Northern Lights Lugger M773LW3 User Manual Download

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OPERATOR’S MANUAL

OM773LW3

For Model: M773LW3 and M773LW3G

www.northern-lights.com

Summary of Contents for Lugger M773LW3

Page 1: ...OPERATOR S MANUAL OPERATOR S MANUAL OM773LW3 For Model M773LW3 and M773LW3G www northern lights com...

Page 2: ...the outside Do not modify or tamper with the exhaust system Do not idle the engine except as necessary For more information go to www P65warnings ca gov diesel CALIFORNIA Proposition 65 Warning North...

Page 3: ...Lube Oil Filter 16 Air Cleaner 17 V Belts 17 Valve Clearances 17 Fuels General 18 Fuel Filters 18 Cooling System General 19 Checking coolant level 19 Cooling System Flushing 19 Injector Service 20 Inj...

Page 4: ...W G 3 M Northern Lights marine generator set Model number of engine block Bore Cylinders 77 mm 3 MODELS INCLUDED This manual covers the operating instructions for M773LW3 and M77LW3G marine generator...

Page 5: ...fety signs Keep signs in good and clean condition Replace missing or damaged signs Be sure new equipment components and repair parts include the current safety signs For replacement signs proper place...

Page 6: ...ld up of grease oil or debris Disconnect battery ground cable before making any adjustments or service work Handle Fuel Safely Avoid Flames WARNING Diesel is highly flammable and should be treated wit...

Page 7: ...open flame away from the top of battery When checking battery electrolyte level use a flashlight Safety Rules Continued Updated 4 12 17 Never check battery charge by contacting the posts with a metal...

Page 8: ...flammable fluids Handle Chemical Products Safely WARNING Direct exposure to hazardous chemicals can cause serious injury Among the potentially hazardous chemicals that may be used with Northern Light...

Page 9: ...o drain fluid Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Do Not Open High Pressure...

Page 10: ...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 each valve handle t...

Page 11: ...OM773LW3 11 20 9 Notes...

Page 12: ...lant recovery bottle 3 Fuel filter 4 Air filter housing 5 Fuel lift pump 6 Fuel injector 7 Lube oil fill top 8 Coolant fill 9 Injection pump 10 Stop solenoid 11 Lube oil fill side 12 Sea water pump 13...

Page 13: ...lenoid 11 Lube oil fill side 12 Sea water pump 13 Lube oil drain 14 Fuel manifold 15 Oil dipstick 16 Fuel filter 17 Control panel plug 18 AC circuit breaker for AVR 19 DC circuit breaker 20 Heat excha...

Page 14: ...tion until the engine is running NOTE Excessive cranking of marine sets equipped with water lift muffler systems can cause engine damage After the engine starts release the switch and it will return t...

Page 15: ...ds 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...

Page 16: ...b Check the engine crankcase oil level c 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...

Page 17: ...ach Service Point SP is listed on the page noted in the page column DAILY SP1 Check oil level in engine SP7 Check primary fuel filter SP10 Check cooling water level AFTER FIRST 50 HOURS SP2 3 Change e...

Page 18: ...mittent cold weather operation 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 whe...

Page 19: ...inder 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 a...

Page 20: ...n This will reduce condensation FUEL FILTERS 1 Your generator set should have a primary fuel filter installed We recommend the Racor brand of fuel filter water separators SP 7 PRIMARY FUEL FILTER a Ch...

Page 21: ...the level should be about 1 in 2 5 cm below the filler cap sealing surface when the engine is cold 2 The pressure valve in the filler cap releases when the pressure is approximately 7 PSI 0 5 bar Use...

Page 22: ...ion a Install a new copper sealing washer in each injector hole Figure 17 b Screw in injector and tighten to 43 or 50 ft lbs 6 to 7 kgm Figure 18 NOTE Overtightening can damage injector c Install retu...

Page 23: ...Figure 10 Remove delivery line flare nuts Figure 11 Remove delivery lines Figure 12 Remove return line nuts Figure 14 Unscrew injector Figure 15 Remove and replace copper sealing washer Figure 16 Rein...

Page 24: ...block using a high quality meter Resistance should be under 1 ohm 3 Check all glow plugs and replace any that are faulty SP 14 HEAT EXCHANGER 1 Clean the heat exchanger core every 24 months or after...

Page 25: ...recommendations on page 16 Run the engine up to at least 140o F from a small clean source of fuel dosed with either Stab il brand fuel system stabilizer diesel engine formula or Stanadyne Performance...

Page 26: ...n 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 B...

Page 27: ...ition Glow plug malfunction Low cylinder compression pressure Engine Runs Irregularly Below normal engine temperature Remove and check thermostat or Stalls Frequently Clogged primary Clean or replace...

Page 28: ...at 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 necessa...

Page 29: ...ion 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 a...

Page 30: ...m 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 fue...

Page 31: ...OM773LW3 11 20 29 Troubleshooting Notes...

Page 32: ...OM773LW3 11 20 30 AC Wiring Diagrams AC Engine Wiring Diagram Taiyo PX300K2 12 Lead Generator w DST 100 2FAK AVR B 9723H Updated 3 10 20...

