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

OPERATOR’S

MANUAL O844K

For Models

M844K, M844LK, M20CL, and M20CR

— 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 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
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
DATA SHEETS
M844K ...............................................................	24
M844LK .............................................................	25
M20CL ..............................................................	26
WIRING DIAGRAMS
DC Electrical .....................................................	27

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 O844K 08/03

O844K 08/03

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 can 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.

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.

My Northern Lights generator set MODEL number is:

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:

844

L, C

M - Northern Lights marine generator set

Model number of engine block

L - Long stroke version

Bore

Cylinders

C - Commercial version

84 mm

M844K

M844LK

=	Northern Lights marine diesel generator set with		M20CL	=	Northern Lights 20 kW (@ 60 Hz) commercial grade
	an 844 engine and a PX-300K generator end.				marine generator set with a special generator end.

=Northern Lights marine diesel generator set with an 844L engine and a PX-300K generator end.

O844K 08/03

Serial Numbers

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

Warranty

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 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 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.

•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.

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

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

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	9.	Belt Guard	18.	Oil Fill (Top)	27.	Oil Dipstick
2.	Expansion Tank/Exhaust	10.	Raw Water Pump	19.	Fresh Water Pump	28.	Oil Filter
	Manifold/Heat Exch.Tank	11.	Alternator	20.	Injection Pump	29.	Lube Oil Drain
3.	Coolant Drain	12.	Water Temperture Sender	21.	Oil Fill (Side)	30.	Control Panel Plug-in
4.	Wet Exhaust Elbow	13.	DC Circuit Breaker	22.	Raw Water Inlet	31.	Fuel Lift Pump
5.	Junction Box	14.	Secondary Fuel Filter	23.	Oil Pressure Sender	32.	AC Circuit Breaker for
6.	Vibration Mount	15.	Fuel Return Line	24.	Freshwater Block Drain		Automatic Voltage Regulator
7.	Starter	16.	Crankcase Vent	25.	Fuel Return Line	33.	PTO (Optional)
8.	Coolant Thermostat (behind)	17.	Fuel Injector	26.	Fuel Inlet Line

O844K 08/03

Commercial Generator Set Component Locations

▼

Non-Service Side

Service Side

▼

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

1.	Air Filter	8.	Vibration Mount	16.	Injection Pump	24.	Generator End
2.	Coolant Thermostat (behind)	9.	DC Alternator	17.	Oil Fill (Side)	25.	DC Circuit Breaker
3.	Expansion Tank/Manifold/	10.	Keel Cooler Return	18.	Freshwater Block Drain 26.		Secondary Fuel Filter
	Heat Exchanger Tank	11.	Water Temperature Sender	19.	Oil Dipstick	27.	Fuel Lift Pump
4.	Coolant Drain	12.	Oil Pressure Switch	20.	Oil Filter	28.	Fuel Return Line
5.	Manifold End Caps (2)	13.	Coolant Fill	21.	Fuel Inlet	29.	Crankcase Vent
6.	Junction Box	14.	Fuel Injector	22.	Lube Oil Drain	30.	Oil Fill (Top)
7.	Starter	15.	Fresh Water Pump	23.	Control Panel Plug-in

O844K 08/03

Control Panels

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

Figure 4-B: Series 3 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.

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.
10.	A.C. AMMETER
	Shows the generator load on each phase. The phase is
Figure 4-C: Series 4 Generator Control Panel	selected with the Ammeter Selector switch (Item 9).

O844K 08/03

Notes

O844K 08/03

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