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Northern Lights NL773LW3 Operator's Manual

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ONL773LW3
For Model: NL773LW3
OPERATOR'S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators

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Summary of Contents for Northern Lights NL773LW3

  • Page 1 ONL773LW3 For Model: NL773LW3 OPERATOR’S MANUAL Marine Generators | Marine Diesel Engines | Land-Based Generators...
  • Page 2 This label is to state: LOW OR ULTRA LOW SULFUR FUEL ONLY Northern Lights is providing this label for application to the fuel inlet of the fuel supply tank for each engine or generator set.

  • 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 ONL773LW3 11/13...

  • Page 4: Introduction

    This manual covers the operating instructions for: NL773LW3 industrial generator set. Model Numbers Model numbers give the unit's application, block model, aspiration, and RPM: Model number of engine block Designates new NL - Northern Lights industrial generator set Bore Cylinders winding within 77 mm generator set...

  • 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 Revised 3-12-12 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.
  • Page 7 16 o C (60 o F). with Northern Lights products are lubricants, coolants, paints and adhesives. Always remove grounded (-) battery clamp first and replace ground clamp last.
  • 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: Safety Rules

    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: 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.

  • Page 11: Industrial Generator

    Industrial Generator Component Locations Figures 2-A and B: NL773LW3 13. Hourmeter 7. Fuel Lift Pump 1. Junction Box 14. Control Panel 8. Dipstick 2. Air Filter 15. Starter 3. Crankcase Vent 9. Fuel Inlet and Return 10. Oil Filter 16. Alternator 4.

  • Page 12: Control Panel

    Control Panel Figure 3: Series 1-B Generator Control Panel 1. SHUTDOWN BYPASS-PREHEAT SWITCH There are two functions built into this switch: preheating the engine and bypassing the engine safety shutdown circuit, enabling a quicker start. Hold the switch in the ON position for approximately 10 to 20 seconds before starting a cold engine.

  • Page 13: Operating Procedures

    Updated 1-10-13 Operating Procedures BREAK-IN PERIOD engine. Holding the switch too long can burn out the glow plugs. This step is not necessary if the engine is already warm. 1. The first 100 hours on a new or reconditioned 2. While holding the Shutdown Bypass-Preheat switch engine are critical to its life and performance.

  • Page 14: Shutdowns And Alarms

    Operating Procedures parts are available from your local Northern Lights oil pressure. dealer. Other alarms and shutdowns are available as optional equipment. 2. All owners should have the following: NOTE: Do not rely on your shutdown to the a. Primary and secondary fuel filter elements exclusion of careful gauge monitoring.

  • Page 15: Servicing Schedule Chart

    Updated 7-9-13 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. EVERY 500 HOURS: DAILY: SP2/3 Change engine oil and filter...

  • Page 16: Servicing

    Updated 7-9-13 Servicing SP2. OIL CHANGES LUBRICATION - GENERAL 1. The set is delivered with special break-in oil. 1. Use only clean, high quality lubricants stored in Change the engine oil and oil filter after 50 hours clean containers in a protected area. of operation.

  • Page 17: Air Filter

    2. Industrial sets: the element cannot be cleaned. Replace it when necessary. Part numbers are: NL773LW3 – #24-27301 4. NOTE: Make absolutely sure no impurities enter Figure 5: Valve Adjustment the engine while changing the element. Do NOT run the engine with the air cleaner removed.

  • Page 18: Fuels - General

    Servicing FUELS - GENERAL 1. Use only clean, high quality fuels of the following 6. Storing fuel: specifications, as defined by ASTM designation a. Keep dirt, scale, water, and other foreign matter D975 for diesel fuels: out of fuel. a. Use grade no. 2 diesel at ambient temperatures b.

  • Page 19: Bleeding The Fuel System

    Figure 6: The Fuel System - the NL773LW3 varies slightly from this depiction 3. Loosen bleed screw “C”. Pump hand primer “B” 1. The fuel system is self-bleeding. However, any until pure fuel (no bubbles) escapes.
  • Page 20 Servicing For illustration purposes only - the NL773LW3 may look a little different. Figure 7: Remove delivery line flare nuts. Figure 11: Unscrew injector. Figure 8: Remove delivery lines. Figure 12: Remove and replace copper sealing washer. Figure 9: Remove return line nuts.

  • Page 21: Injector Service

    1. Injectors should be checked every 1000 hours. is difficult to give a definite interval for checking the Check should be made by a Northern Lights dealer injection pump. But as a rule, pump settings, or local injection repair station.

  • Page 22: Cooling System Flushing

    revised 11-8-13 Servicing SP14. COOLING SYSTEM FLUSHING 2. Here are acceptable water quality specifications: 1. Flush the cooling system every 2500 hours or every Parts Grains Contaminates per Million per Gallon 12 months, whichever comes first. 2. Industrial sets: Maximum Chlorides Remove radiator cap and open drain cocks on radiator and engine block.

  • Page 23: Glow Plugs

    Servicing GLOW PLUGS SP 18-19. BATTERY CARE 1. Each cylinder is supplied with a glow plug which 1. Check electrolyte level every 50 hours or once per serves to heat the combustion chamber. month. Add distilled water to manufacturer’s 2. To check the glow plugs, loosen the current recommended level.

  • Page 24: Troubleshooting

    Faulty connection • 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. ONL773LW3 11/13...

  • Page 25: Engine

    Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) Engine Hard to Start Improper starting procedure • See starting section of this manual. Take or Will Not Start special note of Bypass Switch operation. No fuel • Check level of fuel in fuel tank. Low battery output •...
  • Page 26 Injection pump timing off • See your dealer. Engine not at proper temperature • Check your thermostats. • Check water temperature with thermometer and replace gauge if necessary. If you cannot correct problems with these procedures, see your Northern Lights dealer. ONL773LW3 11/13...

  • Page 27: Engine

    Cold engine • Warm up engine to normal operating temperature. Defective thermostat • Remove and check thermostat. Engine injectors timing off • See your dealer. If you cannot correct problems with these procedures, see your Northern Lights dealer. ONL773LW3 11/13...

  • Page 28: Wiring Diagrams

    Revised 2-1-12 Wiring Diagrams ONL773LW3 11/13...
  • Page 29 Added 2-1-12 Wiring Diagrams ONL773LW3 11/13...
  • Page 30 Added 2-1-12 Wiring Diagrams ONL773LW3 11/13...
  • Page 31 Revised 2-1-12 Wiring Diagrams ONL773LW3 11/13...
  • Page 32 Added 2-1-12 Wiring Diagrams ONL773LW3 11/13...
  • Page 34 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. © 2013 All rights reserved. Litho USA.

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