Northern Lights O843K, M843JK, M843NK, NL843NK Owner's Manual

OPERATOR’S

OPERATOR’S

MANUAL

MANUAL

M843JK, M843NK, NL843NK

O843K

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.
P.O. Box 70543
Seattle, WA 98107
Tel: [phone]
Fax: [phone]

Copyright ©2003 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.: O843K 05/03

OPERATOR'S MANUAL

for Models

M843JK, M843NK, and NL843NK

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

M843JK and M843NK Marine Generator ...........4

NL843NK Industrial Generator ........................... 5

CONTROL PANELS

Northern Lights Generator Sets...................... 6 - 7

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

Exhaust Elbow................................................... 19

TROUBLESHOOTING

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

Engine........................................................ 21 - 23

DATA SHEETS

M843JK ............................................................. 24

M843NK............................................................ 25

WIRING DIAGRAMS

DC Electrical ............................................. 26 - 27

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 O843K 05/03

Proprietary Information

This publication is the property of Alaska Diesel Electric, Inc.

O843K 05/03

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 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:

M843JK marine generator sets,

M843NK marine generator sets, and

NL843NK 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:

M / NL

M - Northern Lights marine generator set

NL - Northern Lights industrial generator set

Northern Lights marine diesel generator set with

M843JK

M843NK

=

a J-series 843 engine and a PX-300K generator end
with an AVR.

Northern Lights marine diesel generator set with

=

an N-series 843 engine and a PX-300K generator
end.

Model number of engine block

+

Bore Cylinders

84 mm 3

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843

=NL843NK

J / K

Additional letter
designates series

+

within model number

Northern Lights industrial generator set with an N­series 843 engine, PX-300K generator with an AVR,
and a radiator.

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 in Figure 1.

Fill in the serial number of
your unit in the box provided.

Figure 1: Generator set serial number plate.

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.

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.

My Northern Lights generator set SERIAL number is:

Warranty

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

• Keep your hands, feet, hair and clothing away from
power-driven parts.

• Check for any loose electrical connections or faulty
wiring.

• 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.

• 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.

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Marine Generator Component Locations

▼

Service Side

Non-Service Side

▼

Figure 2: M843JK, M843NK, service and non-service views

1. DC Circuit Breaker

2. AC Circuit Breaker for AVR

3. Fuel Filter

4. Air Filter (inside Manifold)

5. Intake Manifold

6. Fuel Lift Pump

7. Oil Fill (2)

8. Crankcase Vent

9. Fuel Injector

10. Coolant Fill

11. Heat Exchanger End Cap

12. Injection Pump

13. Seawater Pump

14. Freshwater Block Drain

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15. Fuel Inlet & Return

16. Oil Filter

17. Oil Dipstick

18. Oil Drain

19. Control Panel Plug-In

20. Generator Set Plate

21. Expansion Tank

22. Wet Exhaust Elbow

23. Junction Box

24. Starter

25. Vibration Mount

26. DC Alternator

Industrial Generator Set Component Locations

Service Side

▼

Non-Service Side

▼

Figure 3: NL843NK, service and non-service views

1. DC Alternator

2. Exhaust Outlet

3. Air Filter

4. Starter

5. DC Circuit Breaker

6. Generator Junction Box

7. Starter

8. Lube Oil Drain

9. AC Circuit Breaker

11. Secondary Fuel Filter

12. Crankcase Vent

13. Lube Oil Fill

14. Coolant Fill

15. Injection Pump

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16. Fuel Inlet and Return

17. Oil Filter

18. Fuel Lift Pump

19. Block Water Drain

20. Dipstick

Control Panels

Figure 4-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 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 4-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 4-C: Series 4 Generator Control Panel

10. A.C. AMMETER

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Shows the generator load on each phase. The phase is
selected with the Ammeter Selector switch (

Item 9).

Figure 5: Series 7.0 through Series 7.6 Generator
Control Panels

1. SHUTDOWN BYPASS SWITCH

Manual Start Panels
(S-7.1 and S-7.3)

Hold the switch in the START position until the engine is
running

NOTE: Excessive cranking may cause engine damage.

After the engine starts, release the switch and it will return
to the RUN position. To stop the engine, hold the switch in
the STOP position.

Auto Start Panels
(S-7.0, S-7.2, S-7.4, S-7.5, and S-7.6)

After the engine starts, release the switch and it will return
to the RUN position. To stop the engine, hold the switch in
the STOP position.

Control Panels

6. STATUS INDICATOR PANEL

Engine monitoring alarms and lamps for monitoring
engine functions.

7. ALARM LAMP TEST AND RESET BUTTON

Press UP to test the indicator lights and press DOWN
to reset the alarm.

8. AC VOLTAGE ADJUSTMENT RHEOSTAT

Voltage has been set at the factory and should only be
adjusted by factory-trained personnel.

9. AMMETER SELECTOR SWITCH

Used to check each phase for load condition.

NOTE: Always leave this switch in the ON position
while the unit is running.

10. FREQUENCY METER (HERTZ)

The frequency meter indicates alternator current
frequency: 60 Hz (1200 or 1800 RPM), or 50 Hz
(1500 RPM).

11. A.C. VOLTMETER

Shows the generator output voltage.

12. A.C. AMMETER

Shows the generator load on each phase. The phase is
selected with the Ammeter Selector switch.

2. OIL PRESSURE GAUGE

Shows the oil pressure in the engine lubricating system.

3. HOUR METER

Keeps track of engine running time.

4. ENGINE TEMPERATURE GAUGE

Registers the temperature of the coolant.

5. DC VOLTMETER

When the engine is running, the voltmeter indicates the
voltage output of the alternator.

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