OPERATOR`S MANUAL
Contents
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4. OPERATOR S MANUAL A 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 206 789 3880 Fax 206 782 5455 Copyright 2013 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 OM843NW3 11 13 NORTHERN LIGHTS OPERATOR S MANUAL for Model 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 SERVICING continued Models 2 u uu u uuu EANES 17 Model Numbers 2 Valve C C010 ES 17 Serial Numbers 2 Fuels General 18 Facel TINON u E 18 WARRANTY eesis 3 Bleeding the 19 De VIO 20 21 SAFETY RULES 3 7 jection PUn 21 Cooling System General 21 LOCK OUT TAG OUT PROCEDURES 8 Coolin
5. When No 1 cylinder is at Top Dead Center C C C in the compression stroke With the crankshaft turned 360 in normal direction from above Valve Arrangement Valve Adjustment Screw Rocker Arm 0 008 in i 0 200 mm j Figure 7 Valve Adjustment SP6 VALVE CLEARANCES 1 Adjust valve clearance after 1000 hours or as needed 2 Valve adjustments should be done after the cylinder head bolts have been re tightened Engine should be cold and NOT running 3 Watch the valves while turning the engine over by hand Turn until the inlet valve starts to open and the exhaust valve starts to close the valves are rocking Then turn the crankshaft one more full turn and adjust the clearance on both valves for this cylinder Align the top mark of the crank pulley with the top mark of the timing gear case 4 Loosen the lock nut and adjust the clearance between the rocker arm and valve guide of both the intake and exhaust valves with the adjustment screw Figure 7 Clearance on both intake and exhaust valves should be 0 008 in 0 2 mm 5 Repeat steps 3 and 4 for each cylinder Each set of valves must be adjusted individually 6 Replace the rocker arm cover Tighten cover nuts to 5 8 ft Ibs 0 8 2 3 kg m OM843NW3 11 13 17 Servicing FUELS GENERAL SP7 9 FUEL FILTERS 1 Use only clean high
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7. M Northern Lights marine generator set Model number of engine block w winding Bore Cylinders 84 mm 3 _ Northern Lights marine diesel generator set with M843NW3 X an 843 engine and a PX 312K2 generator end Tier Ill 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 Serial No Model Use the serial number on the generator set plate when ordering parts pedo Lights or in correspondence The generator set plate is found on the service 4420 14th Ave NW Seattle WA 98107 side of the generator and resembles the drawing at left NORTHERN LIGHTS Generator set serial number plate OM843NW3 11 13 2 Revised 7 10 13 Warranty A warranty registration certificate is supplied with your set The extent of coverage 15 described in the Limited Warranty Statement We recommend that you study the statement carefully NOTE If the warranty 15 to apply the servicing instructions outlined in this manual must be followed If further information 1s needed please contact an authorized dealer or the factory Safety Rules A NOTICE 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 IMPORTANT SAFETY INSTRUCTIONS Electromagnetic equipment including gener
8. The fuel system is self bleeding However any system may need manual bleeding when a A new fuel filter 1s installed b The engine has run out of fuel c The fuel lines injection pump or any other fuel system component has been removed and installed Loosen bleed bolt Figure 9 on top of the filter Pump hand primer B on fuel lift pump until pure fuel no bubbles escapes from bleed bolt Tighten bleed screw A Loosen bleed screw Pump hand primer B until pure fuel no bubbles escapes Then tighten bleed screw If the engine does not start after the above bleeding process loosen a fuel line at the injector while cranking the engine with the starter motor until pure fuel escapes Then tighten the connection Do each line one at a time After the engine has started use a piece of cardboard to look for fuel leaks OM843NW3 11 13 19 Servicing For illustrative purposes only may not be your exact model Figure 13 Remove return line nuts Figure 17 Reinstall injector Torque to proper tightness OM843NW3 11 13 20 revised 11 8 13 Servicing SP11 INJECTOR SERVICE 2 Injectors should be checked every 1000 hours or more often as needed Check should be made by a Northern Lights dealer or local injection repair station Have your dealer check the fuel injection nozzle spray pattern with injection nozzle tester If the starting pressure is
9. Tighten return line retaining bolts to 22 30 ft Ibs d Install delivery lines Leave loose at injectors for bleeding e Crank engine to fill lines Tighten lines at injectors to 11 18 ft Ibs Start engine and check for leaks using a piece of paper or cardboard DO NOT use hand to check for leaks SP12 INJECTION PUMP 1 Since operating conditions may vary considerably it is difficult to give a definite interval for checking the injection pump But as a rule pump settings maximum speed idle speed and exhaust smoke should be checked after every 2500 hours of operation Service of the fuel injection pump should only be done if checks indicate pump malfunction Black smoke can be an indication of pump malfunction Before servicing the pump check other possible causes a Check cleanliness of air filter b Check valve clearances c Clean and check injectors Any repair which involves disassembly of the injection pump must be carried out by specially trained mechanics with the proper tools and test equipment NOTE All warranties on the engine become null and void if the injection pump seals are broken by unauthorized persons COOLING SYSTEM GENERAL NO TE Be sure to close the sea cock before working on the engine cooling system CAUTION The cooling water in the engine reaches extremely high temperatures You must use extreme caution when working on hot engines to avoid burns Allow the
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11. Q3M MOTI3A Z Oif S Al O gu olf ANB els dau oif ool ax og e lt V did ce s 40018 3NION3 _ TON PN T LINDYIO mm BON s EIER olo yovid OL fT i YOLOW 3M3lNVIS navo 1 xXovi8 01 I pue vor OL SSANAYVH 29014 27 H 11919 4 NN 3SOlVH3N39 OM843NW3 11 13 35 Added 3 13 12 Wiring Diagrams 53 c61v v HL S Arc 9 JoJiuo AANET SIN 6L7 Y WO Y Y a Ti o 3 OLGISI AALAWANOW AN Y NMOGINHS 4 lvanaAud D AA ANA S 10 wd LN 2 ANTON OM843NW3 11 13 36 Added 3 13 12 iagrams D iring W gr6sz y OC S Apg 19 10900 AANETSIN weibeig O99 20 M r 9 9019 SSAINYVH 3415 I3NVd MZ G SWHO OZZ 6 SWHO OZv 38 OL 33V 540151535 Z C3LON SV 1d3O0X3 Q3QNVMIS 2 601 OVAOOS9 MIW 3dAL 9MV 38 OL SYOLONGNOOD NOILVTIVLSNI TIV O lt N3339 Do ovia xov1i8 aay a1dund yowla anig VY sidan watai 3j9nvo uov18 O 3nd ga dWal ama S v Pp 6 ovia MOVIE aay NN didind lt 4ov38 ov18 3ma dq
