Northern Lights NL1064D, NL1064T1, NL1064T2, NL1064H1, NL1066T Owner's Manual
...
ONL2-2
For Models: NL1064D, NL1064T1, NL1064T2,
NL1064H1, NL1066T, NL1066H1,
NL1066H2, and NL1066H3
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
Copyright ©2013 Northern Lights, Inc.
All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Northern Lights, Inc.
Printed in U.S.A.
PART NO.: ONL2-2 7/13
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 - 7
COMPONENT LOCATIONS
NL1064T2 ...........................................................8
NL1066T .............................................................9
NL1066H2, H3 ................................................ 10
ENGINE & GENERATOR CONTROL PANELS
Series 3B & 1B .................................................11
OPERATING PROCEDURES
Before Starting ................................................. 12
Shutdown Procedures ...................................... 12
Break-In Period ................................................ 13
SERVICING SCHEDULE CHART .................14
SERVICE RECORD ......................................... 15
Bleeding the Fuel System ........................ 20 - 22
Injection Pump ......................................... 22 - 25
Turbocharger .................................................... 25
Turbo Boost ..................................................... 25
Cooling System - General ................................25
Engine Coolant Specifi cations ................. 26 - 27
Cooling System Flushing .........................27 - 28
Generator Ends ................................................ 28
Electrical System - General ............................. 28
Booster Batteries .............................................. 28
Battery Care ..................................................... 29
Winterizing / Out-of-Service ........................... 29
TROUBLESHOOTING
Electrical .......................................................... 30
Engine ...................................................... 31 - 32
WIRING DIAGRAMS
AC Wiring ........................................................ 33
DC Wiring ................................................ 34 - 40
SERVICING
Lubrication - General .......................................16
Checking Oil .................................................... 16
Oil Changes ..................................................... 16
Changing Oil Filter .......................................... 16
Air Filter .......................................................... 16
Belt T ension ..................................................... 17
Valve Clearances .............................................. 18
Fuels - General .................................................19
Crankshaft Vibration Damper (6 Cyl.) ............ 20
Fuel Filters ............................................... 19 - 20
It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc.
© Northern Lights, Inc. All rights reserved. Litho U.S.A. Publication number ONL2-2 7/13
Proprietary Information
This publication is the property of Northern Lights, Inc.
ONL2-2 7/13
1
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
Failures begin with minor problems that are overlooked
and become amplifi ed when not corrected during
routine maintenance.
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.
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
NL - Northern Lights industrial generator set
NL1064D
NL1064T1
NL1064T2
NL1064H1
Northern Lights® naturally aspirated,1800
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
generator set with a John Deere Powertech
=
Tier II 4045 engine block with a mechanically
controlled fuel system.
Northern Lights® turbocharged industrial
generator set with a John Deere Powertech
=
Tier II 4045 engine block with an electronically
controlled fuel system.
Northern Lights® turbocharged industrial
generator set with a John Deere Powertech
=
Tier II 4045 engine block with an electronically
controlled fuel system, high output.
106 mm bore, 4 Cylinder
++
or
106 mm bore, 6 Cylinder
1064 or 1066
Model number
NL1066T
NL1066H1
NL1066H2
NL1066H3
Northern Lights® turbocharged industrial
generator set with a John Deere Powertech
=
Tier II 6068 engine block with an electronically
controlled fuel system.
Northern Lights® turbocharged industrial
generator set with a John Deere Powertech
=
Tier II 6068 engine block with an electronically
controlled fuel system, high output.
Northern Lights® turbocharged industrial
generator set with a John Deere Powertech
=
Tier II 6068 engine block and an electronically
controlled fuel system, high output.
Northern Lights® turbocharged industrial
generator set with a John Deere Powertech
=
Tier II 6068 engine block and an electronically
controlled fuel system, high output.
D, T, H
D - Naturally aspirated
T - Turbocharged
H - High output
When referencing Alaska Diesel Electric equipment by serial number, please refer only to the number
stamped on the Northern Lights® serial number plate.
Serial Numbers
ONL2-2 7/13
2
Revised 7/10/13
Warranty
A warranty registration certifi cate is supplied
with your set. The extent of coverage is described
in the Limited Warranty Statement. We
recommend that you study the statement carefully.
Safety Rules
NOTICE: 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.
IMPORTANT SAFETY INSTRUCTIONS.
