Northern Lights L844D Operator's Manual

OPERATOR’S

MANUAL

OL844

For Model:

L844D

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constituents

are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

Northern Lights

4420 14th Avenue N.W. P.O. Box 70543 Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455

Printed in U.S.A. PART NO.: OL844 04/04

OPERATOR'S MANUAL

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

OL844 for Model:

L844D

INTRODUCTION ................................................... 2

Models Included ................................................ 2

Model Numbers................................................. 2

Serial Numbers .................................................. 2

WARRANTY ........................................................... 3

SAFETY RULES .................................................... 3

COMPONENT LOCATIONS

L844D................................................................ 4

OPERATING PROCEDURES

Before Starting .................................................. 6

Shutdown Procedures ...................................6 - 7

Break-In Period ................................................. 7

SERVICING SCHEDULE CHART ...................... 8

SERVICE RECORD .............................................. 9

SERVICING

Lubrication - General ...................................... 10

Checking Oil ................................................... 10

Oil Changes ..................................................... 10

Changing Oil Filter.......................................... 10

Air Filter .......................................................... 10

Valve Clearances............................................. 11

Fuels - General ................................................ 11

Fuel Filters....................................................... 12

Bleeding the Fuel System........................12 - 13

Cooling System - General ............................... 13

Engine Coolant Specifications ................ 13 - 15

Cooling System Flushing ................................ 15

Heat Exchanger Cleaning................................ 15

Zinc Electrodes................................................ 15

Raw Water Pump ............................................ 16

Electrical System - General............................. 16

Booster Batteries ............................................. 17

Battery Care..................................................... 17

Winterizing / Out-of-Service........................... 17

TROUBLESHOOTING

Engine...................................................... 18 - 19

DATA SHEETS

Unit Specifications .......................................... 20

WIRING DIAGRAMS

12 and 24 Volt ......................................... 21 - 22

ON-BOARD SPARE PARTS............................. 23

Proprietary Information

This publication is the property of Alaska Diesel Electric, Inc.

It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc.

OL844 04-04

Introduction

Servicing of marine engines and generator sets presents unique problems. In many cases boats cannot be moved to a repair facility. Marine engines cannot be compared

Failures begin with minor problems that are overlooked and become amplified when not corrected during

routine maintenance. to the servicing of automobiles, trucks or even farm equipment. Failures often occur in remote areas far from competent assistance. Marine engines are taxed far more severely than auto or truck engines; therefore, maintenance schedules must be adhered to more strictly.

As operator, it is your obligation to learn about your

equipment and its proper maintenance. This is not a

comprehensive technical service manual. Nor will it

make the reader into an expert mechanic. Its aim is to

aid you in maintaining your unit properly.

Model Numbers

Model numbers give the unit's application, block model, and aspiration:

L - Lugger propulsion engine

L844D

Northern Lights® naturally aspirated propulsion

engine with a 844 engine.

4 Cylinders 84 mm bore

844

Model number

D - Natural Aspirated

Serial Numbers

When referencing Alaska Diesel Electric equipment by serial number, please refer only to the number stamped on the Northern Lights® serial number plate.

OL844 04-04

Warranty

A warranty registration certificate is supplied with your set. The extent of coverage is described

followed. If further information is needed, please contact an authorized dealer or the factory.

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

Safety Rules

CAUTION:

You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.

• Never leave engine without proper security.

• Turn the coolant tank cap slowly to relieve

pressure before removing. Add coolant only when the engine is stopped and cool.

• Mount a fire extinguisher near engine.

• Always disconnect the battery ground strap

before making adjustments.

• Operate engines in properly ventilated areas.

• Keep trash and other objects away from engine.

• Escaping fluids under pressure can penetrate

your skin. Use a piece of cardboard or wood, not your hands, to search for leaks.

• Avoid wearing loose clothing when working around engines.

Accident reports show that careless use of engines causes a high percentage of accidents.

• Use caution in handling fuel. Never refuel a hot or running engine. Do not smoke while filling fuel tank or servicing fuel system.

• 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 knowledgeable, 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 an unsafe operating condition is noted, tag the set and control panel so others will also know about the problem.

• Do not oil or grease engine while it is running.

