1. DL manuals
  2. Northern Lights
  3. Portable Generator
  4. and NL1066H3
  5. Operator's Manual

Northern Lights and NL1066H3 Operator's Manual

Summary of and NL1066H3

  • Page 2

    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. — california — proposition 65 warning: northern lights 4420 14th avenue n.W. Seattle, wa 98107 tel: (206) 789-3880 fax: (206) 782-5455 copyright ©201...

  • Page 3: Operator'S Manual

    Onl2-2 7/13 1 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. Operator's manual # onl2-2 for models : nl1064d, nl1064t1, nl1064t2, nl1064h1, nl1066t, nl1066h1, nl1066h2, and nl1066h3 in...

  • Page 4

    Onl2-2 7/13 2 servicing of marine engines and generator sets presents unique problems. In many cases boats cannot be moved to a repair facility. Marine engines cannot be compared to the servicing of automobiles, trucks or even farm equipment. Failures often occur in remote areas far from competent a...

  • Page 5

    Onl2-2 7/13 3 a warranty registration certifi cate is supplied with your set. The extent of coverage is described in the limited warranty statement. We recommend that you study the statement carefully. Note: if the warranty is to apply, the servicing instructions outlined in this manual must be foll...

  • Page 6

    Onl2-2 7/13 4 safety rules updated 2/23/12 operating equipment requires the 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, serv...

  • Page 7

    Onl2-2 7/13 5 safety rules (continued) updated 2/23/12 install all safety guards 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-fi tting clothes. Stop the engine and be sure all fans, bel...

  • Page 8

    Onl2-2 7/13 6 safety rules (continued) updated 2/23/12 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 ...

  • Page 9

    Onl2-2 7/13 7 safety rules (continued) updated 2/23/12 material containing asbestos. Keep all bystanders away from any area where asbestos dust may be generated. Use proper lifting equipment and techniques lifting heavy components incorrectly can cause severe injury or damage to machinery. Avoid unb...

  • Page 10

    Onl2-2 7/13 8 general policy to avoid dangerous or hazardous situations, refrain from any of the following: • 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 opera...

  • Page 11

    Onl2-2 7/13 9 notes.

  • Page 12

    Onl2-2 7/13 10 1. Junction box 2. Control panel 3. Air cleaner 4. Rain cap 5. Exhaust elbow 6. Radiator shroud 7. Alternator 8. Vibration mount 9. Lube oil filter 10. Fuel manifold 11. Lube oil dipstick 12. Starter 13. Fuel filter 14. Turbocharger 15. Exhaust manifold 16. Electronic control unit com...

  • Page 13

    Onl2-2 7/13 11 component locations 1. Junction box 2. Control panel 3. Air cleaner 4. Rain cap 5. Exhaust elbow 6. Low coolant level gauge (optional) 7. Radiator shroud figure 3 & 4: nl1066t (electronically controlled fuel system) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 2 17 18 8. Alternator 9. Vibra...

  • Page 14

    Onl2-2 7/13 12 1. Junction box 2. Control panel 3. Air cleaner 4. Rain cap 5. Turbocharger 6. Exhaust elbow 7. Radiator shroud 8. Low coolant level gauge (optional) 9. Alternator 10. Oil filter 11. Dipstick 12. Low oil level gauge (optional) 13. Fuel filter/ water separator (optional) 14. Fuel filte...

  • Page 15

    Onl2-2 7/13 13 northern lights control panels figure 7: series 3-b generator control panel figure 8: series 1-b generator control panel 1. Shutdown bypass-preheat switch two functions are built into this switch: the preheat- ing of the engine, and bypassing of the engine safety shutdown circuit. Hol...

  • Page 16

    Onl2-2 7/13 14 operating 1.Check gauges often: oil pressure must be above 29 psi (if not above 15 psi within 5 seconds of starting, the engine should be stopped and the problem should be explored). Normal oil pres- sure is 50 psi at rated load speed (1800 to 2500 rpm). Oil temperature should be 115 ...

  • Page 17

    Onl2-2 7/13 15 operating procedures do not remove the water fi ll 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. B. Use the trouble shooting guide on pages 27- 29 to isolate the ...

  • Page 18

    Onl2-2 7/13 16 the servicing schedule chart below shows the service schedule required for proper maintenance of your marine engine or generator set. More detailed coverage of each service point (sp) is listed on the page noted in the ‘page’ column. Daily: sp1 check oil level in engine sp8 check prim...

  • Page 19

    Onl2-2 7/13 17 service point hours/date service record operation 50 hours sp21 check electrolyte in batteries 250 hours sp2 change engine oil* sp3 change lubricating oil fi lters* 500 hours sp4 check air cleaner*, replace as needed sp5 check belt condition sp9 change primary fuel fi lter element sp1...

  • Page 20

    Onl2-2 7/13 18 lubrication break-in oil 1. Use one of the following during the fi rst 100 hours of operation: a. John deere engine break-in oil b. Api service cc, cd, or ce oil c. Acea specifi cation e1 or e2 2. Do not use john deere plus-50 oil or engine oils meeting api ci-4, ch-4, cg-4, cf-4, or ...

  • Page 21

    Onl2-2 7/13 19 servicing sp5. Belt tension 1. Inspect the belt for cracks, stretched out areas, or frays and replace if needed. 2. Twist the belt in the middle of a 10 to 12 inch span (254- 305 mm) with two fi ngers. It should turn 75 to 85 degrees if it is properly tensioned. If it turns more it ne...

  • Page 22

    Onl2-2 7/13 20 sp6. Valve clearances the following special tools will be needed: jde 281a or jde 83 flywheel turning tool. Jdg1571 timing pin. Make sure the negative battery terminal is discon- nected before starting valve adjustments. Engine must be cold to check and adjust valve clearances. 1. Rem...

  • Page 23

    Onl2-2 7/13 21 servicing 6-cylinder engines: note: firing order is 1 - 5 - 3 - 6 - 2 - 4 reproduced by permission of deere & company, c2005. Deere & company. All rights reserved. Rg4777 figure 14 a - front of engine b - no. 1 piston at tdc compression stroke c - no. 6 piston at tdc compression strok...

  • Page 24

    Onl2-2 7/13 22 sp7. Crankshaft vibration damper (6 cylinder engines only) 1. Remove belts. 2. Try to turn the vibration damper in both direc- tions while grasping it with both hands. If rotation can be felt, the damper is defective and should be replaced. Note: the vibration damper assembly should b...

  • Page 25

    Onl2-2 7/13 23 1. Whenever the fuel system has been opened for service, (lines disconnected, fi lter changed, etc.) it will be necessary to bleed air from the system. A. To bleed the fuel system, loosen the bleed plug (figure 17-d) on the fuel fi lter. Operate the primer pump lever on fuel transfer ...

  • Page 26

    Onl2-2 7/13 24 note: do not scrape or disturb the tefl on coat- ing on the nozzle body above the carbon stop seal groove. This coating will become discolored during normal operation, but this is not harmful. Do not use a motor driven brush to clean up nozzle body. Figure 19 5. Install seals on injec...

  • Page 27

    Onl2-2 7/13 25 a. Check cleanliness of air fi lter. B. Check valve clearances. C. Clean and check injectors. 3. Any repair which involves disassembly of the injection pump must be carried out by specially-trained mechanics with the proper tools and test devices. Note: all warranties on the engine be...

  • Page 28

    Onl2-2 7/13 26 servicing important: injection pump mounting fl ange timing mark (figure 23-a ) and front plate timing mark ( figure 23-b) presence and alignment must be verifi ed before removing pumps from engine. Do not reference internal timing marks (on pump cam ring and governor weight retainer)...

  • Page 29

    Onl2-2 7/13 27 servicing figure 26 reproduced by permission of deere & company, c.2005. Deere & company, all rights reserved. Rg5664 figure 27 reproduced by permission of deere & company, c.2005. Deere & company, all rights reserved. Rg9089 12. Tighten fuel delivery (pressure) lines to 20 foot lbs. ...

  • Page 30

    Onl2-2 7/13 28 servicing 2. Vapor bubbles (figure 28-c) are formed when the piston's impact causes the liner walls to vibrate, sending pressure waves into the coolant. 3. These tiny vapor bubbles collect on the surface of metal parts. As the bubbles collapse (pop) a microscopic piece of metal is ero...

  • Page 31

    Onl2-2 7/13 29 servicing egc: ethylene glycol concentrate (antifreeze) continued important 1. Do not use methyl alcohol or methoxy propanol base egc. These concentrates are not compatible with chemi- cals used in supplemental coolant additives. Damage can occur to rubber seals on cylinder liners whi...

  • Page 32

    Onl2-2 7/13 30 servicing 1. Flush the cooling system and check for leaks and blockage after the fi rst 3 years or 3000 hours. Then every 2 years or 2000 hours. The engine must be stopped and cold. 2. Remove the pressure cap from the expansion tank with caution. If applicable, open the cooling system...

  • Page 33

    Onl2-2 7/13 31 servicing sp21-22. Battery care - lead/acid type batteries 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 cleaned every 100 hours. Clean corrosion with...

  • Page 34

    Onl2-2 7/13 32 if you cannot correct problems with these procedures, see your lugger or northern lights dealer. Loose or corroded connections: • clean and tighten loose connections. Starter and hour meter function but rest of electrical system does not function blown fuse on magnetic switch. • repla...

  • Page 35

    Onl2-2 7/13 33 troubleshooting if you cannot correct problems with these procedures, see your lugger or northern lights dealer. Dirty or faulty injection nozzles: • replace injectors. Best done by dealer. • see your local dealer. Engine overheats engine overloaded. • reduce the load. Low coolant lev...

  • Page 36

    Onl2-2 7/13 34 if you cannot correct problems with these procedures, see your lugger or northern lights dealer. High fuel consumption engine overloaded. • reduce load. Air in fuel system: • bleed fuel system. Improper type of fuel: • use correct fuel for temperature. Clogged or dirty air cleaner: • ...

  • Page 37

    Onl2-2 7/13 35 ac wiring diagram a.C. Wiring - all voltages with a sx460 v oltage regulator drawing b-5703c.

  • Page 38

    Onl2-2 7/13 36 dc wiring diagram d.C. Wiring - 12 v olt standard ground for nl1064d drawing c-5775.

  • Page 39

    Onl2-2 7/13 37 dc wiring diagram d.C. Wiring - 24 v olt standard ground for nl1064d drawing c-5776.

  • Page 40

    Onl2-2 7/13 38 notes.

  • Page 41

    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. © 2013 all rights reserved. Litho usa..