Northern Lights NL773LW4, Operator'S Manual

Page 1: ...OPERATOR S MANUAL OPERATOR S MANUAL ONL773LW4 For Models NL773LW4 and NL773LW4E www northern lights com...

Page 2: ...tank ULTRA LOW SULFUR FUEL ONLY RE529956 Breathing Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Al...

Page 3: ...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 F...

Page 4: ...hts industrial generator set Model number of engine block Bore Cylinders 77 mm 3 Serial Numbers MODELS INCLUDED This manual covers the operating instructions for NL773LW4 NL773LW4E industrial generato...

Page 5: ...y 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 Warranty Safety Rules NOTICE Accid...

Page 6: ...arts have stopped before making any adjustments connections or performing any other type of service to the engine or other driven equipment Prevent accidental discharge of starting fluids by storing a...

Page 7: ...ous 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...

Page 8: ...of paint and solvent properly Service Cooling System Safely Opening a pressurized cooling system can release explosive fluids and causing serious burns Before opening any pressurized cooling system m...

Page 9: ...e components between the high pressure fuel pump and nozzles on engines with high pressure fuel systems ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH PRESSURE FUEL INJECTION SYSTEMS Avoid...

Page 10: ...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 eac...

Page 11: ...lternator 17 Radiator Shroud 1 Junction Box 2 Air Filter 3 Crankcase Vent 4 Lube Oil Fill 5 Coolant Fill 6 Injection Pump Figures 2 A and B NL773LW4 7 Fuel Lift Pump 8 Dipstick 9 Fuel Inlet and Return...

Page 12: ...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...

Page 13: ...while the engine is running the battery charging regulator could be ruined STARTING 1 Hold the Shutdown Bypass Preheat switch in the ON position for 10 to 20 seconds before starting a cold engine Hol...

Page 14: ...s activated and the temperature gauge shows temperature within normal temperature range a Check the engine crankcase oil level b If the oil level is low fill with recommended lubricating oil and resta...

Page 15: ...evel in engine SP5 Check V belt tension SP7 Check primary fuel filter SP13 Check coolant level SP18 Check electrolyte in batteries AFTER FIRST 50 HOURS SP2 3 Change engine oil and filter SP6 Adjust va...

Page 16: ...ion change oil every 100 hours or six weeks whichever comes first 4 Change oil at any seasonal change in temperature when a new viscosity of oil is required 5 Change oil when engine is warm 6 Dispose...

Page 17: ...fter 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 exh...

Page 18: ...commended The petroleum part of the biodiesel blend must meet ASTM D975 or EN590 EU specifications Biodiesel blends must be used within 90 days of their manufacture When biodiesel blends are used the...

Page 19: ...system may need manual bleeding when a A new fuel filter is 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 installe...

Page 20: ...lines Figure 9 Remove return line nuts Figure 10 Remove return line Figure 11 Unscrew injector Figure 12 Remove and replace copper sealing washer Figure 13 Reinstall injector Torque to proper tightnes...

Page 21: ...rs for bleeding e Pump hand level on fuel pump to fill lines Tighten lines at injectors Start engine and check for leaks using a piece of paper or cardboard DO NOT use hand to check for leaks SP12 INJ...

Page 22: ...tely Close drain cock and refill with recommended coolant mixture Clean fins on radiator 3 Coolant Specifications Use 50 water 50 ethylene glycol antifreeze mix Antifreeze mixture is recommended as a...

Page 23: ...SP 18 19 BATTERY CARE 1 Check electrolyte level every 50 hours or once per month Add distilled water to manufacturer s recommended level 2 Batteries cables and cable terminals should be checked and cl...

Page 24: ...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 b...

Page 25: ...s Occurred Lamp Code Analysis Before starting the engine 1 Check all connections before powering the Engine ECU on 2 When the Engine ECU is powered on assuming no failures the lamp will flash one time...

Page 26: ...eck injection nozzles Uneven compression pressure Check cylinder compression pressure between cylinders Engine Runs Irregularly Below normal engine temperature Remove and check thermostat or Stalls Fr...

Page 27: ...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 broke...

Page 28: ...n Replace governor 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...

Page 29: ...ONL773LW4 5 21 27 AC Wiring Diagrams AC Engine Wiring Diagram AC 4W NL773LW4 Drawing B 9724J Wiring diagrams are subject to change without notice Updated 4 13 20...

Page 30: ...ONL773LW4 5 21 28 AC Wiring Diagrams AC Engine Wiring Diagram AC 12W NL773LW4 Drawing B 9723H Wiring diagrams are subject to change without notice Updated 3 17 20...

Page 31: ...ONL773LW4 5 21 29 DC Engine Wiring Diagram DC 12 VDC Standard Drawing B 10767E Wiring diagrams are subject to change without notice Updated 4 13 20 DC Wiring Diagrams...

Page 32: ...ONL773LW4 5 21 30 Engine Wiring Diagram NL773LWE4 12 VDC Standard Ground Drawing C 7447B Wiring diagrams are subject to change without notice Updated 10 9 20 DC Wiring Diagrams...

Page 33: ...ONL773LW4 5 21 31 Panel Wiring Diagrams DC Engine Wiring Diagram S 1 panel B Deutsch Drawing A 12789B Wiring diagrams are subject to change without notice Updated 10 8 20...

Page 34: ...VDC Standard Ground Drawing B 10834C Wiring diagrams are subject to change without notice Updated 10 8 20 Panel Wiring Diagrams DC Engine Wiring Diagram S 1B panel B Deutsch Drawing A 12791C Wiring d...

Page 35: ...ONL773LW4 5 21 33 Panel Wiring Diagrams Updated 10 8 20 DC Engine Wiring Diagram S 3B S 3C panel B Deutsch Drawing A 12790D Wiring diagrams are subject to change without notice...

Page 36: ...ONL773LW4 5 21 34 DC Wiring Diagrams DC Standard Ground Engine Wiring Diagram Drawing B 9852 Wiring diagrams are subject to change without notice Updated 2 1 12 NON CURRENT MODEL...

Page 37: ...ONL773LW4 5 21 35 DC Engine Wiring Diagram NL773LW4E 12VDC standard Drawing C 6985B Wiring diagrams are subject to change without notice DC Wiring Diagrams Updated 7 9 13 NON CURRENT MODEL...

Page 38: ...NL773LW4 5 21 36 Panel Diagrams 12 Volt DC Standard Ground Engine Wiring Diagram NL773LW4 with S 3C Drawing A12572B Wiring diagrams are subject to change without notice Updated 2 1 12 NON CURRENT MODE...

Page 39: ...NL773LW4 5 21 37 Panel Diagrams 12 Volt DC Standard Ground Engine Wiring Diagram NL773LW4 with S 1B Drawing A 3170 Wiring diagrams are subject to change without notice Updated 2 1 12 NON CURRENT MODEL...

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Page 42: ...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 2021 All rights reserved Litho USA...