Northern Lights NL498K2 Operator's Manual

OPERATOR’S

MANUAL

Publication #ONL498-2 for Models:

NL498K2 and NL498D2

— 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: (206) 789-3880 Fax: (206) 782-5455

Printed in U.S.A. PART NO.: ONL498-2 03/06

OPERATOR'S MANUAL

for Models

NL498K2 and NL498D2

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

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

Retightening Cylinder Head Bolts .................. 13

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

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 - 22

DC Electrical ........................................... 23 - 24

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.

Proprietary Information

ONL498-2 03/06

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:

NL498K2 and NL498D2 industrial generator sets.

Model Numbers

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

498

K2 & D2

NL - Northern Lights industrial generator set

NL498K2

Northern Lights industrial generator

set with a 498 engine and a PX-332K generator end, Tier II.

Serial Numbers

Northern Lights

4420- 14th Ave. NW Seattle, WA 98107

Figure 1: Generator set serial number plate.

Model number of engine block

Cylinders Bore

498 mm

NL498D2

Northern Lights industrial generator set with

a 498 engine and a UCI224C16 generator end, Tier II, 4 valve.

K2 - Taiyo Generator End D2 - Stamford Generator End

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.

ONL498-2 03/06

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

ONL498-2 03/06

Industrial Generator Component Locations

10 12

Figure 2A & B: NL498D2

1. Control Panel

2. Generator Junction Box

3. DC Circuit Breaker

4. AVR Fuse

5. Air Cleaner

6. Exhaust Elbow

7. Muffler

8. Secondary Fuel Filter

9. Rocker Arm Cover

10. Fuel Injection Pump

11. Lube Oil Fill

12. Radiator Shroud

13. Lube Oil Filter

14. Fuel Return Manifold

15. Lube Oil Dipstick

16. Primary Fuel Filter

17. Alternator

18. Exhaust Manifold

19. Oil Pan

20. Flywheel Housing

21. Starter

ONL498-2 03/06

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.

ONL498-2 03/06

Control Panels

Figure 4: Series 7.1 through Series 7.6 Generator

1. SHUTDOWN BYPASS SWITCH

Manual Start Panels (S-7.1 and S-7.3)

NOTE: Three position Engine Control switches must be in the RUN position during preheating. Preheat switch must be held in ON position during starting.

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.

4. ENGINE TEMPERATURE GAUGE

Registers the temperature of the coolant.

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.

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).

ONL498-2 03/06

Operating Procedures

BREAK-IN PERIOD

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

2. Constantly check the engine temperature and oil pressure gauges.

3. Oil consumption is greater during break-in as piston rings take time to seat.

4. Break-In Oil Changes: Change engine oil and filter at 50 hours. Change oil and filter again at 100 hours (consult Lubricants section for oil recommendation), then every 250 hours.

5. Retighten head bolts at 50 hours.

Operating Instructions:

Maintain at least a 75% load on your generator set for the first 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 water level by removing the pressure cap from the radiator. In order to give the cooling water an opportunity to expand, the level should be about 1 in. (2.5 cm) below the filler cap sealing surface when the engine is cold.

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

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

OPERATING

1. Units with Series 3 and Series 7 Control Panels: check gauges often. Oil pressure must be above 15 PSI. The D.C. voltmeter should read between 11 and 15 volts at 80°F (25°C) ambient temperature. The water temperature gauge must be below 200°F (94°C). Check the A.C. voltage and frequency meters (Series 7 panel). If the gauges deviate from normal levels, shut down the generator set and investigate.

2. Let the unit run unloaded for a three to five minute warm-up period.

3. Add electrical load.

STOPPING

2. Check the oil level in the crankcase with the dipstick. The oil level must be between high and low marks 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 on the tank and at the secondary fuel filter.

4. Turn on any optional battery switch that may have been installed.

ONL498-2 03/06

1. Remove electrical load from the generator set.

2. Run the engine for a three to five minute cool-down period.

3. Move the Engine Control switch to the STOP position until the engine stops completely.

4. Shut off fuel valve at the tank.

+ 18 hidden pages

Northern Lights NL498K2 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual