Northern Lights M1276A1, M1276A2 Operator's Manual

OM1276

For Models: M1276A1 and M1276A2

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.: M1276 08/06

OPERATOR'S MANUAL

OM1276 for Models:

M1276A1 and M1276A2

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
M1276.................................................................	6
ENGINE & GENERATOR CONTROL Panels
Series 3B & 4B..............................................	7 - 8
Operating Procedures
Before Starting....................................................	9
Shutdown Procedures..........................................	9
Break-In Period................................................	10
Servicing Schedule ChartS ...............	11
ServicE RECORD .........................................	12
Servicing
Lubrication - General.......................................	13
Checking Oil.....................................................	13
Oil Changes......................................................	13
Changing Oil Filter...........................................	13
Air Filter...........................................................	13
Valve Clearances..............................................	14
Electronic Unit Injector Preload.......................	15
Fuels - General.................................................	16
Fuel Filters................................................	16 - 17
Bleeding the Fuel System.................................	18
Crankshaft Vibration Damper ..........................	18

Turbocharger....................................................	19
Turbo Boost......................................................	19
Cooling System - General................................	19
Engine Coolant Specifications..................	19 - 20
Cooling System Flushing.................................	21
Heat Exchanger Cleaning.................................	21
Zinc Electrodes.................................................	21
Raw Water Pump..............................................	22
Generator Ends.................................................	22
Electrical System - General..............................	22
Booster Batteries..............................................	22
Battery Care......................................................	23
Winterizing / Out-of-Service............................	23
Troubleshooting
Electrical...........................................................	24
Engine.......................................................	24 - 27
ON-BOARD SPARE PARTS ..........................	28
Wiring Diagrams
AC Wiring........................................................	29
DC Wiring........................................................	30

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 OM1276 08/06

OM1276 08/06

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:

1276

M - Northern Lights marine generator set

Model number

A- Aftercooled

176 mm bore, 6 Cylinder

M1276A1

M1276A2

Northern Lights® aftercooled, 1800 or 1500

=RPM marine diesel generator set with a John Deere Powertech engine block and an electronically controlled fuel system.

Northern Lights® aftercooled, 1800 or 1500

=RPM marine generator set with a John Deere Powertech engine block and an electronically controlled fuel system, different generator end.

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.

OM1276 08/06

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.

OM1276 08/06

Northern Lights M1276A1, M1276A2 Operator's Manual

Component Locations
		2	3		4		5	6	7	8
	1
										9
										10
										11
										12
		18	17	16	15	14	13
		18
								19
	23
	22
	21
	20
Figures 1 & 2: M1276
1.	Junction Box	7. Coolant Fill		14. Oil Fill				20. Engine Control Unit
2.	Turbocharger	8. Expansion Tank		15. Lube Oil Dipstick				21. Starter
3.	Exhaust Manifold	9. Heat Exchanger		16. Oil Cooler				22. Raw Water Pump
4.	Low Water Flow Switch	10. Belt Guard		17. Fuel/ Water Separator				23. Heat Exchanger Zinc
5.	Thermostat Housing	11. Alternator		18. Intake Manifold
6.	Low Coolant Level	12. Optional Hydrolastic Mount		19. Air Cleaner
	Switch/ Gauge (optional)	13. Lube Oil Filter
			OM1276 08/06

Northern Lights Control Panels

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

OM1276 08/06

Northern Lights Control Panel

Figure 4: Series 4 B Generator Control Panel

1.shutdown bypass switch

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

2.engine control switch

The control switch starts and stops the engine.

3.oil pressure gauge

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

7.ac voltmeter

The voltmeter shows the generator output voltage, phase to phase. If the voltage fluctuates greatly from the normal reading, shut down the unit and investigate.

8.frequency meter

Indicates engine speed. The correct reading for 1800 and 1200 RPM sets is 60 Hz. For 1500 RPM sets, it is 50 Hz. If meter does not indicate correct hertz, stop and investigate.

9.ammeter selector switch

The ammeter switch is used for checking each phase for load condition. Leave it in the ON position while the engine is running.

