OM843NW2 - Northern Lights
Contents
1. OL 931 JNO INN 6 LSNPAV 39 SLOWSY 31 NOILYONddY Yad SMS 135 701 2 021 001 LON SI JNVLIOA Y3MO7 31 IHOWSIS SFOVIIOA TV YO4 NOUISOd Ado _ CNASZUd 21 ONY HOLONGNOD 313130 JHL OL 135 38 OL SI LMS HOLMS ONISNAS LNdNI XAY 6 ZH 09 YO OS LNSYYND ZMS 135 4 ja i aS T H N c 9 5310 335 cA LA in cA in LNdLNO 01 3 39 54 31 104110 YOLWAIN3O 50 31 LAdLNO 01 83 39 cA Ln SQV31 1 OLNI 32145 ANY MY S9VLIOA 135 39 NFHLO ONIZIS MYOLONGNOD LND IVLSOSHY 15 SOVLIOA 04 Z NIXJJNI NI LINSNOD JOVLIOA 031511 153 01 2 009 CGNVULSILINW 2 601 MLN SUNN NOS 03215 SHOLONGNOD 8 38 OL SYOLONGNOD G3ITNWLSNI Tv 1 5310 2 eg rg 0 22 2 ee 4 ALON 335 1 335 ALON 335 ZH 09 2 2 0 2 002 611 001 ZH 06 DWAIL gt O8S OPZ 61LZ ZH OS 2 0 2 002 021 001 9 435 2 09 DWAOSP O8S Z Z 61Z ZH 09 2 2 002 661 001 539 ZH 09 002 021 00 9 ALON2. 3 NN of 0 8 2 Q yds 98 AD 66 AVIAN 1 5 Gau MOTGA Zo 1 1 7 09 08 7 amp 996 9019 SSSINYVH 3015 TANVd NOILOJNNOO LV YSEWNN Ad QSISILNAG 38 LSNW OL SYOLONGNOD GSTIVISNI 43009 SSFINN 8310 SV 1439 3 GNVYLSLLINN 2 601 MLN vl SMV 38 OL SYOLONGNOD NOILVTIVLSNI 11 71 SASSANYVH 71 191 NOISNALX3 SILON YOLVOIGNI 4015 HOLIMS NMOGLNHS 03 HOLIMS OM843NW2 10 09 25 NORTHERN LIGHTS 4420 14th Ave NW Seattle WA 98107 Tel 206 789 3880 1 800 762 0165 Fax 206 782 5455 Northern Lights and Lugger are registered trademarks of Northern Lights Inc www northern lights com 2009 rights reserved Litho USA
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4. 17 Cooling System 17 COMPONENT LOCATIONS Cooling System 18 M843NW2 Marine 6 Heat Exo Han eT aatre n 18 Raw Water 18 CONTROL PANELS 7 Generator 18 Electrical System 18 OPERATING PROCEDURES Clow PUG 19 Breakin Period 8 Booster Batteries 19 Before 8 Battery AE esur rare EErEE 19 2 8 19 DCT 8 Winterizing 1 19 a 8 Shutdowns Alarms 9 TROUBLESHOOTING BO se IS 9 20 21 23 SERVICING SCHEDULE 10 WIRING DIAGRAMS SERVICING AC PC CICA 24 12 25 Checking 12 12 Changing Oil Filtet acecacenesaactaxsnaceessssentecsesaneviencts 12 AE 13 Proprietary Information This publication
5. 24 22009 3 NOTE Make absolutely sure no impurities enter the engine while changing the element Do NOT run the engine with the air cleaner removed SP5 V BELTS 1 Check the tension and wear on the V belt daily 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 3 16 in 5 mm ae Nave Adjustment Screw Rocker Arm Figure 7 Valve Adjustment SP6 VALVE CLEARANCES 1 Adjust valve clearance after 1000 hours or as needed 2 Valve adjustments should be done after the cylinder head bolts have been re tightened Engine should be cold and NOT running 3 Watch the valves while turning the engine over by hand Turn until the inlet valve starts to open and the exhaust valve starts to close the valves are rocking Then turn the crankshaft one more full turn and adjust the clearance on both valves for this cylinder Align the top mark of the crank pulley with the top mark of the timing gear case 4 Loosen the lock nut and adjust the clearance between the rocker arm and valve guide of both the intake and exhaust valves with the adjustment screw Figure 7 Clearance on both intake and exhaust valves should be 0 008 in 0 2 mm 5 Repeat steps 3 and 4 for each cylinder Each set of valves must be adjusted individually 6 Replace the rocker arm cover Tighten cover nuts to 5
6. Oil filters Air filter Alternator belt Thermostat and gaskets Seawater pump impeller amp gaskets Glow plug Injector and washer io Oo So Ss 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 OM843NW2 10 09 9 Servicing Schedule Chart 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 EVERY 500 HOURS SP1 Check oil level in engine SP8 Change primary fuel filter element SP5 Check V belt tension SP9 Change secondary fuel filter SP7 Check primary fuel filter SP22 Inspect condition of exhaust elbow SP13 Check coolant level Check sea strainer EVERY 1000 HOURS Check raw water pump for leaks SP6 Check valve clearances SP18 Check electrolyte in batteries SP11 Check injectors SP17 Change impeller in raw water pump AFTER FIRST 50 HOURS SP2 3 Change engine oil and filter EVERY 2500 HOURS SP6 Adjust valves SP12 Check fuel injection pump AFTER FIRST 100 HOURS 22 SP2 3 Change engine oil and filter and clean heat exchanger EVERY 250 HOURS SP2 3 Change engine oil and filter SP4 Check air cleaner SP19 Check state of charge of batteries SERVICE 250 500 1000 P
7. OPERATOR 5 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 2009 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 OM843NW2 10 09 NORTHERN LIGHTS OPERATOR S MANUAL M843NW2 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 4 SERVICING continued Models Included 4 SB GS oct cece 13 Model NUM DCIS 4 Wall Ve 13 Serial 5 25 5 14 Fuel Filters 14 5 Bleeding the Fuel System 15 16 17 SAFETY PUES 5
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9. alert you to possible danger areas Please take special notice of these sections OM843NW2 10 09 Generator Com ponent Locations Figure 1 and 2 MS amp 43NW2 1 Circuit Breaker for AVR 9 Belt Guard 2 DC Circuit Breaker 10 Injection Pump 16 Filter 3 Coolant Recovery Tank 11 Oil Fill 2 Places 17 Drain 23 Expansion Tank 4 Fuel Filter 12 Seawater Pump 18 Generator Eet Piate 24 Wet Exhaust Elbow 5 Air Filter inside manifold 13 Fresh water Block Drain 19 Control Panel Plua in 25 Junction Box 6 Intake Manifold behind hoses oh 9 26 Vibration Mount 7 Crankcase Vent 14 Fuel Inlet amp Return 21 Heat eyehan EndC 27 Starter 8 Fuel Injector 15 Dipstick ee are 28 DC Alternator 22 Coolant Fill OM843NW2 10 09 6 Control Panels PREHEAT amp SHUT GENERATOR GENERATOR DOWN BYPASS START HOURS Hobbs o o owe TOTAL NOVIS 3 6 Control Panel NORTHERN LIGHTS Series 4 a Generator Set 6 engine lemparahra ete ee ee 352 Wohmeisr 11 1 Figure 3 Series 4 Generator Control Panel SHUTDOWN BYPASS PREHEAT SWITCH Two functions are built into this switch the preheating of the engine and bypassing of the engine safety shut down circuit Hold switch in the ON position 10 20 seconds before starting the engine and continue holding on during
10. dealer OM843NW2 10 09 20 ENGINE PROBLEM Engine Hard to Start or Will Not Start Engine Runs Irregularly or Stalls Frequently Lack of Engine Power POSSIBLE CAUSE Improper starting procedure No fuel Low battery output 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 Lift pump malfunction Clogged secondary fuel filter element Dirty or faulty injection nozzles 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 Control lever adjusted incorrectly Improper type of fuel Uneven compression pressure between cylinders Intake air restriction Clogged primary fuel filter element Clogged secondary fuel filter element Injection pump not getting fuel Improper type of fuel OM843NW2 10 09 21 Troubleshooting RECOMMENDATION S e See starting section of this manual Take special note of Bypass Switch operation e Check level of fuel in fuel tank e Check electrolyte level and condition e Clean and tighten all battery connections e Use oil of proper viscosity e Consult fuel supplier and use proper type of fuel for operating condition e Drain flush fill and bleed system e Clean or replace filter element e
11. engine cranking Release the switch as soon as the engine is running Holding the switch on too long can burn out the heater element 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 7 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 I panels only and has a light that glows when the set is running HOUR METER Keeps track of engine running time OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system ENGINE TEMPERATURE GAUGE Registers the temperature of the engine coolant D C VOLTMETER 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 10 A C VOLTMETER Shows the generator output voltage FREQUENCY METER Hertz The frequency meter indicates alternating current frequency 60 Hz 1800 RPM or 50 Hz 1500 RPM AMMETER VOLTMETER SELECTOR SWITCH Used to check voltage and current of each phase A C AMMETER Shows the generator load on each phase The phase is sele
12. every 100 hours or six weeks whichever comes first Change oil at the end of each season and the begin ning of each season Change oil when engine 15 warm Dispose of waste oil in an approved manner Never use a flushing oil Loosen the clamp on the oil change tube Remove cap Drain oil Replace the cap and tube Refill engine with recommended oil for the season 10 Engine capacity with new oil filter 15 843NW2 5 8 quarts 5 5 liters SP3 CHANGING LUBE OIL FILTER Change the lube oil filter every 250 hours Use a filter wrench to remove old filter Dispose of filter in approved manner Make sure the gasket from the old filter 1s removed and discarded Clean mount face 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 Using hands only no wrench tighten filter one half turn farther Overtightening can do damage to filter housing 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 Oil filter part number 15 843NW2 24 03100 OM843NW2 10 09 12 Servicing SP4 AIR CLEANER 1 Inspect air cleaner every 250 hours In dusty condi tions check more often 2 Marine sets if dirty wash element in soapy water Rinse and dry thoroughly before re installing Replace if necessary Part numbers are M843NW2
