Northern Lights OM150C12 Owner's Manual
OM150C12
For Model: M150C12
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 ©2011 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.: OM150C12 10/11
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
OPERATOR'S MANUAL
#OM150C12 for Model:
M150C12
INTRODUCTION ....................................................2
Models Included .................................................2
Model Numbers ..................................................2
Serial Numbers ...................................................2
WARRANTY ............................................................3
SAFETY RULES ................................................. 3-7
COMPONENT LOCATIONS
M150C12 ............................................................8
ENGINE & GENERATOR CONTROL PANELS
Series 3B .............................................................9
OPERATING PROCEDURES
Before Starting ................................................. 10
Shutdown Procedures ...................................... 10
Break-In Period .................................................11
SERVICING SCHEDULE CHART .................... 12
SERVICING
Lubrication - General ....................................... 13
Checking Oil .................................................... 13
Oil Changes ..................................................... 13
Changing Oil Filter .......................................... 13
Air Filter .......................................................... 13
Valve Clearances .............................................. 14
Fuels - General ................................................. 15
Crankshaft Vibration Damper (6 Cyl.) ............ 16
Fuel Filters ....................................................... 16
The Fuel System ...................................... 17 - 18
High Pressure Common Rail ........................... 18
Turbocharger .................................................... 18
Turbo Boost ..................................................... 18
Cooling System - General ................................ 18
Engine Coolant Specications ................. 18 - 19
Cooling System Flushing ......................... 19 - 20
Heat Exchanger Cleaning ................................ 21
Zinc Electrodes ................................................ 22
Raw Water Pump ..................................... 22 - 24
Generator Ends ................................................ 24
Electrical System - General ............................. 24
Booster Batteries .............................................. 24
Battery Care ..................................................... 25
Winterizing / Out-of-Service ........................... 25
TROUBLESHOOTING
Electrical .......................................................... 26
Engine ...................................................... 27 - 28
WIRING DIAGRAMS
AC Electrical .................................................. 29
DC Electrical ................................................... 30
Panel Wiring Diagram ............................... 31
ON-BOARD SPARE PARTS .............................. 32
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 OM150C12 11/11
Proprietary Information
This publication is the property of Northern Lights, Inc.
OM150C12 11/11
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
Failures begin with minor problems that are overlooked
and become amplied when not corrected during routine maintenance.
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:
M
M - Northern Lights marine generator set
+
150 kW at 60 Hertz
150
Model number
C
C - Commercial Series
+
When referencing Northern Lights equipment by serial number, please refer only to the number
stamped on the Northern Lights® serial number plate.
Serial Numbers
OM150C12 11/11
2
Warranty
A warranty registration certicate is supplied
with your set. 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
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.
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 INSTALLATION 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
will use the CAUTION warning to
outline potential dangers of a specic nature.
CAUTION indicates the presence of a potential hazard
that can or will cause severe or minor property damage,
personal injury or death.
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
followed. If further information is needed, please
contact an authorized dealer or the factory.
repair parts include the current safety signs. For
replacement signs, proper placement of safety signs
or clarication on any safety issue, consult your
Northern Lights dealer or the factory.
There can be additional safety information contained
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.
Handle Fuel Safely - Avoid Flames
Diesel is highly ammable and should be treated
with care at all times. Do do not refuel while
smoking or when near sparks or open ame.
OM150C12 11/11
3
Safety Rules
ALWAYS STOP ENGINE BEFORE FUELING
MACHINE. Always ll
portable fuel tank outdoors.
Never fuel a hot engine.
Prevent accidental discharge
of starting uids by storing
all cans in a cool, safe place,
away from sparks or open ame. Store with cap
securely on container. Never incinerate or puncture a
fuel container.
Prevent 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 re starts. Keep a rst aid kit and re
extinguisher handy. Keep emergency contact numbers
for 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.
Wear Protective Clothing
To prevent catching anything in moving machinery,
always wear close 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.
Operating equipment requires the full attention of
the operator. Do not use radio or music headphones
while operating machinery.
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
power-driven 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 specically 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
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 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.
OM150C12 11/11
4
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-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
Prevent Battery Explosions
Battery gas is highly
ammable. Battery
explosions can cause severe
injury or death. To help
prevent battery explosions,
keep sparks, lighted matches
and open ame away from
the top of battery. When
checking battery electrolyte level, use a 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).
To Avoid 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
WARNING: 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.
Always remove grounded (-) battery clamp rst and
replace ground clamp last.
Sulfuric 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.
All potentially hazardous
chemicals come with a Material Data Safety Sheet
(MSDS). The MSDS provides specic details on
chemical products, including physical hazards, safety
procedures and emergency response techniques
.
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.
OM150C12 11/11
5
Safety Rules (Continued)
Contact your Northern Lights dealer or Northern
Lights factory for MSDS’s used on Northern Lights
products.
Work in Well Ventilated Areas
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.
Service Cooling System Safely
Opening a pressurized cooling
system can release explosive
uids and causing serious burns.
Before opening any pressurized
cooling system, make sure the
engine has been shut off. Do
not remove a 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 uid
under pressure can
penetrate the skin causing
serious injury. Always
relieve pressure before
disconnecting hydraulic or other pressurized lines.
Tighten all connections 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 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 uid lines,
resulting in severe burns and
bodily injury. Pressurized
lines can rupture when heat
goes beyond the immediate
ame area. Do not weld,
solder or use a torch or open ame near pressurized
lines or other ammable uids.
Do Not Open High-Pressure Fuel System
Many Northern Lights engines use high-pressure
fuel injection. High-pressure uid remaining in fuel
lines can cause serious injury. Do not disconnect
or attempt any repair of fuel lines, sensors, or other
components between the high-pressure fuel pump
and nozzles on engines with high pressure fuel
systems.
ONLY AUTHORIZED TECHNICIANS CAN
PERFORM REPAIRS ON AN HIGH PRESSURE
FUEL INJECTION SYSTEMS.
OM150C12 11/11
6
Safety Rules (Continued)
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 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 lters.
During auto or manual/stationary exhaust 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 bers may cause lung cancer.
Avoid breathing any dust that may be generated
when handling
components containing
asbestos 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
specications.
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, lters and
batteries.
Use leakproof containers to drain 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.
OM150C12 11/11
7
Component Locations
Figures 1 & 2: M150C12
1. Coolant Fill
2. DC Alternator
3. Crankcase
Breather Filter
4. Belt Guard
5. Electric Starter
6. Lube Oil Fill & Dipstick
7. Coolant Pump
8. Center Banded Mounts
9. Oil Pan & Filter
10. Lube Oil Drain
11. Expansion Tank
12. Junction Box
13. Air Cleaner
14. Aftercooler
OM150C12 11/11
8
15. Exhaust Manifold
16. Turbocharger
17. Fuel Filters
18. Fuel Injection Pump
19. Thermostat Cover
Northern Lights Control Panel
Figure 5: SeriesS-3C Generator Control Panel
1. 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 mufer systems can cause engine
damage.
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.
2. SHUTDOWN BYPASS SWITCH
This switch bypasses the safety shutdown feature during the starting process.
3. DC VOLTMETER
When the engine is running, it indicates the voltage output of the alternator.
4. HOUR METER
Keeps track of the engine running time.
5. COOLANT TEMPERATURE GAUGE
Water temperature gauge shows the temperature of the cooling water. If the gauge registers over
200° (93.30C) or drops below 140° (600C), stop the engine and investigate.
6. OIL PRESSURE GAUGE
The oil pressure gauge shows the oil pressure in the engine lubricating system. If the pressure drops
below 15 PSI at a speed higher than idling, stop the engine and investigate.
OM150C12 11/11
9
Loading...