Northern Lights M844W2, M844LW2, M20CRW2 Operator's Manual

OPERATOR’S

MANUAL

M844W2, M844LW2, and M20CRW2

OM844W2

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. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455

Printed in U.S.A. PART NO.: OM844W2 02/05

OPERATOR'S MANUAL

for Models

M844W2, M844LW2, and M20CRW2

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

M844W2 Marine Generator ................................. 4

M20CRW2 Commercial Generator .....................5

CONTROL PANELS ................................................6

OPERATING PROCEDURES

Break-in Period ....................................................7

Before Starting .....................................................7

Starting .................................................................7

Operating ..............................................................7

Stopping ...............................................................7

Shutdowns and Alarms......................................... 8

Spare Parts............................................................8

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 (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.

OM844W2 02/05

WIRING DIAGRAMS

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

DC Electrical ............................................. 25 - 28

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:

M844W2 marine generator sets,

M844LW2 marine generator sets, and

M20CRW2 commercial generator sets.

NOTE: There are two versions of the 844W2 engine. The standard engine is designated 844W2. The long-stroke engine is designated 844LW2. 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 - Northern Lights marine generator set

Northern Lights marine diesel generator set with

M844W2

M844LW2

an 844 engine and a PX-300K2 generator end.

Northern Lights marine diesel generator set with

an 844L engine and a PX-300K2 generator end.

Model number of engine block

Bore Cylinders

84 mm 4

844

M20CRW2

My Northern Lights generator set MODEL number is:

W, L, C, 2

W - New winding 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.

OM844W2 02/05

Generator set serial number plate.

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 at left.

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.

• 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.

• 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.

OM844W2 02/05

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

Marine Generator Component Locations

Service Side

▼

Non-Service

Side

Figure 1A and 1B: M844W2

1. DC Circuit Breaker

2. Coolant Recovery Tank

3. Secondary Fuel Filter

4. Fuel Return Line

5. Fuel Injector

6. Oil Fill (Top)

7. Coolant Fill

8. Fresh Water Pump

9. Injection Pump

▼

10. Oil Fill (Side)

11. Raw Water Pump

12. Raw Water Inlet

13. Vibration Mount

14. Oil Pressure Sender

15. Freshwater Block Drain

16. Fuel Inlet Line

17. Fuel Return Line

18. Oil Dipstick

19. Oil Filter

20. Lube Oil Drain

21. Fuel Lift Pump

22. Control Panel Plug-in

23. AC Circuit Breaker for Automatic Voltage Regulator

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

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25. Coolant Drain

26. Wet Exhaust Elbow

27. Junction Box

28. Starter

29. Alternator

30. Belt Guard

31. Coolant Thermostat (behind)

32. Water Temperature Sender

Commercial Generator Component Locations

Figure 2A and 2B: M20CRW2

1. DC Circuit Breaker

2. Secondary Fuel Filter

3. Fuel Return Line

4. Fuel Injector

5. Oil Fill (Top)

6. Coolant Fill

7. Fresh Water Pump

8. Injection Pump

9. Oil Fill (Side)

10. Raw Water Pump

11. Raw Water Inlet

12. Vibration Mount

13. Oil Pressure Sender

14. Freshwater Block Drain

15. Oil Dipstick

16. Oil Filter

17. Oil Drain

18. Fuel Lift Pump

19. Control Panel Plug-in

20. AC Circuit Breaker for Automatic Voltage Regulator

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

22. Coolant Drain

23. Wet Exhaust Elbow

OM844W2 02/05

24. Junction Box

25. Starter

26. Alternator

27. Belt Guard

28. Coolant Thermostat (behind)

29. Water Temperature Sender

Control Panels

Figure 3-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 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

OM844W2 02/05

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 10 seconds consecutively. If the engine fails to start with the first 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 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). 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 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.

OM844W2 02/05

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.

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