WORKSHOP MANUAL - Northern Lights
W844-2For Models: L844D, M844K2, M844W2, M844LK2,M844LW2, NL844K2, NL844LK2, NL844W2,NL844LW2, M20CR2, and M20CRW2WORKSHOP MANUALMarine Generators Marine Diesel Engines Land-Based Generators
— CALIFORNIA —Proposition 65 Warning:Diesel engine exhaust and some of its constituents are known to the State of California to causecancer, birth defects, and other reproductive harm.Northern Lights4420 14th Avenue N.W.Seattle, WA 98107Tel: (206) 789-3880Fax: (206) 782-5455Copyright 2006 Northern Lights, Inc.All rights reserved. Northern Lights , andthe Northern Lights logo are trademarks ofNorthern Lights, Inc.Printed in U.S.A.PART NO.: W844-2 01/06
WORKSHOP MANUALfor ModelsL844D, M844K2, M844W2, M844LK2, M844LW2, NL844K2,NL844LK2, NL844W2, NL844LW2, M20CR2, & M20CRW2Alaska Diesel Electric reserves the right to carry out any design modifications and, for this reason, someof the contents of this manual may not apply to your engine. If further information is needed, we suggestthat you contact an authorized dealer or the ADE factory.TABLE OF CONTENTS1. DISASSEMBLY PROCEDURES. 5- 8Safety Instructions . 43. REASSEMBLY OF ENGINEMAIN COMPONENTS. 24- 30Head Gasket . 282. INSPECTION OF ENGINEMAIN COMPONENTSa. Rocker Arm . 9b. Cylinder Head . 10- 12c. Cylinder Block . 12d. Piston & Piston Rings . 13- 14e. Connecting Rod . 14- 15f. Bearing Holder . 15- 16g. Crankshaft Bearing . 16h. Crankshaft . 17i. Flywheel & Ring Gear . 17j. Camshaft Assembly . 18k. Timing Gear . 18l. Oil Pump . 19m. Oil Filter . 19n. Coolant Pump . 19o. Thermostat . 20p. Radiator . 20q. Fuel Filter . 20r. Injection Pump . 21s. Nozzle and Holder . 22- 234. ELECTRICAL SYSTEM INSPECTIONFuel Solenoid . 31Glow Plugs . 32Oil Pressure Switch . 32- 33Alternator Maintenance Chart . 34Alternator Troubleshooting . 35Starter . 36- 405. TROUBLESHOOTING . 42- 446. ENGINE MAINTENANCE STANDARDS. 45- 48Proprietary InformationThis publication 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 W844-2 01/06W844-2 01/063
INTRODUCTIONSAFETY RULES Use caution in handling fuel. Never refuel ahot or running engine. Do not smoke whilefilling fuel tank or servicing fuel system. Keep your hands, feet, hair and clothing awayfrom power-driven parts. Check for any loose electrical connections orfaulty wiring. Engines should be operated only byknowledgeable, qualified personnel. Look completely around engine to make surethat everything is clear and clean beforestarting. Do not operate an engine that isn't in properworking order. If an unsafe operatingcondition is noted, tag the set and controlpanel so others will also know about theproblem. Provide first aid kits. Do not disassemble parts or engine except forwhat is needed to be worked on - as initiallythe engine was put together with precisionthat could prove to be hard to duplicate. Apply oil to moving parts during reassemblyto form an oil film to fill up the gap beforeregular lubrication occurs.CAUTION: Accident reports showthat careless use of engines causesa high percentage of accidents. Youcan avoid accidents by observingthese safety rules. Study these rulescarefully and enforce them on thejob.Never leave engine without proper security.Turn the coolant tank cap slowly to relievepressure before removing. Add coolant onlywhen the engine is stopped and cool.Mount a fire extinguisher near engine.Always disconnect the battery ground strapbefore making adjustments.Operate engines in properly ventilatedareas.Keep trash and other objects away fromengine.Escaping fluids under pressure canpenetrate your skin. Use a piece of cardboard or wood, not your hands, to search forleaks.Avoid wearing loose clothing without a beltwhen working around engines.Do not oil or grease engine while it isrunning.CAUTION: This symbol is used throughoutthis book to alert you to possible dangerareas. Please take special notice of thesesections.W844-2 01/064