12. Securely support any machinery elements that must be raised for service work with support or lifting machinery specifically intended for that purpose Keep all parts in good conditions and properly installed Fix damage immediately Replace any worn or broken parts Remove any build up of grease oil or debris Disconnect battery ground cable before making any adjustments or service work Stay Clear of Rotating Drivelines Entanglement in rotating drivelines can cause serious injury or death Keep shields in place at all times Make sure that rotating shields turn freely in pace with the drivelines Do not wear loose fitting equipment around rotating drivelines Stop the engine and make sure that all moving parts have stopped before making any adjustments connections or performing any other type of service to the engine or other driven equipment Oy lt OM843NW3 11 13 Revised 3 13 12 Safety Rules Continued Install all Safety Guards 1 WARNING ole Direct contact with rotating fans belts pulley and drives can cause serious injury Keep all guards in place at all times during engine operation Wear close fitting clothes Stop the engine and be sure all fans belts pulleys and drives are stopped before making adjustments connections or cleaning near fans and their components Do not allow anything on your person to dangle into or come in contact with a moving fan belt pulley or
13. drive Fans can act as vacuums and pull materials up from below so avoid that area as well while in service Safe Battery Handling Prevent Battery Explosions Battery gas is highly flammable Battery explosions can cause severe injury or death To help prevent battery explosions keep sparks lighted matches and open flame away from the top of battery When checking battery electrolyte level use a flashlight Never check battery charge by contacting the posts with a metal object Use a volt meter or hydrometer Frozen batteries may explode if charged Never charge a battery that has not been allowed to warm to at least 169 C 60 F Always remove grounded battery clamp first and replace ground clamp last Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin eat holes into clothing and other materials and cause blindness if splashed into eyes To Avoid Hazards Fill batteries only in well ventilated areas Wear appropriate eye protection and rubber gloves Never use air pressure to clean batteries Wear appropriate ventilation equipment to avoid inhaling fumes when adding electrolyte Do not spill or drip electrolyte Use correct jump start procedure if required If acid is spilled on skin or in eyes 1 Flush skin with water 2 Apply baking soda or lime to help neutralize acid 3 Flush eyes with water for 15 30 minutes 4 Get medical attention immediat
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15. oil level must be in the waffled 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 4 Close the sea cock check clean and reassemble the sea strainer and re open the sea cock 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 water temperature gauge on Marine sets must be below 200 F 94 C Normal coolant temperature 15 167 to 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 5 Place the battery switch in the ON position 2 Let the unit run unloaded for a three to five minute 6 NOTE The battery switch must always be kept warm up period ON while the engine is running If the switch is 3 Apply electrical load turned OFF while the engine is running the battery charging regulator could be ruined STOPPING 1 Remove electrical load from the generator set 2 Run the engine for a 3 to 5 minute cool down period 3 Hold the Engine Control switch to the STOP position until the engine comes to a complete stop 4 Shut off the seacock fuel valve and battery switch OM843NW3 11 13 13 updated page 8 27 09 Operating Pro
16. opening drain cocks CAUTION Battery gas can explode b Drain water supply lines and wet exhaust line Keep all flames and sparks away from batteries c Loosen the seawater pump cover and drain pump d Change the crankcase oil and filter 1 Before changing or using booster batteries check bat e Loosen the alternator belt tery electrolyte level Add distilled water 1f necessary f Disconnect and clean battery Remove to warm 2 Booster and main batteries must have the same storage place if possible voltage rating g Clean outside of unit Paint any scratched or 3 First connect positive terminal of booster bat chipped surfaces Put corrosion preventative on tery to positive terminal of main battery Then all exposed metal surfaces connect negative terminal of booster battery to ground on the engine block see Figure 19 4 Remove booster battery after starting engine 5 Sealed batteries See manufacturer charging and booster instructions OM843NW3 11 13 23 Troubleshooting DC ELECTRICAL SYSTEM PROBLEM POSSIBLE CAUSE RECOMMENDATION S Battery Will Not Charge Loose or corroded connections Clean and tighten battery connections Sulfated or worn out batteries Check specific gravity of each battery Check electrolyte level of each battery Loose or defective alternator belt Adjust belt tension Replace belt Starter Inoperative Check DC circuit breaker If the breaker is tripped reset
17. or in part without the written permission of Northern Lights Inc O Northern Lights Inc All rights reserved Litho U S A Publication number OM843NW3 11 13 OM843NW3 11 13 1 Revised 12 19 2011 Introduction Servicing of marine engines and generator sets presents Failures can begin with minor problems that are unique problems In many cases boats cannot be moved overlooked and become amplified when not corrected to a repair facility Marine engines cannot be compared during routine maintenance to the servicing of automobiles trucks or even farm equipment Failures often occur in remote areas far As operator it is your obligation to learn about your from competent assistance Marine engines are taxed equipment and its proper maintenance This 1s not a far more severely than auto or truck engines therefore comprehensive technical service manual Nor will it maintenance schedules must be adhered to more make the reader into an expert mechanic Its aim is to aid strictly you in maintaining your unit properly Unit Identification MODELS INCLUDED This manual covers the operating instructions for M843NW3 marine generator set My Northern Lights generator set MODEL number is Fill in the model number of your unit in the blank space provided This will give you a reference whenever service or maintenance 15 required Model Numbers Model numbers give the unit s application block model aspiration and RPM M 843 W and 3
18. quality fuels of the following specifications as defined by ASTM designation D975 for diesel fuels a Use grade no 2 diesel at ambient temperatures above freezing 32 F 0 C b Use grade no 1 at ambient temperatures below Primary Fuel Filter freezing and for all temperatures at an altitude Part Numbers of above 5 500 ft 1500 meters 2 Use fuel having less that 1 sulphur preferably less that 0 5 3 The cetane number should be a minimum of 45 4 DO NOT use these unsuitable grades of fuel Complete Unit 24 50002 Element 24 50012 a Domestic heating oils all types Class B engine Class D domestic fuels Class E F G or H industrial or marine fuels ASTM D975 60T No 4 D and higher number fuels f Diesel fuel with engine oil mixed in o co Figure 8 Primary Fuel Filter 1 Your generator set should have a primary fuel filter installed We recommend the Racor brand of fuel filter water separators Do not use any fuel additive other than an a Check the primary fuel filter daily as authorized diesel fuel biocide if fungus or bacteria recommended by the filter manufacturer cause fuel system problems Empty the collection bowl as necessary Storing fuel b Change the element as often as necessary or a Keep dirt scale water and other foreign every 500 hours matter out of fuel c If the bowl fills with water change the primary b Avoid storing fuel for long periods of time
