Northern Lights M843NW3 Operator's Manual

OM843NW3

For Model: M843NW3

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: (206) 789-3880 Fax: (206) 782-5455

Printed in U.S.A. PART NO.: OM843NW3 01/08

OPERATOR'S MANUAL

for Model

M843NW3

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 .....................................................5

WARRANTY ............................................................ 5

SAFETY RULES ....................................................... 5

COMPONENT LOCATIONS

M843NW3 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 - 28

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.

OM843NW3 01/08

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 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:

M843NW3 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 - Northern Lights marine generator set

M843NW3

Northern Lights marine diesel generator set with

an 843 engine and a PX-312K2 generator end, Tier III.

Model number of engine block

Bore Cylinders 84 mm 3

843

W - New winding

3 - Tier 3

W and 3

OM843NW3 01/08

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 is not 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.

OM843NW3 01/08

Marine Generator Component Locations

Figure 1 and 2: M843NW3

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

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

OM843NW3 01/08

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.

Figure 3-B: Series 3 Generator Control Panel

3. HOUR METER

Keeps track of engine running time.

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).

Figure 3-C: Series 4 Generator Control Panel

9. AMMETER/VOLTMETER SELECTOR SWITCH

Used to check voltage and current of each phase.

10. A.C. AMMETER

Shows the generator load on each phase. The phase is

selected with the Ammeter Selector switch (Item 9).

OM843NW3 01/08

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 recommendation).

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

consecutively. 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.

OM843NW3 01/08

Operating Procedures

SHUTDOWNS AND ALARMS

1. Your unit is tted 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 ll

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 eld 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 lter elements b. Oil lters c. Air lter

d. Alternator belt e. Thermostat and gaskets f. Seawater pump impeller & gaskets 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, ll 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.

OM843NW3 01/08

+ 19 hidden pages

Northern Lights M843NW3 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual