Nothern Lights M38CR2 Operator's Manual

Manual is about: Marine Generators

Summary of 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 2/11 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 om944...

  • Page 4

    4 om944t 2/11 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 compe...

  • Page 5

    Om944t 2/11 5 a warranty registration certifi cate 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 2/11 figure 2: m944t service side (current baseframe) 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...

  • Page 7

    Om944t 2/11 7 m944t generator 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 24 25 21 updated 2/8/11.

  • Page 8

    8 om944t 2/11 figure 4: m38cr2 service side (representative only - early production) m38cr2 generator set component 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 manifol...

  • Page 9

    Om944t 2/11 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 20 22 23 21 24.

  • Page 10

    10 om944t 2/11 control panels figure 6-b: series 3 generator control panel figure 6-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 11

    Om944t 2/11 11 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 fi ller cap sealing surface when the engine is cold. Caut...

  • Page 12

    12 om944t 2/11 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. Vo...

  • Page 13

    Om944t 2/11 13 shutdowns and alarms 1. Your unit is fi tted 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 14

    14 om944t 2/11 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 fi lter ...

  • Page 15

    Om944t 2/11 15 service point hours/ date service record operation 50 hours sp5 check v-belt tension sp21 check electrolyte in batteries 250 hours sp2 change engine oil sp3 change lubricating oil fi lters sp4 check air cleaner sp14 check turbocharger sp20 check zinc electrodes every 500 hours sp7 che...

  • Page 16

    16 om944t 2/11 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...

  • Page 17

    Om944t 2/11 17 sp3. Changing lube oil filter 1. Change the lube oil fi lter every 250 hours. 2. Use a fi lter wrench to remove old fi lter. Dispose of fi lter in approved manner. 3. Make sure the gasket from the old fi lter is removed and discarded. Clean mount face. 4. Spread a thin fi lm of engine...

  • Page 18

    18 om944t 2/11 servicing sp7. Valve clearances 1. Readjust valve clearance after fi rst 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 19

    Om944t 2/11 19 fuels - general 1. Use only clean, high quality fuels of the following specifi cations, as defi ned 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. I...

  • Page 20

    20 om944t 2/11 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 dam...

  • Page 21

    Om944t 2/11 21 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 suffi cient force to penetrate the skin causing serious perso...

  • Page 22

    22 om944t 2/11 sp13. Injection pump 1. Since operating conditions may vary considerably, it is diffi cult to give a defi nite 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 23

    Om944t 2/11 23 servicing sp14. Turbocharger 1. Checkfor 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, b...

  • Page 24

    24 om944t 2/11 sp18. 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 aga...

  • Page 25

    Om944t 2/11 25 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 a...

  • Page 26

    26 om944t 2/11 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 solu...

  • Page 27

    Om944t 2/11 27 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 batt...

  • Page 28

    28 om944t 2/11 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 • c...

  • Page 29

    Om944t 2/11 29 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 30

    30 om944t 2/11 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 31

    Om944t 2/11 31 northern lights ac wiring diagram – dst -100-2f ak v oltage 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

    Www.Northern-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 reserved. Litho usa..