SECTION 1 – DISASSEMBLY PROCEDURESEngine Overall ISASSEMBLY ESSENTIALSAlternatorOil FilterRelief ValveDipstickEngine stop solenoid, seal washerInjection pipeInjection pump assemblyRemove the injection lines and stop solenoid beforeremoving the injection pump.Raise the injection pump and disconnect the governorlink from the control rack by removing the snap pin.The injection timing has been adjusted by the shimsbetween the injection pump and cylinder block; note thethickness and number when removing the injectionpump.W844-2 01/065
SECTION 1 – DISASSEMBLY PROCEDURESEngine Overall 415161718PARTDISASSEMBLY ESSENTIALSReturn pipeInjection nozzle, gasketOil transfer tube, banjo bolt, seal washerConnector, glow plugsOil pressure switchThermostat housing, gasketRocker arm cover, o-ring, intake manifold, spacerRocker arm assembly, o-ring, capPush rodCylinder head, head gasketTappetW844-2 01/066Remove the caps from intake valves andexhaust valves.Loosen the cylinder head bolts in severalsteps and remove the cylinder headassembly.
SECTION 3 – DISASSEMBLY PROCEDURESEngine Overall DisassemblyW844v belt&fanSEQ.19202122232425PARTDISASSEMBLY ESSENTIALSV-belt, cooling fan, fan housing, fan pulleyWater pump assembly, gasketCrankshaft pulleyTiming gear case assembly, gasketIdle gear, oil pump assemblyCam shaft assembly, plateFront plate, gasketFirst remove the injection pump assemblyand the stop solenoid.Remove the bolts and plate first and pullout the camshaft assembly.W844-2 01/067
SECTION 1 – DISASSEMBLY PROCEDURESEngine Overall PARTDISASSEMBLY ESSENTIALSOil pan, gasket, intake filter, intake pipeFlywheelRear plateOil sealPiston and connecting rod assemblyCrankshaft and bearing holder assemblyRemove the carbon deposit from the topof the cylinder before taking out thepiston.Keep the connecting rod, cap, andbearing in the order of the cylinders asthey are removed.Take out the bolts for the bearing holdersand remove the crankshaft and bearingholder as a set.W844-2 01/068
SECTION 2 – INSPECTION PROCEDURESEngine Main Parts InspectionNotes before assembly:1. Check for wear and leakage on the cylinder block and the cylinder head.2. Check for clogs in oil holes on parts and remove deposits with air.3. Wash each part completely to remove contaminates, oil, carbon, etc.4. For the piston, cylinder, and valves take care in removing deposits (aluminum alloy parts need extra care).5. Valves, pistons, connecting rods, metals, and other parts that are to be put back together should bemarked with their matches so that they can be re-fitted with greater ease.A) Rocker Arm Assembly Disassembly and Inspection1Screw2Rocker arm shaft3Rocker armScrew in a M8 bolt at the front end of the rocker arm4Springshaft and take out the rocker arm shaft.5ShimTake out the spring, shim, and rocker arm from therocker arm bracket.inspec.pg1a1Using a micrometer, check outside diameter of the rocker arm shaft. If the shaft wearexceeds the service limit shown, replace it.Wear of rocker arm shaftStandard assembly value14.95 - 14.972(mm)Service limit14.87Measure the inside diameter of the rocker arm. Calculatethe clearance between the rocker arm and rocker armshaft. If the clearance is past the service limit replacethe part.Clearance between rocker arm and rockerarm shaft(mm)Standard assembly valueService limit0.032 - 0.068More than 0.23Check the valve cap-contact surface for uneven wear andstreaks. Smooth the surface with an oilstone or grinder ifneeded.W844-2 01/069inspec.pg1b