Electromagnetic equipment, including generator sets
and their accessories, can cause bodily harm and
life threatening injuries when improperly installed,
operated or maintained. To prevent accidents be aware
of potential dangers and act safely.
READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUAL,
PRIOR TO THE INSTALLA TION
OF ANY GENERATOR SET OR
ACCESSORY. KEEP THESE
INSTRUCTIONS FOR FUTURE
REFERENCE.
Recognize Safety Symbols and Instructions
In addition to the information found in this section, this
operator’s manual uses three different signal words to
outline potential dangers of a specifi c nature.
DANGER indicates a hazardous situation which, if
not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if
not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation which,
if not avoided, could result in minor or moderate
injury.
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.
on parts and components from outside suppliers
that is not reproduced in this manual. Consult the
suppliers for additional safety information.
Learn how to operate the machine and how to use
the controls properly. Only trained personnel should
operate machines, or work on or around them.
Keep you machine in proper working condition.
UNAUTHORIZED MODIFICATIONS TO THE
MACHINERY MAY IMPAIR ITS FUNCTION
AND SAFETY PARAMETERS.
Prevent Bypass and Accidental Starting
Do not start engine by shorting
across start terminal. Engine will
start if normal circuitry is bypassed,
creating a hazard by runaway
machinery.
Start engine only from operator’s station.
Follow All Safety Instructions
Carefully read and understand
all safety messages in this
manual and on your machine’s
safety signs. Keep signs in good
and clean condition. Replace
missing or damaged signs. Be
sure new equipment components and repair parts
include the current safety signs. For replacement signs,
proper placement of safety signs or clarifi cation on any
safety issue, consult your Northern Lights dealer or the
factory.
There can be additional safety information contained
Handle Fuel Safely - Avoid Flames
Diesel is highly fl ammable and should be treated
with care at all times. Do not refuel while smoking
or when near sparks or open fl ame.
ALWAYS STOP ENGINE
BEFORE FUELING
MACHINE. Always fi ll
portable fuel tank outdoors.
Never fuel a hot engine.
ONL2-2 7/13
3
updated 2/23/12
Safety Rules
Prevent accidental discharge of starting fl uids by
storing all cans in a cool, safe place, away from sparks
or open fl ame. Store with cap securely on container.
Never incinerate or puncture a fuel container.
Operating equipment requires the full attention of
the operator. Do not use radio or music headphones
while operating machinery.
Prevent fi res by keeping machine clean of accumulated
trash, grease and debris. Always clean any spilled fuel
as swiftly as possible. Do not store oily rags, which
can ignite and burn spontaneously.
Be prepared if a fi re starts. Keep a fi rst aid kit and fi re
extinguisher handy. Keep emergency contact numbers
for fi re department, doctors, ambulance and hospital
near the telephone.
Service Machines Safely
Do not wear a necktie, scarf,
necklace, rings or other
jewelry, or any loose clothing
when working near moving
parts. Tie long hair behind your head. If any of these
items get caught in moving machinery, severe injury or
death could result.
Check for any loose electrical connections or faulty
wiring.
Look completely around engine to make sure that
everything is clear before starting.
Practice Safe Maintenance
Understand all service procedures
before starting work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is
in operation.
Keep hands, feet and clothing away from powerdriven equipment. When shutting down an engine,
disengage all power and operator controls. Allow
the engine to cool completely before beginning any
service work.
Securely support any machinery elements that must
be raised for service work with support or lifting
machinery specifi cally intended for that purpose.
Keep all parts in good conditions and properly
installed. Fix damage immediately. Replace any
worn or broken parts. Remove any build up of
grease, oil or debris.
Disconnect battery ground cable (-) before making
any adjustments or service work.
Stay Clear of Rotating Drivelines
Wear Protective Clothing
To prevent catching anything in moving machinery,
always wear close fi tting clothes and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause hearing
loss or impairment.
Wear suitable authorized
hearing protection, such
as earmuffs or plugs to
protect against loud noises.
Entanglement in rotating drivelines can cause serious
injury or death. Keep shields in place at all times.
Make sure that rotating shields turn freely in pace
with the drivelines.
Do not wear loose fi tting equipment around rotating
drivelines. Stop the engine and make sure that all
moving parts have stopped
before making any adjustments,
connections, or performing
any other type of service to
the engine or other driven
equipment.
ONL2-2 7/13
4
Updated 2/23/12
Safety Rules (Continued)
Install all Safety Guards
Direct contact with rotating
fans, belts, pulley and drives
can cause serious injury.
Keep all guards in place at all
times during engine operation.
Wear close-fi tting clothes. Stop the engine and be
sure all fans, belts, pulleys and drives are stopped
before making adjustments, connections, or cleaning
near fans and their components.
Do not allow anything on your person to dangle into
or come in contact with a moving fan, belt, pulley or
drive. Fans can act as vacuums and pull materials
up from below, so avoid that area as well while in
service.
Safe Battery Handling
T o A void Hazards:
• Fill batteries only in well-ventilated areas.
• Wear appropriate eye protection and rubber gloves.
• Never use air pressure to clean batteries.
• Wear appropriate ventilation equipment to avoid
inhaling fumes when adding electrolyte.
• Do not spill or drip electrolyte.
• Use correct jump-start procedure if required.
If acid is spilled on skin or in eyes:
1. Flush skin with water.
2. Apply baking soda or lime to
help neutralize acid.
3. Flush eyes with water for
15-30 minutes.
4. Get medical attention
immediately.
If acid is swallowed:
1. DO NOT induce vomiting.
2. Drink large amounts of
water or milk, without
exceeding 2 liters
(2 quarts)
3. Get medical attention immediately
Prevent Battery Explosions
Battery gas is highly
fl ammable. Battery
explosions can cause severe
injury or death. To help
prevent battery explosions, keep sparks, lighted
matches and open fl ame away from the top of battery.
When checking battery electrolyte level, use a
fl ashlight.
Never check battery charge by contacting the posts
with a metal object. Use a volt-meter or hydrometer.
Frozen batteries may explode if charged. Never
charge a battery that has not been allowed to warm to
at least 16oC (60oF).
Always remove grounded (-) battery clamp fi rst and
replace ground clamp last.
S
ulfuric acid in battery electrolyte is poisonous and
strong enough to burn skin, eat holes into clothing and
other materials, and cause blindness if splashed into eyes.
Battery posts, terminals, and related accessories
can contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
Handle Chemical Products Safely
Direct exposure to hazardous
chemicals can cause serious injury.
Among the potentially hazardous
chemicals that may be used
with Northern Lights
products are lubricants,
coolants, paints and adhesives.
All potentially hazardous chemicals come with a Material
Data Safety Sheet (MSDS). The MSDS provides specifi c
details on chemical products, including physical hazards,
safety procedures and emergency response techniques
ONL2-2 7/13
5
Updated 2/23/12
Safety Rules (Continued)
Read and understand the MSDS for each chemical before
you start any job that includes it. Follow the procedures
and use appropriate equipment exactly as recommended.
Contact your Northern Lights dealer or Northern Lights
factory for MSDS’s used on Northern Lights products.
Work in Well V entilated Ar eas
Exhaust fumes from engines contain carbon monoxide
and can cause sickness or death. Work in well ventilated
areas to avoid prolonged exposure to engine fumes. If it
is necessary to run an engine in an enclosed area, route
the exhaust fumes out of the area with an approved, leak
proof exhaust pipe extension.
Remove Paint Before Welding or Heating
Hazardous fumes can be generated
when paint is heated by welding,
soldering or using a torch. To avoid
potentially toxic fumes and dust,
remove paint before heating.
•
Remove paint a minimum of 100
mm (4 in.) from the
area that will be affected by heat.
•
If paint cannot be removed, wear an approved respirator.
• If you sand or grind paint, use an approved respirator.
• If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove
solvent or paint stripper containers from the area.
• Allow at least 15 minutes for fumes to disperse
before welding or heating.
Do not use a chlorinated solvent in an area where welding
will occur. Work only in areas that are well ventilated.
Dispose of paint and solvent properly .
engine has been shut off. Do not remove a fi ller cap
unless it
is cool enough to comfortably grip with bare
hands. Slowly loosen cap to relieve pressure before
opening fully .
Avoid High Pressure Fluids
Relieve pressure prior to
disconnecting pressurized lines.
Escaping fl uid under pressure
can penetrate the skin causing
serious injury . Always relieve pressure before
disconnecting hydraulic or other pressurized lines.
Tighten all connections fi rmly before re-applying
pressure.
If searching for leaks, use a piece of cardboard.
Always protect your hands and other body parts from
high-pressure fl uids.
If an accident occurs, see a doctor immediately . Any
high pressure spray injected into the skin must be
removed within a few hours to prevent the risk of
gangrene or other infection.
Avoid Heating Near Pressurized Fluid Lines
Flammable spray can be generated
by heating near pressurized fl uid
lines, resulting in severe burns and
bodily injury . Pressurized lines
can rupture when heat goes beyond the immediate
fl ame area. Do not weld, solder or use a torch or
open fl ame near pressurized lines or other fl ammable
fl uids.
Do Not Open High-Pressure Fuel System
Service Cooling System Safely
Opening a pressurized cooling
system can release explosive
fl uids and causing serious burns.
Before opening any pressurized
cooling system, make sure the
Many Northern Lights engines use high-pressure
fuel injection. High-pressure fl uid remaining in fuel
lines can cause serious injury . Do not disconnect or
attempt any repair of fuel lines, sensors, or other
ONL2-2 7/13
6
Updated 2/23/12
Safety Rules (Continued)
components between the high-pressure fuel pump
and nozzles on engines with high pressure fuel
systems.
ONL Y AUTHORIZED TECHNICIANS
CAN PERFORM REPAIRS ON AN HIGH
PRESSURE FUEL INJECTION SYSTEMS.
Avoid Hot Exhaust
Avoid exposure to and physical
contact with hot exhaust
gases. Exhaust parts and streams can reach high
temperatures during operation, leading to burns or
other serious injury.
Cleaning exhaust fi lters can also lead to exposure to
hot exhaust gas and the injury risk associated with
it. Avoid exposure to and physical contact with hot
exhaust gases when cleaning exhaust fi lters.
During auto or manual/stationary exhaust fi lter
cleaning operations, the engine will run at
elevated temperatures for an extended period of
time. Exhaust parts and streams can reach high
temperatures during operation, leading to burns or
other serious injury.
Avoid Harmful Asbestos Dust
Inhaling asbestos fi bers may cause
lung cancer. Avoid breathing any
dust that may be generated when
handling components containing
asbestos fi bers, including some
gaskets.
The asbestos used in these components is usually
found in a resin or otherwise sealed. Normal
handling of these components is not dangerous,
as long as airborne dust containing asbestos is not
generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding materials
containing asbestos. When servicing, wear an
approved respirator. A special vacuum cleaner is
recommended to clean asbestos. If this vacuum is
not available, apply a mist of oil or water on the
material containing asbestos. Keep all bystanders
away from any area where asbestos dust may be
generated.
Use Proper Lifting Equipment and Techniques
Lifting heavy components incorrectly
can cause severe injury or damage
to machinery. Avoid unbalanced
loads. Do not use lifting eyes. Lift the
generator set using lifting bars inserted
through the lifting holes on the skid.
Follow all recommended removal and installation
procedures in this and associated Northern Lights
manuals.
Use Proper Tools
Makeshift tools and procedures
can create safety hazards.
Always use appropriate tools for
the job.
Use power tools only to loosen threaded parts and
fasteners. For loosening and tightening hardware,
always use the correct sized tools.
Do not use US measurement tools on metric
fasteners, or vice versa. Use only service parts that
meet Northern Lights specifi cations.
Dispose of Waste Properly
Disposing of waste improperly can threaten the
environment and lead to unsafe working conditions.
Potentially harmful waste used in Northern Lights
equipment can include oil, fuel, coolant, fi lters and
batteries.
Use leakproof containers to drain fl uid. Do not
use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain or
into any water source.
ONL2-2 7/13
7
Added 2-24-12
Lock Out / Tag Out Procedures
Scope
During maintenance, repairs or retooling of a Northern Lights generator set, simply turning the machine off or unplugging
it while it is being worked on does not give enough protection to others who are not performing the maintenance or
repair. Many serious accidents happen when someone thought the machine was turned of f, or all of its energy was
safely blocked or released.
General Policy
To avoid dangerous or hazardous situations, refrain from
any of the following:
• Removing or bypassing a guard or other safety device
• Placing any part of your body in a position where you
could be caught by moving machinery.
• Cleaning or oiling machinery when in operation.
• Adjusting circuits, chillers, pumps, air handlers, valves,
circuit breakers or fans while in operation.
• Working on piping or high pressure systems.
