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Northern Lights Lugger M773LW, Operator'S Manual

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Northern Lights Lugger M773LW Operator'S Manual Download Page 20

OM773LW2  10/09

20

SP14.  COOLING SYSTEM FLUSHING

1.  Flush the cooling system every 2500 hours or every 

12 months, whichever comes fi rst.

 

a.  Remove expansion tank cap and drain engine 

  block.
 

b.  Open block drain cock. 

 

 

Remove plug in lower left 

 

 

side 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 refi ll with recommended mixture.

2. Coolant Specifi cations:
 

Use 50% water / 50% ethylene glycol antifreeze 

mix. Antifreeze mixture is recommended as a good 
year-round coolant, but not methyl alcohol based 
antifreeze because of it’s effect on non-metallic 

 

components and it’s low boiling point.  Also, anti-

freeze with high silicate should not be used as it 
could case silica gelation problems.

3.  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 out 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.

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 

installing the battery.

3.   When 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 polarize the alternator or regulator.
7.  A D.C. circuit breaker protects your control panel and 

wiring harness. It is located in the side of the generator 
junction box.

Servicing

Summary of Contents for Lugger M773LW

Page 1: ...OM773LW2 For Models M773LW and M773LW2 OPERATOR S MANUAL Marine Generators Marine Diesel Engines Land Based Generators ...

Page 2: ... 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 2009 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 OM773LW2 10 09 ...

Page 3: ...eral 14 Checking Oil 14 SERVICING CONTINUED Oil Changes 14 Changing Oil 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 Flushing 20 Heat Exchanger 20 Raw Water Pump 20 Generator Ends 20 Electrical System General 20 Glow Plugs 21 Booster Batteries 21 ...

Page 4: ...tion L W W2 M Northern Lights marine generator set Model number of engine block Bore Cylinders 77 mm 3 Serial Numbers MODELS INCLUDED This manual covers the operating instructions for M753W W2 marine generator sets Model Numbers Model numbers give the unit s application block model aspiration and RPM Model numbers give the unit s application block model aspiration and RPM L Long stroke W New Windi...

Page 5: ...ean up spilled fuel or oil to prevent potential fires Keep your hands feet hair and clothing away from power driven parts Check for any loose electrical connections or faulty wiring Engines should be operated only by knowledge able qualified personnel Look completely around engine to make sure that everything is clear before starting Do not operate an engine that isn t in proper working order If a...

Page 6: ...Fuel Injector 9 Stop Solenoid 10 Injection Pump 11 Lube Oil Fill Side 12 Seawater Pump 13 Lube Oil Drain 14 Base frame 26 Starter 27 Alternator 28 HeatExchangerEnd Cap 29 Coolant Recovery Tank 15 Block Drain 16 Fuel Inlet and Return 17 Oil Dipstick 18 Lube Oil Filter 19 Control Panel Plug 20 Generator Data Plate 21 ACCircuitBreakerfor AVR 22 DC Circuit Breaker 23 Expansion Tank 24 Wet Exhaust Elbo...

Page 7: ... 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 Seawater Pump 14 Fuel Inlet and Return 15 Oil Dipstick 16 Lube Oil Filter 17 Oil Drain 18 Generator Data Plate 19 Expansion Tank 20 Heat Exchanger End Cap 21 Wet Exhaust Elbow 22 Vibration Mount 23 Starter 24 Alternator ...

Page 8: ...ll return to RUN position To stop the engine hold the switch in the STOP position NOTE The rocker switch is used on Series 1 panels only and has a light that glows when the set is running 3 HOUR METER Keeps track of engine running time 4 OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system 5 WATER TEMPERATURE GAUGE Registers the temperature of the cooling water 6 D C VOLTMETE...

Page 9: ...ltmeter indicates the voltage output of the alternator 6 STATUS INDICATOR PANEL Engine monitoring alarms and lamps for monitoring engine functions 7 ALARM LAMP TEST AND RESET BUTTON Press UP to test the indicator lights and press DOWN to reset the alarm 8 A C VOLTAGE ADJUSTMENT RHEOSTAT Voltage has been set at the factory and should only be adjusted by factory trained personnel 9 AMMETER SELECTOR ...