CALIFORNIA

Proposition 65 Warning:

Diesel engine exhaust and some of its constituents

are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

• Provide first aid kits.

CAUTION: This symbol is used throughout this book to alert you to possible danger areas. Please take special notice of these sections.

OL844 04-04

L844D Component Locations

Figure 1 & 2: L844D

1. Coolant Fill

2. Expansion Tank/ Exhaust Manifold/ Heat Exchanger Tank

3. Coolant Drain

4. Wet Exhaust Elbow

5. Starter

6. Alternator

7. Belt Guard

8. Raw Water Pump

9. Oil Fill (Top)

10. Fresh Water Pump

11. Fuel Injector (4)

12. Fuel Return Line

13. Secondary Fuel Filter

14. Coolant Recovery Tank

15. Lube Oil Drain

16. Oil Filter

17. Oil Dipstick

18. Oil Fill (Side)

19. Injection Pump

OL844 04-04

20. Fuel Return Line

21. Fuel Inlet Line

Notes

OL844 04-04

Operating Procedures

BEFORE STARTING

1. Check the water level by removing the pressure cap from the expansion tank. In order to give the cooling water room to expand, the level should be about 1 in. (2.5 cm) below the filler cap sealing surface when the engine is cold.

CAUTION: Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns.

2. Check the oil level in the crankcase with the dipstick. The oil level should be between the “waffled area” and the “Add”. Never allow the level to go below the “Add”. Do not fill above the crosshatch pattern. Oil levels within the crosshatch are considered in the acceptable operating range. Always add the same viscosity of oil as is already in the crankcase (see Service Point #1).

3. Check the fuel tank level and open any fuel valves.

4. Check the oil level in the reverse gear. Methods may vary from gear to gear. See your Gear Owner's Manual.

5. Close the seacock, check and clean the strainer and reopen the seacock.

6. Place the battery switch in the ON position.

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

regulator could be ruined.

Starting

1. Put the gear control in the neutral position.

2. Move the throttle control to the idle position.

3. Turn the key switch to the first position. Check the voltage meter to see the condition of the batteries. For starting, the voltmeter should not read below 12 volts (24 volts for 24 volt systems).

4. Turn the key to the starting position and as soon as the engine starts, release the key. Move the throttle up until the engine is running at approximately 1000 RPM.

5. Do not crank the starter for more than 15 seconds consecutively. If the engne fails to start with the first attempt, be sure that the starter has stopped completely before re-engaging.

NOTE: Never race a cold engine. Operate at 1000 RPM for a 3 to 5 minute warm-up period.

Operating

1. Check oil pressure as soon as the engine has started. Oil pressure should be above 15 PSI. The engine must never be run if the oil pressure is below 15 PSI.

2. Check the voltmeter. It should read 13 to 14 volts (26-28 volts, 24 volt systems) at 60°F (16°C).

3. Water temperature should not rise over 200°F (94°C). If it does, shut down the engine and investigate the cause of overheating.

4. Do not exceed 800 RPM when shifting marine gear. Repeated shifts at higher engine speeds can damage the reverse gear.

5. Low idle is 800 RPM. Maximum working engine speed is: 2800 RPM for 40 Hp and 2400 RPM for 30 Hp.

6. If the proper propeller is used, the engine should reach its appropriate maximum RPMs at full throttle. If the maximum rated RPMs for your engine application is exceeded at full throttle, then your propeller is too small. If you cannot reach your maximum rated RPMs at full throttle, either your propeller is too large or bottom growth is slowing the boat.

7. To establish Maximum Cruising RPM: Establish the RPM at full throttle and subtract 200-300 RPM. This will promote engine life and reduce fuel consumption.

Shutdown

1. Run engine three to five minutes in neutral at 1000 RPM, for cool down period.

2. Return engine to low idle.

3. Turn the key switch counterclockwise as far as possible to stop the engine.

4. Close the sea cock and fuel valves and put the battery switch in OFF position.

NOTE: Do not turn the battery switch to OFF

while the engine is running.

ALARMS

1. Your unit is fitted with a warning system to indicate high water temperature or low oil pressure.

Propulsion engines have warning horns to sound and warn you of a problem. Remember- when the engine is not running the horn will sound when the key is in the "ON" position because there is no oil pressure.

OL844 04-04

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