Northern Lights M773LW, M773LW2 Operator's Manual

OM773LW2

For Models: M773LW and M773LW2

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: [phone]
Fax: [phone]

Copyright ©2005 Alaska Diesel Electric, Inc.
All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Alaska Diesel Electric, Inc.

Printed in U.S.A.
PART NO.: OM773LW2 06/05

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

M773LW and M773LW2

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

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

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

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

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

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

COMPONENT LOCATIONS

M773LW Marine Generators ..............................6

M773LW2 Marine Generators ............................7

PANELS

Northern Lights Generator Sets ....................8 - 9

OPERATING PROCEDURES

Break-in Period ................................................ 10

Before Starting ................................................. 10

Starting ............................................................. 10

Operating ......................................................... 10

Stopping ........................................................... 10

Shutdowns and Alarms .....................................11

Spare Parts ........................................................11

SERVICING SCHEDULE CHART ........ 12 - 13

SERVICING

Lubrication - General ....................................... 14

Checking Oil .................................................... 14

SERVICING (continued)

Oil Changes ..................................................... 14

Changing Oil Filter .......................................... 14

Air Filter .......................................................... 15

V-Belts ............................................................. 15

Valve Clearances .............................................. 15

Fuels - General ................................................. 16

Fuel Filters ....................................................... 16

Bleeding the Fuel System ................................ 17

Injector Service ........................................ 18 - 19

Injection Pump ................................................. 19

Cooling System - General ................................ 19

Cooling System Flushing ................................. 20

Heat Exchanger ............................................... 20

Raw Water Pump ............................................. 20

Generator Ends ................................................ 20

Electrical System - General ............................. 20

Glow Plugs ....................................................... 21

Booster Batteries .............................................. 21

Battery Care ..................................................... 21

Winterizing / Out-of-Service ........................... 21

TROUBLESHOOTING

Electrical .......................................................... 22

Engine ...................................................... 23 - 25

WIRING DIAGRAMS

AC Electrical ................................................... 26

DC Electrical ........................................... 27 - 30

Proprietary Information

This publication is the property of Alaska Diesel Electric, Inc.

It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc.

© Alaska Diesel Electric, Inc. All rights reserved. Litho U.S.A. Publication number OM773W2 06/05

OM773LW2 06/05

3

Introduction

Servicing of marine engines and generator sets
presents unique problems. In many cases boats
cannot be moved to a repair facility. Marine engines

Failures begin with minor problems that are over-

looked and become amplied when not corrected

during routine maintenance.
cannot be compared to the servicing of automobiles,
trucks or even farm equipment. Failures often occur
in remote areas far from competent assistance.
Marine engines 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 Identication

MODELS INCLUDED

This manual covers the operating instructions for:

M753W & W2 marine generator sets

Model Numbers

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

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

M

M - Northern Lights marine generator set

M773LW

Northern Lights marine diesel generator set

=

with a 773 engine, PX-309K2 generator end, and
an AVR.

Model number of engine block

+

Bore Cylinders
77 mm 3

773

M773LW2

Northern Lights marine generator set with a

=

773 engine, PX-309K2 generator end, AVR,
Tier II compliant.

Serial Numbers

Your set has three serial numbers: 1 an engine number stamped

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.

L, W, W2

L - Long stroke

+

W - New Winding in
Generator End,
2 - Tier II

Figure 1: Generator set serial number plate.

OM773LW2 06/05

4

Warranty

A warranty registration certi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

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.
described in the Limited Warranty Statement. We
recommend that you study the statement carefully.

Safety Rules

CAUTION: 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.

• Never leave engine without proper security.

• Turn the coolant tank cap slowly to relieve pres
sure before removing. Add coolant only when
the engine is stopped and cool.

• Mount a 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.

• Use caution in handling fuel. Never refuel a hot

-

or running engine. Do not smoke while lling

fuel tank or servicing fuel system. Clean up

spilled fuel or oil to prevent potential res.

• 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 knowledge

able, qualied personnel.

-

• Escaping 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.

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

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

• 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.

• Provide rst aid kits.

OM773LW2 06/05

5

Marine Generator Component Locations

Figure 1 & 2: M773LW with PX-309K2 generator

1. Generator Control Box

2. Air Filter

3. Fuel Filter

4. Fuel Lift Pump

5. Crankcase Vent

6. Lube Oil Fill, Top

7. Coolant Fill

8. Fuel Injector

9. Stop Solenoid

10. Injection Pump

11. Lube Oil Fill, Side

12. Seawater Pump

13. Lube Oil Drain

14. Base frame

15. Block Drain

16. Fuel Inlet and Return

17. Oil Dipstick

18. Lube Oil Filter

19. Control Panel Plug

20. Generator Data Plate

OM773LW2 06/05

6

21. AC Circuit Breaker for
AVR

22. DC Circuit Breaker

23. Expansion Tank

24. Wet Exhaust Elbow

25. Vibration Mount

26. Starter

27. Alternator

28. Heat Exchanger End
Cap

29. Coolant Recovery
Tank

Marine Generator Component Locations

Figure 3 & 4: M773LW2 with PX-309K2
generator end.

1. Generator Control Box

2. DC Circuit Breaker

3. Coolant Recovery
Tank

4. Air Filter

5. Fuel Filter

6. Fuel Lift Pump

7. Fuel Injector

8. Coolant Fill

9. Lube Oil Fill, Top

10. Stop Solenoid

11. Injection Pump

12. Lube Oil Fill, Side

13. Seawater Pump

14. Fuel Inlet and Return

15. Oil Dipstick

16. Lube Oil Filter

17. Oil Drain

18. Generator Data Plate

19. Expansion Tank

OM773LW2 06/05

7

20. Heat Exchanger End
Cap

21. Wet Exhaust Elbow

22. Vibration Mount

23. Starter

24. Alternator

Control Panels

Figure 5: Series 1-B Generator Control Panel

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 attempt-

ing 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.

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muf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.

Figure 6-a: Series 3 Generator Control Panel

3. HOUR METER

Keeps track of engine running time.

4. OIL PRESSURE GAUGE

Shows the oil pressure in the engine lubricating system.

5. WATER TEMPERATURE GAUGE

Registers the temperature of the cooling water.

6. D.C. VOLTMETER OR AMMETER

When the engine is stopped, the voltmeter indicates the

condition of the battery. When the engine is running,
the voltmeter indicates the voltage output of the

alternator.

For Series 4 Control Panels Only:

7. A.C. VOLTMETER

Shows the generator output voltage.

8. FREQUENCY METER (Hertz)

The frequency meter indicates engine speed: 1200 or

1800 RPM (60 Hz), or 1500 RPM (50 Hz).

9. AMMETER SELECTOR SWITCH

Used to check each phase for load condition.

NOTE:AlwaysleavethisswitchintheONposition

while the unit is running.

Figure 6-b: Series 4 Generator Control Panel

10. A.C. AMMETER

Shows the generator load on each phase. The phase is

selected with the Ammeter Selector switch (Item 9).

OM773LW2 06/05

8

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. To stop the engine, hold
the switch in the STOP position.

Auto Start Panels

(S-7.0, S-7.2, S-7.4, S-7.5, and S-7.6)

When the switch is placed in the AUTO START posi-

tion, the unit will automatically start when there is a
drop in utility power.

2. OIL PRESSURE GAUGE

Shows the oil pressure in the engine lubricating system.

Figure 7-A:

Control Panels.

Series 7.0 through Series 7.6 Generator

3. HOUR METER

Keeps track of engine running time.

4. ENGINE TEMPERATURE GAUGE

Registers the temperature of the coolant.

5. D.C. VOLTMETER

When the engine is running, the voltmeter indicates the

voltage output of the alternator.

6. STATUS INDICATOR PANEL

Engine monitoring alarms and lamps for monitoring

engine functions.

7. ALARM LAMP TEST AND RESET BUTTON

Press UP to test the indicator lights and press DOWN

to reset the alarm.

8. A.C. VOLTAGE ADJUSTMENT RHEOSTAT

Voltage has been set at the factory and should only be

adjusted by factory-trained personnel.

9. AMMETER SELECTOR SWITCH

Used to check each phase for load condition.

NOTE:AlwaysleavethisswitchintheONposition

while the unit is running.

10. FREQUENCY METER (HERTZ)

The frequency meter indicates alternator current fre-

quency: 60 Hz (1200 or 1800 RPM), or 50 Hz (1500
RPM).

Figure 7-B:

Series 7.6 Generator Control Panels.

Status Indicators for Series 7.0 through

11. A.C. VOLTMETER

Shows the generator output voltage.

12. A.C. AMMETER

Shows the generator load on each phase. The phase is

selected with the Ammeter Selector switch.

OM773LW2 06/05

9