OPERATOR’S MANUAL

ONL844T4E
For Model: NL844T4E

www.northern-lights.com
 ULTRA LOW
SULFUR FUEL
ONLY RE529956

As of January 2011, U.S. EPA regulations require the

application of a permanently applied label near the fuel tank
fill port for diesel driven equipment. This label is to state:
ULTRA LOW SULFUR FUEL ONLY
Northern Lights is providing this label for application to the
fuel inlet of the fuel supply tank for each engine or generator
set. This is to be applied by the installer of the engine or gen
set, or by the manufacturer of the equipment that the engine
or gen set is installed in. The location of the label must be
in clear site of personnel that refill the supply tank.

— CALIFORNIA —
Proposition 65 Warning:
Breathing Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth
defects, and other reproductive harm.
* Always start and operate the engine in a well-ventilated area.
* If in an enclosed area, vent the exhaust to 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.

Northern Lights
4420 14th Avenue NW
Seattle, WA 98107
Tel: (206) 789-3880
Fax: (206) 782-5455

Copyright ©2018 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.: ONL844TE 07/18
 OPERATOR’S MANUAL
for Model
NL844T4E

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.

Table of Contents

INTRODUCTION ...................................................2 SERVICING

Unit identification................................................2 Lubrication - General........................................ 18
Model Numbers...................................................2 Checking Oil..................................................... 18
Serial Numbers....................................................2 Oil Changes...................................................... 18
Changing Oil Filter........................................... 19
WARRANTY............................................................3 Air Cleaner........................................................ 19
V-Belts.............................................................. 19
SAFETY RULES...............................................3 - 7 Valve Clearances............................................... 19
Fuels - General.................................................. 20
LOCK OUT / TAG OUT PROCEDURES........... 8 Fuel Filters........................................................ 20
Bleeding the Fuel System................................. 21
LOCK OUT / TAG OUT PROCEDURES........... 9 Injector Service................................................. 22
Injection Pump.............................................22-23
COMPONENT LOCATIONS Checking Coolant ............................................ 24
NL844T4E Generator Set .........................10 - 11 Cooling System Flush....................................... 24
Clean Radiator.................................................. 24
CONTROL PANELS........................................... 12 Generator Ends................................................. 24
Turbocharger . .................................................. 25
OPERATING PROCEDURES Electrical System - General.............................. 25
Break-in Period................................................. 13 Glow Plugs........................................................ 25
Before Starting.................................................. 13 Booster Batteries............................................... 26
Starting.............................................................. 13 Battery Care...................................................... 26
Operating.......................................................... 13 Winterizing / Out-of-Service............................ 26
Stopping............................................................ 13
Shutdowns and Alarms..................................... 14 TROUBLESHOOTING
Spare Parts........................................................ 14 DC Electrical.................................................... 27
Engine....................................................... 28 - 30
SERVICING SCHEDULE CHART.................. 15
WIRING DIAGRAMS
SERVICE RECORD......................................... 16 AC Electrical............................................ 31 - 32
DC Electrical.................................................... 33
SERVICE NOTES............................................ 17 Panel Diagrams................................................. 34

Proprietary Information
This publication is the property of Northern Lights, Inc.
It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc.
© Northern Lights, Inc. All rights reserved. Litho U.S.A. Publication number ONL844T4E 10/17

ONL844T4E 3/18
1
 Introduction
The servicing of industrial generator sets presents Failures often begin with minor problems that are
unique challenges. Generators cannot be compared overlooked and become amplified when not corrected
to the servicing of automobiles, trucks, or even farm during routine maintenance.
equipment. In many cases, these generators are installed This manual will help you maintain your unit
far from a repair facility. Generators are heavily taxed properly. Consult the factory or technical manual for
and used for critical installations; therefore, maintenance more comprehensive information on repair or rebuild.
schedules must be adhered to strictly.

Unit Identification

This manual covers the operating instructions for:

• NL844T4E industrial generator sets.

Model Numbers
NLI Model numbers provide information about the unit's application, block model, aspiration, emission compliance level
and fuel delivery type:

NL 844 T

Model number of engine block

NL - Northern Lights T - Turbocharged
Bore Cylinders
industrial generator set
84 mm 4

4
E

4 - US EPA Tier IV E - Electronic fuel

compliant delivery

Northern Lights industrial generator set with an 844 engine, turbocharged US EPA Tier IV compliant with an electronic
NL844T4E = fuel delivery system.

Serial Numbers

Your set has three serial numbers: 1 an engine number stamped on

Figure 1: a plate attached to the valve cover, 2 a generator end serial number,
and 3 a generator set serial number.
Serial Duty

Generator set Part

Adapter
Frame
KW
KVA
°Rise

serial number Lead

Amb. °C
RPM
PF
Volts
Volts

plate. Phase
Hertz
Rule NEMA
Amps
Amps
FL V DC
NOTE: Always use the generator set serial number when ordering parts
or in correspondence. The generator set serial number plate is found on
Insula. FL Amp

Northern Lights, Inc., Seattle, WA U.S.A.

the service side of the generator and resembles the drawing in Figure 1.
(206) 789-3880 www.northern-lights.com
ISO:9001 Certified 00-60010

ONL844T4E 3/18
2
 Updated 4-12-17

Warranty
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 carefully.
NOTE: If the warranty is to apply, the servicing instructions outlined in this manual must be followed. If further
information is needed, please contact an authorized dealer or the factory.

Safety Rules
NOTICE: Northern Lights generator sets and /or any other diesel powered equipment provided by NLI is not provided
with spark arresting or explosion proof components, and therefore is not to be installed in the presence of combustible
gasses having a flash point of 43.3 Degrees C (110 Degrees F) or lower, such as Gasoline, Propane, Natural Gas or other
similar fuel sources.

NOTICE: Accident reports show that careless use of engines causes a high percentage of accidents.
You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.

IMPORTANT SAFETY INSTRUCTIONS. repair parts include the current safety signs. For
Electromagnetic equipment, including generator sets replacement signs, proper placement of safety signs
and their accessories, can cause bodily harm and or clarification on any safety issue, consult your
life threatening injuries when improperly installed, Northern Lights dealer or the factory.
operated or maintained. To prevent accidents be aware There can be additional safety information contained
of potential dangers and act safely. on parts and components from outside suppliers
that is not reproduced in this manual. Consult the
READ AND FOLLOW ALL SAFETY suppliers for additional safety information.
INSTRUCTIONS IN THIS MANUAL,
PRIOR TO THE INSTALLATION Learn how to operate the machine and how to use
OF ANY GENERATOR SET OR the controls properly. Only trained personnel should
ACCESSORY. KEEP THESE operate machines, or work on or around them.
INSTRUCTIONS FOR FUTURE
REFERENCE. Keep you machine in proper working condition.
UNAUTHORIZED MODIFICATIONS TO THE
Recognize Safety Symbols and Instructions MACHINERY MAY IMPAIR ITS FUNCTION
In addition to the information found in this section, this AND SAFETY PARAMETERS.
operator’s manual uses three different signal words to
outline potential dangers of a specific nature. Prevent Bypass and Accidental
Starting
! DANGER DANGER indicates a hazardous situation which, if
not avoided, will result in death or serious injury.
! WARNING
! WARNING
WARNING indicates a hazardous situation which, if
not avoided, could result in death or serious injury.
Do not start engine by shorting across start terminal.
CAUTION indicates a hazardous situation which, Engine will start if normal circuitry is bypassed,
! CAUTION if not avoided, could result in minor or moderate
injury. creating a hazard by runaway machinery.

