Nothern Lights M38CR2 Operator'S Manual Download

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OM944T 2/11

DC Wiring Diagram

DC Wiring Diagram

24 VDC Standard Ground

C-6534

Drawings subject to change without notice

Summary of Contents for M38CR2

Page 1: ...OM944T For Models M944T and M38CR2 OPERATOR S MANUAL Marine Generators Marine Diesel Engines Land Based Generators...

Page 2: ...reproductive harm CALIFORNIA Proposition 65 Warning 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 reserve...

Page 3: ...LOCATIONS M944T Generator Set 4 5 M38CR2 Generator Set 6 7 CONTROL PANELS Northern Lights Generator Sets 8 OPERATING PROCEDURES Break in Period 9 Before Starting 9 Starting 10 Operating 10 Stopping 10...

Page 4: ...ern Lights marine generator set Model number of engine block Bore Cylinders 94 mm 4 Serial Numbers MODELS INCLUDED This manual covers the operating instructions for M944T and M38CR2 marine and commerc...

Page 5: ...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...

Page 6: ...er Arm Cover 5 Lube Oil Fill 6 Intake Manifold 7 Fuel Filter 8 Air Cleaner 9 Junction Box 10 Lube Oil Dipstick 11 Oil Filter 12 Vibration Mounts 13 Fuel Manifold 14 Fuel Primer Pump 15 Injection Pump...

Page 7: ...erator Set Component Locations Figure 3 M944T Non Service Side Current Baseframe 19 Turbocharger 20 Wet Exhaust Elbow 21 Exhaust Manifold 22 Alternator 23 Belt Guard 24 Starter 25 Oil Pan 19 20 22 23...

Page 8: ...nent Locations 1 Expansion Tank 2 Coolant Fill 3 Thermostat Housing 4 Fuel Filter 5 Intake Manifold 6 Air Cleaner 7 Junction Box 8 Harness Plug 9 Lube Oil Dipstick 10 Fuel Manifold optional 11 Oil Fil...

Page 9: ...M38CR2 Generator Set Component Locations Figure 5 M38CR2 Non Service Side Representative only early production 19 Turbocharger 20 Exhaust Manifold 21 Alternator 22 Belt Guard 23 Oil Pan 24 Starter 19...

Page 10: ...ch 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 lubricat...

Page 11: ...ea cock check and clean the sea strainer and reopen the sea cock 5 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...

Page 12: ...wn Bypass switch in the ON position 2 While holding the Shutdown Bypass switch in the ON position push the Engine Control switch to the START position 3 As soon as the engine starts release both switc...

Page 13: ...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...

Page 14: ...ernator Servicing Schedule Chart 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 oil1 5 SP3 13 Change lube oil f...

Page 15: ...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 inje...

Page 16: ...nded oil and fill only to the high mark on the dipstick Follow the lubrication recommendations in Figure 7 SP2 OIL CHANGES 1 The set is delivered with special break in oil Change the engine oil and oi...

Page 17: ...f 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 M...

Page 18: ...moment when the two rocker arms are exactly aligned with each other is when they rock Figure 8 Timing Mark 4 Measure the valve clearance for each of the valves with a feeler gauge in the firing order...

Page 19: ...975 60T No 4 D and higher number fuels 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...

Page 20: ...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...

Page 21: ...he 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 3 Injector repair and cleaning...

Page 22: ...a 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 f...

Page 23: ...k 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...

Page 24: ...he 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 co...

Page 25: ...BOOSTER BATTERIES CAUTION Battery gas can explode Keep all flames and sparks away from batteries 1 Before changing or using booster batteries check the battery electrolyte level Add distilled water i...

Page 26: ...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...

Page 27: ...connection Low battery condition Check specific gravity of each battery Check electrolyte level of each battery Defective electrical system Repair or replace ground wire Starter Cranks Slowly Low bat...

Page 28: ...e 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 d...

Page 29: ...our thermostats Check water temperature to see if temperature gauge is working properly Faulty fuel injector Call your dealer Engine overheating See Engine Overheating section High Fuel Consumption Im...

Page 30: ...r dealer Injection nozzles dirty See your dealer Engine overloaded Reduce the electrical load Injection nozzles dirty See your dealer Injection pump faulty Consult your dealer Engine out of time See y...

Page 31: ...OM944T 2 11 31 Northern Lights AC Wiring Diagram DST 100 2FAK Voltage Regulator Drawing B 8280D AC Wiring Diagram...

Page 32: ...32 OM944T 2 11 DC Wiring Diagram DC Wiring Diagram 12 VDC Standard Ground C 6533 Drawings subject to change without notice...

Page 33: ...OM944T 2 11 33 DC Wiring Diagram DC Wiring Diagram 24 VDC Standard Ground C 6534 Drawings subject to change without notice...

Page 34: ...lights com 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 Alaska Diesel Electric Inc 2011 All rights reserv...

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