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Northern Lights ONL843NW4 Operator's Manual

Manual is about: NL843NW4

Summary of ONL843NW4

  • 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

    Onl843nw4 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. Proprietary information this publication is the property of northern lights, inc. It may not be reproduced in whole or ...

  • Page 4

    Onl843nw4 11/13 2 introduction unit identification servicing of generator sets presents unique problems. In many cases boats cannot be moved to a repair facility. Generators cannot be compared to the servicing of automobiles, trucks or even farm equipment. Failures often occur in remote areas far fr...

  • Page 5

    Onl843nw4 11/13 3 a warranty registration certificate 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 described in the limited warranty statement. We recommend that you study the statement ca...

  • Page 6

    Onl843nw4 11/13 4 safety rules always stop engine before fueling machine. Always fill portable fuel tank outdoors. Never fuel a hot engine. 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....

  • Page 7

    Onl843nw4 11/13 5 safety rules (continued) 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-fitting clothes. Stop the engine and be sure all fans, belts, pulleys a...

  • Page 8

    Onl843nw4 11/13 6 safety rules (continued) 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 injury. Always relieve pressure before dis...

  • Page 9

    Onl843nw4 11/13 7 safety rules (continued) use proper lifting equipment and techniques lifting heavy components incorrectly can cause severe injury or damage to machinery. Avoid unbalanced loads. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on...

  • Page 10

    Onl843nw4 11/13 8 22 23 24 20 21 1. Control panel plug-in 2. Generator plate 3. Generator junction box 4. Dc circuit breaker 5. Air filter 6. Crankcase vent 7. Oil fill 8. Fuel injector 9. Coolant fill 10. Injection pump 11. Shutdown solenoid 12. Oil pressure sender 13. Oil dipstick 14. Block drain ...

  • Page 11

    Onl843nw4 11/13 9 control panels figure 3-b: series 3 generator control panel figure 3-a: series 1-b generator control panel figure 3-c: series 4 generator control panel 1. Shutdown bypass-preheat switch two functions are built into this switch: the preheating of the engine, and bypassing of the eng...

  • Page 12

    Onl843nw4 11/13 10 break-in period 1. The first 100 hours on a new or reconditioned engine are critical to its life and performance. 2. Frequently 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...

  • Page 13

    Onl843nw4 11/13 11 shutdowns and alarms 1. Your unit is fitted with a system to protect it from high water temperature or low oil pressure. A. Generator sets have shutdown systems to stop the engine. They have no warning horns. B. Other alarms and shutdowns are available as optional equipment. Note:...

  • Page 14

    Onl843nw4 11/13 12 the servicing schedule chart below shows the service schedule required for proper maintenance of your 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 sp5 check v-belt tension sp...

  • Page 15

    Onl843nw4 11/13 13 service record notes.

  • Page 16

    Onl843nw4 11/13 14 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 cd/ce single viscosity oils. B. Api service cd/sf multi-viscosity oils. 3. Use the proper weight oil for yo...

  • Page 17

    Onl843nw4 11/13 15 sp4. Air cleaner 1. Inspect air cleaner every 250 hours. In dusty conditions, check more often. 2. Replace if necessary. Part number is: nl843nw3 ( element only ) – #24-27302 3. Note: make absolutely sure no impurities enter the engine while changing the element. Do not run the en...

  • Page 18

    Onl843nw4 11/13 16 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 free...

  • Page 19

    Onl843nw4 11/13 17 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 ho...

  • Page 20

    Onl843nw4 11/13 18 figure 10: remove delivery line flare nuts. Figure 11: remove delivery lines. Figure 12: cover lines, inlets and injection pump outlets. Figure 14: remove return line. Figure 15: unscrew injector. Figure 16: remove and replace copper sealing washer. Figure 17: reinstall injector. ...

  • Page 21

    Onl843nw4 11/13 19 sp11. Injector service 1. Injectors should be checked every 1000 hours. 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 serious personal injury....

  • Page 22

    Onl843nw4 11/13 20 servicing 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...

  • Page 23

    Onl843nw4 11/13 21 figure 18: glow plugs. Booster batteries caution: battery gas can explode. Keep all flames and sparks away from batteries. 1. Before changing or using booster batteries, check battery electrolyte level. Add distilled water if necessary. 2. Booster and main batteries must have the ...

  • Page 24

    Onl843nw4 11/13 22 if you cannot correct problems with these procedures, see your northern lights dealer. 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 ...

  • Page 25

    Onl843nw4 11/13 23 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 • ...

  • Page 26

    Onl843nw4 11/13 24 troubleshooting engine problem possible cause recommendation(s) engine overheats low coolant level • fill tank or radiator to proper level. • check hoses for loose connections and leaks. Cooling system needs flushing • flush cooling system. Defective thermostat • remove and check ...

  • Page 27

    Onl843nw4 11/13 25 troubleshooting engine problem possible cause recommendation(s) 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 temperatu...

  • Page 28

    Onl843nw4 11/13 26 kilowatt rating prime 12 kw rated rpm/frequency 1800/ 60hz general information engine type lugger 4 cycle, swirl chamber diesel cylinders inline 3 displacement 91 in 3 (1.5 liters) cycles 4 bore x stroke 3.3 x 3.54 in (84 x 90 mm) rotation (facing flywheel) counter-clockwise compr...

  • Page 29

    Onl843nw4 11/13 27 wiring diagram ac wiring diagram 12 & 4 lead generators, dst -100-2f ak avr b-9724c revised 2-1-12.

  • Page 30

    Onl843nw4 11/13 28 wiring diagram ac wiring diagram 12 & 4 lead generators, dst -100-2f ak avr b-9723a added 2-1-12.

  • Page 31

    Onl843nw4 11/13 29 dc wiring diagram 12 v dc standard ground b-10021 wiring diagram revised 2-1-12.

  • Page 32

    Onl843nw4 11/13 30 dc wiring diagram 12 v dc standard ground w/ s-1b a-3170 wiring diagram added 2-1-12.

  • Page 33

    Onl843nw4 11/13 31 dc wiring diagram 12 v dc standard ground w/ s-3c a-12572b wiring diagram added 2-1-12.

  • Page 34

    Www.Northern-lights.Com 4420 14th ave. Nw., seattle wa 98107 tel: (206) 789-3880 • 1-800-762-0165 • fax: (206) 782-5455 northern lights and lugger are registered trademarks of northern lights, inc. © 2013 all rights reserved. Litho usa..