Follow All Safety Instructions Start engine only from operator’s station.
Carefully read and understand
all safety messages in this
manual and on your machine’s
safety signs. Keep signs in
good and clean condition.
Replace missing or damaged
signs. Be sure new equipment components and
ONL844T4E 3/18
3
 Updated 4-12-17

Safety Rules (Continued)

Handle Fuel Safely - Avoid Flames
Wear Protective Clothing
! WARNING
Diesel is highly flammable and should be treated with
! WARNING
care at all times. Do do not refuel while smoking or To prevent catching anything in moving machinery,
when near sparks or open flame. always wear close fitting clothes and safety
equipment appropriate
ALWAYS STOP ENGINE BEFORE FUELING to the job.
MACHINE. Always fill Prolonged exposure
portable fuel tank outdoors. to loud noise can
Never fuel a hot engine. cause hearing loss or
Prevent accidental impairment. Wear
discharge of starting fluids suitable authorized
by storing all cans in a hearing protection,
cool, safe place, away such as earmuffs or plugs to protect against loud
from sparks or open flame. Store with cap securely noises.
on container. Never incinerate or puncture a fuel
container. Operating equipment requires the full attention of the
operator. Do not use radio or music headphones
Prevent fires by keeping machine clean of accumulated while operating machinery.
trash, grease and debris. Always clean any spilled fuel Practice Safe Maintenance
as swiftly as possible. Do not store oily rags, which
can ignite and burn spontaneously.
! CAUTION
Be prepared if a fire starts. Keep a first aid kit and fire Understand all service
extinguisher handy. Keep emergency contact numbers procedures before starting work.
for fire department, doctors, ambulance and hospital Keep area clean and dry. Never lubricate, service, or
near the telephone. adjust machine while it is in operation.
Service Machines Safely Keep hands, feet and clothing away from power-
driven equipment. When shutting down an engine,
! DANGER disengage all power and operator controls. Allow
the engine to cool completely before beginning any
Do not wear a necktie, scarf, necklace, rings or other service work.
jewelry, or any loose clothing
when working near moving Securely support any machinery elements that must
parts. Tie long hair behind your be raised for service work with support or lifting
head. If any of these items get machinery specifically intended for that purpose.
caught in moving machinery,
severe injury or death could Keep all parts in good conditions and properly
result. installed. Fix damage immediately. Replace any
worn or broken parts. Remove any build up of
Check for any loose electrical connections or faulty grease, oil or debris.
wiring.
Disconnect battery ground cable (-) before making
Look completely around engine to make sure that any adjustments or service work.
everything is clear before starting.

ONL844T4E 3/18
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 Updated 4-12-17

Safety Rules (Continued)

Stay Clear of Rotating Drivelines Never check battery charge
by contacting the posts with
! DANGER a metal object. Use a volt-
meter or hydrometer.
Entanglement in rotating
drivelines can cause serious Frozen batteries may explode
injury or death. Keep if charged. Never charge
shields in place at all times. Make sure that rotating a battery that has not been
shields turn freely in pace with the drivelines. allowed to warm to at least
16oC (60oF).
Do not wear loose fitting equipment around rotating Always remove grounded (-) battery clamp first and
drivelines. Stop the engine and make sure that replace ground clamp last.
all moving parts have stopped before making any
adjustments, connections, or performing any other type Sulfuric acid in battery electrolyte is poisonous and
of service to the engine or other driven equipment. strong enough to burn skin, eat holes into clothing and
other materials, and cause blindness if splashed into eyes.
Install all Safety Guards
To Avoid Hazards:
! WARNING • Fill batteries only in well-ventilated areas.
• Wear appropriate eye protection and rubber gloves.
Direct contact with rotating • Never use air pressure to clean batteries.
fans, belts, pulley and drives • Wear appropriate ventilation equipment to avoid
can cause serious injury. inhaling fumes when adding electrolyte.
• Do not spill or drip electrolyte.
Keep all guards in place • Use correct jump-start procedure if required.
at all times during engine
operation. If acid is spilled on skin or in eyes:
1. Flush skin with water.
Wear close-fitting clothes. Stop the engine and be 2. Apply baking soda or lime to
sure all fans, belts, pulleys and drives are stopped help neutralize acid.
before making adjustments, connections, or cleaning 3. Flush eyes with water for
near fans and their components. 15-30 minutes.
4. Get medical attention
Do not allow anything on your person to dangle into immediately.
or come in contact with a moving fan, belt, pulley or If acid is swallowed:
drive. Fans can act as vacuums and pull materials 1. DO NOT induce vomiting.
up from below, so avoid that area as well while in 2. Drink large amounts of
service. water or milk, without
exceeding 2 liters
Safe Battery Handling (2 quarts)
3. Get medical attention
! WARNING immediately

Prevent Battery Explosions ! WARNING

Battery gas is highly flammable. Battery explosions
can cause severe injury or death. To help prevent Battery posts, terminals, and related accessories
battery explosions, keep sparks, lighted matches can contain lead and lead compounds, chemicals
and open flame away from the top of battery. When known to the State of California to cause cancer and
checking battery electrolyte level, use a flashlight. reproductive harm. Wash hands after handling.

ONL844T4E 3/18
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 Updated 4-12-17

Safety Rules (Continued)

Handle Chemical Products Safely
Do not use a chlorinated solvent in an area where
! WARNING welding will occur. Work only in areas that are well
ventilated. Dispose of paint and solvent properly.
Direct exposure to hazardous
chemicals can cause serious Service Cooling System Safely
injury. Among the potentially
hazardous chemicals that may be ! WARNING
used with Northern Lights Opening a pressurized cooling
products are lubricants, coolants, system can release explosive fluids
paints and adhesives. and causing serious burns.
Before opening any pressurized
All potentially hazardous chemicals come with a Material cooling system, make sure the
Data Safety Sheet (MSDS). The MSDS provides specific engine has been shut off. Do not remove a filler cap
details on chemical products, including physical hazards, unless it is cool enough to comfortably grip with bare
safety procedures and emergency response techniques hands. Slowly loosen cap to relieve pressure before
opening fully.
Read and understand the MSDS for each chemical before
you start any job that includes it. Follow the procedures Avoid High Pressure Fluids
and use appropriate equipment exactly as recommended.
! WARNING
Contact your Northern Lights dealer or Northern Lights
factory for MSDS’s used on Northern Lights products. Relieve pressure prior to
disconnecting pressurized
Work in Well Ventilated Areas lines. Escaping fluid under
pressure can penetrate the
! CAUTION skin causing serious injury. Always relieve pressure
before disconnecting hydraulic or other pressurized
Exhaust fumes from engines contain carbon monoxide lines. Tighten all connections firmly before re-
and can cause sickness or death. Work in well ventilated applying pressure.
areas to avoid prolonged exposure to engine fumes. If it
is necessary to run an engine in an enclosed area, route If searching for leaks, use a piece of cardboard.
the exhaust fumes out of the area with an approved, leak Always protect your hands and other body parts from
proof exhaust pipe extension. high-pressure fluids.

Remove Paint Before Welding or Heating If an accident occurs, see a doctor immediately. Any
high pressure spray injected into the skin must be
! WARNING removed within a few hours to prevent the risk of
gangrene or other infection.
Hazardous fumes can be
generated when paint is heated Avoid Heating Near Pressurized Fluid Lines
by welding, soldering or using a
torch. To avoid potentially toxic ! WARNING
fumes and dust, remove paint
before heating. Flammable spray can be generated
• Remove paint a minimum of 100 mm (4 in.) from the by heating near pressurized fluid
area that will be affected by heat. lines, resulting in severe burns and
• If paint cannot be removed, wear an approved respirator. bodily injury. Pressurized lines
• If you sand or grind paint, use an approved respirator. can rupture when heat goes beyond the immediate
• If you use solvent or paint stripper, remove stripper flame area. Do not weld, solder or use a torch or
with soap and water before welding. Remove open flame near pressurized lines or other flammable
solvent or paint stripper containers from the area. fluids.
• Allow at least 15 minutes for fumes to disperse
before welding or heating.
ONL844T4E 3/18
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 Updated 4-12-17

Safety Rules (Continued)

Do Not Open High-Pressure Fuel System Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding materials
! DANGER containing asbestos. When servicing, wear an
approved respirator. A special vacuum cleaner is
Many Northern Lights engines use high- recommended to clean asbestos. If this vacuum is not
pressure fuel injection. High-pressure fluid available, apply a mist of oil or water on the material
remaining in fuel lines can cause serious containing asbestos. Keep all bystanders away from
injury. Do not disconnect or attempt any area where asbestos dust may be generated.
any repair of fuel lines, sensors, or other
components between the high-pressure fuel pump Use Proper Lifting Equipment and Techniques
and nozzles on engines with high pressure fuel
systems. ! WARNING
ONLY AUTHORIZED TECHNICIANS CAN Lifting heavy components incorrectly
PERFORM REPAIRS ON AN HIGH PRESSURE can cause severe injury or damage
FUEL INJECTION SYSTEMS. to machinery. Avoid unbalanced
loads. Do not use lifting eyes. Lift
Avoid Hot Exhaust the generator set using lifting bars inserted through
the lifting holes on the skid. Follow all recommended
! WARNING removal and installation procedures in this and
associated Northern Lights manuals.
Avoid exposure to and physical
contact with hot exhaust gases. Exhaust parts Use Proper Tools
and streams can reach high temperatures during
operation, leading to burns or other serious injury. ! CAUTION
Cleaning exhaust filters can also lead to exposure to Makeshift tools and procedures
hot exhaust gas and the injury risk associated with can create safety hazards.
it. Avoid exposure to and physical contact with hot Always use appropriate tools for the job.
exhaust gases when cleaning exhaust filters.
Use power tools only to loosen threaded parts and
During auto or manual/stationary exhaust filter fasteners. For loosening and tightening hardware,
cleaning operations, the engine will run at always use the correct sized tools.
elevated temperatures for an extended period of
time. Exhaust parts and streams can reach high Do not use US measurement tools on metric
temperatures during operation, leading to burns or fasteners, or vice versa. Use only service parts that
other serious injury. meet Northern Lights specifications.

Avoid Harmful Asbestos Dust Dispose of Waste Properly

! WARNING ! CAUTION
Inhaling asbestos fibers may Disposing of waste improperly can threaten the
cause lung cancer. Avoid environment and lead to unsafe working conditions.
breathing any dust that may Potentially harmful waste used in Northern Lights
be generated when handling equipment can include oil, fuel, coolant, filters and
components containing asbestos batteries.
fibers, including some gaskets.
Use leakproof containers to drain fluid. Do not
The asbestos used in these components is usually use food or beverage containers that may mislead
found in a resin or otherwise sealed. Normal someone into drinking from them.
handling of these components is not dangerous,
as long as airborne dust containing asbestos is not Do not pour waste onto the ground, down a drain or
generated. into any water source.

ONL844T4E 3/18
7
 Lock Out / Tag Out Procedures
Scope
During maintenance, repairs or retooling of a Northern Lights generator set, simply turning the machine off or unplugging
it while it is being worked on does not give enough protection to others who are not performing the maintenance or
repair. Many serious accidents happen when someone thought the machine was turned off, or all of its energy was
safely blocked or released.

General Policy If shutting off of air, water or other material cannot be

achieved at the local supply valve, shut off valves further
! CAUTION back in the system and re-check the bleed-off point until
To avoid dangerous or hazardous situations, refrain from complete shut-off is achieved.
any of the following:
• Removing or bypassing a guard or other safety device Affix a DO NOT OPERATE tag to each valve handle that
• Placing any part of your body in a position where you requires shut off. Each DO NOT OPERATE tag must be
could be caught by moving machinery. signed and dated by the authorized technician servicing
• Cleaning or oiling machinery when in operation. the equipment.
• Adjusting circuits, chillers, pumps, air handlers, valves,
circuit breakers or fans while in operation. Lock Out/Tag Out Instructions -
• Working on piping or high pressure systems. Air Hose Connected Pneumatic Equipment
! WARNING
Lock Out/Tag Out Instructions - Equipment connected to the compressed air system
Electrical Equipment through an air hose with a detachable fitting must be
shutdown and unplugged. Excess air must be bled prior
! WARNING to removing the air hose, prior to any maintenance or
Be sure the equipment’s ON/OFF switch is in the OFF repair activities.
position and is unplugged from any electrical source before
attempting to perform any type of work on the equipment. Affix a DO NOT OPERATE tag to the air hose near the
Obtain an electrical plug cap cover with a lockset. Secure detachable fitting. Each DO NOT OPERATE tag must be
the plug terminal end using the electrical plug lockout cap. signed and dated by the authorized technician servicing
Lock the cap and retain the key. the equipment. Check that the equipment cannot be
operated by activating the ON switch.
If the equipment is directly wired into an electrical box with
a shut off switch, obtain a lock pad and/or the appropriate Stored Energy
colored tags and place the lock and tag through the shut
off lever. Retain the key until the repair is completed and ! WARNING
the machine is safe to start. Be certain the shut off lever Immediately after applying Lock Out or Tag Out devices,
is in the OFF position before restarting. NEVER give a ensure that all potentially hazardous stored or residual
lock out key to unauthorized personnel. energy is relieved, disconnected, restrained and otherwise
rendered safe.
If the equipment is directly wired into an electrical box
without a shut off switch and lock out capability, then a Verification of Isolation
circuit breaker lock out will be required. Obtain a circuit
lock and tag set. Install the lock onto the circuit breaker ! CAUTION
box. Ensure the unit ON/OFF switch is in the OFF position Verify the machinery or equipment is actually isolated and
before restarting. de-energized prior to beginning work on a machine or on
equipment that has been locked out.
Lock Out/Tag Out Instructions -
Pneumatic and Hydraulic Equipment Restarting Procedures

For servicing pneumatic and hydraulic equipment, the Follow the procedures below prior to restoring energy:
following additional procedures must be implemented, • Ensure that all machinery or equipment is properly
following completion of lock out/tag out procedures for reassembled. Inspect the machinery or equipment to
the unit to be serviced: verify non-essential items have been removed.
• Ensure that all personnel are safely outside danger
Shut off air, water or supply valves at the equipment to zones. Notify personnel that lock out/tag out devices have
be serviced. been removed and energy will be reapplied.
• Only authorized personnel may remove lock out/tag out
Check the local bleed-off point for completed release of devices or notices.
pressurized air, water or oil.

ONL844T4E 3/18
8
 Specifications

NL844T4E

Kilowatt Rating Prime 22 kW

Rated RPM/Frequency 1800/ 60Hz

General Information
Engine Type Lugger 4 cycle, swirl chamber diesel
Cylinders 4 in-line
Displacement 135 in3 (2.216 liters)
Cycles 4
Bore x Stroke 3.30 x 3.90 in (84 x 100 mm)
Rotation (Facing Flywheel) counter-clockwise
Compression Ratio 22:5
Crankcase Capacity including Oil Filter 2.1 gal (8.2 liter)
Aspiration Turbocharger
Fuel injection system High pressure common rail

Rated Horsepower 32 Hp
Approximate Dry Weight 1275 lbs. (580 kg)
Length 55.3 in (1400 mm)
Width 26.5 in (670 mm)
Height 36.5 in (925 mm)

Approx. Coolant Capacity 1.32 gal (5 liters)

Approx. Coolant Capacity (engine only) 0.95 gal (3.6 liters)

Standard Output, Single Phase 120-240 Volts, 83 Amps

Compression Pressure of Cylinder Standard Value:

MPa (kgf/cm2) More than 2.94 MPa (more than 30 kgf/cm2)
Time to be repaired:
Less than 2.45 MPa (less than 25 kgf/cm2)

Cylinder Head Tightening Torque 98 - 103 N•m (10.0- 10.5 kgf/cm2)

N•m (kgf/cm2)

ONL844T4E 3/18
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 NL844T4E Generator Component Locations

Figure 2: NL844T4E service side

7
6

5
2 4

10

12 11
13

1. Circuit breaker 5. Turbo housing 10. Lube Oil Dipstick

2. Emergency E-stop 6. Injector 11. Fuel inlet line
3. S-TSC Control panel 7. High pressure common rail 12. Fuel return line
4. Generator junction box 8. Fuel lift pump 13. Oil filter
9. Fuel filter

ONL844T4E 3/18
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 NL844T4E Generator Component Locations

Figure 3: NL844T4E non-service side

14 15

16

18

17

14. Coolant fill (top of radiator)

15. Air filter
16. Exhaust outlet
17. Starter
18. DC alternator

ONL844T4E 3/18
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 Control Panels

Figure 4: S-TSC control panel

S-TSC CONTROL PANEL

4. Failure
The S-TSC control panel has been factory
programmed and tested with your generator set to
When a failure is detected, the controller shuts down
the engine and displays a reason code. The unit can be
provide optimum performance and protection.
reset using the front panel OFF button.
For a full list of TSC capabilities and
5. Menu
parameters, consult manual OS-TSC.
Menu allows the user to change settings and view

events history.
OPERATING MODES
STARTING MODE
1. Off The controller must be in AUTO mode in order to start,
Engine is stopped and cannot be remotely started. except in the case of manual operation.
2. Auto
Engine will start when it receives a start command. Press the RUN button to start the engine in AUTO
mode.
3. Running
When the engine is running the controller will monitor Press OFF to shut down.
and record engine parameters. Engine will remain
running barring any failures, until stop command is
received.

ONL844T4E 3/18
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 Operating Procedures

BREAK-IN PERIOD STARTING

1. The first 100 hours on a new or reconditioned 1. Hold the Shutdown Bypass-Preheat switch in the
engine are critical to its life and performance. ON position for about 10 seconds before starting a
2. Frequently check the engine temperature and oil cold engine. Holding the switch too long can burn
pressure gauges (sets with Series 3 or 4 panels). out the glow plugs.
3. Oil consumption is greater during break-in as 2. While holding the Shutdown Bypass-Preheat switch
piston rings take time to seat. in the ON position, push the Engine Control switch
4. Break-In Oil Changes: Change engine oil and to the START position.
filter at 50 hours. Change oil and filter again at 3. As soon as the engine starts, release both switches. Do
100 hours (consult Lubricants section for oil not crank the starter for more than 10 seconds
recommendation), then every 250 hours. consecutively. If the engine fails to start with the first
attempt, be sure that it has stopped completely before
Operating Instructions: re-engaging.
Maintain at least a 75% load on your generator
set for the first 100 hours. If this is not possible,
maintain no less than a 50% load to ensure proper OPERATING
seating of the piston rings. Vary the load to help
seat the rings. 1. Units with Series 3 and Series 4 Control Panels:
check gauges often. Oil pressure must be above 15
BEFORE STARTING PSI. The D.C. voltmeter should read between 11
and 15 volts at 80°F (25°C) ambient temperature.
1. Check the water level by removing the pressure Check the A.C. voltage and frequency meters (Series
cap from the radiator. In order to give the cooling 4 panel). If the gauges deviate from normal levels,
water an opportunity to expand, the level should shut down the generator set and investigate.
be about 1 in. (2.5 cm) below the filler cap sealing 2. Let the unit run unloaded for a two to three minute
surface when the engine is cold. warm-up period.
3. Apply electrical load.
CAUTION: Use protective clothing and open the filler
cap carefully when the engine is warm to prevent STOPPING
burns.
1. Remove electrical load from the generator set.
2. Check the oil level in the crankcase with the 2. Run the engine for a 2 to 3 minute cool down period.
dipstick. The oil level must be in the waffled area on 3. Hold the Engine Control switch to the STOP
the stick. Never allow the level to go below this area. position until the engine comes to a complete stop.
Always add the same viscosity of oil as is already in
the crankcase.
3. Check the fuel tank level and open any fuel valves.

4. NOTE: The battery switch must always be kept

ON while the engine is running. If the switch is
turned OFF while the engine is running, the
battery charging alternator could be ruined.

ONL844T4E 3/18
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 Operating Procedures

SHUTDOWNS AND ALARMS SPARE PARTS

1. Your unit is fitted with a system to protect it from 1. Northern Lights recommends that you keep the
high water temperature or low oil pressure. following spare parts on hand for field service. The
a. Generator sets have shutdown systems to stop the parts are available from your local Northern Lights
engine. They have no warning horns. dealer.
b. Other alarms and shutdowns are available as
optional equipment. 2. All owners should have the following spares:
NOTE: Do not rely on any warning to the a. Primary and secondary fuel filter elements
exclusion of careful gauge monitoring. Watching b. Oil filters
your gauges can prevent damage to the unit and c. Air filter
dangerous power losses. d. Alternator belt
e. Thermostat and gaskets
2. Do the following when your warning or shutdown f. Glow plug
system is activated: g. Injector and washer
a. Check the temperature gauge. If above 205°F
(96°C), shut off the engine immediately. 3. If your set is operating a long distance from a
b. Use the Trouble Shooting Guide on page 22 to servicing dealer, add the following:
isolate the cause of the overheat. a. Complete set of injectors
b. Copper washers for injector change
CAUTION: Do not remove the water fill c. Complete set of glow plugs
cap of an overheated engine. Escaping high d. Fuel lift pump
temperature steam can cause severe burns.
Allow the engine to cool and then remove the
cap slowly using protective clothing.

d. Make repairs. Restart your set after the

temperature gauge registers below 200°F (94°C).
e. Watch the temperature gauge regularly and
turn off the unit if the temperature rises
above 205°F (96°C) on units.
Repeat troubleshooting.

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 operation.
c. If the oil level is normal, DO NOT restart the
engine. Call your dealer for assistance.

ONL844T4E 3/18
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 Service Schedule Chart
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: EVERY 250 HOURS:

SP1 Check oil level in engine SP2/3 Change engine oil and filter
SP5 Check V-belt tension SP4 Check air cleaner
SP7 Check primary fuel filter SP15 Check and clean radiator
SP13 Check coolant level SP18 Check state of charge of batteries
SP17 Check electrolyte in batteries
EVERY 500 HOURS:
AFTER FIRST 50 HOURS:
SP8 Change primary fuel filter element
SP2/3 Change engine oil and filter
SP9 Change secondary fuel filter
AFTER FIRST 100 HOURS:
SP2/3 Change engine oil and filter EVERY 1000 HOURS:
SP6 Check and adjust valve clearances SP6 Check valve clearances
SP16 Check turbocharger SP11 Check injectors

EVERY 2500 HOURS:

SP12 Check fuel injection pump
SP14 Check and flush cooling system

SERVICE 50 100 250 500 1000 2500

POINT PAGE OPERATION NOTES DAILY Hours Hours Hours Hours Hours Hours
ENGINE:
SP1 18 Check oil level •
SP2 18 Change engine oil 1) 5) • •
SP3 18 Change lube oil filters 1) 5) • •
SP4 19 Check air cleaner, •
Change element 1) 4)
SP5 18 Check V-belt tension •
SP6 19 Check valve clearances 1) 2) •
FUEL SYSTEM:
SP7 20 Check primary filter •
SP8 20 Change primary filter element 2) 3) •
SP9 20 Change secondary fuel filter 1) 3) •
SP10 21 Bleed the fuel system 3)
SP11 22 Check injectors 1) 3) 6) 7) •
SP12 22 Check fuel injection pump 7) •
COOLING SYSTEM:
SP13 24 Check coolant level •
SP14 24 Check and flush cooling system •
SP15 24 Check and clean radiator 4) •
TURBOCHARGER:
SP16 25 Check for leakage •
ELECTRICAL SYSTEM:
SP17 26 Check battery electrolyte level •
SP18 26 Check condition of batteries 1) 4) •
OUT OF SERVICE:
SP19 26 Winterizing or out-of-service 3)

1) Perform all maintenance once a year even if hour level has not been reached. 6) Clean injection nozzles every 1500 hours.
2) Consult manufacturer's maintenance schedule, note on chart. 7) For EPA emission standards fuel nozzle needs to be cleaned
3) Whenever necessary. every 1500 hours, the fuel nozzle and fuel pump need to be
4) More often if necessary. cleaned, adjusted, or repaired every 3000 hours, and the
5) After first 50 hours, then after 100 hours, then every 250 hours. quality guarantee for these parts is 1500 hours or 2 years.

ONL844T4E 3/18
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 Servicing Record

Service
Point OPERATION HOURS/ DATE

AFTER FIRST 50 HOURS

SP2 Change engine oil

SP3 Change lubricating oil filters

AFTER FIRST 100 HOURS

SP2 Change engine oil

SP3 Change lubricating oil filters

SP4 Check air cleaner, change element

SP6 Check valve clearances

SP16 Check turbocharger

EVERY 250 HOURS

SP2 Change engine oil

SP3 Change lubricating oil filters

SP15 Check and clean radiator

SP18 Check condition of batteries with hydrometer

EVERY 500 HOURS

SP8 Change primary filter element

SP10 Change secondary fuel filter

EVERY 1000 HOURS

SP7 Check valve clearances

SP11 Check injectors

EVERY 2500 HOURS

SP12 Check fuel injection pump

SP18 Check and flush cooling system

ONL844T4E 3/18
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Service Notes

ONL844T4E 3/18
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 Servicing

LUBRICATION - GENERAL SP 2. OIL CHANGES

1. Use only clean, high quality lubricants stored in 1. The set is delivered with special break-in oil.
clean containers in a protected area. Change the engine oil and oil filter after 50 hours
2. These lubricants are acceptable: of operation. Use Service CC 30 weight oil during
a. API Service CC/CD/CE single viscosity oils. the first 100 hours.
b. API Service CC/CD/SF multi-viscosity oils. 2. Change the oil and filter again at 100 hours using the
3. Use the proper weight oil for your average opera- oil recommended in the above diagram. After this,
tion temperature. change oil and filter every 250 hours.
3. During intermittent cold weather operation, change
oil every 100 hours or six weeks, whichever comes
Air Single Multi-
Temperature Viscosity Viscosity first.
4. Change oil at the end of each season and the
Above 32°F
(0°C)
SAE 30W SAE 15-40W beginning of each season.
5. Change oil when engine is warm.
-10 to 32°F 6. Dispose of waste oil in an approved manner.
SAE 10W SAE 10-30W
(-23 to 0°C)
7. Never use a flushing oil.
Below -10°F SAE 5W SAE 5-20W 8. Loosen the clamp on the oil change tube. Remove
(-23°C) cap. Drain oil. Replace the cap and tube.
9. Refill engine with recommended oil for the season.
Figure 4: Lube Oils 10. Engine capacity with new oil filter is:
NL844T4E – 2.1 gallons (8.2 liters)
4. Some increase in oil consumption may be
expected when SAE 5W and SAE 5-20W oils are SP 3. CHANGING LUBE OIL FILTER
used. Check oil level frequently.
5. Never put additives or flushing oil in crankcase. 1. Change the lube oil filter every 250 hours.
2. Use a filter wrench to remove old filter. Dispose of
SP 1. CHECKING OIL LEVEL filter in approved manner.
3. Make sure the gasket from the old filter is removed
1. Check the oil level in the crankcase with the dip- and discarded. Clean mount face.
stick. The oil level must be in the waffled area 4. Spread a thin film of engine oil on the rubber gasket
on the stick. Never allow the level to go below on the new filter and screw it on nipple until gasket
this area. Follow the lubrication recommendations meets the sealing surface.
above. 5. Using hands only – no wrench – tighten filter
one-half turn farther. Overtightening can do
damage to filter housing.
6. Fill engine with recommended oil. Start engine and
check for leakage. Stop engine, wait 3 minutes, and
check oil level. Add additional oil if necessary.
7. Oil filter part number is:
NL844T4E – #24-02002