Lock Out/Tag Out Instructions Electrical Equipment
Be sure the equipment’s ON/OFF switch is in the OFF
position and is unplugged from any electrical source before
attempting to perform any type of work on the equipment.
Obtain an electrical plug cap cover with a lockset. Secure
the plug terminal end using the electrical plug lockout cap.
Lock the cap and retain the key.
If the equipment is directly wired into an electrical box with
a shut off switch, obtain a lock pad and/or the appropriate
colored tags and place the lock and tag through the shut
off lever . Retain the key until the repair is completed and
the machine is safe to start. Be certain the shut off lever
is in the OFF position before restarting. NEVER give a
lock out key to unauthorized personnel.
If the equipment is directly wired into an electrical box
without a shut off switch and lock out capability, then a
circuit breaker lock out will be required. Obtain a circuit
lock and tag set. Install the lock onto the circuit breaker
box. Ensure the unit ON/OFF switch is in the OFF position
before restarting.
Lock Out/Tag Out Instructions Pneumatic and Hydraulic Equipment
If shutting off of air, water or other material cannot be
achieved at the local supply valve, shut off valves further
back in the system and re-check the bleed-off point until
complete shut-off is achieved.
Affi x a DO NOT OPERATE tag to each valve handle that
requires shut off. Each DO NOT OPERATE tag must be
signed and dated by the authorized technician servicing
the equipment.
Lock Out/Tag Out Instructions Air Hose Connected Pneumatic Equipment
Equipment connected to the compressed air system
through an air hose with a detachable fi tting must be
shutdown and unplugged. Excess air must be bled prior
to removing the air hose, prior to any maintenance or
repair activities.
Affi x a DO NOT OPERATE tag to the air hose near the
detachable fi tting. Each DO NOT OPERA TE tag must be
signed and dated by the authorized technician servicing
the equipment. Check that the equipment cannot be
operated by activating the ON switch.
Stored Energy
Immediately after applying Lock Out or Tag Out devices,
ensure that all potentially hazardous stored or residual
energy is relieved, disconnected, restrained and otherwise
rendered safe.
Verifi cation of Isolation
Verify the machinery or equipment is actually isolated and
de-energized prior to beginning work on a machine or on
equipment that has been locked out.
Restarting Procedures
For servicing pneumatic and hydraulic equipment, the
following additional procedures must be implemented,
following completion of lock out/tag out procedures for
the unit to be serviced:
Shut off air, water or supply valves at the equipment to
be serviced.
Check the local bleed-off point for completed release of
pressurized air, water or oil.
Follow the procedures below prior to restoring energy:
• Ensure that all machinery or equipment is properly
reassembled. Inspect the machinery or equipment to
verify non-essential items have been removed.
• Ensure that all personnel are safely outside danger
zones. Notify personnel that lock out/tag out devices have
been removed and energy will be reapplied.
• Only authorized personnel may remove lock out/tag out
devices or notices.
ONL2-2 7/13
8
Notes
ONL2-2 7/13
9
Component Locations
5
4
6
3
2
1
7
13
12
11
10
9
8
14
15
Figures 1 & 2: NL1064T2 (Electronically
Controlled Fuel System)
1. Junction Box
2. Control Panel
3. Air Cleaner
4. Rain Cap
5. Exhaust Elbow
6. Radiator Shroud
7. Alternator
8. Vibration Mount
9. Lube Oil Filter
10. Fuel Manifold
11. Lube Oil Dipstick
12. Starter
13. Fuel Filter
14. Turbocharger
16
15. Exhaust Manifold
16. Electronic Control Unit
ONL2-2 7/13
10
Component Locations
4
6
2
3
5
1
14
7
8
13
12
Figure 3 & 4: NL1066T (Electronically
Controlled Fuel System)
11
10
9
15
2
16
18
1. Junction Box
2. Control Panel
3. Air Cleaner
4. Rain Cap
5. Exhaust Elbow
6. Low Coolant Level Gauge
(optional)
7. Radiator Shroud
8. Alternator
9. Vibration Mount
10. Lube Oil Filter
11. Low Oil Level Gauge (optional)
12. Lube Oil Dipstick
13. Fuel Filter/ Water Separator (optional)
14. Fuel Filter
ONL2-2 7/13
11
17
15. Turbocharger
16. Exhaust Manifold
17. Starter
18. Electronic Control Unit
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