13. is the property of Northern Lights Inc 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 OM843NW2 10 09 OM843NW2 10 09 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 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 Unit Identification Failures can begin with minor problems that are over looked and become amplified when not corrected during routine maintenance 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 MODELS INCLUDED This manual covers the operating instructions for M843NW2 marine generator set 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 th
14. 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 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 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 work ing order If an unsafe operating condition 15 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
15. 8 ft Ibs 0 8 2 3 kg m OM843NW2 10 09 13 Servicing 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 b Use grade no at ambient temperatures below freezing and for all temperatures at an altitude of above 5 500 ft 1500 meters 2 Use fuel having less that 1 sulphur preferably less that 0 5 3 The cetane number should be a minimum of 45 4 DO NOT use these unsuitable grades of fuel a Domestic heating oils all types Class engine Class D domestic fuels Class E F G or H industrial or marine fuels ASTM D975 60T No 4 and higher number fuels f Diesel fuel with engine oil mixed in 5 Do not use any fuel additive other than an authorized diesel fuel biocide if fungus or bacteria cause fuel system problems a o 6 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 and possible biological contamination d If biological contamination is detected or suspected contact your dealer for assistance SP7 9 FUEL FILTERS Primary Fuel Filter Part Numbers Complete Unit 24 50002 Element 24 50012 Figure 8 Primary Fuel Filte
16. OINT OPERATION DAILY Hours Hours Hours ENGINE Check oil level Change engine oil Change lube oil filters Check air cleaner change element 1000 hrs 1 Check V belt tension Check valve clearances FUEL SYSTEM Check primary filter Racor Change primary filter element Racor Change secondary fuel filter Bleed the fuel system Check injectors Check fuel injection pump COOLING SYSTEM Check coolant level Check and flush cooling system Check and clean heat exchanger Change impeller in raw water pump Inspect condition of exhaust elbow ELECTRICAL SYSTEM SP18 19 Check electrolyte level in batteries SP19 Check condition of batteries with hydrometer DRIVEN EQUIPMENT SP20 Clutch and PTO service OUT OF SERVICE SP21 Winterizing or out of service 1 Perform all maintenance once a year even if hour level has not been reached 6 Clean injection nozzles every 1500 hours Consult manufacturer s maintenance schedule note on chart 7 For EPA emission standards fuel nozzle needs to be cleaned every 2 3 Whenever necessary 1500 hours the fuel nozzle and fuel pump need to be cleaned 4 More often if necessary adjusted or repaired every 3000 hours and the quality guarantee for 5 After first 50 hours then after 100 hours then at every 250 hours these parts is 1500 hours or 2 years OM843NW2 10 09 10 Service Record Notes OM843NW2 10 09 11 Fig
17. Repair lift pump e Replace filter element e Have your dealer check injection nozzles Remove and check thermostat e Clean or replace filter element e Replace secondary filter element e Drain flush fill and bleed system e Have your dealer check injection nozzles Inspect clamps and hoses on suction side of fuel pump for air leak e Adjust control lever e Consult fuel supplier and use proper type of fuel for operating condition e Check cylinder compression pressure e Service air cleaner check proper ventilation e Clean or replace filter element e Replace filter element e Have injection pump checked e Consult fuel supplier and use proper type of fuel for operating conditions Troubleshooting ENGINE PROBLEM Lack of Engine Power continued Engine Overheats Engine Knocks High Fuel Consumption POSSIBLE CAUSE Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Poor cylinder compression pressure Low coolant level Air cleaner element clogged Keel cooling tubes have been painted marine Cooling system interior dirty Defective thermostat Defective temperature gauge Water pump impeller worn broken V belts slipping Insufficient oil Injection pump out of time Below normal engine temperature Engine overheating Improper type of fuel Clogged or dirty air cleaner Improper valve clearance I
18. 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 on Marine sets must be below 200 F 94 C Normal coolant temperature is 167 to 194 F 75 C to 90 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 Let the unit run unloaded for a three to five minute warm up period 3 Apply electrical load STOPPING 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 4 Shut off the seacock fuel valve and battery switch OM843NW2 10 09 8 Operating Procedures 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 Do not rely on your warning to the exclusion of careful gauge monitoring Watching your gauges can prevent damage to the unit and dangerous power losses Do the following when your warning or shutdown system 15 activated a Check the temperature gauge I
19. ar or after 2500 hours of operation Drain expansion tank and heat exchanger Remove heat exchanger end covers and remove core Clean the inside of exchanger core tubes using a metal rod Flush inspect and clean again if necessary Reassemble Fill the cooling system start the engine and check for leaks SP17 RAW WATER PUMP 1 Change the seawater pump impeller every 1000 hours or as needed 2 Remove the pump end cover Pry out the impeller using needle nose pliers or two screwdrivers Be sure you remove all pieces of failed impeller NOTE Place some kind of protection under the screwdrivers in order not to damage the pump housing If the impeller has broken into pieces remove front heat exchanger end cover and inspect for impeller pieces Clean inlet to heat exchanger bundle and reassemble 3 Clean the inside of the housing 4 Press in the new impeller and place the sealing washers in the outer end of the impeller center if this has not already been done 5 Replace the cover using a new gasket NOTE Make sure that there is always an extra impeller and cover gasket in reserve on board GENERATOR ENDS 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 Northern Lights dealer ELECTRICAL SYSTEM GENERAL 1 Never switch battery switch off or break the circuit between the alternator and batteri
20. cted with the Ammeter Selector switch Item 9 OM843NW2 10 09 7 Operating Procedures BREAK IN PERIOD 1 The first 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 filter at 50 hours Change oil and filter again at 100 hours consult Lubricants section for oil recommendation Operating Instructions Maintain at least a 75 load on your generator set for the first 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 expansion tank or radiator 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 CAUTION Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns 2 Check the oil level in the crankcase with the dip stick The oil level must be in the waffled 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
21. e unit s application block model aspiration and RPM M Northern Lights marine generator set 1 Model number of engine block Bore Cylinders 84 mm 3 843 W and 2 W New winding 2 Tier 2 Compliant Northern Lights marine diesel generator set with 843 2 843 engine 312 2 generator end Tier compliant OM843NW2 10 09 Serial Numbers NORTHERN LIGHTS Serial No Model No Northern Lights 4420 14th Ave NW Seattle WA 98107 Generator set serial number plate Your set has three serial numbers 1 an engine number stamped on the block 2 a generator plate and 3 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 at left Warranty 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 15 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 con tact an authorized dealer or the factory Safety Rules CAUTION Accident reports show that careless use of engines causes a high
22. electric clutch P T O does not have any scheduled maintenance points However the equipment the P T O powers may require maintenance Consult the manufacturer of the driven equipment SP21 WINTERIZING OUT OF SERVICE 1 Marine sets Figure 18 Glow plugs a Drain fresh water and seawater cooling systems completely Remember to shut off seacocks BOOSTER BATTERIES before opening drain cocks b Drain water supply lines and wet exhaust line A CAUTION Battery gas can explode c Loosen the seawater pump cover and drain pump Keep all flames and sparks away from batteries d Change the crankcase oil and filter e Loosen the alternator belt 1 Before changing or using booster batteries check bat f Disconnect and clean battery Remove to warm tery electrolyte level Add distilled water if necessary storage place if possible 2 Booster and main batteries must have the same volt g Clean outside of unit Paint any scratched or age rating chipped surfaces Put corrosion preventative on 3 First connect positive terminal of booster bat all exposed metal surfaces tery to positive terminal of main battery Then connect negative terminal of booster battery to ground on the engine block see Figure 19 4 Remove booster battery after starting engine 5 Sealed batteries See manufacturer charging and booster instructions Figure 19 Battery connections Battery Booster Battery OM843NW2 10 09 19 Trouble
23. es while the engine is running Regulator damage can result 2 Do NOT reverse the polarity of battery cables when installing the battery 3 If welding on the unit disconnect the regulator and battery Isolate the leads 4 Disconnect the battery cables when servicing the D C alternator 5 Never test with a screwdriver etc against any ter minal to see if it emits sparks 6 Do not polarize the alternator or regulator 7 A D C circuit breaker protects your control panel and wiring harness It is located in the side of the generator junction box OM843NW2 10 09 18 Servicing GLOW PLUGS SP 18 19 BATTERY CARE 1 Each cylinder is supplied with a glow plug which 1 Check electrolyte level daily Add distilled water to serves to heat the combustion chamber manufacturer s recommended level 2 check the glow plugs loosen the current 2 Batteries cables and cable terminals should carrying flat wire between the plus poles of the be checked and cleaned every 100 hours glow plugs Figure 18 Connect a D C test bulb Clean corrosion with a water and baking soda between the plus pole of the battery and the solution Flush with clean water Tighten terminals plus pole of the glow plug If the bulb lights up and grease them to inhibit corrosion the glow plug is functioning properly 3 Check the battery condition with a hydrometer every 3 Check all glow plugs and replace any faulty ones 250 hours SP20 P T O 1 The
24. essive load on engine e Check loads Below Normal Thermostat not working properly Check thermostat Engine Temperature Temperature gauge e Check water temperature with thermometer not working properly Engine Malfunctions at High Output Range Fuel supply insufficient Air in fuel system or clogged fuel filter element Fuel injection amount between plungers uneven e Check fuel injectors Valve clearance adjusted incorrectly Re adjust valve clearances Valve spring broken Replace valve spring Governor spring broken Replace governor spring Low Oil Pressure Low oil level Fill crankcase to proper level Improper type of oil e Drain and fill crankcase with correct oil Partially plugged oil filter Replace filter Check bearings oil pump and relief valve for wear High Oil Consumption Break in period e Oil consumption decreases after break in Crankcase oil too light e Use proper viscosity oil Oil leaks e Check for leaks in lines around gaskets and drain plug Engine Emits Black Clogged or dirty air cleaner e Service air cleaner or Gray Exhaust Smoke Defective muffler e Have dealer check back pressure back pressure too high Improper fuel e Use correct fuel for temperature Injection nozzles dirty e See your dealer Engine timing off e See your dealer Engine Emits Improper fuel Use correct fuel for temperature White Smoke Cold engine e Warm up engine to normal operating temperature Defective the
