Northern Lights M844K2, M844LK2, M20CR2 Operator's Manual

OPERATOR’S

OPERATOR’S

MANUAL

MANUAL

M844K2, M844LK2, and M20CR2

OM844K2

For Models

— 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: [phone]
Fax: [phone]

Copyright ©2004 Alaska Diesel Electric, Inc.
All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Alaska Diesel Electric, Inc.

Printed in U.S.A.
PART NO.: OM844K2 03/04

OPERATOR'S MANUAL

for Models

M844K2, M844LK2, and M20CR2

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

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

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

Serial Numbers .....................................................3

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

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

COMPONENT LOCATIONS

M844

K2 and M844LK2 Marine Generator ...........4

CONTROL PANELS ................................................5

OPERATING PROCEDURES

Break-in Period ....................................................6

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

Starting .................................................................6

Operating ..............................................................6

Stopping ...............................................................6

Shutdowns and Alarms......................................... 7

Spare Parts............................................................7

SERVICING SCHEDULE CHART ................... 8 - 9

SERVICING

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

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

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

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

Air Filter ............................................................ 11

SERVICING (continued)

V-Belts .............................................................. 11

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

Fuels - General .................................................. 12

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

Bleeding the Fuel System.................................. 13

Injector Service ......................................... 14 - 15

Injection Pump .................................................. 15

Cooling System - General ................................. 15

Cooling System Flushing .................................. 16

Heat Exchanger (Marine) .................................. 16

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

Generator Ends .................................................. 16

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

Glow Plugs ........................................................ 17

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

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

PTO Care........................................................... 17

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

TROUBLESHOOTING

Electrical............................................................ 18

Engine........................................................ 19 - 21

DATA SHEETS

M844K2 ............................................................. 22

M844LK2 ........................................................... 23

M20CR2 ............................................................ 24

WIRING DIAGRAMS

DC Electrical ............................................. 25 - 26

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 OM844K2 03/04

OM844K2 03/04

3

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 can 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.

Unit Identification

MODELS INCLUDED

This manual covers the operating instructions for:

M844K2 marine generator sets,

M844LK2 marine generator sets, and

M20CR2 commercial generator sets.

NOTE: There are two versions of the 844K2 engine. The standard engine is designated 844K2. The long-stroke
engine is designated 844LK2. You will need to know which engine you have to use this manual and to order parts.

Fill in the model number of your unit in the blank space provided.
This will give you a reference whenever service or maintenance is required:

Model Numbers

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

M

M - Northern Lights marine generator set

Northern Lights marine diesel generator set with

M844K2

M844LK2

=

an 844 engine and a PX-300K generator end.

Northern Lights marine diesel generator set with

=

an 844L engine and a PX-300K generator end.

Model number of engine block

+

Bore Cylinders

84 mm 4

844

M20CR2

=

My Northern Lights generator set MODEL number is:

L, C, 2

L - Long stroke version
C - Commercial version

+

2 - Tier 2 Compliant

Northern Lights 20 kW (@ 60 Hz) commercial grade
marine generator set with a special generator end.

OM844K2 03/04

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Serial Numbers

Your set has three serial numbers: ➀ an engine number stamped
on the block, ➁ a generator plate, and ➂ a generator set plate.

Use the serial number on the generator set plate when ordering parts
or in correspondence. The generator set plate is found on the service
side of the generator and resembles the drawing in Figure 1.

Fill in the serial number of

My Northern Lights generator set SERIAL number is:

your unit in the box provided.

Figure 1: Generator set serial number plate.

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

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.
in the Limited Warranty Statement. We recommend
that you study the statement carefully.

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.

• Keep your hands, feet, hair and clothing away from

power-driven parts.

• Check for any loose electrical connections or faulty
wiring.

Warranty

• 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 without a belt when
working around engines.

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

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

OM844K2 03/04

• 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.

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

5

Marine Generator Component Locations

▼

Non-Service Side

▲ Optional PTO

Service Side

Figure 2A and 2B: M844LK2 with PXK generator end.

1. Coolant Fill

2. Expansion Tank/Exhaust
Manifold/Heat Exch.Tank

3. Coolant Drain

4. Wet Exhaust Elbow

5. Junction Box

6. Vibration Mount

7. Starter

8. Coolant Thermostat (behind)

9. Belt Guard

10. Raw Water Pump

11. Alternator

12. Water Temperture Sender

13. DC Circuit Breaker

14. Secondary Fuel Filter

15. Fuel Return Line

16. Coolant Recovery Tank

17. Fuel Injector

▼

18. Oil Fill (Top)

19. Fresh Water Pump

20. Injection Pump

21. Oil Fill (Side)

22. Raw Water Inlet

23. Oil Pressure Sender

24. Freshwater Block Drain

25. Fuel Return Line

26. Fuel Inlet Line

OM844K2 03/04

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27. Oil Dipstick

28. Oil Filter

29. Lube Oil Drain

30. Control Panel Plug-in

31. Fuel Lift Pump

32. AC Circuit Breaker for
Automatic Voltage Regulator

33. PTO (Optional)

Figure 3-A: Series 1-B Generator Control Panel

Control Panels

1. SHUTDOWN BYPASS-PREHEAT SWITCH

Two functions are built into this switch: the preheating
of the engine, and bypassing of the engine safety
shutdown circuit. Hold switch in the ON position
10 - 20 seconds before starting the engine, and
continue holding on during engine cranking. Release
the switch as soon as the engine is running. Holding
the switch on too long can burn out the heater element.

