Northern Lights NL1066 Operator's Manual

OPERATOR’S

MANUAL ONL2-2

For Models

NL1064D, NL1064T1, NL1064T2, NL1064H1,

NL1066T, NL1066H1, NL1066H2, and NL1066H3

— 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: [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.: ONL2-2 10/05

OPERATOR'S MANUAL

#ONL2-2 for Models:

NL1064D, NL1064T1, NL1064T2, NL1064H1, NL1066T, NL1066H1, NL1066H2, and NL1066H3

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 ..................................................	2
WARRANTY ...........................................................	3
SAFETY RULES ....................................................	3
COMPONENT LOCATIONS
NL1064T2 .........................................................	4
NL1066T ...........................................................	5
NL1066H2, H3 ..................................................	6
ENGINE & GENERATOR CONTROL PANELS
Series 3B & 1B ..................................................	8
OPERATING PROCEDURES
Before Starting ..................................................	9
Shutdown Procedures ........................................	9
Break-In Period ...............................................	10
SERVICING SCHEDULE CHART ....................	11
SERVICE RECORD ............................................	12
SERVICING
Lubrication - General ......................................	13
Checking Oil ...................................................	13
Oil Changes .....................................................	13
Changing Oil Filter..........................................	13
Air Filter ..........................................................	13
Belt Tension ....................................................	14
Valve Clearances .............................................	15
Fuels - General ................................................	16
Crankshaft Vibration Damper (6 Cyl.) ............	17
Fuel Filters...............................................	16 - 17

Bleeding the Fuel System ........................	17 - 19
Injection Pump ........................................	19 - 22
Turbocharger ...................................................	22
Turbo Boost .....................................................	22
Cooling System - General ...............................	22
Engine Coolant Specifications ................	23 - 24
Cooling System Flushing ........................	24 - 25
Generator Ends ................................................	25
Electrical System - General .............................	25
Booster Batteries .............................................	25
Battery Care .....................................................	26
Winterizing / Out-of-Service ...........................	26
TROUBLESHOOTING
Electrical ..........................................................	27
Engine ......................................................	28 - 29
WIRING DIAGRAMS
AC Wiring .......................................................	30
DC Wiring ...............................................	31 - 36

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 ONL2-2 10/05

ONL2-2 10/05

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 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 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.

Model Numbers

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

NL

1064 or 1066

D, T, H

NL - Northern Lights industrial generator set

+

Model number

+

D - Naturally aspirated

106 mm bore, 4 Cylinder

T - Turbocharged

or

H - High output

106 mm bore, 6 Cylinder

Northern Lights® naturally aspirated,1800

NL1064D = RPM industrial diesel generator set with a

John Deere Powertech Tier II 4045 engine block with a mechanically controlled fuel system.

Northern Lights® turbocharged industrial NL1064T1 = generator set with a John Deere Powertech

Tier II 4045 engine block with a mechanically controlled fuel system.

Northern Lights® turbocharged industrial

NL1064T2 = generator set with a John Deere Powertech Tier II 4045 engine block with an electronically

controlled fuel system.

Northern Lights® turbocharged industrial NL1064H1 = generator set with a John Deere Powertech

Tier II 4045 engine block with an electronically controlled fuel system, high output.

Northern Lights® turbocharged industrial

NL1066T = generator set with a John Deere Powertech Tier II 6068 engine block with an electronically

controlled fuel system.

Northern Lights® turbocharged industrial

NL1066H1 = generator set with a John Deere Powertech

Tier II 6068 engine block with an electronically controlled fuel system, high output.

Northern Lights® turbocharged industrial

NL1066H2 = generator set with a John Deere Powertech Tier II 6068 engine block and an electronically

controlled fuel system, high output.

Northern Lights® turbocharged industrial

NL1066H3 = generator set with a John Deere Powertech Tier II 6068 engine block and an electronically

controlled fuel system, high output.

Serial Numbers

When referencing Alaska Diesel Electric equipment by serial number, please refer only to the number stamped on the Northern Lights® serial number plate.

ONL2-2 10/05

4

			Warranty
A warranty registration certificate is supplied			followed. If further information is needed, please
with your set. The extent of coverage is described			contact an authorized dealer or the factory.
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
			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 when working around engines.

•Do not oil or grease engine while it is running.

•Always disconnect the ECU (Electronic Control Unit) connectors and remove the ground connection for the engine control system-to- machine frame before welding on engine. Make sure no other electronic components are in the ground path also.

•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.

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.

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

ONL2-2 10/05

5

Component Locations

4

5

6

3

2

1

7

13

12

11

10

9

8

14

15

	Figures 1 & 2: NL1064T2 (Electronically				16
	Controlled Fuel System)
	1.	Junction Box	8.	Vibration Mount
	2.	Control Panel	9.	Lube Oil Filter	15. Exhaust Manifold
	3.	Air Cleaner	10.	Fuel Manifold
					16. Electronic Control Unit
	4.	Rain Cap	11.	Lube Oil Dipstick
	5.	Exhaust Elbow	12.	Starter
	6.	Radiator Shroud	13.	Fuel Filter
	7.	Alternator	14.	Turbocharger

ONL2-2 10/05

6

Component Locations

4

5

6

7

2 3

1

8

14

13

12

11

10

9	15

2

16

Figure 3 & 4: NL1066T (Electronically

Controlled Fuel System)

				18
	1.	Junction Box			17
	2.	Control Panel	8.	Alternator
	3.	Air Cleaner	9.	Vibration Mount
	4.	Rain Cap	10.	Lube Oil Filter	15. Turbocharger
	5.	Exhaust Elbow	11.	Low Oil Level Gauge (optional)
					16. Exhaust Manifold
	6.	Low Coolant Level Gauge	12.	Lube Oil Dipstick
					17.	Starter
		(optional)	13.	Fuel Filter/ Water Separator (optional)
					18.	Electronic Control Unit
	7.	Radiator Shroud	14.	Fuel Filter

ONL2-2 10/05

7

Component Locations

		4	6
			7
2	3		5

8

1

9

17

16

15

14

13

12

11

10

Figures 5 & 6: NL1066H2, H3

(Electronically Controlled Fuel

System)

1.	Control Panel	8.	Low Coolant Level
2.	Junction Box		Gauge (optional)
3.	Air Cleaner	9.	Alternator
4.	Rain Cap	10.	Oil Filter
5.	Turbocharger	11.	Dipstick
6.	Exhaust Elbow	12.	Low Oil Level Gauge (optional)
7.	Radiator Shroud

	18	17
	19
13.	Fuel Filter/ Water Separator	17.	Electronic Control Unit
	(optional)	18.	Starter
14.	Fuel Filter	19.	Exhaust Manifold
15.	Fuel Manifold	20.	Vibration Mounts
16.	Secondary Fuel Filter

ONL2-2 10/05

8

Notes

ONL2-2 10/05

9

Northern Lights 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.

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 7: Series 3-B 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.

Figure 8: Series 1-B Generator Control Panel

ONL2-2 10/05

10

Operating Procedures

BEFORE STARTING

1.Check the water level by removing the pressure cap from the expansion tank. In order to give the cooling water room to expand, the level should be about 1 3/4 in. (4-5 cm) below the filler cap sealing surface when the engine is cold. When filling with coolant, the venting cock on top of the turbocharger should be opened to ensure that no air pockets form in the cooling system.

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 should be in the “waffled area” or on or below “full”. 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.Disengage clutch, if equipped.

5.Close the seacock, check and clean the strainer and reopen the seacock.

6.Place the battery switch in the ON position.

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.While holding the Shutdown Bypass switch in the ON position, push the Engine Control switch to the START position.

2.As soon as the engine starts, release both switches.

Do not crank the starter for more than 20 seconds.

3.If the engine fails to start the first time, be sure the starter has stopped before re-engaging.

4.Operate engine at or below 1200 RPM with no-load for 1 to 2 minutes to ensure proper lubrication. When operating at below freezing temperatures extend this period to 2 to 4 minutes.

NOTE: If there is a governor locked at a specific speed on the generator set, there may not be a slow idle function, so in that case operate the engine at high idle for 1 to 2 minutes before adding load. If the stand-by generator set is loaded as soon as it reaches rated speed, this procedure would not apply.

Operating

1.Check Gauges Often: Oil pressure must be above 29 PSI (if not above 15 PSI within 5 seconds of starting, the engine should be stopped and the problem should be explored). Normal oil pressure is 50 PSI at rated load speed (1800 to 2500 RPM). Oil temperature should be 1150C (2400F) for normal

operating temperature. Coolant temperature should be 82 - 94°C (180 - 202°F) for electronically controlled fuel systems, 90 -100°C (194 -212°F) for

mechanically controlled fuel systems. The D.C. voltmeter should read between 13 and 14 volts (2628 volts, 24 volt systems).

2.Check AC voltage and frequency meters (Series 4 Panel). If gauges deviate from normal levels, shut down the set and investigate.

3.Check belt for good alignment.

4.Let the unit run unloaded for a three to five minute warm-up period before applying load.

5.Do not add full electrical load until engine is at maximum operating temperature.

6.If the air temperature is below -10°C (14°F) use an engine block heater.

Shutdown

1.Turn the Engine Control Switch to the OFF position.

2.Close the fuel valves, and put the battery switch in the OFF position if the unit will be off for an extended period.

NOTE: Do not turn the battery switch to OFF while the engine is running.

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 or shutdown system 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 shutdown system is activated:

a.Check the coolant temperature gauge. If the temperature is above 205°F (97°C), shut off the

engine immediately.

ONL2-2 10/05

11