10.ac ammeter

The ammeter indicates the phase load. Check for load unbalance. If the unbalance is greater than 30%, have an electrician balance the load properly. This will ensure longer generator life and better economy.

OM1276 08/06

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 3/4 in. (4-5 cm) below the filler cap sealing surface when the engine is cold. When filling with coolant, the venting cock on top of the turbocharger

should be opened to ensure that no air pockets form in the cooling system (see Service Point #14).

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 “oo”. Never allow the level to go below the “oo”. 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.Disengage clutch, if equipped.

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.While holding the Shutdown Bypass switch in the ON position, push the Engine Control switch to the START position.

2.As soon as the engine starts, release both switches.

Do not crank the starter for more than 20 seconds.

3.If the engine fails to start the first time, be sure the starter has stopped before re-engaging.

NOTE: Avoid prolonged periods of engine idling or sustained running time at maximum load during the first 20 hours. Stop the engine if idling longer than 5 minutes. The engine should have an oil pressure of at least 138 kPa (20 PSI) at low idle.

Operating

1.Check Gauges Often: Oil pressure must be above 29 PSI (if not above 15 PSI within 5 seconds of starting, the engine should be stopped and the problem should be explored). Normal oil pressure is 45

+15 PSI at rated load speed (1800 to 2500 RPM). Coolant temperature should be 820- 940C (1800- 2020F) for normal operating temperature. The D.C. voltmeter should read between 13 and 14 volts (2628 volts, 24 volt systems).

2.Check AC voltage and frequency meters (Series 4 Panel). If gauges deviate from normal levels, shut down the set and investigate.

3.Check belt for good alignment.

4.Let the unit run unloaded for a three to five minute warm-up period before applying load.

5.Do not add full electrical load until engine is at maximum operating temperature.

Shutdown

1.Turn the Engine Control Switch to the OFF position.

2.Close the sea cock and fuel valves, and put the battery switch in the OFF position if the unit will be off for an extended period.

NOTE: Do not turn the battery switch to OFF while the engine is running.

Shutdowns and Alarms

1.Your unit is fitted with a system to protect it from high water temperature or low oil pressure.

a.Generator sets have shutdown systems to stop the engine. They have no warning horns.

b.Other alarms and shutdowns are available as optional equipment.

NOTE: Do not rely on your warning or shutdown system to the exclusion of careful gauge monitoring. Watching your gauges can prevent damage to the unit and dangerous power losses.

2.Do the following when your shutdown system is activated:

a.Check the temperature gauge. If the temperature is above 205°F (97°C), shut off the engine immediately.

b.Use the Trouble Shooting Guide on pages 2628 to isolate the cause of the overheat.

OM1276 08/06

Operating Procedures

Shutdowns and Alarms continued

CAUTION: Do not remove the water fill cap of an overheated engine. Escaping high temperature steam can cause severe burns. Allow the engine to cool and then remove the

cap slowly, using protective clothing.

c.Make repairs and restart after the temperature gauge registers below 180°F (83°C).

d. Watch the temperature gauge regularly and turn off the unit if the temperature rises above 200°F (94°C). Repeat the troubleshooting process.

3.If the shutdown is activated and the temperature gauge shows temperature within normal temperature range:

a.Check the engine crankcase oil level.

b.Iftheoillevelislow,fillwithrecommendedlubricating oil and restart. Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading after a few seconds of operation.

c.If the oil level was normal, DO NOT restart the engine. Call your Northern Lights or Lugger dealer for assistance.

BREAK-IN PERIOD

1.The first 100 hours on a new or reconditioned engine are critical to its life and performance.

2.Constantly check the engine temperature and oil pressure gauges.

3.Oil consumption is greater during break-in as piston rings and cylinder liners take time to seat.

4.Break-In Oil Changes: Change engine oil and filter at 50 hours. Change oil and filter again at 100 hours (See

Gear Owner's Manual for break-in oil change procedures. Consult Lubricants Section for oil

recommendation).

5.Maintain at least a 75% load on your set for the first 100 hours. Maintain no less than a 50% load to ensure proper seating of the piston rings. Vary the load to help seat rings.

OM1276 08/06

+ 21 hidden pages