Northern Lights NL844W2 Operator's Manual

ONL844W2

For Models: NL844W2 and NL844LW2

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: [phone]
Fax: [phone]

Copyright ©2006 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.: ONL844W2 10/06

OPERATOR'S MANUAL

for Models

NL844W2 and NL844LW2

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 ................................................ 4

Models Included .............................................. 4

Model Numbers ............................................... 4

Serial Numbers ................................................ 4

WARRANTY ...................................................... 5

SAFETY RULES .................................... 5

COMPONENT LOCATIONS

NL844LW2 Industrial Generator ....................... 6

CONTROL PANELS

Northern Lights Generator Sets ......................... 7

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

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

Generator Ends .............................................. 18

Electrical System - General ............................ 18

Glow Plugs ................................................... 18

Booster Batteries ........................................... 19

Battery Care .................................................. 19

Winterizing / Out-of-Service ........................... 19

TROUBLESHOOTING

Electrical ...................................................... 20

Engine ................................................... 19 - 23

DATA SHEETS

NL844LW2 & W2 ......................................... 24

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.

© Alaska Diesel Electric, Inc. All rights reserved. Litho U.S.A. Publication number ONL844W2 10/06

ONL844W2 10/06

WIRING DIAGRAMS

DC Electrical ................................................ 25

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

Failures can begin with minor problems that are over-

looked and become amplied 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 Identication

MODELS INCLUDED

This manual covers the operating instructions for:

NL844W2 and NL844LW2 industrial generator sets

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:

NL

Northern Lights industrial generator set

NL844W2

Northern Lights industrial diesel generator set with

=

an 844 engine and a PX-316K2 generator end.

Model number of engine block

+

Bore Cylinders
84 mm 4

844

NL844Lk

Serial Numbers

Your set has three serial numbers: 1 an engine number stamped
on the block,

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.

a generator plate, and 3 a generator set plate.

2

L, W

L: Long stroke version

+

W: New winding

Northern Lights industrial diesel generator set with

=

an 844L engine and a PX-320K2 generator end.

Figure 1: Generator set serial number plate.

ONL844W2 10/06

4

Warranty

A warranty registration certicate 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 re 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 uids 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,

qualied 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 rst 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 lling fuel

tank or servicing fuel system.

ONL844W2 10/06

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

5

Industrial Generator Component Locations

9

7

6

8

2

5

3

4

10

1

11

12

20

1819

21

151617

1314

23

Figure 2A and 2B:
NL844LW2

1. Control Panel Plug-in

2. Generator Junction Box

3. DC Circuit Breaker

4. Generator Plate

5. Air Filter

6. Crankcase Vent

7. Oil Fill

8. Fuel Injector

9. Coolant Fill

10. Injection Pump

11. Shutdown Solenoid

12. Oil Pressure Sender

ONL844W2 10/06

22

13. Fuel Inlet Line

14. Oil Dipstick

15. Fuel Return Line

16. Block Drain

17. Oil Filter

18. Fuel Lift Pump

6

19. Fuel Filter

20. Coolant Temperature
Sender

21. Exhaust Outlet

22. Starter

23. DC Alternator

Figure 3-A: Series 1-B Generator Control Panel

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.
NOTE: Excessive cranking of marine sets equipped

 withwaterliftmufer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 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 fre-

quency: 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

Shows the generator load on each phase. The phase is

selected with the Ammeter Selector switch (Item 9).

ONL844W2 10/06

7

Operating Procedures

BREAK-IN PERIOD

1. The rst 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

lter at 50 hours. Change oil and lter again at

100 hours (consult Lubricants section for oil
recommendation).

Operating Instructions:

Maintain at least a 75% load on your generator

set for the rst 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 radiator. In order to give the cooling

water an opportunity to expand, the level should

be about 1 in. (2.5 cm) below the ller cap sealing

surface when the engine is cold.

CAUTION: Use protective clothing and open

the ller cap carefully when the engine is warm

to prevent burns.

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 20 seconds

consecutively. If the engine fails to start with the rst

attempt, be sure that it has stopped completely before
re-engaging.

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.
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 ve minute

warm-up period.

3. Apply electrical load.

STOPPING

2. Check the oil level in the crankcase with the

dipstick. The oil level must be in the wafed 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. 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.

ONL844W2 10/06

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.

8