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  5. Operator's Manual

Northern Lights M773LW3 Operator's Manual

Manual is about: Marine Generators

Summary of M773LW3

  • 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

    Om773lw3 11/13 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 for model m773lw3 introduction ....................................................2 models included ....

  • Page 4

    Om773lw3 11/13 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 competen...

  • Page 5: Warning

    Om773lw3 11/13 3 warranty a warranty registration certificate 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 m...

  • Page 6: Caution

    Om773lw3 11/13 4 safety rules (continued) revised 3-13-12 operating equipment requires the full attention of the operator. Do not use radio or music headphones while operating machinery. Practice safe maintenance ! Caution understand all service procedures before starting work. Keep area clean and d...

  • Page 7: Warning

    Om773lw3 11/13 5 safety rules (continued) revised 7-9-12 install all safety guards ! Warning 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 al...

  • Page 8: Caution

    Om773lw3 11/13 6 safety rules (continued) revised 3-13-12 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 us...

  • Page 9: Warning

    Om773lw3 11/13 7 safety rules (continued) revised 3-13-12 material containing asbestos. Keep all bystanders away from any area where asbestos dust may be generated. Use proper lifting equipment and techniques ! Warning lifting heavy components incorrectly can cause severe injury or damage to machine...

  • Page 10: Caution

    Om773lw3 11/13 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 op...

  • Page 11

    Om773lw3 11/13 9 notes.

  • Page 12

    Om773lw3 11/13 10 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 marine generator component locations 8. Fuel injector 9. Stop solenoid 10. Injection pump 11. Lube oil fill, side 12. Seawater pump 13. Lube oil drain 14....

  • Page 13

    Om773lw3 11/13 11 marine generator component locations 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. Seawat...

  • Page 14

    Om773lw3 11/13 12 figure 6-a: series 3 generator control panel control panels figure 5: series 1-b generator control panel figure 6-b: series 4 generator control panel 1. Shutdown bypass-preheat switch there are two functions built into this switch: 1. Preheats the fuel before beginning the starting...

  • Page 15

    Om773lw3 11/13 13 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...

  • Page 16

    Om773lw3 11/13 14 break-in period 1. The first 100 hours on a new or reconditioned engine are critical to its life and performance. 2. Operate the engine under various conditions, particularly heavy loades with minimal idling, to help seat engine components properly. 3. Constantly check the engine t...

  • Page 17

    Om773lw3 11/13 15 shutdowns and alarms 1. Generator sets have shutdown systems to stop the engine in the event of high water temperature or low oil pressure. A. Other alarms and shutdowns are available as optional equipment. Note: do not rely on your shutdown to the exclu- sion of careful gauge moni...

  • Page 18

    Om773lw3 11/13 16 service 50 200 250 500 1000 2500 point page operation daily hours hours hours hours hours hours engine: sp1 10 & 14 check oil level • sp2 14 change engine oil 1) 5) • • sp3 14 change lube oil filters 1) 5) • • sp4 15 check air cleaner, change element @ 1000 hrs. 1) 4) 5 • sp5 15 ch...

  • Page 19

    Om773lw3 11/13 17 service record notes.

  • Page 20

    Om773lw3 11/13 18 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 f...

  • Page 21

    Om773lw3 11/13 19 sp4. Air cleaner 1. Inspect air cleaner every 250 hours. In dusty condi- tions, check more often. 2. If dirty, wash element in soapy water. Rinse and dry thoroughly before re-installing. Replace if necessary. Part numbers are: m773lw3 – #24-28602 3. Note: make absolutely sure no im...

  • Page 22

    Om773lw3 11/13 20 servicing fuels - general 1. Use only clean, high 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 freez...

  • Page 23

    Om773lw3 11/13 21 servicing sp10. Bleeding the fuel system 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 hos...

  • Page 24

    Om773lw3 11/13 22 figure 12: remove delivery line flare nuts. Figure 13: remove delivery lines. Figure 14: remove return line nuts. Figure 15: remove return line. Figure 16: unscrew injector. Figure 17: remove and replace copper sealing washer. Figure 18: reinstall injector. Torque to proper tightne...

  • Page 25

    Om773lw3 11/13 23 sp11. Injector service 1. Injectors should be checked every 1000 hours, or whenever necessary. Check should be made by a northern lights dealer or local injection repair station. Caution: escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing se...

  • Page 26

    Om773lw3 11/13 24 2. Here are acceptable water quality specifications: 3. If chlorides, 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. If total hardness is higher tha...

  • Page 27

    Om773lw3 11/13 25 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 installing the battery. 3. When welding on the un...

  • Page 28

    Om773lw3 11/13 26 troubleshooting if you cannot correct problems with these procedures, see your northern lights dealer. 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 b...

  • Page 29

    Om773lw3 11/13 27 troubleshooting engine problem possible cause recommendation(s) engine hard to start improper starting procedure • see starting section of this manual. Take or will not start special note of bypass switch operation. No fuel • check level of fuel in fuel tank. Low battery output • c...

  • Page 30

    Om773lw3 11/13 28 troubleshooting engine problem possible cause recommendation(s) lack of engine power, continued below normal engine temperature • remove and check thermostat. Injection pump fuel supply • air mixing in injection pump. Insufficient • fuel filter clogged. Improper valve clearance • r...

  • Page 31

    Om773lw3 11/13 29 troubleshooting engine problem possible cause recommendation(s) below normal engine temperature thermostats not working properly • check thermostats. Temperature gauge • check water temperature with thermometer. Not working properly low oil pressure low oil level • fill crankcase t...

  • Page 32

    Om773lw3 11/13 30 wiring diagrams ac engine w iring diagram t aiyo px300k2 4 lead generator with dst -1002f ak avr b-9724c updated page 3-13-12.

  • Page 33

    Om773lw3 11/13 31 wiring diagrams ac engine w iring diagram m773l w3, 12 lead generators with avr dst -100-2f ak b-9723a updated page 3-13-12.

  • Page 34

    Om773lw3 11/13 32 wiring diagrams dc engine w iring diagram m773l w3 12 v olt standard ground b-9852a updated page 3-13-12.

  • Page 35

    Om773lw3 11/13 33 dc engine w iring diagram m773l w3 12 v olt isolated ground b-10130b wiring diagrams updated page 7-9-12.

  • Page 36

    Om773lw3 11/13 34 wiring diagrams added page 7-9-12 panel w iring diagram s-3c v iewline panels 12v drawing a-12645a.

  • Page 37

    Om773lw3 11/13 35 wiring diagrams dc w iring diagram m773l w3, control panel s-3c, 12 v a-12572b added page 3-13-12.

  • Page 38

    Om773lw3 11/13 36 wiring diagrams added page 7-9-12.

  • Page 39

    Om773lw3 11/13 37 wiring diagrams dc engine w iring diagram m773l w3 24 vdc standard ground b-b-9908 updated page 3-13-12.

  • Page 40

    Om773lw3 11/13 38 dc engine w iring diagram m773l w3 24 v olt isolated ground b-8662c wiring diagrams.

  • Page 41

    Om773lw3 11/13 39 wiring diagrams dc engine w iring diagram m773l w3, control panel s-1b 24v a-4792 added page 3-13-12.

  • Page 42

    Om773lw3 11/13 40 wiring diagrams dc w iring diagram m773l w3, control panel s-3c, 24v a-12594b added page 3-13-12.

  • Page 44

    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..