SECTION 2 – INSPECTION PROCEDURESEngine Main Parts InspectionB) Cylinder Head Assembly1Valve guide seal2Spring3Retainer4Valve5Valve keeperUsing a valve spring replacer, compress the valvespring to remove the valve keeper, retainer, spring, andvalve. Then remove the valve guide seal.inspec.pg2ainspec.pg2b1. To measure the distortion of the cylinder head bottom surface; apply a straight edge to thebottom surface of the cylinder head and insert a gauge to measure thickness at 6 points fromA to F as shown above. If the distortion measured exceeds the repair value as shownbelow, smooth with a surface grinder or something similar.Distortion at cylinder head bottomsurface(mm)Standard assembly valueRepair valueLess than 0.05More than 0.122. Valve guide and stem:Inspect the head and stem of each valve and replace ifdamaged or badly worn.Measure the outside diameter at 1,2,3 positions (figureat right) with a micrometer and replace if the result isless than the service limit as seen in the below table.inspec.pg2cWear of valve stem o (mm)Intake ValveExhaust ValveStandardService e6.955-6.976.89 6.94-6.956.843. Valve head:If the head thickness is less than the service limit below,replace.Valve head thickness (mm)Standard assembly valueService Limit0.8-1.1Less than 0.5W844-2 01/0610inspec.pg2d
SECTION 2 – INSPECTION PROCEDURESEngine Main Parts Inspection4. Valve Guide and Valve:If the clearance between the valve stem andguide exceeds the service limit, replace thevalve.Clearance between valve stem and guideIntake ValveExhaust semblyLimitvaluevalue0.03-0.06 More than 0.2 0.045-0.075 More than 0.25W844stem&guide5. Valve Seat:Check the valve guide first for wear conditionbefore correcting the valve seat as the valveseat is corrected according to the valve guide.Use seat cutter of 15 , 45 , and 75 to correctthe seat to the standard assembling values.Valve Seat Contact Width (mm)Standard assembly value Repair eseatwidth6. Replace the cylinder head if the seatrecess exceeds the service limit.Distortion at cylinder head bottom surface (mm)Standard assembly valueRepair valueLess than 0.05More than 0.127. To correct the valve seat, coat the valveseat with compound and lap the contactsurface turning the valve. Make sure thevalve contact surface is within the standardvalue and the contact position is even.If the cylinder head is replaced with a newone, adjust the seat contact width and seatrecess to the specified values (see abovetables) with a seat cutter before lapping.W844valveseatrecessW844valvelapperW844-2 01/0611
SECTION 2 – INSPECTION PROCEDURESEngine Main Parts Inspection8. Valve SpringCheck the valve spring for damage.Measure the squareness of the spring using a square ona surface plate and if the surface limit is exceeded,replace the spring. Check the free length and springforce with a spring tester and replace the spring ifthe service limit is exceeded.Squareness (mm)Free LengthSpring force(compressedto 30.4 mm)Standardassembly value1.23579.8 N(8.1 kgf)ServiceLimit233.5W844spring68.6 N(7 kgf)ReassemblyReassemble the components in the reverse order to that previously discussed.Take care to not damage the valve guide seal when assembling the valve spring, retainer,and cotter.Tighten the glow plugs to:15-20 N m (1.5 2.0 kgf m)C. Cylinder BlockCheck for cracks and damage on the top of the block just like on thecylinder head. There should be no scratches, rust, or corrosion inthe cylinder bore. Measure the cylinder bore at the top, center,and the bottom in the crankshaft direction (A on figure to the right)and also right angle to it (B).Replace the engine long block if the repair value in exceeded.Distortion at cylinder block top surface (mm)Standard assembly valueRepair valueLess than 0.05More than 0.12W844ringslideCylinder bore diameter (mm)Standard assembly valueRepair value84 - 84.01984.2Replace with long block assemblyW844-2 01/0612
SECTION 2 – INSPECTION PROCEDURESEngine Main Parts InspectionD. Piston and Piston RingTo disassemble - use a piston ring tool to remove thepiston ring. Then remove the snap ring and extractthe piston pin.1. Inspection of the Piston:Check the outside of the piston for cracks, streaks, orburnouts, replace if needed.Measure the bore of the cylinder in the thrust direction,and measure the longer diameter 10 mm above the lowerend of the piston skirt. Calculate the clearance andreplace if it exceeds the repair value.Also measure the piston pin hole diameter and piston pinoutside diameter, replace if the