ONL844T4E 3/18
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 Servicing

SP 4. AIR CLEANER

1. Inspect air cleaner every 250 hours. In dusty

conditions, check more often.
2. Replace if necessary. Part number is:
NL844T4E (element only) – #24-27302

3. NOTE: Make absolutely sure no impurities enter Figure 6: Valve Adjustment

the engine while changing the element. Do NOT
run the engine with the air cleaner removed.
SP 6. VALVE CLEARANCES
SP 5. V-BELTS
1. Adjust valve clearance after the first 50 hours and
1. Check the tension and wear on the V-belt daily. then at 1000 hours, or as needed.
2. Use your thumb to press on the belt at the midpoint 2. Engine should be cold and NOT running.
between the crankshaft and alternator pulleys. The 3. Watch the valves while turning the engine over by
tension is correct if the belt can be depressed about hand. Turn until the inlet valve starts to open and the
3/16 in. (5 mm). Fan belt slackness should be about exhaust valve starts to close (the valves are rock-
3/16 in. (5 mm). ing). Then turn the crankshaft one more full turn and
3. To adjust the belt tension loosen the alternator adjust the clearance on both valves for this cylinder.
adjusting plate bolt and the alternator mounting bolt. Align the top mark of the crank pulley with the TOP
Pivot the alternator at the mounting bolt as needed. mark of the timing gear case.
4. Tighten the mounting bolt and the adjusting bolt. 4. Loosen the lock nut and adjust the clearance between
5. Operate engine at low idle speed and recheck the the rocker arm and valve guide of both the intake
belt tension. and exhaust valves with the adjustment screw (Figure
6). Clearance on both intake and exhaust valves
should be 0.008 in. (0.2 mm).
5. Repeat steps 3 and 4 for each cylinder. Each set of
valves must be adjusted individually.
6. Replace the rocker arm cover. Tighten cover nuts to
5 - 8 ft/lbs (0.8 - 2.3 kg/m).

Cylinder No. 1 No. 2 No. 3 No. 4

Valve
In Ex In Ex In Ex In Ex
Arrangement

When No. 1
cyl. is at TDC
in compression
stroke

With the
crankshaft
turned by 3600
in normal
direction from
above

Figure 7: NL844T4E Valve sequence

Figure 5: Timing mark

ONL844T4E 3/18
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 Servicing

FUELS - GENERAL Request a certificate of analysis from an approved

biodiesel fuel distributor to make sure the biodiesel blend
1. Use only clean, high quality fuels of the following meets specifications.
specifications, as defined by ASTM designation
D975 for diesel fuels: 6. Storing fuel:
a. Use grade no. 2 diesel at ambient temperatures a. Keep dirt, scale, water, and other foreign
above freezing 32°F (0°C). matter out of fuel.
b. Use grade no. 1 at ambient temperatures below b. Avoid storing fuel for long periods of time.
freezing and for all temperatures at an altitude c. Fill the fuel tank at the end of each day’s
of above 5,500 ft. (1500 meters). operation. This will reduce condensation and
2. Use fuel having less that 1% sulphur (preferably possible biological contamination.
less that 0.5%). d. If biological contamination is detected or
3. The cetane number should be a minimum of 45. suspected, contact your dealer for assistance.
4. DO NOT use these unsuitable grades of fuel:
a. Domestic heating oils, all types. SP 7-9. FUEL FILTERS
b. Class B engine.
c. Class D domestic fuels. Optional Primary
Optional
Fuel Filter
d. Class E, F, G or H industrial or marine fuels. Primary Fuel
e. ASTM-D975-60T No. 4-D and higher number Filter P/N
fuels. Part Numbers
Complete:
Complete
24-50013 Unit:
5. Biodiesel: 24-50002
Biodiesel involves the transesterification of vegetable oils Element:
Element:
or animal fats. It can involve animal fats, yellow greases 24-50012
24-50012
(used greases), cotton seed, sunflower seed, coconut oil,
or sesame seed, but mainly in the US soybean methyl
ester is used (SME). In Europe mainly rapeseed (canola) Figure 8: Primary Fuel Filter (if provided by Northern
methyl ester is made (RME), and in Asia palm methyl Lights)
ester (PME) is made. 100% biodiesel (B100) is made in 1. Your generator set may have a primary fuel filter
compliance with ASTM D6751 or EN14214 (EU) installed. We recommend the Racor brand of fuel
specifications. filter-water separators.
Biodiesel may be used in a 5% blend (5% biodiesel/ a. Check the primary fuel filter daily as
95% diesel) from a BQ-9000 accredited producer. 20% recommended by the filter manufacturer.
biodiesel blends (20% biodiesel/ 80% diesel) can only be Empty the collection bowl as necessary.
used if they meet ASTM D6751 or EN14214 (EU) b. Change the element as often as necessary or
specifications. A 2% reduction in power and a 3% every 500 hours.
reduction in fuel economy can be expected if a 20% c. If the bowl fills with water, change the primary
blend is used. With a 20% biodiesel blend, an approved and secondary element immediately.
fuel conditioner is recommended. The petroleum part 2. Change secondary fuel filter every 500 hours.
of the biodiesel blend must meet ASTM D975 or EN590 NOTE: The fuel filter on the engine is considered the
(EU) specifications. Biodiesel blends must be used “secondary fuel filter.”
within 90 days of their manufacture. When biodiesel a. Remove the spin-on filter by turning it
blends are used the oil level must be checked daily and counterclockwise with a filter wrench. Fill the
storage, leaking, possible microbial growth, plugging, new cartridge with fuel and install it after
and components degradation must all be checked more applying engine oil to gasket surface. Screw on
frequently. until the gasket surface comes into contact with
Note: Using raw pressed or partially refined vegetable sealing surface of filter base. Then, tighten it
oils or recycled greases as fuel (which have not been two-thirds of a turn by hand. Do not overtighten.
through transesterification) could cause engine failure. b. Secondary fuel filter cartridge part number is:
NL844T4E – #24-52020

ONL844T4E 3/18
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 Servicing

SP 10. 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 hoses are not damaged. Fuel escaping from a very small hole
can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected
leaks. If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if proper
medical treatment is not administered immediately.

