turbocharger not functioning Consult Authorized Dealer...
  • Page 70 Engine Emits Black or Gray Exhaust Smoke Clogged or dirty air cleaner Service air cleaner Engine overloaded Reduce load Fuel injectors dirty Use Northern Lights approved biodiesel or diesel fuel conditioners containing detergents. If no improvement is seen, consult authorized dealer. OM-C3 11/21...
  • Page 71 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) Engine Emits Black or Engine out of time Consult Authorized Dealer Gray Exhaust Smoke Turbocharger not functioning Consult Authorized Dealer (cont.) Electronic fuel system problem Consult Authorized Dealer Engine Overheats Engine overloaded Reduce load Low coolant level Fill coolant tank to proper level.
  • Page 72 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) High Fuel Consumption Engine out of time Consult Authorized Dealer (cont.) Defective turbocharger Consult Authorized Dealer Low engine temperature Check thermostat ELECTRICAL PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) Excessive electrical load from Remove accessories or install higher output Undercharged Electrical System added accessories...

  • Page 73: Electrical Troubleshooting

    Troubleshooting ELECTRICAL PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) Starter Cranks Slowly Low battery output Consult Authorized Dealer Crankcase oil too heavy Use proper viscosity oil Loose or corroded connections Clean and tighten loose connections Only Starter and Blown fuse on magnetic switch Replace fuse Hourmeter Function Entire Electrical System...

  • Page 74: Specifications

    Specifications General Marine Engine Specifications M50C13 M65C13 M80C13 ITEM - UNIT OF MEASURE General Data Engine Type/Cycle In-line/4 In-line/4 In-line/4 Aspiration Turbocharged Turbocharged Turbocharged Number of Cylinders Bore - mm (in.) 106 (4.17) 106 (4.17) 106 (4.17) Stroke - mm (in.) 127 (5.00)
  • Page 75 Specifications General Marine Engine Specifications - 4.5L M99C13 M120C13 M150C13 ITEM - UNIT OF MEASURE General Data Engine Type/Cycle In-line/4 In-line/6 In-line/6 Aspiration Turbocharged Turbocharged Turbocharged Number of Cylinders Bore - mm (in.) 106 (4.17) 106 (4.17) 106 (4.17) Stroke - mm (in.) 127 (5.00) 127 (5.00) 127 (5.00)

  • Page 76: Ac Wiring Diagrams

    Updated 11-17-21 AC Wiring Diagram OM-C3 11/21...
  • Page 77 Updated 11-17-21 AC Wiring Diagram OM-C3 11/21...

  • Page 78: Dc Wiring Diagrams

    DC Wiring Diagram OM-C3 11/21...
  • Page 79 DC Wiring Diagram OM-C3 11/21...
  • Page 80 DC Wiring Diagram OM-C3 11/21...

  • Page 81: Ac Wiring Diagrams

    Updated 11-17-21 AC Wiring Diagram OM-C3 11/21...
  • Page 84 4420 14th Ave. NW., Seattle WA 98107 Tel: (206) 789-3880 • 1-800-762-0165 • www.northern-lights.com Northern Lights and Lugger are registered trademarks of Northern Lights, Inc. © 2021 All rights reserved. Litho USA.

This manual is also suitable for:

M80c13M65c13M99c13M120c13M150c13

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