Northern Lights Lugger OM773LW2, OM773LW3, Lugger M773LW2, Lugger M773LW Owner'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 ©2009 Northern Lights, Inc.
All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Northern Lights, Inc.

Printed in U.S.A.
PART NO.: OM773LW2 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

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

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

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

© Northern Lights, Inc. All rights reserved. Litho U.S.A. Publication number OM773W2 10/09

Proprietary Information

This publication is the property of Northern Lights, Inc.

OM773LW2 10/09

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 over­looked and become amplifi 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 Identifi 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

L, W, W2

L - Long stroke

+

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

Figure 1.

Figure 1: Generator set serial number plate.

OM773LW2 10/09

4

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

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 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.

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 fi lling
fuel tank or servicing fuel system. Clean up
spilled fuel or oil to prevent potential fi 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 knowledge­able, qualifi ed personnel.

• 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.

• 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 fi rst aid kits.

OM773LW2 10/09

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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 10/09

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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 10/09

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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 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.

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

OM773LW2 10/09

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Shows the generator load on each phase. The phase is
selected with the Ammeter Selector switch (Item 9).

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: Series 7.0 through Series 7.6 Generator
Control Panels.

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.

Figure 7-B: Status Indicators for Series 7.0 through
Series 7.6 Generator Control Panels.

10. FREQUENCY METER (HERTZ)

The frequency meter indicates alternator current fre-

quency: 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.

OM773LW2 10/09

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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 gauges (sets with Series 3 or 4 panels).

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
100 hours, then at every 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 water level by removing the pressure

cap from the expansion tank. 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.

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 10 seconds

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

attempt, be sure that it has stopped completely for at
least 30 seconds before re-engaging.

6.

NOTE: Excessive cranking of the starter on Marine

sets equipped with a water lift muffl er can cause
engine damage. If the engine does not start after
three 10-second cranks, remove the impeller from the
raw water pump. This will prevent the muffl er from
fi lling with water and backfi lling the exhaust line and
engine. Once the engine starts, shut it off

immediately and re-install the impeller. Re-start the

engine and check the exhaust overboard outlet for
gushes of water.

OPERATING

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 between
maximum and minimum level 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.

4. Close the sea-cock, check and clean the sea strainer
and reopen the sea-cock.

5. Place the battery switch in the ON position.

6. 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.

1. Units with Series 3 and Series 4 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
coolant temperature gauge must be between167°F
and 194°F (75°C to 90°C). Check the A.C. voltage
and frequency meters (Series 4 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 fi ve minute
warm-up period.

3. Add electrical load.

STOPPING

1. Remove electrical load from the generator set.

2. Move the Engine Control switch to the STOP

position momentarily.

3. Shut off the seacock, fuel valve, and battery switch.

OM773LW2 10/09

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