Page 10: ...s 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 Holding the switch too long can burn out the glow plugs This step is not necessary if the engine is already warm 2 While holding the Shutdown Bypass Preheat switch in the ON position push the Engine Control switch to the S...

Page 11: ... 96 C on Marine units Repeat trouble shooting 3 If shutdown is 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 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 ope...

Page 12: ...ted 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 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 250 HOURS SP2 3 Change engine oil and filter SP4 Check air cleaner SP...

Page 13: ...OM773LW2 10 09 13 Service Record Notes ...

Page 14: ...y 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 of waste oil in an approved manner 7 Never use a flushing oil 8 Loosen the clamp on the oil change tube Remove cap Drain oil Replace the cap and tube 9 Refill engine with recommended oil 10 Engine capacity with new oil ...

Page 15: ...er the cylinder head bolts have been re tightened Engine should be cold and NOT running 3 To bring the No 1 cylinder to top dead center in the compression stroke align the timing mark the top mark of the crank pulley with that of the timing gear case Remove the rocker arm cover and turn the crankshaft foward and backward If the inlet and exhaust valves of the No 1 cylinder do not move it is in top...

Page 16: ...ing fuel for long periods of time c Fill the fuel tank at the end of each day s operation This will reduce condensation SP7 9 FUEL FILTERS 1 Your generator set should have a primary fuel filter installed We recommend the Racor brand of fuel filter water separators a Check the primary fuel filter daily as recommended by the filter manufacturer Empty the collection bowl as necessary b Change the ele...

Page 17: ...ystem 1 The fuel system is self bleeding However any 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 installed 2 Loosen bleed bolt A Figure 11 on top of the filter Pump hand primer B on fuel lift pump until pure fuel no bubbles escapes from bleed bolt A Tig...

Page 18: ... 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 tightness Servicing ...

Page 19: ...gine 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 opera tion Service of the fuel injection p...

Page 20: ...eawater pump impeller every 1000 hours or as needed 2 Remove the pump end cover Pry out 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 3 Clean the inside of the housing 4 Press in the new impeller and place the sealing washers in the outer en...

Page 21: ...charging and booster instructions SP 18 19 BATTERY CARE 1 Check electrolyte level daily 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 a water and baking soda solu tion Flush with clean water Tighten terminals and grease them to inhibit corrosion 3 Check the battery condition with a h...

Page 22: ...s 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 If low fill cells with distilled water of e...

Page 23: ... Fuel injected but no ignition Glow plug malfunction Injection timing not correct Low cylinder compression pressure Engine Runs Irregularly Below normal engine temperature Remove and check thermostat or Stalls Frequently Clogged primary Clean or replace filter element fuel filter element Clogged secondary Replace secondary filter element fuel filter element Water or dirt in the fuel system Drain f...

Page 24: ... 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 Engine Knocks Insufficient oil Call your dealer Injection pump out of time Call your dealer Below normal engine temperature Check your thermostats Check water temperature to see if tempera...

Page 25: ...onsumption 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 ...

Page 26: ...OM773LW2 10 09 26 Wiring Diagrams AC Engine Wiring Diagram M773LW and M773LW2 12 4 Lead Generators with AVR DST 100 2FAK B 8280E ...

Page 27: ...OM773LW2 10 09 27 Wiring Diagrams DC Engine Wiring Diagram M773LW and M773LW2 12 Volt Standard Ground B 8659A ...

Page 28: ...OM773LW2 10 09 28 DC Engine Wiring Diagram M773LW and M773LW2 12 Volt Isolated Ground B 8660A Wiring Diagrams ...

Page 29: ...OM773LW2 10 09 29 Wiring Diagrams DC Engine Wiring Diagram M773LW and M773LW2 24 Volt Standard Ground B 8661C ...

Page 30: ...OM773LW2 10 09 30 DC Engine Wiring Diagram M773LW and M773LW2 24 Volt Isolated Ground B 8662C Wiring Diagrams ...

Page 31: ...hern 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 2009 All rights reserved Litho USA ...

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