OPERATOR`S MANUAL - Northern Lights generatoren
Contents
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3. Check water temperature with thermometer and replace gauge if necessary Below Normal Engine Temperature Thermostats not working properly Temperature gauge not working properly Check thermostats Check water temperature with thermometer Low Oil Pressure Low oil level Improper type of oil Partially plugged oil filter Fill crankcase to proper level Drain and fill crankcase with correct oil Replace filter If you cannot correct problems with these procedures see your Northern Lights dealer OM944T 2 11 29 Troubleshooting PROBLEM High Oil Consumption ENGINE POSSIBLE CAUSE Break in period Crankcase oil too light Oil leaks Crankcase over full RECOMMENDATION S Oil consumption decreases after break in Use proper viscosity oil Check for leaks in lines around gaskets and drain plug Remove excess oil Engine Emits Black or Gray Exhaust Smoke Clogged or dirty air cleaner Defective muffler back pressure too high Improper fuel Fuel pump faulty Injection nozzles dirty Engine overloaded Injection nozzles dirty Injection pump faulty Engine out of time Incorrect valve clearance Service air cleaner Have dealer check back pressure Use correct fuel for temperature See your dealer See your dealer Reduce the electrical load See your dealer Consult your dealer See your dealer Consult your dealer
4. OPERATOR S MANUAL A 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 2008 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 OM944T 2 11 NORTHERN LIGHTS OPERATOR S MANUAL for Northern Lights M944T and M38CR2 Diesel Generator Sets 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 INTRODUCTION c 2 SERVICING Continued Model Nur bets ice rte he ers 2 V Belts ie tiber te e eo 15 Serial Numbers sesc sssiesseriseersrsnessrneisrnrostosisensisna 2 Valve OClearances eic ei 16 F els General ettet ens 17 WARRANTY eres 3 Fiel Filt rS aeter rte retis 17 Bleeding the Fuel System 18 SAFETY RULES e re 3 Inj ctor Servic s iron te ote erre ete pats 19 Injection PUnip cori erre ea 20 COMPONENT LOCATIONS T EDOCHAFBet eese eerte iret epa rt ERE ER S 21 MO944T Generator Set esses 4 5 Cooling System esiisa tert rn ern iet 21 M38CR2 Genera
5. ENGINE POSSIBLE CAUSE Low compression pressure worn piston rings etc Troubleshooting RECOMMENDATION S Consult dealer Engine Overheats Engine overloaded Low coolant level Keel cooling tubes marine sets have been painted Cooling system needs flushing Defective thermostat Defective temperature gauge Water pump impeller worn or broken Reduce the electrical load Fill tank or radiator to proper level Check hoses for loose connections and leaks Remove paint from tubes Flush cooling system Remove and check thermostat Check water temperature with thermometer and replace gauge if necessary Check the impeller and replace if necessary Engine Knocks Insufficient oil Injection pump out of time Below normal engine temperature Faulty fuel injector Engine overheating Call your dealer Call your dealer Check your thermostats Check water temperature to see if temperature gauge is working properly Call your dealer See Engine Overheating section High Fuel Consumption Improper type of fuel Clogged or dirty air cleaner Engine overloaded Improper valve clearance Injection nozzles dirty Injection pump out of time Engine not at proper temperature Use correct fuel for temperature Service air cleaner Reduce the electrical load See your dealer See your dealer See your dealer Check your thermostats
6. 50 hours of operation Check valves every 500 hours thereafter 2 Check the valves when the engine is cold 3 Rotate the crankshaft in a clockwise direction in the front 180 to bring each piston to the top dead center on the compression stroke Top dead center TDC is when notch on the pulley aligns with the pointer and the two valves on cylinder No 1 rock Rocking is when the rocker arms for the two valves on a given cylinder are moving in opposite directions one up closing the valve and one down opening the other valve The moment when the two rocker arms are exactly aligned with each other is when they rock Timing Mark Figure 8 Timing Mark 4 Measure the valve clearance for each of the valves with a feeler gauge in the firing order 1 3 4 2 Standard valve clearances for a cold engine are Intake IN 0 0098 in 0 25 mm Exhaust EX 0 0098 in 0 25 mm 5 To adjust valve clearance loosen the lock nut on the adjustment screw Insert a feeler gauge between the rocker arm and the valve stem cap Adjust while measuring the clearance until the feeler gauge slides with a slight drag Tighten the lock nut and recheck the clearance Figure 9 Adjusting screw 0 25 mm 0 0098 Figure 9 Valve Adjustment 6 Adjust the remaining valves 7 Replace the rocker arm cover Front o 014 11 7 3 2 6 10 Tightening Cylinder Head Bolts Order 17 bolts total Tig
7. Engine Emits White Smoke Improper fuel Cold engine Defective thermostat Engine out of time Low Compression Pressure Low engine oil viscosity Excessive amount of engine oil Fuel injection nozzles faulty uneven injection Use correct fuel for temperature Warm up engine to normal operating temperature Remove and check thermostat See your dealer See your dealer Use proper viscosity of oil to ambient temperature Maintain correct oil level See your dealer OM944T 2 11 30 AC Wiring Diagram qogz8 g Bumeiq JoyeinBay eDeyoA xv42 001 LSG wesbeiq Duu OV S4467 WeYyLON EN Ke 6 310N 335 3 verleen Sr E 310N 33S sg mm EL 3LON 335 W3Z 00 1850 yoivino34 d 39vL10 FV ZH O a og ZH 0S OWASIL 00 iowogz ooz sii ooi WAOZZ 002 ZH 09 i ZH 09 i ZH 09 OVAOZ 00 9vAOvZ O0Z OZ 00 OvAOvZ 00Z 3svHd JIONIS 3svHd 319NIS 35vHd 319NIS JIM Y i RM i JIM Y 9 310N 33S 9 310N 33S 8 310N 33S 291 N32 i 3Wv J N39 i JNVYJ N39 yg078 2 1 07 9N3 9018 ON3 D 5310N xd H NON ISL 9 SION 335 ae in X 4 9 S310N 335 y Cj ich gn zh wm an aw zn an S0v3 ANALNO YOLVYINI S0Y31 1ndinO sOLvd3N3S SOV3l 410 YOLVEINJ 310N 33S Ov31 v OMV Q3H V ONIS M Waal 32018 LNdLNO NIV OL 3 WMD YAY 193NNOO 31V10SI L SA NOIYTWVISNI Vid O3NIWH31
8. ON 3 EROS ER L SONI 0s Tina i Di Tuna r3 em am t j J s Tad E DER e y ml SEK 86 X355 66 B m g als ma 35v3 2 ake eu DI NROGLAHS HOLIMS o or oa MO 3NIBN3 Le Ki ox OF Got o e gt Y ri 1NVIS o Z Lu aay Maria R ee amp eerst SAZ Y ZE sama dob sua OW c Loa oF 9 sin mag mei jg op Hd Taoa oF EEA oTa gus O3 oF J aa om EL aay oW ut Tu a V PUE ND vc W i Sec 30S wien 14 S P ALON 33S E ii JNION3 OL HION31 OF C OF XVN 318v2 0 SMV v S TWNOUdO NO S ER at XO8 NOLVH3N39 Ni Q3v201 SE IONLNOO OM944T 2 11 33 NORTHERN LIGHTS 4420 14th Ave NW Seattle WA 98107 NORTHERI Needed Tel 206 789 3880 e 1 800 762 0165 e Fax 206 782 5455 FIT Northern Lights and Lugger are registered trademarks of Alaska Diesel Electric Inc www northern lights com 2011 Allrights reserved Litho USA
9. air only needs to be bled from the fuel filter To do this a Loosen the air vent plug 1 on Figure 10 on the fuel filter by about 1 1 2 turns Be sure to cover the vent with a cloth to prevent fuel from splashing b Turn the priming pump cap on the fuel feed pump counterclockwise to unlatch it Move the priming pump plunger 2 on Figure 10 up and down To close the pump turn the cap clockwise while depressing it c Close the air vent plug when no more air bubbles can be seen in the fuel flowing from the air vent plug hole Figure 10 Fuel Feed Pump 3 To bleed air at the fuel injection pump a Turn the air vent plug 3 on Figure 10 about 1 1 2 turns to loosen it Cover the vent with a cloth to prevent fuel from splashing b Pump the feed pump cap up and down c When there are no air bubbles to be seen in the fuel flowing from the air vent plug hole push down the priming pump cap and turn it clockwise to lock it in place NOTE Do not close the air vent plug before locking the priming pump cap in place because the internal pressure in the pump will prevent the priming pump cap from returning to the original position If the engine does not start after this bleeding process loosen a fuel line at the injector while cranking the engine with the starter motor until pure fuel escapes Then tighten the connections Do each line one at a time After the engine has started use a piece of cardboard to l
10. and filter SP13 Check fuel injection pump SP18 Check and clean heat exchanger EVERY 250 HOURS SP24 Inspect starter and alternator SP2 3 Change engine oil and filter SERVICE 50 100 250 500 2000 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours ENGINE SP1 12 Check oil level SP2 12 Change engine oilt 5 SP3 13 Change lube oil filters 5 SP4 13 Check air cleaner SP5 13 Check V belt tension 5 SP7 14 Check valve clearances e SP8 15 Check primary filter SP9 15 Change primary filter element SP10 15 Change secondary fuel filter 3 SP11 16 Bleed the fuel system SP12 17 Check injectors s SP13 18 Check fuel injection pump TURBOCHARGER SP14 19 Check air oil amp cooling water lines for leakage ere SP16 20 Check cooling water level e SP17 20 Check and flush cooling system SP18 21 Check and clean heat exchanger SP19 21 Change impeller in raw water pump SP20 21 Check zinc electrodes ELECTRICAL SYSTEM SP21 23 Check electrolyte level in batteries SP22 23 Check condition of batteries with hydrometer e SP24 24 Inspect alternator and starter e 1 Perform maintenance once a year even if hour level has not been reached 2 Consult manufacturer s maintenance schedule note on chart 3 Or Whenever necessary 4 Change at 1000 hours After first 50 hours Fuel inj valve opening pressure 11 77 MPa 120 kgf cm 1710 PSI 5 6 7 Or every 2 years 8 Valve cleara
11. to 18 1 to 25 3 ft Ibs 24 5 to 34 3 Nem or 2 5 to 3 5 kgfem Do not overtighten b Reinstall the return line using new sealing washers Tighten bolts to 13 0 to 15 9 ft Ibs 17 7 to 21 6 Nem or 1 8 to 2 2 kgfem NOTE Overtightening can damage injectors c Reinstall injection lines Tighten flare nuts at injection pump to 19 5 to 23 9 ft Ibs 26 5 to 32 4 Nem or 2 7 to 3 3 kgfem Leave the lines loose at injectors for bleeding d Bleed the injection lines Crank the engine to fill the lines Tighten flare nuts at injectors to 14 5 to 17 4 ft Ibs 21 0 to 23 0 Nem 2 0 to 2 4 kgfem e Start the engine and check for leaks using a piece of paper or cardboard Do not use your hand to check for leaks OM944T 2 11 21 Servicing SP13 INJECTION PUMP 1 Since operating conditions may vary considerably it is difficult to give a definite interval for checking the injection pump But as arule pump settings maximum speed and exhaust smoke should be checked after every 2000 hours of operation Service of the fuel injection pump should only be done if checks indicate pump malfunction 2 Black smoke can be an indication of pump malfunction Before servicing the pump check other possible causes a Check cleanliness of the air filter b Check valve clearances c Clean and check injectors 3 Any repair which involves disassembly of the injection pump must be carried out by specially trained mec
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13. 4T 2 11 23 Servicing SP18 HEAT EXCHANGER SP20 ZINC ELECTRODES 1 Clean the heat exchanger core once a year or after 1 2000 hours of operation 2 Drain the expansion tank and heat exchanger 3 Remove the heat exchanger end covers 2 4 Clean the inside of the exchanger core tubes using a metal rod Flush inspect and clean again if necessary 3 5 Reassemble the heat exchanger Fill the cooling system Start the engine and check for leaks SP19 RAW WATER PUMP 4 1 Change the raw water pump impeller every 500 hours or as needed 5 2 Remove the pump cover Pry out the impeller using needle nose pliers or two screwdrivers Be sure to remove all pieces of the failed impeller NOTE Place some kind of protection under the screwdrivers in order to not damage the pump housing 3 Clean the inside of the housing 4 Press in the new impeller and place the sealing plug in the outer end of the impeller center if this has not already been done NOTE Make sure that there is always an extra impeller and cover gasket in reserve on board A zinc electrode is installed in the heat exchanger cooling system to protect the engine from electrolysis Check it faithfully every 250 hours If you are in warm saltwater or where electrolysis is a known problem check it more often Remove the zinc holder from the bottom of the exchanger This will drain raw water from the exchanger Scrape or steel brush th
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16. Injector and washer go no 0 0 c0 amp 9 2 If your set is operating a long distance from a servicing dealer add the following a Complete set of injectors b Copper washers for injector change c Complete set of glow plugs d Fuel lift pump OM944T 2 11 13 SP5 SP21 SP5 SP21 Servicing Schedule Chart Check oil level in engine Check primary fuel filter Check cooling water level Check sea strainer AFTER FIRST 50 HOURS SP2 3 Change engine oil and filter Check V belt tension Check electrolyte level in batteries EVERY 50 HOURS Check V belt tension Check electrolyte level in batteries EVERY 250 HOURS cont SP4 Check air cleaner SP14 Check turbocharger SP20 Check zinc electrodes EVERY 500 HOURS SP6 Check valve clearances SP9 Change primary fuel filter element SP10 Change secondary fuel filter SP12 Check injectors SP17 Check cooling system SP19 Change impeller SP22 Check state of charge of batteries EVERY 1000 HOURS or as needed The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your generator set More detailed coverage of each Service Point SP is listed on the page noted in the page column DAILY SP1 SP8 SP16 OUT OF SP23 23 SERVICE Winterizing or out of service AFTER FIRST 100 HOURS SP4 Change air cleaner SP2 3 Change engine oil
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18. OR GENERATOR DOWN BYPASS START HOURS This switch serves two functions 1 Preheats air before beginning the starting process tr x Press switch for 10 20 seconds before attempting j TOTAL HOURS startup 2 Bypasses the safety shutdown feature during the starting process Keep switch engaged while starting engine and for 2 to 3 seconds afterwards allowing oil pressure to build beyond shutdown setpoint 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 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 4 OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system Generator SS 5 WATER TEMPERATURE GAUGE Registers the temperature of the cooling water 6 D C VOLTMETER 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 Series Shows the generator output voltage Generator Set Control Panel 8 FREQUENCY METER Hertz The frequency meter indicates alternating current frequency 60 Hz 1800 rpm or 50 Hz 1500 rpm
19. ank 8 2 Coolant Fill 9 3 Thermostat Housing 10 4 Rocker Arm Cover 11 5 Lube Oil Fill 12 6 Intake Manifold 13 7 Fuel Filter 14 Air Cleaner Junction Box Lube Oil Dipstick Oil Filter Vibration Mounts Fuel Manifold Fuel Primer Pump OM944T 2 11 6 15 16 17 18 19 Injection Pump Lube Oil Drain Raw Water Pump Heat Exchanger Raw Water Drain and Zinc Heat Exchanger Updated 2 8 11 M944T Generator Set Component Locations Figure 3 M944T Non Service Side Current Baseframe 19 Turbocharger 24 Starter 20 Wet Exhaust Elbow 25 Oil Pan 21 Exhaust Manifold 22 Alternator 23 Belt Guard OM944T 2 11 7 M38CR2 Generator Set Component Locations Figure 4 M38CR2 Service Side Representative only early production Expansion Tank Coolant Fill Thermostat Housing Fuel Filter Intake Manifold Air Cleaner Junction Box BO Pen 8 9 10 11 12 13 14 Harness Plug Lube Oil Dipstick Fuel Manifold optional Oil Filter Fuel Primer Pump Injection Pump A C Coolant Heater optional OM944T 2 11 8 M38CR2 Generator Set Component Locations Figure 5 M38CR2 Non Service Side Representative only early production 19 Turbocharger 23 Oil Pan 20 Exhaust Manifold 24 Starter 21 Alternator 22 Belt Guard OM944T 2 11 9 Control Panels e 1 PREHEAT SHUTDOWN BYPASS PREHEAT amp SHUT GENERAT