25. f above 205 F 96 C shut off the engine immediately b Use the Trouble Shooting Guide on page 22 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 d Make repairs Restart your Marine set after the temperature gauge registers below 200 F 94 C e Watch the temperature gauge regularly and turn off the unit if the temperature rises above 205 F 96 C on Marine units Repeat troubleshooting 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 SPARE PARTS 1 Northern Lights recommends that you the following spare parts on hand for field service The parts are available from your local Northern Lights dealer Some marine models already have On Board Kits a handy box that contains the most common parts you will need All owners should have the following spares Primary and secondary fuel filter elements
26. fection or reaction can develop if proper medical treatment is not administered immediately Figure 9 S43NW Fuel System 1 The fuel system is self bleeding However any 3 Loosen bleed screw Pump hand primer B system may need manual bleeding when until pure fuel no bubbles escapes Then tighten a Anew fuel filter is installed bleed screw b The engine has run out of fuel 4 If the engine does not start after the above c The fuel lines injection pump or any other fuel bleeding process loosen a fuel line at the injector system component has been removed and while cranking the engine with the starter motor installed until pure fuel escapes Then tighten the connection 2 Loosen bleed bolt A Figure 9 on top of the filter Do each line one at a time Pump hand primer B on fuel lift pump until pure 5 After the engine has started use a piece of cardboard fuel no bubbles escapes from bleed bolt to look for fuel leaks Tighten bleed screw OM843NW2 10 09 15 Servicing Figure 13 Remove return line nuts Figure 17 Reinstall injector Torque to proper tightness OM843NW2 10 09 16 Servicing SP11 INJECTOR SERVICE Injectors should be checked every 1000 hours or more often as needed Check should be made by a Northern Lights dealer or local injection repair station Have your dealer check the fuel injection nozzle spray pattern with injection nozzle te
27. fuel valves Close the sea cock check clean and reassemble the sea strainer and re open the sea cock 5 Place the battery switch in the ON position 6 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 bat tery charging regulator could be ruined STARTING 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 15 not necessary if the engine 15 already warm While holding the Shutdown Bypass Preheat 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 consecu tively If the engine fails to start with the first attempt be sure that it has stopped completely wait at least 30 seconds before re engaging 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 three 20 second cranks remove the impeller from the raw water pump This will prevent the muffler from filling with water and backfilling the exhaust line and engine Once the engine starts shut it off immediately and re install the impeller Re start the engine and check the exhaust overboard outlet for gushes of water OPERATING i
28. king 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 SP13 CHECK THE COOLANT LEVEL 1 Check the coolant level each day before starting the engine 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 15 cold The pressure valve in the filler cap releases when the pressure is approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it is faulty OM843NW2 10 09 17 Servicing SP14 COOLING SYSTEM FLUSHING Flush the cooling system every 2500 hours or every 12 months whichever comes first Marine sets a Remove expansion tank cap and drain engine block b Open block drain cock Remove hose from bottom of heat exchanger tank c Pour clean water into expansion tank until water coming from drains 15 free of discoloration and sediment Let water drain completely Close drains and refill with recommended mixture Coolant Specifications Use 50 distilled water 50 ethylene glycol anti freeze mix Antifreeze mixture 1s recommended as a good year round coolant Check hoses and connections and repair any leakage SP15 HEAT EXCHANGER 1 Clean the heat exchanger core once a ye
29. njection nozzles dirty Injection pump out of time Engine not at proper temperature RECOMMENDATION S e See Engine Overheats in next category Remove and check thermostat e Reset valves Best done by dealer e Replace injectors Best done by dealer e See your local dealer e Check bore for wear or check alignment of nozzle holder Re adjust valve clearance e Fill tank or radiator to proper level with proper mixture of coolant e Check hoses for loose connections and leaks e Clean or replace e Remove paint from tubes e Flush cooling system e Remove and check thermostat e Check water temperature with thermometer and replace gauge if necessary e Check impeller and replace if necessary e Fix belts to proper tension e Call your dealer e Call your dealer e Check your thermostats e Check water temperature to see if temperature gauge is working properly e See Engine Overheating section e Use correct fuel for temperature e Service air cleaner e See your dealer e See your dealer e See your dealer e Check your thermostats e Check water temperature with thermometer and replace gauge if necessary If you cannot correct problems with these procedures see your Northern Lights dealer OM843NW2 10 09 22 Troubleshooting ENGINE PROBLEM OFAN US RECOMMENDATION S High Fu Consumption Fuel leakage e Improper installation or tightening Exc
30. r 1 Your generator set should have a primary fuel filter installed We recommend the Racor brand of fuel filter water separators a Check the primary fuel filter daily as recommended by the filter manufacturer Empty the collection bowl as necessary b Change the element as often as necessary or every 500 hours c Ifthe bowl fills with water change the primary and secondary element immediately 2 Change secondary fuel filter every 500 hours NOTE The fuel filter on the engine is considered the secondary fuel filter a Remove the spin on filter by turning it counterclockwise with a filter wrench Fill the new cartridge with fuel and install it after applying engine oil to gasket surface Screw on until the gasket surface comes into contact with sealing surface of filter base Then tighten it two thirds of a turn by hand Do not overtighten b Fuel filter part numbers are 843NW2 130336020 OM843NW2 10 09 Servicing SP10 BLEEDING THE FUEL SYSTEM CAUTION Escaping diesel fuel under pressure can penetrate skin causing serious personal injury A Before disconnecting lines be sure to relieve all pressure Before applying pressure be sure all connections are tight and lines pipes and hoses are not damaged Fuel escaping from a very small hole can be almost invisible Use a piece of cardboard or wood rather than hands to search for suspected leaks If injured by escaping fuel see a doctor at once Serious in
31. rmostat Remove and check thermostat Engine timing off e See your dealer If you cannot correct problems with these procedures see your Northern Lights dealer OM843NW2 10 09 23 108 8 MVAc 00l LSG YAV 10 pea 10 8 CMNEY8N SLON 335 AVJI OMV Y ONISN 401d LNdLNO OL IWNINNAL LOSNNOD ALVIS weibeiq OV 0 31 LOINNOOSIC 76 WAS OL R A 123 00 HONOYHL OL 31 10 ORO A ONE ee a eds GNV 50 31 LOANNOOSIG 5 01103 SY 3 YAWOLSNO JLYOIANI SININ Z 38 OL JHL NOWVYNSISNOD 318104 JHL 21 53002 1 201 318 0 144 ANY ANY 3009 1 2 121312373 NI 38 OL ONiddVYM 31 1051 LAN 201 JYV 5136 39 WIYLSNGNI NOWSYNOSIG S YaWOLSNOD 1108 ONISN SNOLLOANNOD 5 42018 1 43401502 GAGNNOND 3 5135 39 INIYYN 79 4 50 31 312344 SAOWSY QAYINOIY 41 SYOLONGNOD 3802 21 12313 JHL 30 8 51 YFOYV LON TIIM 540018 WNINYAL 711 FTOUMY 32 05020 NI 1 356344 SI daSN SI 1 1503
32. shooting DC ELECTRICAL SYSTEM PROBLEM POSSIBLE CAUSE RECOMMENDATION S Battery Will Not Charge Loose or corroded connections e Clean and tighten battery connections Sulfated or worn out batteries e Check specific gravity of each battery e Check electrolyte level of each battery Loose or defective alternator belt Adjust belt tension e Replace belt Starter Inoperative Check DC circuit breaker If the breaker is tripped reset it Loose or corroded connections e Clean and tighten loose battery harness plug connection Low battery output e Check specific gravity of each battery e Check electrolyte level of each battery Defective electrical system Repair or replace ground wire Starter Cranks Slowly Low battery output e Battery is too small e Battery cables are too small Check specific gravity Replace battery if necessary of each battery Check electrolyte level If low fill cells with distilled water of each battery Crankcase oil too heavy e Fill with oil of appropriate viscosity Loose or corroded connections e Clean and tighten loose connections Entire Electrical System Check DC circuit breaker breaker is tripped reset it Does Not Function Faulty connection e Clean and tighten battery and harness plug connections Sulfated or worn out batteries e Check specific gravity and electrolyte level of each battery If you cannot correct problems with these procedures see your Northern Lights
33. ster If the starting pressure is too high or the spray pattern is off abnormal fuel combustion could take place causing low engine output and black exhaust smoke 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 2 Injector removal a Clean loose dirt from around the injectors and the fuel lines Relieve high pressure in the fuel lines by loosening the delivery line flare nuts at each injector Figure 10 Remove delivery lines by disconnecting from injectors and injection pump Figure 11 Remove all lines as an assembly do not remove the spacers Cover the ends of the lines the injector inlets and Injection pump outlets to keep dirt out Figure 12 Remove the return line retaining bolts Figure 13 Remove the return line Figure 14 Unscrew and remove the injectors Figure 15 NOTE Do not use pry bars to remove injectors from cylinder head f After removing the injectors discard the copper sealing washers from the injector hole in the head Figure 16 Cover holes to prevent dirt and debris from entering the cylinders Injector installation a Install a new copper sealing washer in each injector hole Figure 16 Screw in injector and tighten to 44 51 1 16 6 to 7 kgm Figure 17 NOTE Overtightening can damage injector Install return line using a ne
34. ure 5 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 CC CD CE single viscosity oils b API Service CC CD SF multi viscosity oils 3 Use the proper weight oil for your average opera tion temperature Single Air Temperature Viscosity Above 32 F 0 C SAE 30W 10 to 32 F 23 to 0 C Multi Viscosity SAE 15 40W SAE 10 30W SAE 10W SAE 5W Figure 4 Lube Oils Below 10 F 23 C SAE 5 20W 4 Some increase in oil consumption may be expected when SAE 5W and SAE 5 20W oils are used Check oil level frequently 5 Never put additives or flushing oil in crankcase Maximum Level lt q Minimum Level SP1 CHECKING OIL LEVEL Check the oil level in the crankcase with the dipstick Fig 5 The oil level must be in the waffled area on the stick Never allow the level to go below this area Follow the lubrication recommendations above SP2 OIL CHANGES 9 The set is delivered with special break in oil Change the engine oil and oil filter after 50 hours of operation Use Service CC 30 weight oil during the first 100 hours Change the oil and filter again at 100 hours using the oil recommended in the above diagram After this change oil and filter every 250 hours During intermittent cold weather operation change oil
35. w sealing washer below each connection Tighten return line retaining bolts to 22 30 ft Ibs Install delivery lines Leave loose at injectors for bleeding Crank engine to fill lines Tighten lines at injectors to 11 18 ft lbs Start engine and check for leaks using a piece of paper or cardboard DO NOT use hand to check for leaks SP12 INJECTION PUMP 1 NO Since operating conditions may vary considerably it is difficult to give a definite interval for checking the injection pump But as a pump settings maximum speed idle speed and exhaust smoke should be checked after every 2500 hours of operation Service of the fuel injection pump should only be done if checks indicate pump malfunction Black smoke can be an indication of pump malfunction Before servicing the pump check other possible causes a Check cleanliness of air filter b Check valve clearances c Clean and check injectors Any repair which involves disassembly of the injection pump must be carried out by specially trained mechanics 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 OLING SYSTEM GENERAL TE Be sure to close the sea cock before working on the engine cooling system A CAUTION The cooling water in the engine reaches extremely high temperatures You must use extreme caution when wor
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