19. repair Many serious accidents happen when someone thought the machine was turned off or all of its energy was safely blocked or released x 44 CAUTION x To avoid dangerous or hazardous situations refrain from any of the following e Removing or bypassing a guard or other safety device Placing any part of your body in a position where you could be caught by moving machinery Cleaning or oiling machinery when in operation Adjusting circuits chillers pumps air handlers valves circuit breakers or fans while in operation Working on piping or high pressure systems Lock Out Tag Out Instructions Electrical Equipment Be sure the equipment s ON OFF switch is in the OFF position and is unplugged from any electrical source before attempting to perform any type of work on the equipment Obtain an electrical plug cap cover with a lockset Secure the plug terminal end using the electrical plug lockout cap Lock the cap and retain the key If the equipment is directly wired into an electrical box with a shut off switch obtain a lock pad and or the appropriate colored tags and place the lock and tag through the shut off lever Retain the key until the repair is completed and the machine is safe to start Be certain the shut off lever is in the OFF position before restarting NEVER give a lock out key to unauthorized personnel If the equipment is directly wired into an electrical box without a shut off switch and lock out ca
20. too high or the spray pattern is off abnormal fuel combustion could take place causing low engine output and black exhaust smoke CAUTION Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury If injured by escaping diesel fuel see a doctor at once Injector removal a Clean loose dirt from around the injectors and the fuel lines b Relieve high pressure in the fuel lines by loosening the delivery line flare nuts at each injector Figure 10 c Remove delivery lines by disconnecting from injectors and injection pump Figure 11 Remove all lines as an assembly do not remove the spacers Cover the ends of the lines the injector inlets and injection pump outlets to keep dirt out Figure 12 d Remove the return line retaining bolts Figure 13 Remove the return line Figure 14 e Unscrew and remove the injectors Figure 15 NOTE Do not use pry bars to remove injectors from cylinder head f After removing the injectors discard the copper sealing washers from the injector hole in the head Figure 16 Cover holes to prevent dirt and debris from entering the cylinders Injector installation a Install a new copper sealing washer in each injector hole Figure 16 b Screw in injector and tighten to 44 51 ft Ibs 6 to 7 kgm Figure 17 NOTE Overtightening can damage injector c Install return line using a new sealing washer below each connection
21. 3u 3ma8 VY 31dund Isd 08 0 sus 3 xXovi8 A 1 911 39nvo E lt a e A349 O O HOMIMS SSvdA8 NMOGINHS O 4015 AOV IB O LYVLS HOLIMS 3NION3 QE Q34 MOT13A V lt SSANYVH 19 3NVd 3NVd IOYULNOO OM843NW3 11 13 37 Notes OM843NW3 11 13 38 4420 14th Ave NW Seattle WA 98107 Tel 206 789 3880 1 800 762 0165 www northern lights com Northern Lights and Lugger are registered trademarks of Northern Lights Inc NORTHERN LIGHTS 2013 All rights reserved Litho USA
22. Change the lube oil filter every 200 hours Use a filter wrench to remove old filter Dispose of filter in approved manner Make sure the gasket from the old filter is removed and discarded Clean mount face Spread a thin film of engine oil on the rubber gasket on the new filter and screw it on nipple until gasket meets the sealing surface Using hands only no wrench tighten filter one half turn farther Overtightening can do damage to filter housing Fill engine with recommended oil Start engine and check for leakage Stop engine wait 3 minutes and check oil level Add additional oil if necessary Oil filter part number is 843NW3 24 03100 OM843NW3 11 13 16 Servicing SP4 AIR CLEANER 1 Inspect air cleaner every 250 hours In dusty conditions check more often 2 Marine sets if dirty wash element in soapy water Rinse and dry thoroughly before re installing Replace if necessary Part number for the element is M843NW3 24 22009 3 NOTE Make absolutely sure no impurities enter the engine while changing the element Do NOT run the engine with the air cleaner removed SP5 V BELTS 1 Check the tension and wear on the V belt daily 2 Use your thumb to press on the belt at the midpoint between the crankshaft and alternator pulleys The tension is correct if the belt can be depressed about 3 16 in 5 mm Cylinder No 1 2 3 Valve Arrangement nt Exh Int Exh Int Exh
23. FIOILYVY HLIM 3ONVQM0OOOV NI IN3S3Nd SI 1VMIQ3N N3HM 39NV3MO Q3MNVA 38 OL 931 H9IH JNO OL Qv31 vl 9Mv AAY V ONISN M Wall 9018 LAdLNO NIVW OL WNINYSL 193NNOO 3110s WOMJ QV31 LOSNNOOSIG WH3l OL QV31 L03NNOO 80 HOnOMHI v WN3l OL GV31 193NNOO MAV WONJ SQV31 193NNOOSIQ SMOTIOJ SV 38 OL SHL SAYINDAY NOILVYENSISNOO vr13d 318n0G0 AHL 6 SONILVY MM 39VITOA I3SN39 YSHLO LY ONIZIS YOLONGNOD 304 ONIM33NION3 TN LINSNOD SOVLIOA 31511 1S3MO1 3HL LV SLINA MAOL 03215 SYOLONGNOOD WHYLNAN 8 NOLVTIVISNI Y3d GSNINYSLAG 38 OL ONIZIS SYOLONGNOD INdLNO Q3193NNOO YANOLSNOD 31VOIQNI SININ lt N3QQIH MOIHL 4 S3002 W901 3d18vOllddv 3000 WOIlNLOSTS IVNOILYN SHL HLIM 3ONVO8OOOV NI Q3 NRO9 38 OL 38V SLIJSN39 lVIMISQQNI NOILAYOSIC S YSWOLSNOD LV YSWOLSND AG GSGNNOYS 3NV 5135335 3NIMVW 9 LON SI 39VI1OA N3MO1 JI 1IN3S3Nd JI N3dW f ONY YOLONGNOD WHYLNAN 313130 G SQv3l OLNI ANY sS3dWnf 109 IVLISOSHY LSANFAV JOVLIOA 310W38 YO4 v 351 SI LVLSOSHY 1Sff V 39VLIOA 31034 3 Ydd EMS LAS ZH 09 YO OS NOllvOllddV INSYYND ZMS 13S OvA009 Q3QNVMIS 5 601 MLW 3dAL 38 OL 3HY SYOLONGNOD Q3TIVISNI NN TIV L SALON a S ALON 335 ZH OS l O Z SI1 002 001 ZH 09 l Ovz OZzL 002 001 9VZ 912 cl
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25. UEL INJECTION SYSTEMS 1 WARNING Avoid Hot Exhaust Lifting heavy components incorrectly can cause severe injury or damage to machinery Avoid unbalanced NGI loads Do not use lifting eyes Lift the MB Avoid exposure to and physical ie generator set using lifting bars inserted contact with hot exhaust through the lifting holes on the skid gases Exhaust parts and streams can reach high Follow all recommended removal and installation temperatures during operation leading to burns or procedures in this and associated Northern Lights other serious injury manuals Cleaning exhaust filters can also lead to exposure to hot exhaust gas and the injury risk associated with Use Proper Tools it Avoid exposure to and physical contact with hot exhaust gases when cleaning exhaust filters A C AUTION During auto or manual stationary exhaust filter Makeshift tools and procedures cleaning operations the engine will run at can create safety hazards elevated temperatures for an extended period of Always use appropriate tools for time Exhaust parts and streams can reach high the job temperatures during operation leading to burns or other serious injury Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware always use the correct sized tools Avoid Harmful Asbestos Dust Do not use US measurement tools on metric fasteners or vice versa Use only service parts that meet Norther
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27. W SAE 5 20W Figure 4 Lube Oils 4 Some increase in oil consumption may be expected when SAE 5W and SAE 5 20W oils are used Check oil level frequently 5 Never put additives or flushing oil in crankcase 4 Maximum Level 4 Minimum L evel Figure 5 Figure 6 SP1 CHECKING OIL LEVEL Check the oil level in the crankcase with the dipstick Fig 5 The oil level must be in the waffled area on the stick Never allow the level to go below this area Follow the lubrication recommendations above SP2 OIL CHANGES The set is delivered with special break in oil Change the engine oil and oil filter after 50 hours of operation Use Service CC 30 weight oil during the first 100 hours Change the oil and filter again at 100 hours using the oil recommended in the above diagram After this change oil and filter every 200 hours During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes first Change oil at the end of each season and the beginning of each season Change oil when engine is warm Dispose of waste oil in an approved manner Never use a flushing oil Loosen the clamp on the oil change tube Remove cap Drain oil Replace the cap and tube Refill engine with recommended oil for the season 10 Engine capacity with new oil filter 1s 843NW3 5 8 quarts 5 5 liters SP3 CHANGING LUBE OIL FILTER
28. and fire extinguisher handy Keep emergency contact numbers for fire department doctors ambulance and hospital near the telephone Service Machines Safely Do not wear a necktie scarf necklace rings or other jewelry or any loose clothing when working near moving parts Tie long hair behind your head If any of these items get caught in moving machinery severe injury or death could result ec Check for any loose electrical connections or faulty wiring Look completely around engine to make sure that everything 1s clear before starting Wear Protective Clothing To prevent catching anything in moving machinery always wear close fitting clothes and safety equipment appropriate to the job Prolonged exposure to loud noise can cause hearing loss or impairment Wear suitable authorized G hearing protection such as earmuffs or plugs to s GO protect against loud noises d 4 Operating equipment requires full attention of the operator Do not use radio or music headphones while operating machinery Practice Safe Maintenance Understand all service procedures before starting work Keep area clean and dry Never lubricate service or adjust machine while it 1s in operation Keep hands feet and clothing away from power driven equipment When shutting down an engine disengage all power and operator controls Allow the engine to cool completely before beginning any service work
29. ator sets and their accessories can cause bodily harm and life threatening injuries when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL PRIOR TO THE INSTALLATION OF ANY GENERATOR SET OR ACCESSORY KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE Recognize Safety Symbols and Instructions In addition to the information found in this section this operator s manual uses three different signal words to outline potential dangers of a specific nature D AN G E DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a hazardous situation which A G AUTION if not avoided could result in minor or moderate injury Follow All Safety Instructions Carefully read and understand all safety messages in this manual and on your machine s safety signs Keep signs in good and clean condition Replace missing or damaged signs Be sure new equipment components and repair parts include the current safety signs For replacement signs proper placement of safety signs or clarification on any safety issue consult your Northern Lights dealer or the factory There can be additional safety information contained on parts and components from outside suppliers t
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31. c Fill the fuel tank at the end of each day s operation This will reduce condensation and possible biological contamination d If biological contamination is detected or suspected contact your dealer for assistance and secondary element immediately 2 Change secondary fuel filter every 500 hours NOTE The fuel filter on the engine is considered the secondary fuel filter a b 3 Remove the spin on filter by turning it counterclockwise with a filter wrench Fill the new cartridge with fuel and install it after applying engine oil to gasket surface Screw on until the gasket surface comes into contact with sealing surface of filter base Then tighten it two thirds of a turn by hand Do not overtighten Fuel filter part numbers are 843NW3 11224 52020 OM843NW3 11 13 18 SP10 BLEEDING THE FUEL SYSTEM li Servicing CAUTION Escaping diesel fuel under pressure can penetrate skin causing serious personal injury Before disconnecting lines be sure to relieve all pressure Before applying pressure be sure all connections are tight and lines pipes and hoses are not damaged Fuel escaping from a very small hole can be almost invisible Use a piece of cardboard or wood rather than hands to search for suspected leaks If injured by escaping fuel see a doctor at once Serious infection or reaction can develop if proper medical treatment is not administered immediately Figure 9 843NW Fuel System
32. cedures SHUTDOWNS AND ALARMS 1 Your unit is fitted with a system to protect it from high water temperature or low oil pressure a b Generator sets have shutdown systems to stop the engine They have no warning horns Other alarms and shutdowns are available as optional equipment NOTE Do not rely on your warning to the exclusion of careful gauge monitoring Watching your gauges can prevent damage to the unit and dangerous power losses 2 Dothe following when your warning or shutdown system 15 activated b Engage the preheat switch to check the temperature gauge If above 205 F 96 use the Trouble Shooting Guide on page 20 to isolate the cause of the overheat CAUTION Do not remove the water fill cap of an overheated engine Escaping high temperature steam can cause severe burns Allow the engine to cool and then remove the cap slowly using protective clothing Make repairs Restart your Marine set after the temperature gauge registers below 200 94 Watch the temperature gauge regularly and turn off the unit if the temperature rises above 205 F 96 C on Marine units Repeat troubleshooting 3 Ifshutdown is activated and the temperature gauge shows temperature within normal temperature range a This shutdown could have happened because of a too high exhaust temperature This could have been caused by a damaged impeller or a partially blocked sea water strai
33. condition Check cylinder compression pressure Service air cleaner check proper ventilation Clean or replace filter element Replace filter element Have injection pump checked Consult fuel supplier and use proper type of fuel for operating conditions Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION S Lack of Engine Power continued Overheated engine See Engine Overheats in next category Below normal engine temperature Remove and check thermostat Improper valve clearance Reset valves Best done by dealer Dirty or faulty injection nozzles Replace injectors Best done by dealer See your local dealer Poor cylinder compression pressure Check bore for wear or check alignment of nozzle holder Re adjust valve clearance Engine Overheats Low coolant level Fill tank or radiator to proper level with proper mixture of coolant Check hoses for loose connections and leaks Air cleaner element clogged Clean or replace Keel cooling tubes Remove paint from tubes have been painted marine Cooling system interior dirty Flush cooling system Defective thermostat Remove and check thermostat Defective temperature gauge Check water temperature with thermometer and replace gauge if necessary Water pump impeller worn broken Check impeller and replace if necessary V belts slipping Fix belts to proper tension Engine Knocks Insufficient oil Call your deale
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35. e cranking Release the switch as soon as the engine is running Holding the switch on too long can burn out the heater element 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 muffler systems can cause engine damage See page 7 After the engine starts release the switch and it will return to RUN position To stop the engine hold the 200 COMM TUNE switch in the STOP position until the engine has Did NGS i s completely stopped e NOTE The rocker switch is used on Series 1 panels only and has a light that glows when the set is running voo QUARTZ 3 HOUR METER H Keeps track of engine running time 4 OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system 5 ENGINE TEMPERATURE GAUGE Registers the temperature of the engine coolant Figure 3 B Series 3 Generator Control Panel 6 D C VOLTMETER OR AMMETER p 10 When the engine is stopped the voltmeter indicates the Sra Cosa condition of the battery When the engine is running the 17 207 S voltmeter indicates the voltage output of the alternator _ 100 EE Z 1 300 CYCLES P SECOND For Series 4 Control Panels Only Generator Set 6 7 A C VOLTMETER
36. ely If acid is swallowed 1 DO NOT induce vomiting 2 Drink large amounts of water or milk without exceeding 2 liters 2 quarts 3 Get medical attention immediately Battery posts terminals and related accessories can contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injur Among the potentially hazardous chemicals that may be used with Northern Lights products are lubricants coolants paints and adhesives All potentially hazardous chemicals come with a Material Data Safety Sheet MSDS The MSDS provides specific details on chemical products including physical hazards safety procedures and emergency response techniques OM843NW3 11 13 Revised 3 13 12 Safety Rules Continued Read and understand the MSDS for each chemical before you start any job that includes it Follow the procedures and use appropriate equipment exactly as recommended Contact your Northern Lights dealer or Northern Lights factory for MSDS s used on Northern Lights products Work in Well Ventilated Areas Exhaust fumes from engines contain carbon monoxide and can cause sickness or death Work in well ventilated areas to avoid prolonged exposure to engine fumes If it is necessary to run an engine in an enclosed area route the exhaust fumes o
37. engine to cool before working on the cooling system Open the filler cap carefully using protective clothing when the engine is warm WATER QUALITY l Distilled deionized soft water 1s preferred for use in cooling systems Bottled distilled water from a food store or water supplier is recommended Tap water often has a high mineral content Tap water should NEVER be put in a cooling system unless first tested by a water quality laboratory Do not use water made by the reverse osmosis method unless it has been PH neutralized OM843NW3 11 13 revised 11 8 13 Servicing 2 Here are acceptable water quality specifications Grains per Gallon Parts Contaminates per Million Maximum Chlorides 40 25 Maximum Sulfates 100 5 9 Maximum Dissolved Solids 340 20 0 Maximum Total Hardness 170 10 0 PH Level 5 5 to 9 0 3 fchlorides sulfates or total dissolved solids are higher than the above given specification the water must be distilled demineralized or deionized before it is used in a cooling system 4 Iftotal hardness is higher than 170 ppm and all other parameters are within the given specifications the water must be softened before it is used to make coolant solution SP13 CHECK THE COOLANT LEVEL 1 Check the coolant level each day before starting the engine Check the water level by removing the pressure cap from the expansion tank In order to give the cooling water an opportunity to expand t
38. g System Flushing 22 Heat Exc hanp Et u 22 COMPONENT LOCATIONS Raw Water 22 M843NW3 Marine Generator 10 11 Generator BEnds sense u 22 Electrical System General 22 CONTROL PANELS 12 CHOW PU G8 tide item aaa 23 Booster sientas eate tendi ien Peta b 23 OPERATING PROCEDURES Battery dfe te HIM UMS 23 Break in 1 13 23 Before Starting esee tenens 13 Winterizing ODICOISSET VICE 23 Si u u u a ee 13 13 TROUBLESHOOTING Stopping tice 55 ite eects 5 13 J i er 24 Shutdowns and Alarms 14 Engine 25 27 we S L TIO 14 WIRING DIAGRAMS SERVICING SCHEDULE CHART 15 AC Electrical 28 29 DC Be CUA a 30 37 SERVICING Lubrication General 16 l Lina O iL 16 Oil Chana uu ee re 16 Chaicine Oil hilla 16 ieu 17 Proprietary Information This publication is the property of Northern Lights Inc It may not be reproduced in whole
39. hat is not reproduced in this manual Consult the suppliers for additional safety information Learn how to operate the machine and how to use the controls properly Only trained personnel should operate machines or work on or around them Keep you machine in proper working condition UNAUTHORIZED MODIFICATIONS TO THE MACHINERY MAY IMPAIR ITS FUNCTION AND SAFETY PARAMETERS Prevent Bypass and Accidental Starting Do not start engine by shorting NZ across start terminal Engine will start if normal circuitry 1s bypassed creating a hazard by runaway machinery Start engine only from operator s station Handle Fuel Safely Avoid Flames Diesel is highly flammable and should be treated with care at all times Do not refuel while smoking or when near sparks or open flame Sa NS ALWAYS STOP ENGINE BEFORE FUELING MACHINE Always fill portable fuel tank outdoors Never fuel a hot engine OM843NW3 11 13 3 Revised 3 13 12 Safety Rules Continued Prevent accidental discharge of starting fluids by storing all cans in a cool safe place away from sparks or open flame Store with cap securely on container Never incinerate or puncture a fuel container Prevent fires by keeping machine clean of accumulated trash grease and debris Always clean any spilled fuel as swiftly as possible Do not store oily rags which can ignite and burn spontaneously Be prepared if a fire starts Keep a first aid kit
40. he level should be about 1 in 2 5 cm below the filler cap sealing surface when the engine is cold 2 The pressure valve in the filler cap releases when the pressure 1s approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it is faulty SP14 COOLING SYSTEM FLUSHING 1 Flush the cooling system every 2500 hours or every 12 months whichever comes first 2 Marine sets a Remove expansion tank cap and drain engine block b Open block drain cock Remove hose from bottom of heat exchanger tank c Pour clean water into expansion tank until water coming from drains is free of discoloration and sediment Let water drain completely Close drains and refill with recommended mixture 3 Coolant Specifications Use 50 distilled water 50 ethylene glycol anti freeze mix Antifreeze mixture is recommended as a good year round coolant 4 Check hoses and connections and repair any leakage SP15 HEAT EXCHANGER 1 Clean the heat exchanger core once a year or after 2500 hours of operation 2 Drain expansion tank and heat exchanger 3 Remove heat exchanger end covers and remove core 4 Clean the inside of exchanger core tubes using a metal rod Flush inspect and clean again if necessary 5 Reassemble Fill the cooling system start the engine and check for leaks SP17 RAW WATER PUMP 1 Change the seawater pump impeller every 1000 hours or as needed 2 Remove the pump end cover Pry ou
41. it Loose or corroded connections Clean and tighten loose battery and harness plug connection Low battery output Check specific gravity of each battery Check electrolyte level of each battery Defective electrical system Repair or replace ground wire Starter Cranks Slowly Low battery output Battery is too small Battery cables are too small Check specific gravity Replace battery if necessary of each battery Check electrolyte level f low fill cells with distilled water of each battery Crankcase oil too heavy Fill with oil of appropriate viscosity Loose or corroded connections Clean and tighten loose connections Entire Electrical System Check DC circuit breaker If breaker is tripped reset it Does Not Function Faulty connection Clean and tighten battery and harness plug connections Sulfated or worn out batteries Check specific gravity and electrolyte level of each battery If you cannot correct problems with these procedures see your Northern Lights dealer OM843NW3 11 13 24 ENGINE PROBLEM Troubleshooting POSSIBLE CAUSE RECOMMENDATION S Engine Hard to Start or Will Not Start Engine Runs Irregularly or Stalls Frequently Lack of Engine Power Improper starting procedure No fuel Low battery output Excessive resistance in starting circuit Crankcase oil too heavy Improper type of fuel Water dirt or air in fuel system Clogged primary fuel filter elemen
42. ize the alternator or regulator T Fi 19 7 A D C circuit breaker protects your control panel eens Battery Booster Battery and wiring harness It is located in the side of the BOC CONNECTORS generator junction box GLOW PLUGS SP 18 19 BATTERY CARE 1 Each cylinder is supplied with glow plug which serves to heat the combustion chamber 1 Check electrolyte level daily Add distilled water to 2 To check the glow plugs loosen the current manufacturer s recommended level carrying flat wire between the plus poles of the 2 Batteries cables and cable terminals should glow plugs Figure 18 Connect a D C test bulb be checked and cleaned every 100 hours between the plus pole of the battery and the Clean corrosion with a water and baking soda plus pole of the glow plug If the bulb lights up solution Flush with clean water Tighten terminals the glow plug is functioning properly and grease them to inhibit corrosion 3 Check all glow plugs and replace any faulty ones 3 Check the battery condition with a hydrometer every 250 hours SP20 P T O 1 The electric clutch P T O does not have any scheduled maintenance points However the equipment the P T O powers may require maintenance Consult the manufacturer of the driven equipment SP21 WINTERIZING OUT OF SERVICE Figure 18 Glow plugs 1 Marine sets a Drain fresh water and seawater cooling systems BOOSTER BATTERIES completely Remember to shut off seacocks before
43. ld behind hoses 20 Fuel Lift Pum 26 Vibration Mount p 7 Crankcase Vent 14 Fuel Inlet amp Return 21 Heat Exchanger End Cap 27 Starter 8 Fuel Injector 15 Oil Dipstick 22 Coolant Fill 28 DC Alternator OM843NW3 11 13 10 Figure 1 and 2 M843NWS3 with New Baseframe SAO E added page 11 24 10 Marine Generator Component Locations GS E un mi 4 gt kal AC Circuit Breaker for AVR 9 Belt Guard DC Circuit Breaker 10 Injection Pump 16 Oil Filter Coolant Recovery Tank 11 Oil Fill 2 Places 18 Generator Set Plate Fuel Filter 12 Seawater Pump U w x NE 19 Control Panel Plug in Air Filter inside manifold 13 Fresh water Block Drain I 20 FuelLift Pump Intake Manifold behind hoses 21 Heat Exchanger End Cap Crankcase Vent 14 Fuel Inlet amp Return i Fuel Inject 15 Oil Dipstick c aside 23 Expansion Tank OM843NW3 11 13 11 24 25 26 28 Wet Exhaust Elbow Junction Box Vibration Mount Starter DC Alternator Control Panels PROXEATA GENERATOR 1 SHUTDOWN BYPASS PREHEAT SWITCH MUTOOWN CONTROL CAUTION Ovenronhing onguns BYPASS START come your manoni Two functions are built into this switch the preheating w of the engine and bypassing of the engine safety shut amp 2 down circuit Hold switch in the ON position 10 20 seconds before starting the engine and continue holding on during engin
44. n Lights specifications Inhaling asbestos fibers may cause lung cancer Avoid breathing any dust that may be generated when handling components containing asbestos fibers including some A CAUTION gaskets Disposing of waste improperly can threaten the Dispose of Waste Properly The asbestos used in these components is usually environment and lead to unsafe working conditions found in a resin or otherwise sealed Normal Potentially harmful waste used in Northern Lights handling of these components is not dangerous equipment can include oil fuel coolant filters and as long as airborne dust containing asbestos is not batteries generated Avoid creating dust Never use compressed air for Use leakproof containers to drain fluid Do not cleaning Avoid brushing or grinding materials use food or beverage containers that may mislead containing asbestos When servicing wear an someone into drinking from them approved respirator A special vacuum cleaner 1s recommended to clean asbestos If this vacuum 15 Do not pour waste onto the ground down a drain or not available apply a mist of oil or water on the into any water source OM843NW3 11 13 T Added 3 13 12 Lock Out Tag Out Procedures During maintenance repairs or retooling of a Northern Lights generator set simply turning the machine off or unplugging it while itis being worked on does not give enough protection to others who are not performing the maintenance or
45. ner Check the sea water strainer first If it 1s clear then check the condition of the sea water pump impeller Check the engine crankcase oil level If the oil level 1s low fill with recommended lubricating oil and restart Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading 20 60 PSI after a few seconds of operation OM843NW3 11 13 14 l d If the oil level 15 normal DO NOT restart the engine Call your dealer for assistance SPARE PARTS Northern Lights recommends that you keep the following spare parts on hand for field service The parts are available from your local Northern Lights dealer Some marine models already have On Board Kits a handy box that contains the most common parts you will need All owners should have the following spares Primary and secondary fuel filter elements Oil filters Air filter Alternator belt Thermostat and gaskets Seawater pump impeller amp gaskets Glow plug Injector and washer If your set is operating a long distance from a servicing dealer add the following a Complete set of injectors b Copper washers for injector change c Complete set of glow plugs d Fuel lift pump Eg Oo C O g updated page 2 25 13 Servicing Schedule Chart The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your generator set More detailed coverage of each Service Poi
46. nsion 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 filler cap sealing surface when the engine is cold 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 1f the engine is already warm While holding the Shutdown Bypass Preheat switch in the ON position push the Engine Control switch to the START position 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 first attempt be sure that it has stopped completely wait at least 30 seconds before re engaging NOTE Excessive cranking of the starter on Marine sets equipped with a water lift muffler can cause engine damage If the engine does not start after three 20 second cranks remove the impeller from the raw water pump This will prevent the muffler from filling with water and backfilling 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 CAUTION Use protective clothing and open the filler OPERATING cap carefully when the engine is warm to prevent burns 1 A 2 Check the oil level in the crankcase with the dipstick The
47. nt SP is listed on the page noted in the page column DAILY SP1 Check oil level in engine SP5 Check V belt tension SP7 Check primary fuel filter SP13 Check coolant level Check sea strainer Check raw water pump for leaks SP18 Check electrolyte in batteries AFTER FIRST 50 HOURS SP2 3 Change engine oil and filter SP6 Adjust valves AFTER FIRST 100 HOURS SP2 3 Change engine oil and filter EVERY 200 HOURS SP2 3 Change engine oil and filter SERVICE 250 500 1000 2400 POINT PAGE OPERATION DAILY Hours Hours Hours Hours ENGINE Check oil level EVERY 250 HOURS SP4 Check air cleaner SP19 Check state of charge of batteries EVERY 500 HOURS SP8 Change primary fuel filter element SP9 Change secondary fuel filter SP22 Inspect condition of exhaust elbow EVERY 1000 HOURS SP6 Check valve clearances SP11 Check injectors SP17 Change impeller in raw water pump EVERY 2500 HOURS SP12 Check fuel injection pump SP14 Check and flush cooling system SP15 Check and clean heat exchanger Change engine oil Change lube oil filters Check air cleaner change element 1000 hrs 1 4 Check V belt tension Check valve clearances FUEL SYSTEM Check primary filter Racor Change primary filter element Racor Change secondary fuel filter Bleed the fuel system Check injectors Check fuel injection pump 15 COOLING SYSTEM 15 Check cooling water level 16 Check and fl
48. overnor spring Low Oil Pressure Low oil level Fill crankcase to proper level Improper type of oil Drain and fill crankcase with correct oil Partially plugged oil filter Replace filter Check bearings oil pump and relief valve for wear High Oil Consumption Break in period Oil consumption decreases after break in Crankcase oil too light Use proper viscosity oil Oil leaks Check for leaks in lines around gaskets and drain plug Engine Emits Black Clogged or dirty air cleaner Service air cleaner or Gray Exhaust Smoke Defective muffler Have dealer check back pressure back pressure too high Improper fuel Use correct fuel for temperature Injection nozzles dirty See your dealer Engine timing off See your dealer Engine Emits Improper fuel Use correct fuel for temperature White Smoke Cold engine Warm up engine to normal operating temperature Defective thermostat Remove and check thermostat Engine timing off See your dealer If you cannot correct problems with these procedures see your Northern Lights dealer OM843NW3 11 13 27 Revised 3 13 12 iagrams D iring W Ovc46 g Buimeiq MV43c 00L LSQ sJ0jeJeueD pee p 9 Z 101 eANETSIN weibeig OV cd dNV Z N39 Wows ZH OG l 6 00 ASVHd JIONIS v 9 SILON 33S lo lt lc le p tc gt CA LA en Ih
49. pability then a circuit breaker lock out will be required Obtain a circuit lock and tag set Install the lock onto the circuit breaker box Ensure the unit ON OFF switch is in the OFF position before restarting Lock Out Tag Out Instructions Pneumatic and Hydraulic Equipment For servicing pneumatic and hydraulic equipment the following additional procedures must be implemented following completion of lock out tag out procedures for the unit to be serviced Shut off air water or supply valves at the equipment to be serviced Check the local bleed off point for completed release of pressurized air water or oil If shutting off of air water or other material cannot be achieved at the local supply valve shut off valves further back in the system and re check the bleed off point until complete shut off is achieved Affix a DO NOT OPERATE tag to each valve handle that requires shut off Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment Lock Out Tag Out Instructions Air Hose Connected Pneumatic Equipment Equipment connected to the compressed air system through an air hose with a detachable fitting must be shutdown and unplugged Excess air must be bled prior to removing the air hose prior to any maintenance or repair activities Affix a DO NOT OPERATE tag to the air hose near the detachable fitting Each DO NOT OPERATE tag must be signed and dated by the authorized
50. r Injection pump out of time Call your dealer Below normal engine temperature Check your thermostats Check water temperature to see if temperature gauge 15 working properly Engine overheating See Engine Overheating section High Fuel Consumption Improper type of fuel Use correct fuel for temperature Clogged or dirty air cleaner Service air cleaner Improper valve clearance See your dealer Injection nozzles dirty See your dealer Injection pump out of time See your dealer Engine not at proper temperature Check your thermostats Check water temperature with thermometer and replace gauge if necessary If you cannot correct problems with these procedures see your Northern Lights dealer OM843NW3 11 13 26 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION S High Fuel Consumption Fuel leakage Improper installation or tightening continued Excessive load on engine Check loads Below Normal Thermostat not working properly Check thermostat Engine Temperature Temperature gauge Check water temperature with thermometer not working properly Engine Malfunctions at High Output Range Fuel supply insufficient Air in fuel system or clogged fuel filter element Fuel injection amount between plungers uneven Check fuel injectors Valve clearance adjusted incorrectly Re adjust valve clearances Valve spring broken Replace valve spring Governor spring broken Replace g
51. t Lift pump malfunction Clogged secondary fuel filter element Dirty or faulty injection nozzles Below normal engine temperature Clogged primary fuel filter element Clogged secondary fuel filter element Water or dirt in the fuel system Dirty or faulty injection nozzles Air in fuel system Control lever adjusted incorrectly Improper type of fuel Uneven compression pressure between cylinders Intake air restriction Clogged primary fuel filter element Clogged secondary fuel filter element Injection pump not getting fuel Improper type of fuel OM843NW3 11 13 25 See starting section of this manual Take special note of Bypass Switch operation Check level of fuel in fuel tank Check electrolyte level and condition Clean and tighten all battery connections Use oil of proper viscosity Consult fuel supplier and use proper type of fuel for operating condition Drain flush fill and bleed system Clean or replace filter element Repair lift pump Replace filter element Have your dealer check injection nozzles Remove and check thermostat Clean or replace filter element Replace secondary filter element Drain flush fill and bleed system Have your dealer check injection nozzles nspect clamps and hoses on suction side of fuel pump for air leak Adjust control lever Consult fuel supplier and use proper type of fuel for operating
