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Northern Lights M843JK, Operator'S Manual

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Diesel engine exhaust and some of its constituents

are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

— CALIFORNIA —

Proposition 65 Warning:

Northern Lights

4420 14th Avenue N.W.
P.O. Box 70543
Seattle, WA 98107
Tel:

(206) 789-3880

Fax: (206) 782-5455

Copyright ©2003 Alaska Diesel Electric, Inc.
All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Alaska Diesel Electric, Inc.

Printed in U.S.A.
PART NO.: O843K 05/03

Summary of Contents for M843JK

Page 1: ...OPERATOR S MANUAL OPERATOR S MANUAL O843K For Models M843JK M843NK NL843NK ...

Page 2: ...uctive harm CALIFORNIA Proposition 65 Warning Northern Lights 4420 14th Avenue N W P O Box 70543 Seattle WA 98107 Tel 206 789 3880 Fax 206 782 5455 Copyright 2003 Alaska Diesel Electric Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Alaska Diesel Electric Inc Printed in U S A PART NO O843K 05 03 ...

Page 3: ...K Industrial Generator 5 CONTROL PANELS Northern Lights Generator Sets 6 7 OPERATING PROCEDURES Break in Period 8 Before Starting 8 Starting 8 Operating 8 Stopping 8 Shutdowns and Alarms 9 Spare Parts 9 SERVICING SCHEDULE CHART 10 11 SERVICING Lubrication General 12 Checking Oil 12 Oil Changes 12 Changing Oil Filter 12 Air Filter 13 SERVICING continued V Belts 13 Retightening Cylinder Head Bolts 1...

Page 4: ... maintaining your unit properly J K MODELS INCLUDED This manual covers the operating instructions for M843JK marine generator sets M843NK marine generator sets and NL843NK industrial generator sets Fill in the model number of your unit in the blank space provided This will give you a reference whenever service or maintenance is required Additional letter designates series within model number North...

Page 5: ...s 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 ser...

Page 6: ...xchanger End Cap 12 Injection Pump 13 Seawater Pump 14 Freshwater Block Drain 15 Fuel Inlet Return 16 Oil Filter 17 Oil Dipstick 18 Oil Drain 19 Control Panel Plug In 20 Generator Set Plate 21 Expansion Tank Marine Generator Component Locations 4 Non Service Side 22 Wet Exhaust Elbow 23 Junction Box 24 Starter 25 Vibration Mount 26 DC Alternator Service Side Figure 2 M843JK M843NK service and non ...

Page 7: ...tion Pump 16 Fuel Inlet and Return 17 Oil Filter 18 Fuel Lift Pump 19 Block Water Drain 20 Dipstick 1 DC Alternator 2 Exhaust Outlet 3 Air Filter 4 Starter 5 DC Circuit Breaker 6 Generator Junction Box 7 Starter Industrial Generator Set Component Locations 5 Non Service Side Service Side Figure 3 NL843NK service and non service views ...

Page 8: ...it will return to RUN position To stop the engine hold the switch in the STOP position until the engine has completely stopped NOTE The rocker switch is used on Series 1 panels only and has a light that glows when the set is running 3 HOUR METER Keeps track of engine running time 4 OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system 5 ENGINE TEMPERATURE GAUGE Registers the t...

Page 9: ... phase The phase is selected with the Ammeter Selector switch Figure 5 Series 7 0 through Series 7 6 Generator Control Panels 1 SHUTDOWN BYPASS SWITCH Manual Start Panels S 7 1 and S 7 3 Hold the switch in the START position until the engine is running NOTE Excessive cranking may cause engine damage After the engine starts release the switch and it will return to the RUN position To stop the engin...

Page 10: ... STARTING 1 Hold the Shutdown Bypass Preheat switch in the ON position for 10 to 20 seconds before starting a cold engine Holding the switch too long can burn out the glow plugs This step is not necessary if the engine is already warm 2 While holding the Shutdown Bypass Preheat switch in the ON position push the Engine Control switch to the START position 3 As soon as the engine starts release bot...

Page 11: ...regularly and turn off the unit if the temperature rises above 205 F 96 C on Marine units 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 ...

Page 12: ...xchanger marine only 1 Perform all maintenance once a year even if hour level has not been reached 2 Consult manufacturer s maintenance schedule note on chart 3 Whenever necessary 4 More often if necessary 5 After first 50 hours Servicing Schedule Chart 10 SERVICE 50 100 200 600 2400 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours ENGINE SP1 8 12 Check oil level SP2 12 Change engine oil 1...

Page 13: ...P8 Change primary filter element Racor SP9 Change secondary fuel filter SP21 Inspect condition of exhaust elbow EVERY 600 HOURS SP6 Check valve clearances SP11 Check injectors SP14 Check and flush cooling system SP17 Change impeller in raw water pump SP19 Check condition of batteries with hydrometer 2400 HOURS SP12 Check fuel injection pump SP15 Check and clean heat exchanger Service Point HOURS D...

Page 14: ...change oil every 100 hours or six weeks whichever comes first 4 Change oil at the end of each season and the beginning of each season 5 Change oil when engine is warm 6 Dispose of waste oil in an approved manner 7 Never use a flushing oil 8 Loosen the clamp on the oil change tube Remove cap Drain oil Replace the cap and tube 9 Refill engine with recommended oil for the season 10 Engine capacity wi...

Page 15: ... below Tighten bolts evenly in 2 or 3 passes ending at the specified torque in final pass 843JK 843NK 60 64 ft lbs 9 0 9 5 kg m Servicing Figure 7 843N Head Torque Sequence Figure 8 Valve Adjustment SP6 VALVE CLEARANCES 1 Adjust valve clearance after first 50 hours of operation and every 600 hours thereafter 2 Valve adjustments should be done after the cylinder head bolts have been re tightened En...

Page 16: ...will reduce condensation and possible biological contamination d If biological contamination is detected or suspected contact your dealer for assistance SP7 9 FUEL FILTERS 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 b...

Page 17: ...stem 1 The fuel system is self bleeding However any system may need manual bleeding when a A new fuel filter is installed b The engine has run out of fuel c The fuel lines injection pump or any other fuel system component has been removed and installed 2 Loosen bleed bolt A Figure 9 on top of the filter Pump hand primer B on fuel lift pump until pure fuel no bubbles escapes from bleed bolt A Tight...

Page 18: ...very lines Figure 12 Cover lines inlets and injection pump outlets Figure 14 Remove return line Figure 15 Unscrew injector Figure 16 Remove and replace copper sealing washer Figure 17 Reinstall injector Torque to proper tightness Servicing 16 Figure 13 Remove return line nuts ...

Page 19: ... and check for leaks using a piece of paper or cardboard DO NOT use hand to check for leaks SP12 INJECTION PUMP 1 Since operating conditions may vary considerably it is difficult to give a definite interval for checking the injection pump But as a rule pump settings maximum speed idle speed and exhaust smoke should be checked after every 2400 hours of operation Service of the fuel injection pump s...

Page 20: ... radiator with compressed air or steam cleaner every 100 hours Clean in the reverse direction of the airflow SP17 RAW WATER PUMP Marine 1 Change the seawater pump impeller every 600 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 screwdriver...

Page 21: ... solution Flush with clean water Tighten terminals and grease them to inhibit corrosion 3 Check the battery condition with a hydrometer every 600 hours P T O 1 The 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 SP20 WINTERIZING OUT OF SERVICE 1 Marine sets a Drain f...

Page 22: ...plug connection Low battery output Check specific gravity of each battery Check electrolyte level of each battery Defective electrical system Repair or replace ground wire Starter Cranks Slowly Low battery output Battery is too small 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 eac...

Page 23: ...rature Remove and check thermostat or Stalls Frequently Clogged primary Clean or replace filter element fuel filter element Clogged secondary Replace secondary filter element fuel filter element Water or dirt in the fuel system Drain flush fill and bleed system Dirty or faulty injection nozzles Have your dealer check injection nozzles Air in fuel system Inspect clamps and hoses on suction side of ...

Page 24: ...ng section High Fuel Consumption Improper type of fuel Use correct fuel for temperature Clogged or dirty air cleaner Service air cleaner Improper valve clearance See your dealer Injection nozzles dirty See your dealer Injection pump out of time See your dealer Engine not at proper temperature Check your thermostats Check water temperature with thermometer and replace gauge if necessary Below Norma...

Page 25: ...e too high Improper fuel Use correct fuel for temperature Injection nozzles dirty See your dealer Engine out of time See your dealer Engine Emits Improper fuel Use correct fuel for temperature White Smoke Cold engine Warm up engine to normal operating temperature Defective thermostat Remove and check thermostat Engine out of time See your dealer If you cannot correct problems with these procedures...

Page 26: ...mp Cap 9 0 gpm 34 lpm 7 7 gpm 29 lpm Maximum Seawater Pump Suction Head 39 in 1M 39 in 1M Keel Cooler TurboTube Length 4 feet 1 2 M 4 feet 1 2 M Keel Cooler Head Diameter 1 in 25 4 mm 1 in 25 4 mm Keel Cooler Water Hose ID 1 25 in 31 75 mm 1 25 in 31 75 mm D C Electrical Minimum Battery Capacity 120 Amp Hour 120 Amp Hour Battery Cable Size 1 1 Starting Voltage Standard 12 Volt 12 Volt A C Electric...

Page 27: ...l min 34 ltr min 7 7 gal min 29 ltr min Maximum Seawater Pump Suction Head 39 in 1M 39 in 1M Keel Cooler Turbo Tube Length 4 feet 1 2 M 4 feet 1 2 M Keel Cooler Head Diameter 1 in 25 4 mm 1 in 25 4 mm Keel Cooler Water Hose ID 1 25 in 31 75 mm 1 25 in 31 75 mm D C Electrical Minimum Battery Capacity 120 Amp Hour 120 Amp Hour Battery Cable Size 1 1 Starting Voltage Standard 12 Volt 12 Volt A C Elec...

Page 28: ...O843K 05 03 Wiring Diagrams 26 Engine Wiring Schematic M843 12V DC Drawing B 7915 ...

Page 29: ...O843K 05 03 27 Wiring Diagrams Engine Wiring Schematic NL843NK 12V DC Drawing B 6124D ...

Page 30: ...O843K 05 03 Notes 28 ...

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