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. See page 6.

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 until the engine has
completely stopped.

NOTE: The rocker switch is used on Series 1 panels
only, and has a light that glows when the set is running.

3. HOUR METER

Keeps track of engine running time.

Figure 3-B: Series 3 Generator Control Panel

4. OIL PRESSURE GAUGE

Shows the oil pressure in the engine lubricating system.

5. ENGINE TEMPERATURE GAUGE

Registers the temperature of the engine coolant.

6. D.C. VOLTMETER OR AMMETER

When the engine is stopped, the voltmeter indicates the
condition of the battery. When the engine is running, the
voltmeter indicates the voltage output of the alternator.

For Series 4 Control Panels Only:

7. A.C. VOLTMETER

Shows the generator output voltage.

8. FREQUENCY METER (Hertz)

The frequency meter indicates alternating current
frequency: 60 Hz (1800 RPM), or 50 Hz (1500 RPM).

9. AMMETER/VOLTMETER
SELECTOR SWITCH

Used to check voltage and current of each phase.

Figure 3-C: Series 4 Generator Control Panel

10. A.C. AMMETER

OM844K2 03/04

7

Shows the generator load on each phase. The phase is
selected with the Ammeter Selector switch (

Item 9).

Operating Procedures

BREAK-IN PERIOD

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

2. Frequently check the engine temperature and oil
pressure gauges (sets with Series 3 or 4 panels).

3. Oil consumption is greater during break-in as
piston rings 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 (consult Lubricants section for oil
recommendation).

Operating Instructions:

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
seating of the piston rings. Vary the load to help
seat the rings.

BEFORE STARTING

1. Check the water level by removing the pressure
cap from the expansion tank or radiator. In order to
give the cooling water an opportunity 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 must be in the waffled area on
the stick. Never allow the level to go below this area.
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. Close the sea-cock; check, clean, and reassemble the
sea strainer and re-open the sea-cock.

5. Place the battery switch in the ON position.

6. 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. Hold the Shutdown Bypass-Preheat switch in the
ON position for 10 to 20 seconds before starting a
cold engine. Holding the switch too long can burn
out the glow plugs. This step is not necessary if the
engine is already warm.

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

3. As soon as the engine starts, release both switches. Do not
crank the starter for more than 20 seconds consecutively.
If the engine fails to start with the first attempt, be sure
that it has stopped completely before re-engaging.

6.

NOTE: Excessive cranking of the starter on Marine
sets equipped with a water lift muffler can cause
engine damage. If the engine does not start after three
20-second cranks, remove the impeller from the raw
water pump. This will prevent the muffler from filling
with water and backfilling the exhaust line and engine.
Once the engine starts, shut it off immediately and
re-install the impeller. Re-start the engine and check
the exhaust overboard outlet for gushes of water.

OPERATING

1. Units with Series 3 and Series 4 Control Panels:
check gauges often. Oil pressure must be above 15
PSI. The D.C. voltmeter should read between 11 and
15 volts at 80°F (25°C) ambient temperature. The
water temperature gauge on Marine sets must be
below 200°F (94°C). Check the A.C. voltage and
frequency meters (Series 4 panel). If the gauges
deviate from normal levels, shut down the generator
set and investigate.

2. Let the unit run unloaded for a three to five minute
warm-up period.

3. Apply electrical load.

STOPPING

1. Remove electrical load from the generator set.

2. Run the engine for a 3 to 5 minute cool down period.

3. Hold the Engine Control switch to the STOP
position until the engine comes to a complete stop.

4. Shut off the seacock, fuel valve, and battery switch.

OM844K2 03/04

8

Operating Procedures

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 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 warning or shutdown
system is activated:
a. Check the temperature gauge.

If above 205°F (96°C), shut off the engine
immediately.

b. Use the Trouble Shooting Guide on page 20 to

isolate the cause of the overheat.

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.

SPARE PARTS

1. ADE recommends that you keep the following spare
parts on hand for field service. The parts are
available from your local Northern Lights dealer.
Some marine models already have “On-Board-Kits,”
a handy box that contains the most common parts
you will need.

2. All owners should have the following spares:
a. Primary and secondary fuel filter elements
b. Oil filters
c. Air filter
d. Alternator belt
e. Thermostat and gaskets
f. Seawater pump impeller & gaskets (marine only)
g. Glow plug
h. Injector and washer

3. If your set is operating a long distance from a
servicing dealer, add the following:
a. Complete set of injectors
b. Copper washers for injector change
c. Complete set of glow plugs
d. Fuel lift pump

d. Make repairs. Restart your Marine 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 Marine 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.

OM844K2 03/04

9