Northern Lights M1064H, M1066H Operator's Manual

OM2-4

For Models: M1064H and M1066H

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

— 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.

Seattle, WA 98107

Tel: (206) 789-3880

Fax: (206) 782-5455

Printed in U.S.A.

PART NO.: OM2-4 11/04

OPERATOR'S MANUAL

#OM2-4 for Models:

M1064H and M1066H

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 ....................................................	4
Models Included..................................................	4
Model Numbers...................................................	4
Serial Numbers....................................................	4
Warranty.............................................................	5
Safety Rules......................................................	5
Component Locations
M1064.................................................................	6
M1066.................................................................	7
ENGINE & GENERATOR CONTROL Panels
Series 3B..............................................................	8
Operating Procedures
Before Starting.................................................	10
Shutdown Procedures.......................................	10
Break-In Period.................................................	11
Servicing Schedule Chart.....................	12
ServicE RECORD.............................................	13
Servicing
Lubrication - General.......................................	14
Checking Oil.....................................................	14
Oil Changes......................................................	14
Changing Oil Filter...........................................	14
Air Filter...........................................................	14
Valve Clearances......................................	15 - 16
Fuels - General.................................................	16
Crankshaft Vibration Damper (6 Cyl.).............	17
Fuel Filters........................................................	17
The Fuel System.......................................	18 - 19

High Pressure Common Rail....................	18 - 19
Turbocharger....................................................	19
Turbo Boost......................................................	19
Cooling System - General................................	19
Engine Coolant Specifications..................	20 - 21
Cooling System Flushing.........................	21 - 22
Heat Exchanger Cleaning.................................	22
Zinc Electrodes.................................................	22
Raw Water Pump..............................................	22
Generator Ends.................................................	23
Electrical System - General..............................	23
Booster Batteries..............................................	23
Battery Care......................................................	23
Winterizing / Out-of-Service............................	23
Troubleshooting
Electrical...........................................................	24
Engine.......................................................	24 - 26
Wiring Diagrams
AC Electrical ...................................................	27
DC Electrical............................................	28 - 31
ON-BOARD SPARE PARTS .............................	32

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. © Alaska Diesel Electric, Inc. All rights reserved. Litho U.S.A. Publication number OM2-4 11/04

OM2-4 11/04

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 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.

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

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, aspiration, and RPM:

1064 or 1066

Model number

H - High Powered

M - Northern Lights marine generator set

106 mm bore, 4 Cylinder

106 mm bore, 6 Cylinder

Northern Lights® turbocharged, marine

Northern Lights® turbocharged marine

M1064H

M1066H

diesel generator set with a John Deere

generator set with a John Deere

Powertech Tier II 4045 engine block with an

Powertech Tier II 6068 engine block with

electronically controlled fuel system, high

an electronically controlled fuel system,

pressured common rail.

high pressured common rail.

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.

OM2-4 11/04

Warranty

A warranty registration certificate is supplied with your set. 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

CAUTION: 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.

•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.

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

•Always disconnect the ECU (Electronic Control Unit) connectors and remove the ground connection for the engine control system-to- machine frame before welding on engine. Make sure no other electronic components are in the ground path also.

•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.

•Provide first aid kits.

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.

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

OM2-4 11/04

Component Locations

Figures 1 & 2: M1064H

1.	Coolant Fill	8.	Electric Starter	14. Optional Hydrolastic		19.	Heat Shield
2.	Expansion Tank	9.	Heat Exchanger Zinc (2)		Mounts	20. Junction Box
3.	DC Alternator	10.	Oil Pan	15.	Drive Belt Cover	21.	Wet Exhaust Elbow
4.	Lube Oil Fill	11.	Turbocharger	16.	Fuel Manifold	22.	Electronic Control Unit
5.	Oil Filter	12.	Heat Exchanger	17.	Fuel Filter (Secondary)
6.	Lube Oil Dipstick	13.	Thermostat Cover	18.	Aftercooler
7.	Lube Oil Drain

				OM2-4 11/04

Northern Lights M1064H, M1066H Operator's Manual

Component Locations

Figure 3 & 4: M1066H

1.	Coolant Fill	7.	Lube Oil Drain	13. Optional Hydrolastic		18.	Heat Shield
2.	Expansion Tank	8.	Starter		Mounts	19.	Junction Box
3.	DC Alternator	9.	Heat Exchanger Zinc (2)	14. Drive Belt Cover		20.	Electronic Control Unit
4.	Lube Oil Fill	10.	Turbocharger	15.	Fuel Manifold	21.	Optional PTO
5.	Oil Filter	11.	Heat Exchanger	16.	Fuel Filter (Secondary)
6.	Lube Oil Dipstick	12. Thermostat cover		17.	Aftercooler

				OM2-4 11/04

Northern Lights Control Panel

1. shutdown bypass switch

This switch bypasses the safety shutdown feature during the starting process.

2. engine control switch

To start the engine, hold this switch in the START position 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 to RUN position. To stop the engine, hold the switch in the STOP position.

3. oil pressure gauge

The oil pressure gauge shows the oil pressure in the engine lubricating system. If the pressure drops

Figure 5: Series 3B Generator Control Panel below 15 PSI at a speed higher than idling, stop the engine and investigate.

4. coolant temperature gauge

Water temperature gauge shows the temperature of the cooling water. If the gauge registers over 200° or drops below 140°, stop the engine and investigate.

5. hour meter

Keeps track of the engine running time.

6. dc voltmeter

When the engine is running, it indicates the voltage output of the alternator.

OM2-4 11/04

Notes

OM2-4 11/04

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