Northern Lights M844K, M844LK, M20CL, and M20CR Operator's Manual

OPERATOR’S

MANUAL

M844K, M844LK, M20CL, and M20CR

O844K

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

Printed in U.S.A. PART NO.: O844K 08/03

OPERATOR'S MANUAL

for Models

M844K, M844LK, M20CL, and M20CR

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

M844K and M844LK Marine Generators .............4

M20CL Marine Generators .................................. 5

CONTROL PANELS

Northern Lights Generator Sets............................ 6

OPERATING PROCEDURES

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

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

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

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

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

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

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

SERVICING (continued)

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

Retightening Cylinder Head Bolts .................... 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 (Marine) .................................. 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

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

SERVICING

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

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

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

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

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

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.

O844K 08/03

DATA SHEETS

M844K ............................................................... 24

M844LK ............................................................. 25

M20CL .............................................................. 26

WIRING DIAGRAMS

DC Electrical ..................................................... 27

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:

M844K marine generator sets,

M844LK marine generator sets, and

M20CL commercial generator sets.

NOTE: There are two versions of the 844 engine. The standard engine is designated 844. The long-stroke engine is designated 844L. 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:

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

Northern Lights marine diesel generator set with

M844K

M844LK

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

O844K 08/03

844

M20CL

L, C

L - Long stroke version

C - Commercial version

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

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.

• 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.

O844K 08/03

Marine Generator Component Locations

Non-Service Side

▼

▲ Optional PTO

Service Side

Figure 2A and 2B: M844K and M844LK with PXK generator ends.

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. Crankcase Vent

17. Fuel Injector

▼

O844K 08/03

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

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)

Commercial Generator Set Component Locations

Non-Service Side

▼

Service Side

▼

Figure 3A and 3B: M20CL with special generator end.

1. Air Filter

2. Coolant Thermostat (behind)

3. Expansion Tank/Manifold/ Heat Exchanger Tank

4. Coolant Drain

5. Manifold End Caps (2)

6. Junction Box

7. Starter

8. Vibration Mount

9. DC Alternator

10. Keel Cooler Return

11. Water Temperature Sender

12. Oil Pressure Switch

13. Coolant Fill

14. Fuel Injector

15. Fresh Water Pump

O844K 08/03

16. Injection Pump

17. Oil Fill (Side)

18. Freshwater Block Drain

19. Oil Dipstick

20. Oil Filter

21. Fuel Inlet

22. Lube Oil Drain

23. Control Panel Plug-in

24. Generator End

25. DC Circuit Breaker

26. Secondary Fuel Filter

27. Fuel Lift Pump

28. Fuel Return Line

29. Crankcase Vent

30. Oil Fill (Top)

Control Panels

Figure 4-A: Series 1-B Generator Control Panel

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 10.

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 4-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 4-C: Series 4 Generator Control Panel

10. A.C. AMMETER

O844K 08/03

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

Item 9).

Notes

O844K 08/03

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