20. ark as shown in Figure 11 above When the alignment marks of the timing gears align as in the diagram to the right the No piston is top dead center in the compression stroke b Install the injection pump to the side of the engine first then put in the end bolts and then the tube with its bolts and then the side bracket c Torque mounting bolts to 13 0 18 1 ft Ibs 17 7 to 24 5 Nem 1 8 to 2 5 kgfem OM944T 2 11 22 SP14 TURBOCHARGER 1 Check for air leaks every 250 hours Air leakage will lower engine output and may cause black exhaust smoke and soot 2 Listen along air line while the engine is running A whistling or hissing sound indicates leakage 3 Leakage on the pressure side between turbo and engine can be found by applying soapy water to the air line 4 Tighten the hose clamps and replace hoses or gaskets as required 5 Check to see that the lubrication and cooling lines are tight and without leaks COOLING SYSTEM GENERAL NOTE Be sure to close the sea cock before working on the engine cooling system CAUTION The cooling water in the engine reaches extremely high temperatures You must use extreme caution when working on hot engines to avoid burns Allow the engine to cool before working on the cooling system Open the filler cap carefully using protective clothing when the engine is warm SP16 CHECK THE COOLANT LEVEL 1 Check the coolant level each day before start
21. ase oil too heavy Loose or corroded connections Battery is too small Battery cables are too small Replace battery if necessary If low fill cells with distilled water Fill with oil of appropriate viscosity Clean and tighten loose connections Entire Electrical System Does Not Function Check DC circuit breaker Faulty connection Sulfated or worn out batteries f breaker is tripped reset it Clean and tighten battery and harness plug connections Check specific gravity and electrolyte level of each battery If you cannot correct problems with these procedures see your Northern Lights dealer OM944T 2 11 27 Troubleshooting PROBLEM Engine Hard to Start or Will Not Start ENGINE POSSIBLE CAUSE Improper starting procedure No fuel Low battery condition Excessive resistance in starting circuit Crankcase oil too heavy Improper type of fuel Water dirt or air in fuel system Clogged primary fuel filter element Clogged secondary fuel filter element Dirty or faulty injection nozzles RECOMMENDATION S See starting section of this manual Take special note of Bypass Switch operation Check level of fuel in fuel tank Check electrolyte level and condition Clean and tighten all battery connections Use oil of proper viscosity Consult fuel supplier and use proper type of fuel for operating condition Drain flush fill and
22. bleed system Clean or replace filter element Replace filter element Have your dealer check injection nozzles Engine Runs Irregularly or Stalls Frequently Below normal engine temperature Clogged primary fuel filter element Clogged secondary fuel filter element Water or dirt in the fuel system Dirty or faulty injection nozzles Air in fuel system Improper type of fuel Remove and check thermostat Clean or replace filter element Replace secondary filter element Drain flush fill and bleed system Have your dealer check injection nozzles Inspect clamps and hoses on suction side of fuel pump for air leak Consult fuel supplier and use proper type of fuel for operating condition Lack of Engine Power Engine overloaded Intake air restriction Clogged primary fuel filter element Clogged secondary fuel filter element Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Reduce the load Service air cleaner Clean or replace filter element Replace filter element Consult fuel supplier and use proper type of fuel for operating conditions See Engine Overheats in next category Remove and check thermostat Reset valves Best done by dealer Replace injectors Best done by dealer OM944T 2 11 28 PROBLEM Lack of Engine Power continued
23. e zinc electrode clean If more than 50 of the electrode is corroded away replace it with a new zinc The electrode screws out of the holder Reinstall the zinc holders Be sure the threads are clean for good metal to metal contact Do not use thread sealant Refill the cooling system Start the engine and check for leaks OM944T 2 11 24 GENERATOR END The maintenance and operation recommendations for the generator end are in a separate Owner s Manual If you do not have one of these manuals contact your local dealer ELECTRICAL SYSTEM GENERAL 1 Never switch the battery switch off or break the circuit between the alternator and the batteries while the engine is running Alternator damage can result 2 Do not reverse the polarity of the battery cables when installing the battery Servicing BOOSTER BATTERIES St CAUTION Battery gas can explode Keep all flames and sparks away from batteries Before changing or using booster batteries check the battery electrolyte level Add distilled water if necessary Booster and main batteries must have the same voltage rating First connect the positive terminal of the booster battery to the positive terminal of the main battery Then connect the negative terminal of the booster battery to ground on the engine block Figure 10 Remove the booster battery after starting the engine Sealed Batteries See the manufact
24. en the seawater pump cover and drain the pump 5 Loosen the alternator belt Cover the terminals and openings of the starter and alternator with adhesive fabric tape Cover the starter and alternator with polyethylene sheets and put desiccant inside covering Disconnect and clean the battery Remove the battery to a cool dry storage place if possible Clean the outside of the unit Paint any scratched or chipped surfaces Put corrosion preventative on all exposed metal surfaces Cover the engine OM944T 2 11 26 DC ELECTRICAL SYSTEM PROBLEM Battery Will Not Charge POSSIBLE CAUSE Loose or corroded connections Sulfated or worn out batteries Loose or defective alternator belt Troubleshooting RECOMMENDATION S Clean and tighten battery connections Check specific gravity of each battery Check electrolyte level of each battery Adjust belt tension Replace belt Starter Inoperative Check DC circuit breaker Loose or corroded connections Low battery condition Defective electrical system ground wire f the breaker is tripped reset it Clean and tighten loose battery and harness plug connection Check specific gravity of each battery Check electrolyte level of each battery Repair or replace Starter Cranks Slowly Low battery condition Check specific gravity of each battery Check electrolyte level of each battery Crankc
25. er as often as necessary or every 250 hours Remove the fuel filter with a filter wrench d Apply a coating of fuel to the o ring of the new fuel filter e Tighten the new filter by hand do not use a filter wrench for tightening f The filter should be dry g Do not add fuel to the fuel filter before installation as this could cause unfiltered fuel to enter the fuel pump Bleed the air out of the filter b e The fuel filter part number is 18 isi ihe Hose 24 51201 OM944T 2 11 19 Servicing SP11 BLEEDING THE FUEL SYSTEM CAUTION Escaping diesel fuel under pressure can penetrate skin causing serious personal injury Before disconnecting lines be sure to relieve all pressure Before applying pressure be sure all connections are tight and lines pipes and hoses aren t damaged Fuel escaping from a very small hole can be almost invisible Use a piece of card board or wood rather than hands to search for suspected leaks If injured by escaping fuel see a doctor at once Serious infection or reaction can develop if proper medical treatment is not administered immediately Fuel system air bleeding may be needed when a After fuel has been added to a newly installed engine b A new fuel filter is installed The engine has run out of fuel d The fuel lines injection pump or any other fuel system component has been removed and installed e After changing the fuel filter
26. fied when not corrected be moved to a repair facility Marine engines cannot be during routine maintenance compared to the servicing of automobiles trucks or As operator it is your obligation to learn about your even farm equipment Failures often occur in remote equipment and its proper maintenance This is not a areas far from competent assistance Marine engines are comprehensive technical service manual Nor will it make taxed far more severely than auto or truck engines the reader into an expert mechanic Its aim is to aid you in therefore maintenance schedules must be adhered to maintaining your unit properly MODELS INCLUDED This manual covers the operating instructions for M944T and M38CR2 marine and commercial generator sets which use the 944 engine block turbocharged Model Numbers Model numbers give the unit s application block model aspiration and RPM M 944 T E OL M Northern Lights marine generator set Model number of engine block T Turbocharged Bore Cylinders 94 mm 4 Northern Lights marine diesel generator set with M944T a 944 engine and a LX E 34E series generator end M38CR2 Serial Numbers Northern Lights commercial marine diesel generator set with a 944 engine and a Newage series generator end 38 kW o o NORTHERN LIGHTS Your set has three serial numbers 1 an engine number stamped on a plate attached to the valve cover 2 a generator end serial nu
27. hanics with the proper tools and test equipment NOTE All warranties on the engine become null and void if the injection pump seals are broken by unauthorized persons 4 Injection Pump Removal CAUTION Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury If injured by escaping diesel fuel see a doctor at once a Clean the injection pump hoses and area around the pump with a cleaning solvent or steam cleaner NOTE Never steam clean or pour cold water on an injection pump while the engine is running or the pump is warm b Remove the injection lines from the pump and injectors Remove all lines as an assembly Do not remove the spacers Cover the ends of the lines the injector inlets and the injection pump outlets to keep dirt out of the injectors lines and pump c Remove the injection pump drive gear cover plate and the sea water pump d Align timing marks on timing gears e Remove the pump support bracket on rear of pump f Remove the 4 mounting nuts g Take the pump to your Northern Lights dealer or an injection repair station for testing and service Camshaft gear Idler gear Fuel Injection Pump gear Crankshaft gear Oil Pump gear Figure 11 Timing Marks Injection Pump Installation a Install the fuel injection pump after having aligned its gear alignment mark with that of the idler gear alignment m
28. he 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 Remove the negative battery terminal cable before servicing electrical components or welding e Use caution in handling fuel Never refuel a hot or running engine Do not smoke while filling fuel tank or servicing fuel system e 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 e Provide first aid kits this book to alert you to possible danger areas A CAUTION This symbol is used throughout Please take special notice of these sections OM944T 2 11 Updated 2 8 11 M944T Generator Set Component Locations Figure 2 M944T Service Side Current Baseframe 1 Expansion T
29. htening Torque 113 to 123 Nem 11 5 to 12 5 kgfem 83 2 to 90 4 Ibfeft OM944T 2 11 18 FUELS GENERAL 1 Use only clean high quality fuels of the following specifications as defined by ASTM designation D975 for diesel fuels a Use grade No 2 diesel at ambient temperatures above freezing 32 F 0 C Use grade No 1 at ambient temperatures below freezing c International fuel specifications JIS K2204 ISO 8217 DMA BS 2869 Part 1 Class Al BS 2869 Part 2 Class A2 Use fuel having less that 0 2 sulphur of weight less than 0 05 recommended 3 The cetane number should be 45 or higher Particulate contaminate should be 5 0 mai 0 00018 oz U S gal or lower 5 DO NOT use these unsuitable grades of fuel a Domestic heating oils all types Class B engine Class D domestic fuels Class E F G or H industrial or marine fuels ASTM D975 60T No 4 D and higher number fuels Ch aoa co Storing fuel a Keep dirt scale water and other foreign matter out of fuel b Avoid storing fuel for long periods of time c Fill the fuel tank at the end of each day s operation This will reduce condensation Servicing SP8 10 FUEL FILTER 1 Your generator set should have a primary fuel filter installed We recommend the Northern Lights brand of fuel filters a Check the primary fuel filter daily as recommended by the filter manufacturer Change the engine mounted filt
30. ick The oil level must be between high and low marks 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 Check the fuel tank level and open any fuel valves on the tank and at the secondary fuel filter Close the sea cock check and clean the sea strainer and reopen the sea cock 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 alternator could be damaged OM944T 2 11 11 Operating Procedures STARTING 1 Hold the Shutdown Bypass switch in the ON position While holding the Shutdown Bypass switch in the ON position push the Engine Control switch to the START position As soon as the engine starts release both switches Do not crank the starter for more than 10 seconds consecutively If the engine fails to start with the first attempt be sure that it has stopped completely before re engaging the starter NOTE Excessive cranking of the starter on marine sets equipped with a water lift muffler can cause engine damage If the engine does not start after 3 consecutive 10 second cranks remove the impeller from the seawater pump This will prevent the muffler from filling with water and backfilling the exhaust line and engine Once the engine starts shut if off immediately and re
31. ing the engine a Check the water level by removing the pressure cap from the expansion tank In order to give the cooling water an opportunity to expand the level should be about 1 in 2 5 cm below the filler cap sealing surface when the engine is cold b Soft water with about a pH about 6 5 to 8 5 combined with an antifreeze in a 30 to 50 maximum solution should be used c The antifreeze should not contain amine silicate or borate Servicing SP17 COOLING SYSTEM FLUSHING 1 Flush the cooling system every 2000 hours or every 12 months whichever comes first 2 Remove fill cap and open drains on engine block The engine block drain is on the service side of the engine above the dipstick next to the flywheel housing 3 Pour clean water into the engine until water coming from engine is clear of discoloration Close drains and refill the engine with recommended coolant mixture 4 Use 50 water 50 maximum ethylene glycol antifreeze mix Antifreeze mixture is recommended as a good year round coolant 5 Coolant capacity is approximately 3 gal 11 4 liters 6 Check hoses and connections and repair any leakage 7 Start the engine and check for leaks Run the engine for five minutes then shut it down Let engine cool and then check the coolant level in the engine Add coolant as needed NOTE Be sure to open the sea cock after working on the engine cooling system and starting the engine OM94
32. install the impeller Restart and check the exhaust overboard outlet for gushes of water 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 The water temperature gauge must be below 200 F 94 C 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 Add electrical load STOPPING 1 Remove electrical load from the generator set 2 Run the engine for a two to three minute cool down period 3 Move the Engine Control switch to the STOP position OM944T 2 11 12 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 If your unit is equipped with optional shutdowns and alarms 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 warning or shutdown system is activated a Check the temperature gauge If above 205 F 96 C shut off the engine immediately b Use the Troub
33. le Shooting Guide on page 25 to isolate the cause of the overheat CAUTION Do not remove the water fill cap of an overheated engine Escaping high temperature steam can cause severe burns Allow the engine to cool and then remove the cap slowly using protective clothing c Make repairs and restart after the temperature gauge registers below 200 F 94 C d Watch the temperature gauge regularly and turn off the unit if the temperature rises above 205 F 96 C Repeat troubleshooting 3 If shutdown is activated and the temperature gauge shows temperature within normal temperature range a Check the engine crankcase oil level b If the oil level is low fill with recommended lubricating oil and restart Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading 20 60 PSI after a few seconds of operation c If the oil level is normal DO NOT restart the engine Call your dealer for assistance Operating Procedures SPARE PARTS 1 ADE recommends that you keep the following spare parts on hand for field service The parts are available from your local Northern Lights dealer Some marine models may already have On Board Kits a handy box that contains the most common parts you will need Primary and secondary fuel filter elements Oil filters Air filter elements Alternator belt Thermostat and gaskets Seawater pump impeller and gaskets Glow plugs h
34. mber and 3 a generator set serial number NOTE Always use the generator set serial number when ordering parts or in correspondence The generator set serial number plate is found on o the service side of the generator and resembles the drawing in Figure 1 Alaska Diesel Electric 4420 14th Ave N W Seattle WA 98107 206 789 3880 o o Generator Set Data o Set Serial No tM I No o Set Model No o Figure 1 Generator set serial number plate OM944T 2 11 4 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 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 A 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 t
35. nce 25 mm 0 0098 OM944T 2 11 14 Service Record Service Point SP5 OPERATION Check V belt tension HOURS DATE SP21 Check electrolyte in batteries SP2 Change engine oil SP3 Change lubricating oil filters SP4 Check air cleaner SP14 Check turbocharger SP20 Check zinc electrodes EVERY 500 HOURS SP7 Check valve clearances SP8 Change primary filter element SP10 Change secondary fuel filter SP12 Check injectors SP19 Change impeller in seawater pump SP22 Check condition of batteries with hydrometer 1000 HOURS or as required SP13 Check fuel injection pump SP18 Check and clean heat exchanger Service Notes OM944T 2 11 15 Servicing LUBRICATION GENERAL 1 Use only clean high quality lubricants stored in clean containers in a protected area 2 These lubricants are acceptable a API Service CD CE and CF 4 single viscosity oils b API Service CD CE and CF 4 multi viscosity oils 3 Use the proper weight oil for your average operation temperature Air Single Multi Temperature Viscosity Viscosity Above 32 F SAE30W SAE 15 40W 0 C 10 to 32 F SAEIOW SAE 10 30W 23 to 0 C Figure 7 Lube Oils 4 Never put additives or flushing oil in cra
36. nkcase SP1 CHECKING OIL LEVEL 1 While the engine is stopped check the oil level in the crankcase with the dipstick daily The oil level must be between the high and low marks on the stick Fill with the recommended oil and fill only to the high mark on the dipstick Follow the lubrication recommendations in Figure 7 SP2 OIL CHANGES The set is delivered with special break in oil Change the engine oil and oil filter after 50 hours of operation Use Service CC30 weight oil during the first 100 hours 2 Change the oil and filter again at 100 hours using the oil recommended in the above paragraph After this change oil and filter every 250 hours 3 During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes first 4 Change oil at any seasonal change in temperature when a new viscosity of oil is required 5 Change oil when engine is warm but not hot 6 Dispose of waste oil in an approved manner 7 Never use a flushing oil 8 Loosen clamp on oil change tube Remove cap Drain oil Replace cap and tube 9 Refill engine with recommended oil 10 Engine capacity with new oil filter is TER 2 64 gallons 10 liters OM944T 2 11 Servicing SP3 CHANGING LUBE OIL FILTER SP5 V BELTS me Change the lube oil filter every 250 hours 1 Check the tension and wear on the V belt after every 50 hours 2 Use a filter wrench to remove old filter Di
37. ook for fuel leaks OM944T 2 11 20 SP12 INJECTOR SERVICE L A Injectors should be checked every 500 hours This check should be made by a Northern Lights dealer or local injection repair station CAUTION Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury If injured by escaping fuel see a doctor at once Injector removal a Clean loose dirt from around the injectors and the fuel lines b Relieve high pressure in the fuel lines by loosening the delivery line flare nuts at each injector c Remove delivery lines by disconnecting them from the injectors and injection pump Remove all lines as an assembly do not remove the spacers Cover the ends of the lines the injector inlets and the injection pump outlets to keep dirt out d Remove the return line retaining bolts washers and return line e Loosen the injector retaining nuts at the same time a little at a time Remove the injector f Remove the injector seat Cover the holes to prevent debris from entering the cylinders Note Do not use pry bars to remove injectors from the cylinder head Servicing Injector repair and cleaning a Take injectors to your Northern Lights dealer or local injection repair station for testing and service Injector installation a Install new injector seal washer seat and injector Evenly tighten the injector retaining nuts
38. spose of filter in approved manner 2 Use your thumb to press on the belt at the midpoint between the crankshaft and alternator pulleys The tension is correct if the belt can be depressed about 39 to 47 in 10 12 mm with 22 Ibs 10 kg force 3 Make sure the gasket from the old filter is removed and discarded Clean mount face 4 Spread a thin film of engine oil on the rubber gasket on the new filter and screw it on nipple until gasket meets the sealing surface 5 Using hands only no wrench tighten filter one half turn farther Overtightening can do damage to filter housing 6 Fill engine with recommended oil Start engine and check for leakage Stop engine wait 3 minutes and check oil level Add additional oil if necessary 7 Oil filter part number is 24 01201 SP4 AIR CLEANER 1 Visually inspect air cleaner every 250 hours 2 Take off the hose clamp on the bracket and the hump hose to detach the air cleaner 3 Make sure the hump hose is clean inside and also that the new filter element is absolutely clean and installed properly Note Make absolutely sure no impurities enter the engine while changing the element and do not run the engine with the air cleaner removed Do not clean the filter with diesel fuel solvent or gasoline Serious engine damage can result OM944T 2 11 17 Servicing SP7 VALVE CLEARANCES 1 Readjust valve clearance after first
39. tor Set sss 6 7 Heat Exchahget erneute 22 Raw Water Pump essere 22 CONTROL PANELS Zime Electrodes eiser ee e 22 Northern Lights Generator Sets 8 Electrical System General 23 Booster Batteries ecce tere 23 OPERATING PROCEDURES Battery e 24 Breakin Period eee eerte 9 Winterizing Out of Service 24 Before Starting essere 9 e EE 10 TROUBLESHOOTING Operating ire eter bettered 10 l t eeneg geed e terreat 25 Nin T 10 EE 26 28 Shutdowns and Alarms sees 11 Spare Patz 11 WIRING DIAGRAMS AC Electti al sioe tette tete teet 29 SERVICING SCHEDULE CHART 12 13 DC Electrical rossis neies iiidid 30 31 SERVICING Lubrication Genera 14 Checkang OM eene deer tees 14 Oil Changes nne tte rper 14 Changing Oil Filter eee 15 Air Filter even root RR edo 15 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 O Alaska Diesel Electric Inc All rights reserved Litho U S A Publication number OM944T 10 08 OM944T 2 11 3 Introduction The servicing of marine engines and generator sets more strictly Failures begin with minor problems that presents unique problems In many cases boats cannot are overlooked and become ampli
40. urer s charging and booster instructions Battery Booster Battery Figure 12 Booster Battery Connections OM944T 2 11 25 Servicing SP21 22 BATTERY CARE 1 Check the electrolyte level every 50 hours or once a month Add distilled water to the manufacturer s recommended level 2 Batteries cables and cable terminals should be checked and cleaned every 100 hours Clean corrosion with a water and baking soda solution Flush with clean water Tighten terminals and grease them to inhibit future corrosion 3 Check the battery condition with a hydrometer every 500 hours SP23 WINTERIZING OUT OF SERVICE NOTE Remember to close the sea cock before opening drain cocks For engines not going to be used for more than 3 months 1 Change the crankcase oil and filter Fill with rust preventative oil and make a mixture of rust preventative oil and fuel 1 1 and fill the fuel tank with the mixture Start the engine and operate it with no load for 5 to 10 minutes Stop the engine spray rust preventative agent into intake pipe Drain the rust preventative oil and fuel 2 Drain fresh water and seawater cooling systems completely Flush fresh water systems and refill with the proper antifreeze mixture 3 Drain the water supply lines and wet exhaust line Cover the intake and exhaust ports with adhesive fabric tape 4 Loos
41. w mise fP 4NVd IOYLNOD OM944T 2 11 32 DC Wiring Diagram eau noyym abueyo oj j2e qns sbulmesq gt lt 1 NON QHVOSH AV Te wx 31X3 ONY TIVLOld i lt j Nyd EE Hum Ee E Tux o oo punourc piepuelsS OCA vc We ORO OD wesbeiq BuutM 20 s V m EEN WS Em Slee vEOZ way O08 E ON i e VEL e pes S69 wae 005 xvi WEN x X X 3e ae Pas E 1 s psi vz Wolndo Old ZH Doan Way disl d33ds 031V ORT WNOUdO n p Ta p qn SONILLSS HOLMS Q33dSMH3AO VNOILdO NC H Q38 NMOU8 d 85 0 ANUS Fo ETS I E dOLS 2 IINYIHILIMS T3A31 P X di MIN 3dAL 91 OMY 38 OL JYV SHOIOnONOO TANVd v S IVNOILdO r 1NV1002 IVNOULdO xy a LUE n EA LiL es e COXN 2 oc e D O31V9IONI LNIOd 1Y GNNOND M p cc l LI
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