Figure 9: M844Lk Fuel System (for illustration purposes).

1. The fuel system is self-bleeding. However, any 3. Loosen bleed screw “C”. Pump hand primer “B”
system may need manual bleeding when: until pure fuel (no bubbles) escapes. Then tighten
a. A new fuel filter is installed; bleed screw “C”.
b. The engine has run out of fuel; 4. If the engine does not start after the above
c. The fuel lines, injection pump or any other fuel bleeding process, loosen a fuel line at the injector
system component has been removed and while cranking the engine with the starter motor
installed. until pure fuel escapes. Then tighten the connection.
2. Loosen bleed bolt “A” (Figure 9) on top of the filter. Do each line one-at-a-time.
Pump hand primer “B” on fuel lift pump until pure 5. After the engine has started, use a piece of cardboard
fuel (no bubbles) escapes from bleed bolt “A”. to look for fuel leaks.
Tighten bleed screw “A”.

ONL844T4E 3/18
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 Servicing

SP 11. INJECTOR SERVICE SP 12. INJECTION PUMP

1. Injectors should be checked every 1000 hours, or as 1. Since operating conditions may vary considerably, it
needed. Check should be made by a Northern Lights is difficult to give a definite interval for checking the
dealer or local injection repair station. injection pump. But as a rule, pump settings,
maximum speed, idle speed, and exhaust smoke
CAUTION: Escaping diesel fuel under pressure should be checked after every 2500 hours of
can have sufficient force to penetrate the skin operation. Service of the fuel injection pump should
causing serious personal injury. If injured by only be done if checks indicate pump malfunction.
escaping diesel fuel, see a doctor at once. 2. Black smoke can be an indication of pump
malfunction. Before servicing the pump, check other
2. Injector removal: possible causes:
a. Clean loose dirt from around the injectors and a. Check cleanliness of air filter.
the fuel lines. b. Check valve clearances.
b. Relieve high pressure in the fuel lines by c. Clean and check injectors.
loosening the delivery line flare nuts at each 3. Any repair which involves disassembly of the
injector (Figure 10). injection pump must be carried out by specially trained
c. Remove delivery lines by disconnecting from mechanics with the proper tools and test equipment.
injectors and injection pump (Figure 11). Remove NOTE: All warranties on the engine become null
all lines as an assembly; do not remove the spacers. and void if the injection pump seals are broken by
Cover the ends of the lines, the injector inlets and unauthorized persons.
injection pump outlets to keep dirt out (Figure 12).
d. Remove the return line retaining bolts (Figure 13).
Remove the return line (Figure 14).
e. Unscrew and remove the injectors (Figure 15).
NOTE: Do not use pry bars to remove injectors
from cylinder head.
f. After removing the injectors, discard the copper
sealing washers from the injector hole in the head
(Figure 16). Cover holes to prevent dirt and debris
from entering the cylinders.

3. Injector installation:
a. Install a new copper sealing washer in each
injector hole (Figure 16).
b. Screw in injector and tighten to 44 - 51 ft/lbs
(6 to 7 kgm) (Figure 17).
NOTE: Overtightening can damage injector.
c. Install return line using a new sealing washer
below each connection. Tighten return line
retaining bolts to 22 - 30 ft/lbs.
d. Install delivery lines. Leave loose at injectors for
bleeding.
e. Crank engine to fill lines. Tighten lines at
injectors to 11-18 ft./lbs. Start engine and check
for leaks using a piece of paper or cardboard.
DO NOT use hand to check for leaks.

ONL844T4E 3/18
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 Servicing

Figures 10-17: For illustrative purposes only, may not be exact model.

Figure 10: Remove delivery line flare nuts. Figure 14: Remove return line.

Figure 11: Remove delivery lines. Figure 15: Unscrew injector.

Figure 12: Cover lines, inlets and injection pump outlets. Figure 16: Remove and replace copper sealing washer.

Figure 13: Remove return line nuts. Figure 17: Reinstall injector. Torque to proper tightness.

ONL844T4E 3/18
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 Servicing

COOLING SYSTEM - GENERAL SP 14. COOLING SYSTEM FLUSHING

CAUTION: The cooling water in the engine 1. Flush the cooling system every 2500 hours or every
reaches extremely high temperatures. You must 12 months, whichever comes first.
use extreme caution when working on hot 2. Industrial sets:
engines to avoid burns. Allow the engine to cool a. Remove radiator cap and the radiator drain and
before working on the cooling system. Open the drain engine block.
filler cap carefully, using protective clothing b. Pour clean water into radiator until water
when the engine is warm. coming from radiator is free of discoloration and
sediment.
SP13. CHECK THE COOLANT LEVEL c. Close the radiator drain and continue flushing
until water from the engine drain is clear.
1. Check the coolant level each day before starting the d. Open all drain cocks and drain completely.
engine. Check the water level by removing the pres- e. Close drain cock and refill with recommended
sure cap from the radiator. mixture.
In order to give the cooling water an opportunity to f. Clean leaves, dust, and other debris off the
expand, the level should be about 1 in. (2.5 cm) below radiator fins.
the filler cap sealing surface when the engine is cold. 3. Coolant Specifications:
2. The pressure valve in the filler cap releases when the Use 50% distilled water / 50% ethylene glycol
pressure is approximately 7 PSI (0.5 bar). Use a cap antifreeze mix. Antifreeze mixture is recommended
pressure tester to check cap if you suspect it is faulty. as a good year-round coolant.
4. Check hoses and connections and repair any leakage.

SP 15. CLEAN RADIATOR

1. Remove debris from radiator fins daily.
2. In very dusty applications, clean the radiator with
compressed air or steam cleaner every 100 hours.
and check for leaks.

GENERATOR ENDS

The maintenance and operation recommenda-

tions for the generator end are in Owner’s Manual
OPX300K2. To obtain one of these manuals, contact
your local Northern Lights dealer or www.northern-
lights.com.

ONL844T4E 3/18
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 Servicing

SP 16. TURBOCHARGER ELECTRICAL SYSTEM - GENERAL

1. Check for air leaks every 250 hours. Air leak- 1. Never switch battery switch off or break the circuit
age will lower engine output and may cause black between the alternator and batteries while the engine
exhaust smoke and soot. is running. Regulator damage can result.
2. Listen along air line while the engine is running. 2. Do NOT reverse the polarity of battery cables when
Leaking is indicated by a whistling or hissing sound. installing the battery.
3. Leakage on the pressure side, between the turbo and 3. If welding on the unit, disconnect the regulator and
the engine, can be found by applying soapy water to battery. Isolate the leads.
the air line. 4. Disconnect the battery cables when servicing the
4. Tighten the hose clamps and replace hoses and gas- D.C. alternator.
kets as needed. 5. Never test with a screwdriver, etc., against any
5. Ensure that lubrication and cooling lines are tight terminal to see if it emits sparks.
and not leaking. 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.

