Northern Lights M773LW3 Operator's Manual
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Northern Lights M773LW3 Operator's Manual

Marine generators
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OM773LW3
For Model: M773LW3
OPERATOR'S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators

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Summary of Contents for Northern Lights M773LW3

  • Page 1 OM773LW3 For Model: M773LW3 OPERATOR’S MANUAL Marine Generators | Marine Diesel Engines | Land-Based Generators...
  • 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.: OM773LW3 11/13...

  • 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 OM773LW3 11/13...

  • Page 4: Introduction

    RPM: Model numbers give the unit’s application, block model, aspiration, and RPM L, W, 3 Model number of engine block L - Long stroke M - Northern Lights marine generator set Bore Cylinders W - New Winding in 77 mm...

  • Page 5: M773Lw

    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 3-13-12 Safety Rules (Continued) Prevent accidental discharge of starting fluids by Operating equipment requires the full attention of storing all cans in a cool, safe place, away from sparks the operator. Do not use radio or music headphones or open flame. Store with cap securely on container. while operating machinery.
  • 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: 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 Notes OM773LW3 11/13...

  • Page 12: Component Locations M773Lw Marine Generators

    Marine Generator Component Locations Figure 1 & 2: M773LW with PX-309K2 generator 1. Generator Control Box 8. Fuel Injector 15. Block Drain 21. AC Circuit Breaker for 26. Starter 2. Air Filter 9. Stop Solenoid 16. Fuel Inlet and Return 27.

  • Page 13: M773Lw3 Marine Generators

    Updated 9-16-10 Marine Generator Component Locations Figure 3 & 4: M773LW3 with PX-309K2 generator end. 1. Generator Control Box 13. Seawater Pump 7. Fuel Injector 20. Heat Exchanger End 2. DC Circuit Breaker 14. Fuel Inlet and Return 8. Coolant Fill 3.

  • Page 14: Northern Lights Generator Sets

    Control Panels 1. SHUTDOWN BYPASS-PREHEAT SWITCH There are two functions built into this switch: 1. Preheats the fuel before beginning the starting process. Press switch 10-20 seconds before attempting start-up. 2. Bypasses the safety shutdown feature during starting process. Keep switch engaged while starting engine and for 2 to 3 seconds afterwards, allowing oil pressure to build beyond shutdown set point.
  • Page 15 Control Panels 1. SHUTDOWN BYPASS SWITCH Manual Start Panels (S-7.1 and S-7.3) Hold the switch in the START position until the engine is running. NOTE: Excessive cranking may cause engine damage. After the engine starts, release the switch and it will return to the RUN position.

  • Page 16: Operating Procedures

    updated page 1-9-13 Operating Procedures STARTING BREAK-IN PERIOD 1. Hold the Shutdown Bypass-Preheat switch in the ON 1. The first 100 hours on a new or reconditioned engine are critical to its life and performance. position for 10 to 20 seconds before starting a cold engine.

  • Page 17: Shutdowns And Alarms

    Operating Procedures SHUTDOWNS AND ALARMS 1. Generator sets have shutdown systems to stop the 1. Northern Lights recommends that you keep the engine in the event of high water temperature or low following spare parts on hand for field service. The oil pressure.

  • Page 18: Servicing Schedule Chart

    updated 12/18/12 Servicing Schedule Chart The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your generator set. More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’ column. DAILY: EVERY 250 HOURS: Check oil level in engine...

  • Page 19: Servicing Record Notes

    Service Record Notes OM773LW3 11/13...

  • Page 20: Servicing

    updated 12/18/12 Servicing LUBRICATION - GENERAL SP2. OIL CHANGES 1. Use only clean, high quality lubricants stored in 1. The set is delivered with special break-in oil. clean containers in a protected area. Change the engine oil and oil filter after 50 hours 2.

  • Page 21: Air Filter

    Replace if necessary. Part numbers are: cold and NOT running. M773LW3 – #24-28602 3. To bring the No. 1 cylinder to top dead center in the compression stroke, align the timing mark; the top 3. NOTE: Make absolutely sure no impurities enter mark of the crank pulley with that of the timing gear the engine while changing the element.

  • Page 22: Fuels - General

    Servicing FUELS - GENERAL SP7-9. FUEL FILTERS 1. Use only clean, high quality fuels of the following 1. Your generator set should have a primary fuel filter specifications, as defined by ASTM designation installed. We recommend the Racor brand of fuel D975 for diesel fuels: filter-water separators.

  • Page 23: Bleeding The Fuel System

    Servicing SP10. 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.
  • Page 24 Servicing Figure 12: Remove delivery line flare nuts. Figure 16: Unscrew injector. Figure 13: Remove delivery lines. Figure 17: Remove and replace copper sealing washer. Figure 14: Remove return line nuts. Figure 18: Reinstall injector. Torque to proper tightness. Figure 15: Remove return line. OM773LW3 11/13...

  • Page 25: Injector Service

    Check should be made by a injection pump. But as a rule, pump settings, Northern Lights dealer or local injection repair maximum speed, idle speed and exhaust smoke station.

  • Page 26: Cooling System Flushing

    Owner’s Manual. sediment. Let water drain completely. Close If you do not have one of these manuals, contact your drains and refill with recommended mixture. local Northern Lights dealer. OM773LW3 11/13...

  • Page 27: Electrical System - General

    revised 11-8-13 Servicing 3. First, connect positive (+) terminal of booster bat- ELECTRICAL SYSTEM - GENERAL tery to positive (+) terminal of main battery. Then, connect negative (-) terminal of booster battery to 1. Never switch battery switch off or break the circuit ground on the engine block ( between the alternator and batteries while the engine see Figure 20...

  • Page 28: 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. OM773LW3 11/13...

  • Page 29: 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 30 Engine overloaded • Check load usage. 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. OM773LW3 11/13...

  • Page 31: Engine

    White Smoke Cold engine • Warm up engine to normal operating temperature. Defective thermostat • Remove and check thermostat. Engine timing off • See your dealer. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM773LW3 11/13...

  • Page 32: Wiring Diagrams

    updated page 3-13-12 Wiring Diagrams OM773LW3 11/13...
  • Page 33 updated page 3-13-12 Wiring Diagrams OM773LW3 11/13...

  • Page 34: Dc Electrical

    UPdated page 3-13-12 Wiring Diagrams OM773LW3 11/13...
  • Page 35 Updated page 7-9-12 Wiring Diagrams OM773LW3 11/13...
  • Page 36 Added page 7-9-12 Wiring Diagrams OM773LW3 11/13...
  • Page 37 Added page 3-13-12 Wiring Diagrams OM773LW3 11/13...
  • Page 38 Added page 7-9-12 Wiring Diagrams OM773LW3 11/13...
  • Page 39 updated page 3-13-12 Wiring Diagrams OM773LW3 11/13...
  • Page 40 Wiring Diagrams OM773LW3 11/13...
  • Page 41 Added page 3-13-12 Wiring Diagrams OM773LW3 11/13...
  • Page 42 added page 3-13-12 Wiring Diagrams OM773LW3 11/13...
  • Page 44 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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