Northern Lights NL773LW3 Operator's Manual

ONL773LW3

For Model: NL773LW3

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

As of January 2008, U.S. EPA regulations require the

application of a permanently applied label near the fuel tank

ll port for diesel driven equipment. This label is to state:

LOW OR ULTRA LOW SULFUR FUEL ONLY
Northern Lights is providing this label for application to the
fuel inlet of the fuel supply tank for each engine or generator
set. This is to be applied by the installer of the engine or gen
set, or by the manufacturer of the equipment that the engine
or gen set is installed in. The location of the label must be

in clear site of personnel that rell the supply tank.

Note: Starting in 2011, the label will state:
ULTRA LOW SULFUR ONLY.

— 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 ©2007 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.: ONL773LW3 08/07

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 Model

NL773LW3

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 CHARTS ...........10 - 11

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

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 ONL773LW3 08/07

ONL773LW3 08/07

3

Introduction

Servicing of industrial engines and generator sets
presents unique problems. Marine engines cannot
be compared to the servicing of automobiles, trucks
or even farm equipment. Failures often occur in
remote areas far from competent assistance.
Industrial engines are often taxed far more severely
than auto or truck engines; therefore, maintenance
schedules must be adhered to more strictly.
Failures begin with minor problems that are

Unit Identication

MODELS INCLUDED

This manual covers the operating instructions for:

NL773LW3 industrial generator set.

Model Numbers

overlooked and become amplied when not

corrected during routine maintenance.

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.

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

NL

NL - Northern Lights industrial generator set

NL773LW3

Northern Lights industrial generator set with a

=

773 engine and PX-309K2 generator end, Tier III.

Model number of engine block

+

Bore Cylinders
77 mm 3

773

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

W

Designates new

+

an engine number stamped

winding within

generator set

Figure 1: Generator set serial number plate.

ONL773LW3 08/07

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

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
pressure 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.

• 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.

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 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, quali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.

•

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

• Provide rst aid kits.

ONL773LW3 08/07

5

Industrial Generator Component Locations

2

3 4

5

1

6

7

8

9

10

12

11

13

Figures 2-A and B: NL773LW3

1. Junction Box

2. Air Filter

3. Crankcase Vent

4. Lube Oil Fill

5. Coolant Fill

6. Injection Pump

17

16

7. Fuel Lift Pump

8. Dipstick

9. Fuel Inlet and Return

10. Oil Filter

11. Block Water Drain

12. Secondary Fuel Filter

ONL773LW3 08/07

14

15

13. Hourmeter

14. Control Panel

15. Starter

16. Alternator

17. Radiator Shroud

6

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.

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 has a light that glows when

the set is running.

3. HOUR METER

Keeps track of engine running time.

ONL773LW3 08/07

7

Operating Procedures

BREAK-IN PERIOD

1. The 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

lter at 50 hours. Change oil and 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 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 water 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 ller

cap sealing surface when the engine is cold.

CAUTION: Use protective clothing and open the

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 waf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 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 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.

ONL773LW3 08/07

8