Northern Lights Lugger ONL753W2 Owner's Manual

ONL753W2

For Models: NL753W and NL753W2

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constitu-

ents are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

Northern Lights

4420 14th Avenue N.W. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455

Printed in U.S.A. PART NO.: ONL753W2 10/09

OPERATOR'S MANUAL

Read this operator's manual thoroughly before starting to operate your equipment.

This manual contains information you will need to run and service your new unit.

Table of Contents

for Models

NL753W & NL753W₂

INTRODUCTION ....................................................4

Models Included .................................................4

Model Numbers ..................................................4

Serial Numbers ...................................................4

WARRANTY ............................................................5

SAFETY RULES .....................................................5

COMPONENT LOCATIONS

Industrial Generator ............................................6

CONTROL PANEL

S-1B Control Panel .............................................7

OPERATING PROCEDURES

Break-in Period ...................................................8

Before Starting ....................................................8

Starting ................................................................8

Operating ............................................................8

Stopping ..............................................................8

Shutdowns and Alarms .......................................9

Spare Parts ..........................................................9

SERVICING SCHEDULE CHART .................... 10

SERVICING

Lubrication - General ....................................... 12

Checking Oil .................................................... 12

Oil Changes ..................................................... 12

Changing Oil Filter .......................................... 12

Air Filter .......................................................... 13

V-Belts ............................................................. 13

Valve Clearances .............................................. 13

Fuels - General ................................................. 14

Fuel Filters ....................................................... 14

Bleeding the Fuel System ................................ 15

Injector Service ........................................ 16 - 17

Injection Pump ................................................. 17

Cooling System - General ................................ 17

Cooling System Flushing ................................. 18

Clean Radiator ................................................. 18

Generator End .................................................. 18

Electrical System - General ............................. 18

Glow Plugs ....................................................... 19

Booster Batteries .............................................. 19

Battery Care ..................................................... 19

Winterizing / Out-of-Service ........................... 19

TROUBLESHOOTING

Electrical .......................................................... 20

Engine ...................................................... 21 - 23

WIRING DIAGRAMS

DC Electrical ................................................... 24

AC Electrical ................................................... 25

It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc.

Proprietary Information

This publication is the property of Northern Lights, Inc.

ONL753W2 10/09

Introduction

Servicing of generator sets presents unique problems. In many cases boats cannot be moved to a repair facility. Generator sets cannot be compared to the

Failures begin with minor problems that are overlooked and become ampliﬁ ed when not

corrected during routine maintenance. servicing of automobiles, trucks or even farm equipment. Failures often occur in remote areas far from competent assistance. Generator sets are taxed far more severely than auto or truck engines; therefore, maintenance schedules must be adhered to more strictly.

As operator, it is your obligation to learn about your

equipment and its proper maintenance. This is not a

comprehensive technical service manual. Nor will it

make the reader into an expert mechanic. Its aim is

to aid you in maintaining your unit properly.

Unit Identiﬁ cation

MODELS INCLUDED

This manual covers the operating instructions for:

NL753W and NL753W2 industrial generator sets.

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:

NL - Northern Lights industrial generator set

NL753W

Northern Lights industrial generator set with a

753 engine, PXK2 series generator end, and AVR.

Model number of engine block

Bore Cylinders 75 mm 3

753

NL753W2

Northern Lights industrial generator set with a 753

engine, PXK2 series generator end, AVR, Tier II.

Serial Numbers

Your set has three serial numbers: on the block, 2 a generator plate, and 3 a generator set plate.

Use the serial number on the generator set plate when ordering parts or in correspondence. The generator set plate is found on the service side of the generator and resembles the drawing in Figure 1.

1

an engine number stamped

Designates new

winding within

generator set

Figure 1: Generator set serial number plate.

ONL753W2 10/09

Warranty

A warranty registration certiﬁ cate is supplied with your set. It entitles the original purchaser of our equipment to a warranty covering material or assembly faults. The extent of coverage is described in the Limited Warranty Statement. We recommend that you study the statement carefully.

CAUTION:

You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.

Accident reports show that careless use of engines causes a high percentage of accidents.

• Never leave engine without proper security.

• Turn the coolant tank cap slowly to relieve pressure before removing. Add coolant only

when the engine is stopped and cool.

• Mount a ﬁ re extinguisher near engine.

• Always disconnect the battery ground strap before making adjustments.

• Operate engines in properly ventilated areas.

• Keep trash and other objects away from engine.

• Escaping ﬂ uids under pressure can penetrate your skin. Use a piece of cardboard or wood, not your hands, to search for leaks.

• Avoid wearing loose clothing without a belt when working around engines.

NOTE: If the warranty is to apply, the servicing instructions outlined in this manual must be followed. If further information is needed, please contact an authorized dealer or the factory.

Safety Rules

• Use caution in handling fuel. Never re-fuel a hot or running engine. Do not smoke while ﬁ lling fuel tank or servicing fuel system.

• Keep your hands, feet, hair and clothing away from power-driven parts.

• Check for any loose electrical connections or faulty wiring.

• Engines should be operated only by

knowledgeable, qualiﬁ ed personnel.

• Look completely around engine to make sure that everything is clear before starting.

• Do not operate an engine that isn't in proper

working order. If an unsafe operating condition is

noted, tag the set and control panel so others will also know about the problem.

• Do not oil or grease engine while it is running.

• Provide ﬁ rst aid kits.

CAUTION: This symbol is used throughout this book to alert you to possible danger areas. Please take special notice of these sections.

ONL753W2 10/09

Industrial Generator Component Locations

Figures 2-A and B: NL753W

1. Junction Box

2. Air Filter

3. Crankcase Vent

4. Lube Oil Fill

5. Coolant Fill

6. Injection Pump

7. Dipstick

8. Fuel Inlet & Return

9. Block Water Drain

10. Oil Filter

11. Fuel Lift Pump

12. Secondary Fuel Filter

13. Hourmeter

14. Control Panel

15. Exhaust Outlet

16. DC Circuit Breaker

17. Starter

ONL753W2 10/09

18. Alternator

19. Radiator Shroud

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. Holding the switch ON for too long can burn out the glow plugs.

NOTE: Three position Engine Control switches must be

in the RUN position during preheating. Preheat switch must be held in ON position during starting.

Control Panel

2. ENGINE CONTROL SWITCH

To start the engine, hold this switch in the START

position until the engine is running. NOTE: Excessive cranking of marine sets equipped

with water lift mufﬂ er systems can cause engine

damage. See page 8.

After the engine starts, release the switch and it will

return to RUN position. To stop the engine, hold the switch in the STOP position.

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

Keeps track of engine running time.

ONL753W2 10/09

Operating Procedures

BREAK-IN PERIOD

1. The ﬁ rst 100 hours on a new or reconditioned engine are critical to its life and performance.

2. Constantly check the engine temperature and oil pressure.

3. Oil consumption is greater during break-in as

piston rings take time to seat.

4. Break-In Oil Changes: Change engine oil and

ﬁ lter at 50 hours. Change oil and ﬁ lter again at 250 hours (consult Lubricants section for oil recommendation).

Operating Instructions:

Maintain at least a 75% load on your generator set for the ﬁ rst 100 hours. If this is not possible,

maintain no less than a 50% load to ensure proper seating of the piston rings. Vary the load to help

seat the rings.

BEFORE STARTING

1. Check the coolant level by removing the pressure

cap from the expansion tank or radiator. In order to

give the cooling water an opportunity to expand, the level should be about 1 in. (2.5 cm) below the ﬁ ller cap sealing surface when the engine is cold.

CAUTION: Use protective clothing and open the ﬁ ller cap carefully when the engine is warm to prevent burns.

2. Check the oil level in the crankcase with the dipstick. The oil level must be in the wafﬂ ed area on the stick. Never allow the level to go below this area. Always add the same viscosity of oil as is already in the crankcase.

3. Check the fuel tank level and open any fuel valves.

STARTING

1. Hold the Shutdown Bypass-Preheat switch in the ON position for 10 to 20 seconds before starting a cold engine. Holding the switch too long can burn out the glow plugs. This step is not necessary if the engine is already warm.

2. While holding the Shutdown Bypass-Preheat switch in the ON position, push the Engine Control switch to the START position.

3. As soon as the engine starts, release both switches. Do not crank the starter for more than 20 seconds

consecutively. If the engine fails to start with the ﬁ rst

attempt, be sure that it has stopped completely before re-engaging.

OPERATING

1. Check oil pressure often. Oil pressure must be above 15 PSI. The water temperature must be below 225°F (107°C). Check the AC voltage and frequency. If these deviate from normal levels, shut down the generator set and investigate.

1. Let the unit run unloaded for a three to ﬁ ve minute warm-up period.

2. Add electrical load.

STOPPING

1. Remove electrical load from the generator set.

2. Move the Engine Control switch to the STOP

position momentarily.

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.

ONL753W2 10/09

Operating Procedures

SHUTDOWNS AND ALARMS

1. Generator sets have shutdown systems to stop the engine in the event of high water temperature or low oil pressure.

Other alarms and shutdowns are available as optional equipment. NOTE: Do not rely on your shutdown to the

exclusion of careful gauge monitoring. Watching

your gauges can prevent damage to the unit and dangerous power losses.

2. Do the following when your warning or shutdown system is activated:

a. Check the temperature gauge. Industrial sets: If above 230°F (110°C), shut off the engine immediately. b. Use the Trouble Shooting Guide on page 19 to isolate the cause of the overheat.

CAUTION: Do not remove the water ﬁ ll 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.

SPARE PARTS

1. Northern Lights, Inc. recommends that you keep the following spare parts on hand for ﬁ eld service. The parts are available from your local Northern Lights dealer.

2. All owners should have the following:

a. Primary and secondary fuel ﬁ lter elements b. Oil ﬁ lters c. Air ﬁ lter (industrial units only) d. Alternator belt e. Thermostat and gaskets f. Glow plug g. Injector and washer

3. If your set is operating a long distance from a

servicing dealer, add the following:

a. Complete set of injectors b. Copper washers for injector change c. Complete set of glow plugs d. Fuel lift pump

c. Make repairs. Restart your Industrial set after the temperature gauge registers below 225°F (107°C). d. Watch the temperature gauge regularly and turn off the unit if the temperature rises above 230°F (110°C) on Industrial sets. Repeat trouble

shooting.

3. If shutdown is activated and the temperature gauge shows temperature within normal temperature range:

a. Check the engine crankcase oil level. b. If the oil level is low, ﬁ ll with recommended lubricating oil and restart. Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading (20-60 PSI) after a few seconds of operation. c. If the oil level is normal, DO NOT restart the engine. Call your dealer for assistance.

ONL753W2 10/09

+ 18 hidden pages

Northern Lights Lugger ONL753W2 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual