Northern Lights NL382W Operator's Manual

OPERATOR’S

OPERATOR’S

MANUAL

MANUAL

Publication #ONL382 for Model:

NL382W

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constituents

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.: ONL382 08/05

OPERATOR'S MANUAL

for Model

NL382W

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

INTRODUCTION ................................................... 2

Model Included ................................................. 2

Model Number .................................................. 2

Serial Numbers .................................................. 2

WARRANTY ........................................................... 3

SAFETY RULES .................................................... 3

COMPONENT LOCATION

Industrial Generator........................................... 4

CONTROL PANELS

Northern Lights Generator Sets....................5 - 6

OPERATING PROCEDURES

Break-in Period ................................................. 7

Before Starting .................................................. 7

Starting .............................................................. 7

Operating ........................................................... 7

Stopping ............................................................ 7

Shutdowns and Alarms...................................... 8

Spare Parts......................................................... 8

SERVICING SCHEDULE CHART .............. 9 - 10

V-Belts ............................................................ 12

Retightening Cylinder Head Bolts .................. 12

Valve Clearances............................................. 12

Fuels - General ................................................ 13

Fuel Filters....................................................... 13

Bleeding the Fuel System................................ 14

Injector Service ....................................... 14 - 15

Injection Pump ................................................ 15

Cooling System - General ............................... 15

Checking Coolant Level.................................. 15

Cooling System Flushing ................................ 15

Clean Radiator................................................. 15

Generator Ends ................................................ 16

D.C. Electrical System - General .................... 16

Booster Batteries ............................................. 16

Battery Care..................................................... 16

Winterizing / Out-of-Service........................... 16

TROUBLESHOOTING

Electrical.......................................................... 17

Engine...................................................... 18 - 20

WIRING DIAGRAMS

AC Electrical ................................................... 21

DC Electrical ................................................... 22

SERVICING

Lubrication - General ...................................... 11

Checking Oil ................................................... 11

Oil Changes .....................................................11

Changing Oil Filter.......................................... 11

Air Filter .......................................................... 11

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 ONL382 08/05

Proprietary Information

ONL382 08/05

3

Introduction

The servicing of generator sets presents unique
problems. In many cases, the generator sets cannot
be moved to a repair facility. Failures often occur
in remote areas far from competent assistance;
therefore, maintenance schedules must be adhered

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.
to more strictly. Failures begin with minor problems
that are overlooked and become amplified when not
corrected during routine maintenance.

Unit Identification

MODELS INCLUDED

This manual covers the operating instructions for:

NL382W industrial generator sets.

Model Numbers

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

NL

382

NL - Northern Lights industrial generator set

NL382W

Northern Lights industrial generator

=

set with a 382 engine and a
PX-310K2 generator end.

Serial Numbers

Model number of engine block

+

Your set has three serial numbers: ➀ an engine number stamped
on a plate attached to the valve cover, ➁ a generator end serial
number, and ➂ a generator set serial number.

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

Cylinders Bore

382 mm

Figure 1: Generator set serial number plate.

ONL382 08/05

4

Warranty

A warranty registration certificate 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:

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

pressure before removing. Add coolant only
when the engine is stopped and cool.

• Mount a fire 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 fluids 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.

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

• Use caution in handling fuel. Never refuel a hot
or running engine. Do not smoke while filling
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, qualified 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.

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

Proposition 65 Warning:

Diesel engine exhaust and some of its constituents

are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

• Provide first aid kits.

CALIFORNIA

ONL382 08/05

5

Industrial Generator Component Locations

2

1

3

4

5

6

7

13

Figure 2A & B: NL382W

12

16

13

11

10

9

14

8

6

15

1. Generator Junction Box

2. DC Circuit Breaker

3. AVR Fuse

4. Secondary Fuel Filter

5. Air Cleaner

6. Muffler

7. Fuel Injection Pump

8. Lube Oil Fill

9. Lube Oil Filter

10. Fuel Return Manifold

11. Lube Oil Dipstick

12. Primary Fuel Filter

13. Centerbonded Mounts

ONL382 08/05

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14. Alternator

15. Muffler Outlet with

Rain Cap

16. Starter

Control Panels

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.

Figure 3-A: Series 1-B Generator Control Panel

Figure 3-B: Series 3 Generator Control Panel

2. ENGINE CONTROL SWITCH

To start the engine, hold this switch in the START
position until the engine is running.

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.

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.

ONL382 08/05

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Control Panels

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.

Figure 4: Series 7.1 through Series 7.6 Generator

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

When the switch is placed in the AUTO START
position, 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.

3. HOUR METER

Keeps track of engine running time.

10. FREQUENCY METER (HERTZ)

The frequency meter indicates alternator current
frequency: 60 Hz (1200 or 1800 RPM), or 50 Hz (1500
RPM).

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 (

Item 9).

4. ENGINE TEMPERATURE GAUGE

Registers the temperature of the coolant.

ONL382 08/05

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