52. t the impeller using needle nose pliers or two screwdrivers Be sure you remove all pieces of failed impeller NOTE Place some kind of protection under the screwdrivers in order not to damage the pump housing If the impeller has broken into pieces remove front heat exchanger end cover and inspect for impeller pieces Clean inlet to heat exchanger bundle and reassemble 3 Clean the inside of the housing 4 Press in the new impeller and place the sealing washers in the outer end of the impeller center if this has not already been done 5 Replace the cover using a new gasket NOTE Make sure that there is always an extra impeller and cover gasket in reserve on board GENERATOR ENDS The maintenance and operation recommendations for the generator end are in a separate Owner s Manual If you do not have one of these manuals contact your local Northern Lights dealer ELECTRICAL SYSTEM GENERAL 1 Never switch battery switch off or break the circuit between the alternator and batteries while the engine is running Regulator damage can result 2 Do NOT reverse the polarity of battery cables when OM843NW3 11 13 revised 11 8 13 Servicing installing the battery 3 If welding on the unit disconnect the regulator and battery Isolate the leads 4 Disconnect the battery cables when servicing the D C alternator 5 Never test with a screwdriver etc against any terminal to see if it emits sparks 6 Do not polar
53. technician servicing the equipment Check that the equipment cannot be operated by activating the ON switch Immediately after applying Lock Out or Tag Out devices ensure that all potentially hazardous stored or residual energy is relieved disconnected restrained and otherwise rendered safe x CAUTION x Verify the machinery or equipment is actually isolated and de energized prior to beginning work on a machine or on equipment that has been locked out x 44 CAUTION x Follow the procedures below prior to restoring energy Ensure that all machinery or equipment is properly reassembled Inspect the machinery or equipment to verify non essential items have been removed Ensure that all personnel are safely outside danger zones Notify personnel that lock out tag out devices have been removed and energy will be reapplied Only authorized personnel may remove lock out tag out devices or notices OM843NW3 11 13 8 Notes OM843NW3 11 13 9 Marine Generator Component Locations B H 4 Figure and 2 843 1 AC Circuit Breaker for AVR 9 Belt Guard 2 DC Circuit Breaker 10 Injection Pump 16 Oil Filter 3 Coolant Recovery Tank 11 Oil Fill 2 Places 17 Oil Drain 23 Expansion Tank 4 Fuel Filter 12 Seawater Pump 18 Generator Set Plate 24 Wet Exhaust Elbow 5 Air Filter inside manifold 13 Fresh water Block Drain 19 Control Panel Plug in 25 Junction Box 6 Intake Manifo
54. ush cooling system 16 Check and clean heat exchanger 16 Change impeller in raw water pump Inspect condition of exhaust elbow ELECTRICAL SYSTEM SP18 17 Check electrolyte level in batteries SP19 17 Check condition of batteries with hydrometer DRIVEN EQUIPMENT SP20 17 Clutch and PTO service 2 OUT OF SERVICE SP21 17 Winterizing or out of service Perform all maintenance once a year even if hour level has not been reached Consult manufacturer s maintenance schedule note on chart More often if necessary 1 2 3 Whenever necessary 4 5 After first 50 hours then at 100 hours then every 200 hours 6 Clean injection nozzles every 1500 hours 7 For EPA emission standards fuel nozzle needs to be cleaned every 1500 hours the fuel nozzle and fuel pump need to be cleaned adjusted or repaired every 3000 hours and the quality guarantee for these parts is 1500 hours or 2 years OM843NW3 11 13 updated 12 18 12 Servicing LUBRICATION GENERAL 1 Use only clean high quality lubricants stored in clean containers in a protected area 2 These lubricants are acceptable a API Service CC CD CE single viscosity oils b API Service CC CD SF multi viscosity oils 3 Use the proper weight oil for your average operation temperature Air Single Multi Temperature Viscosity Viscosity SAE30W SAE 15 40W 0 C 10 to 32 F 23 to 0 C SAE 10W SAE 10 30W Below 10 F 23 C SAE 5
55. ut of the area with an approved leak proof exhaust pipe extension Remove Paint Before Welding or Heating Hazardous fumes can be generated when paint is heated by welding soldering or using a torch To avoid potentially toxic fumes and dust remove paint before heating Remove paint a minimum of 100 mm 4 in from the area that will be affected by heat f paint cannot be removed wear an approved respirator f you sand or grind paint use an approved respirator f you use solvent or paint stripper remove stripper With soap and water before welding Remove solvent or paint stripper containers from the area Allow at least 15 minutes for fumes to disperse before welding or heating Do not use a chlorinated solvent in an area where welding will occur Work only in areas that are well ventilated Dispose of paint and solvent properly Service Cooling System Safely ty ic NH Opening a pressurized cooling system can release explosive A fluids and causing serious burns Before opening any pressurized cooling system make sure the engine has been shut off Do not remove a filler cap unless it is cool enough to comfortably grip with bare hands Slowly loosen cap to relieve pressure before opening fully Avoid High Pressure Fluids Relieve pressure prior to disconnecting pressurized lines Escaping fluid under pressure can penetrate the skin causing serious injur
56. y Always relieve pressure before disconnecting hydraulic or other pressurized lines Tighten all connections firmly before re applying pressure If searching for leaks use a piece of cardboard Always protect your hands and other body parts from high pressure fluids If an accident occurs see a doctor immediately Any high pressure spray injected into the skin must be removed within a few hours to prevent the risk of gangrene or other infection Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns and bodily injury Pressurized lines can rupture when heat goes beyond the immediate flame area Do not weld solder or use a torch or open flame near pressurized lines or other flammable fluids Do Not Open High Pressure Fuel System Many Northern Lights engines use high pressure fuel injection High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt any repair of fuel lines sensors or other OM843NW3 11 13 6 Revised 3 13 12 Safety Rules Continued components between the high pressure fuel pump material containing asbestos Keep all bystanders and nozzles on engines with high pressure fuel away from any area where asbestos dust may be systems generated ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH Use Proper Lifting Equipment and Techniques PRESSURE F
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