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  5. Operator's Manual

Northern Lights and M38CR2 Operator's Manual

Other manuals for and M38CR2: Parts Manual

Summary of and M38CR2

  • Page 2

    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. — california — proposition 65 warning: northern lights 4420 14th avenue n.W. Seattle, wa 98107 tel: (206) 789-3880 fax: (206) 782-5455 copyright ©200...

  • Page 3: Operator'S Manual

    Om944t 10/08 3 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. © alaska diesel electric, inc. All rights reserved. Litho u.S.A. Publication number om94...

  • Page 4

    4 om944t 10/08 the 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 comp...

  • Page 5

    Om944t 10/08 5 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 caref...

  • Page 6

    6 om944t 10/08 figure 2: m944t service side m944t generator set component locations 1. Expansion tank 2. Coolant fill 3. Thermostat housing 4. Rocker 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 ...

  • Page 7

    Om944t 10/08 7 m944t generator set component locations figure 3: m944t non-service side 19. Turbocharger 20. Wet exhaust elbow 21. Exhaust manifold 22. Alternator 23. Belt guard 24. Starter 25. Oil pan 19 20 22 23 24 25 21.

  • Page 8

    8 om944t 10/08 control panels figure 4-b: series 3 generator control panel figure 4-a: series 1-b generator control panel 1. Preheat/ shutdown bypass this switch serves two functions: 1. Preheats air before beginning the starting process. Press switch for 10-20 seconds before attempting startup. 2. ...

  • Page 9

    Om944t 10/08 9 operating procedures before starting 1. 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. Cauti...

  • Page 10

    10 om944t 10/08 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. V...

  • Page 11

    Om944t 10/08 11 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...

  • Page 12

    12 om944t 10/08 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 check oil level in engine sp8 check primary fuel filter ...

  • Page 13

    Om944t 10/08 13 service point hours/ date service record operation 50 hours sp5 check v-belt tension sp19 check electrolyte in batteries 250 hours sp2 change engine oil sp3 change lubricating oil filters sp4 check air cleaner sp18 check zinc electrodes every 500 hours sp7 check valve clearances sp8 ...

  • Page 14

    14 om944t 10/08 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 prope...

  • Page 15

    Om944t 10/08 15 sp3. Changing lube oil filter 1. Change the lube oil filter every 250 hours. 2. Use a filter wrench to remove old filter. Dispose of filter in approved manner. 3. Make sure the gasket from the old filter is removed and discarded. Clean mount face. 4. Spread a thin film of engine oil ...

  • Page 16

    16 om944t 10/08 servicing sp7. Valve clearances 1. Readjust valve clearance after first 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 0 to bring each piston to the top de...

  • Page 17

    Om944t 10/08 17 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. 1 at ambient temperatures below freezing. C. In...

  • Page 18

    18 om944t 10/08 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 da...

  • Page 19

    Om944t 10/08 19 servicing sp12. Injector service 1. 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 perso...

  • Page 20

    20 om944t 10/08 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 a rule, pump settings, maximum speed, and exhaust smoke should be checked after every 2000 hours of operation. Service of the ...

  • Page 21

    Om944t 10/08 21 servicing 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 ...

  • Page 22

    22 om944t 10/08 sp16. Heat exchanger 1. Clean the heat exchanger core once a year or after 2000 hours of operation. 2. Drain the expansion tank and heat exchanger. 3. Remove the heat exchanger end covers. 4. Clean the inside of the exchanger core tubes using a metal rod. Flush, inspect, and clean ag...

  • Page 23

    Om944t 10/08 23 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 ...

  • Page 24

    24 om944t 10/08 sp19-20. 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 sol...

  • Page 25

    Om944t 10/08 25 if you cannot correct problems with these procedures, see your northern lights dealer. Troubleshooting dc electrical system problem possible cause recommendation(s) battery will not charge loose or corroded connections • clean and tighten battery connections. Sulfated or worn out bat...

  • Page 26

    26 om944t 10/08 troubleshooting engine problem possible cause recommendation(s) engine hard to start improper starting procedure • see starting section of this manual. Take or will not start special note of bypass switch operation. No fuel • check level of fuel in fuel tank. Low battery condition • ...

  • Page 27

    Om944t 10/08 27 troubleshooting engine problem possible cause recommendation(s) lack of engine power low compression pressure • consult dealer. (continued) (worn piston rings, etc...) engine overheats engine overloaded • reduce the electrical load. Low coolant level • fill tank or radiator to proper...

  • Page 28

    28 om944t 10/08 engine problem possible cause recommendation(s) high oil consumption break-in period • oil consumption decreases after break in. Crankcase oil too light • use proper viscosity oil. Oil leaks • check for leaks in lines around gaskets and drain plug. Crankcase over full • remove excess...

  • Page 29

    Om944t 10/08 29 northern lights ac wiring diagram – dst -100-2f ak v oltage regulator drawing b-8280d ac wiring diagram.

  • Page 30

    30 om944t 10/08 dc wiring diagram dc wiring diagram 12 vdc standard ground c-6533 drawings subject to change without notice ..

  • Page 31

    Om944t 10/08 31 dc wiring diagram dc wiring diagram 24 vdc standard ground c-6534 drawings subject to change without notice ..