Page 33: ...OM773LW3 11 20 31 AC Wiring Diagrams AC Engine Wiring Diagram Taiyo Px300K2 4 Lead Generator w DST 100 2FAK AVR B 9724J Updated 3 10 20...

Page 34: ...OM773LW3 11 20 32 AC Wiring Diagrams Updated 10 8 20 AC Engine Wiring Diagram Marine 4 Wire PX300K2 Generators 6kW 20kW w optional Unit Mounted Circuit Breaker B 8399K...

Page 35: ...OM773LW3 11 20 33 AC Wiring Diagrams Updated 3 10 20 AC Engine Wiring Diagram Marine 4 Wire PX300K2 Generators 7kW 20kW w optional Unit Mounted Circuit Breaker B 10686B...

Page 36: ...OM773LW3 11 20 34 DC Wiring Diagrams DC Wiring Diagram M NL 773LW 12 VDC Standard Ground B Control B 10767E Updated 10 8 20...

Page 37: ...OM773LW3 11 20 35 DC Wiring Diagrams Updated 10 8 20 DC Wiring Diagram M773LW 12 VDC Isolated Ground B 10835D...

Page 38: ...OM773LW3 11 20 36 DC Wiring Diagrams DC Wiring Diagram M773 24 VDC Standard Ground B only B 10834C Updated 10 8 20...

Page 39: ...OM773LW3 11 20 37 DC Wiring Diagrams DC Wiring Diagram M773LW 24 VDC Isolated Ground B Only B 10880C Updated 10 8 20...

Page 40: ...OM773LW3 11 20 38 DC Wiring Diagrams Updated 10 8 20 DC Engine Wiring Diagram M773LW3 12 VDC Standard Ground Gem series base frame B 11745A...

Page 41: ...OM773LW3 11 20 39 DC Wiring Diagrams DC Engine Wiring Diagram M773LW3 12 VDC Isolated Ground Gem series base frame B 11746 Updated 4 16 20...

Page 42: ...OM773LW3 11 20 40 DC Wiring Diagrams DC Engine Wiring Diagram M773LW3 24 VDC Standard Ground Gem series base frame B 11747A Updated 10 8 20...

Page 43: ...OM773LW3 11 20 41 DC Engine Wiring Diagram M773LW3 24 VDC Isolated Ground Gem series base frame B 11748 DC Wiring Diagrams...

Page 44: ...OM773LW3 11 20 42 DC Wiring Diagrams Updated 10 8 20 DC Engine Wiring Diagram M773LW3 12 VDC Standard Ground Ignition Protection Option B 11781A...

Page 45: ...OM773LW3 11 20 43 Panel Wiring Diagram S 1 Panel B Deutsch A 12798B Updated 8 22 19 Panel Wiring Diagrams...

Page 46: ...OM773LW3 11 20 44 Panel Wiring Diagrams Panel Wiring Diagram S 1B Panel B A 12791C Updated 8 22 19...

Page 47: ...OM773LW3 11 20 45 Panel Wiring Diagrams Panel Wiring Diagram S 3B S 3C Panel Viewline B A 12790D Updated 8 22 19...

Page 48: ...OM773LW3 11 20 46 DC Wiring Diagrams DC Engine Wiring Diagram M773LW3 12 VDC Standard Ground non Gem series base frame B 9852A Updated 8 22 19 NON CURRENT MODEL...

Page 49: ...OM773LW3 11 20 47 NON CURRENT MODEL DC Engine Wiring Diagram M773LW3 12 VDC Isolated Ground non Gem series base frame B 10130B DC Wiring Diagrams Updated 7 9 12...

Page 50: ...OM773LW3 11 20 48 DC Wiring Diagrams DC Engine Wiring Diagram M773LW3 24 VDC Standard Ground non Gem series base frame B 9908 Updated 3 13 12 NON CURRENT MODEL...

Page 51: ...OM773LW3 11 20 49 DC Engine Wiring Diagram M773LW3 24 VDC Isolated Ground non Gem series base frame B 8662C DC Wiring Diagrams NON CURRENT MODEL...

Page 52: ...OM773LW3 11 20 50 Panel Wiring Diagrams Panel Wiring Diagram S 3C Viewline Panels 12V Drawing A 12645A Updated 7 9 12 NON CURRENT MODEL...

Page 53: ...OM773LW3 11 20 51 Panel Wiring Diagrams Panel Wiring Diagram M773LW3 Control Panel S 3C 12 V A 12572B Updated 3 13 12 NON CURRENT MODEL...

Page 54: ...OM773LW3 11 20 52 Panel Wiring Diagrams Panel Wiring Diagram M773LW3 Control Panel S 3C Viewline A 12645B Updated 7 9 12 NON CURRENT MODEL...

Page 55: ...OM773LW3 11 20 53 Panel Wiring Diagrams Panel Wiring Diagram M773LW3 Control Panel S 1B 24V A 4792 Updated 3 13 12 NON CURRENT MODEL...

Page 56: ...OM773LW3 11 20 54 Panel Wiring Diagrams Panel Wiring Diagram M773LW3 Control Panel S 3C 24V A 12594B Updated 3 13 12 NON CURRENT MODEL...

Page 57: ......

Page 58: ...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 2020 All rights reserved Litho USA...

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