GLOW PLUGS

1. Each cylinder is supplied with a glow plug which

serves to heat the combustion chamber.
2. To check the glow plugs, loosen the current
carrying flat wire between the plus-poles of the
glow plugs (Figure 18). Connect a D.C. test bulb
between the plus-pole of the battery and the
plus-pole of the glow plug. If the bulb lights up,
the glow plug is functioning properly.
3. Check all glow plugs and replace any that are faulty.

Figure 18: Glow plugs.

ONL844T4E 3/18
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 Servicing

BOOSTER BATTERIES SP 19. WINTERIZING / OUT-OF-SERVICE

1. Industrial sets:
CAUTION: Battery gas can explode. a. Drain and flush the radiator and cooling system.
Keep all flames and sparks away from batteries. Refill with antifreeze-water mixture. Start the
engine and run to circulate the antifreeze.
1. Before changing or using booster batteries, check b. Fill the fuel tank or add biocide as per the
battery electrolyte level. Add distilled water if manufacturer's instructions.
necessary. c. Change the crankcase oil and filter.
2. Booster and main batteries must have the same d. Seal the air cleaner inlet, exhaust opening,
voltage rating. crankcase breather pipe, and fuel tank vent with
3. First, connect positive (+) terminal of booster plastic bags and tape.
battery to positive (+) terminal of main battery. e. Loosen the alternator belt.
Then, connect negative (-) terminal of booster f. Disconnect and clean battery. Remove to warm
battery to ground on the engine block (see Figure storage place if possible.
19). g. Clean outside of unit. Paint any scratched or
4. Remove booster battery after starting engine. chipped surfaces. Put corrosion preventative on
5. Sealed batteries: See manufacturer charging and all exposed metal surfaces.
booster instructions. h. Store the set in a dry, protected place. If the unit
must be stored outside, be sure it is well
SP 17-18. BATTERY CARE protected with a cover.

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
solution. Flush with clean water. Tighten terminals
and grease them to inhibit corrosion.
3. Check the battery condition with a hydrometer
every 250 hours.

Figure 19:
Battery connections.

ONL844T4E 3/18
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 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 batteries • Check specific gravity of each battery.
• Check electrolyte level of each battery.
Loose or defective alternator belt • Adjust belt tension.
• Replace belt.

Starter Inoperative Check DC circuit breaker • If the breaker is tripped, reset it.
Loose or corroded connections • Clean and tighten loose battery and
harness 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 each battery
Crankcase oil too heavy • Fill with oil of appropriate viscosity.
Loose or corroded connections • Clean and tighten loose connections.

Entire Electrical System Check DC circuit breaker • If breaker is tripped, reset it.
Does Not Function
Faulty connection • Clean and tighten battery and harness
plug connections.
Sulfated or worn out batteries • Check specific gravity and electrolyte
level of each battery.

If you cannot correct problems with these procedures, see your Northern Lights dealer.

ONL844T4E 3/18
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 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 • Check electrolyte level and condition.
Excessive resistance • Clean and tighten all battery connections.
in starting circuit
Crankcase oil too heavy • Use oil of proper viscosity.
Improper type of fuel • Consult fuel supplier and use proper type
of fuel for operating condition.
Water, dirt or air in fuel system • Drain, flush, fill and bleed system.
Clogged primary • Clean or replace filter element.
fuel filter element
Clogged secondary • Replace filter element.
fuel filter element
Dirty or faulty injection nozzles • Have your dealer check injection nozzles.

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, flush, fill and bleed system.
Dirty or faulty injection nozzles • Have your dealer check injection nozzles.
Air in fuel system • Inspect clamps and hoses on suction side
of fuel pump for air leak.
Improper type of fuel • Consult fuel supplier and use proper type
of fuel for operating condition.

Lack of Engine Power Intake air restriction • Service air cleaner.

Clogged primary • Clean or replace filter element.
fuel filter element
Clogged secondary • Replace filter element.
fuel filter element
Improper type of fuel • Consult fuel supplier and use proper type of
fuel for operating conditions.
Overheated engine • See “Engine Overheats” in next category.
Below normal engine temperature • Remove and check thermostat.
Improper valve clearance • Reset valves. Best done by dealer.
Dirty or faulty injection nozzles • Replace injectors. Best done by dealer.
• See your local dealer.

ONL844T4E 3/18
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 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 thermostat.
Defective temperature gauge • Check water temperature with thermometer
and replace gauge if necessary.

Engine Knocks Insufficient oil • Contact your dealer.

Injection pump out of time • Contact your dealer.
Below normal engine temperature • Check your thermostats.
• Check water temperature to see if
temperature gauge is working properly.
Engine overheating • See “Engine Overheating” section.

High Fuel Consumption Improper type of fuel • Use correct fuel for temperature.
Clogged or dirty air cleaner • Service air cleaner.
Improper valve clearance • Contact your dealer.
Injection nozzles dirty • Contact your dealer.
Injection pump timing off • Contact your dealer.
Engine not at proper temperature • Check your thermostats.
• Check water temperature with thermometer
and replace gauge if necessary.

Below Normal Thermostat not working properly • Check thermostat.

Engine Temperature
Temperature gauge • Check water temperature with thermometer.
not working properly

Low Oil Pressure Low oil level • Fill crankcase to proper level.
Improper type of oil • Drain and fill crankcase with correct oil.
Partially plugged oil filter • Replace filter.

High Oil Consumption Break-in period • Oil consumption decreases after break in.
Crankcase oil too light • Use proper viscosity oil.
Oil leaks • Check for leaks in lines around gaskets
and drain plug.

If you cannot correct problems with these procedures, see your Northern Lights dealer.

ONL844T4E 3/18
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 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 temperature.
Injection nozzles dirty • Contact your dealer.
Engine timing off • Contact your dealer.

Engine Emits Improper fuel • Use correct fuel for temperature.

White Smoke
Cold engine • Warm up engine to normal operating
temperature.
Defective thermostat • Remove and check thermostat.
Engine injection timing wrong • Contact your dealer.

If you cannot correct problems with these procedures, see your Northern Lights dealer.

ONL844T4E 3/18
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31
ONL844T4E 3/18
AC Wiring Diagram

Northern Lights AC Wiring Diagram –

PX300K2 12 lead generator w/
DST-100-2FAK AVR
Drawing B-9723

Drawings subject to change without notice.

32
ONL844T4E 3/18
AC Wiring Diagram

Northern Lights AC Wiring Diagram –

PX300K2 4 lead generator w/
DST-100-2FAK AVR
Drawing B-9724

Drawings subject to change without notice.

33
ONL844T4E 3/18
DC Wiring Diagram

Northern Lights DC Wiring Diagram –

NL844T4E
12 VDC Standard Ground B+ Control
Drawing C-7291

Drawings subject to change without notice.

34
ONL844T4E 3/18
Panel Wiring Diagram

Northern Lights Panel Wiring Diagram –

NL844T4E
S-TSC
Drawing C-7318

Drawings subject to change without notice.

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