Northern Lights M843NW2 Operator's Manual

OM843NW2

For Model: M843NW2

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constitu-

ents 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: [phone]
Fax: [phone]

Copyright ©2005 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.: OM843NW2 03/05

OPERATOR'S MANUAL

for Model

M843NW2

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

M843NW2 Marine Generator ............................... 6

CONTROL PANELS ............................................... 7

OPERATING PROCEDURES

Break-in Period ..................................................... 8

Before Starting ...................................................... 8

Starting .................................................................. 8

Operating ..............................................................8

Stopping ................................................................ 8

Shutdowns and Alarms ......................................... 9

Spare Parts ............................................................ 9

SERVICING SCHEDULE CHART ...........10 - 11

SERVICING

Lubrication - General .......................................... 12

Checking Oil .......................................................12

Oil Changes ........................................................12

Changing Oil Filter ............................................. 12

Air Filter .............................................................13

SERVICING (continued)

V-Belts ................................................................13

Valve Clearances ................................................. 13

Fuels - General .................................................... 14

Fuel Filters .......................................................... 14

Bleeding the Fuel System ...................................15

Injector Service ...........................................16 - 17

Injection Pump ....................................................17

Cooling System - General ................................... 17

Cooling System Flushing .................................... 18

Heat Exchanger ................................................... 18

Raw Water Pump ................................................18

Generator Ends ...................................................18

Electrical System - General ................................18

Glow Plugs .......................................................... 19

Booster Batteries ................................................. 19

Battery Care ........................................................ 19

PTO Care ............................................................19

Winterizing / Out-of-Service ..............................19

TROUBLESHOOTING

Electrical ............................................................. 20

Engine ......................................................... 21 - 23

WIRING DIAGRAMS

AC Electrical ......................................................24

DC Electrical ......................................................25

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 OM843NW2 03/05

OM843NW2 03/05

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 over-

looked and become amplied 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 Identication

MODELS INCLUDED

This manual covers the operating instructions for:

M843NW2 marine generator set.

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:

My Northern Lights generator set MODEL number is:

Model Numbers

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

M

M - Northern Lights marine generator set

M843NW2

Northern Lights marine diesel generator set with
an 843 engine and a PX-312K2 generator end, Tier II

=

compliant.

Model number of engine block

+

Bore Cylinders
84 mm 3

843

W and 2

W - New winding

+

2 - Tier 2 Compliant

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Generator set serial number plate.

Serial Numbers

Your set has three serial numbers: 1 an engine number stamped
on the block, 2 a generator plate, and 3 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 at left.

Warranty

A warranty registration certicate 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.

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 re 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 uids 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.

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

• 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,

qualied 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 rst aid kits.

• 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 lling fuel

tank or servicing fuel system.

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

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Marine Generator Component Locations

Figure 1 and 2: M843NW2

1. AC Circuit Breaker for AVR

2. DC Circuit Breaker

3. Coolant Recovery Tank

4. Fuel Filter

5. Air Filter (inside manifold)

6. Intake Manifold

7. Crankcase Vent

8. Fuel Injector

9. Belt Guard

10. Injection Pump

11. Oil Fill (2 Places)

12. Seawater Pump

13. Fresh water Block Drain
(behind hoses)

14. Fuel Inlet & Return

15. Oil Dipstick

OM843NW2 03/05

16. Oil Filter

17. Oil Drain

18. Generator Set Plate

19. Control Panel Plug-in

20. Fuel Lift Pump

21. Heat Exchanger End Cap

22. Coolant Fill

6

23. Expansion Tank

24. Wet Exhaust Elbow

25. Junction Box

26. Vibration Mount

27. Starter

28. DC Alternator

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mufersystemscancauseenginedamage.

See page 7.

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

Shows the generator load on each phase. The phase is

selected with the Ammeter Selector switch (Item 9).

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Operating Procedures

BREAK-IN PERIOD

1. The rst 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

lter at 50 hours. Change oil and lter again at

100 hours (consult Lubricants section for oil recom-

mendation).

Operating Instructions:

Maintain at least a 75% load on your generator

set for the rst 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 ller

cap sealing surface when the engine is cold.

CAUTION: Use protective clothing and open

the ller cap carefully when the engine is warm

to prevent burns.

2. Check the oil level in the crankcase with the dip-

stick. The oil level must be in the wafed 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 10 seconds consecu-

tively. If the engine fails to start with the rst attempt,

be sure that it has stopped completely (wait at least 30
seconds) before re-engaging.

NOTE: Excessive cranking of the starter on Marine

sets equipped with a water lift mufer can cause engine

damage. If the engine does not start after three 20­second cranks, remove the impeller from the raw water

pump. This will prevent the mufer from lling with
water and backlling 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). Normal coolant temperature is
167° to 194°F (75°C to 90°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 ve 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.

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