clearance exceeds theservice limit.W844pistonW844boreClearance between cylinder and piston (mm)Standard assembly valueService limit0.0375- 0.07150.25Piston skirt bottom longer diameter o (mm)Standard assembly valueService limit83.948- 83.96383.7Clearance between piston pin hole and pistonpin (mm)Standard assembly valueService limit-0.001 0.0110.022. Inspection of the Piston ring:Replace worn out or damaged piston rings.3. To measure the clearance of the piston, insert a ringat a right angle to the least worn out skirt of a cylinderand measure the clearance of the ring end gap with athickness gauge. Replace it if the end gap exceeds theservice limit.Top RingSecond RingOil RingPiston ring end gap (mm)Standard assembly value0.2- 0.350.20- 0.400.25- 0.50Service limit1.01.01.2W844-2 01/0613W844pistonringgap
SECTION 2 – INSPECTION PROCEDURESEngine Main Parts InspectionD. Piston and Piston Ring continued4. Measure the clearance between the pistonring groove and ring and replace it if theservice limit is exceeded.5. Install the piston ring to the piston asshown in the figure on the right.Clearance between piston ring groove and ring (mm)Standard assembly valueService limitTop Ring0.07- 0.110.25Second Ring0.04- 0.080.25Oil Ring0.02- 0.060.25Inspection of the Piston Pina. Measure the outside diameter of thepiston pin and replace if the service limitas shown below is exceeded.Piston outside diameter o (mm)Standard assembly valueService limit27.994 - 28.027.97E. Connecting RodW844pistonring1. Check the rod for torsion, parallelism, andpossible damage. Using a connecting rodaligner, measure the torsion and parallelism.Replace or correct the rod if the repair value isexceeded.Torsion and parallelism of connecting rod (mm)Standard assembly value Repair valueTorsion (per 100 mm)Less than 0.080.2Parallelism (per 100Less than 0.050.15mm)2. Measure the bore of the connecting rodsmall end bush and replace it if the clearanceto the piston pin exceeds the service limit.3. Measure the axial play after re-attachingthe connecting rod to the crankshaft, replacethe connecting rod if the service limit isexceeded.1. Gauge2. Piston pin3. Torsion4. Flat part of aligner5. PinW844connectingrodClearance between bush and piston pin (mm)Standard assembly valueService limit0.010 - 0.027More than 0.08Axial play of connecting rod and crank pin (mm)Standard assembly valueService limit0.1 - 0.3More than 0.7W844-2 01/0614
SECTION 2 – INSPECTION PROCEDURESEngine Main Parts InspectionConnecting Rod Metal1. Check the metal and replace it if peeling,melting, or other damage is noticed.2. Use the plasti-gauge and measure the oilclearance of the crank pin and metal. Removeany foreign matter or oil dust stuck to themetal or crank pin. Cut the plasti-gauge to thesame length as the metal width and put it onthe crank pin parallel with the crankshaft,avoiding the oil hole. Install the connectingrod metal and connecting rod cap and tightento below specified torque.Note: Do not turn the connecting rod.Clearance between crank pin and connectingrod metal (Oil clearance) (mm)Standard assembly valueService limit0.035 - 0.0850.2Tightening torque: 49 - 54 N m (5.0 - 5.5kgf m) [36 - 39.8 ft. lb.]Set a plasti-gauge3. Remove the connecting rod cap andmeasure the plasti-gauge width, the widestpart of the plasti-gauge, with the scale printedon the gauge envelope.If the oil clearance exceeds the service limit,replace the metal.Measure the oil clearanceCrankshaft pin outside oFinishing dimension o (mm)51.964 - 51.975Reassembly of the Piston and Connecting Rod1. Heat the piston to about 100 C with a pistonheater and install while aligning theSHIBAURA mark in the piston and match markat “A” of the connecting rod (as seen on rightfigure), using care at the match marks.2. Install the piston ring to the piston facingthe stamp up towards the end surface of thering end gap.F. Bearing Holder1. Remove the center bearing holder and replace themetal if peeling, melting, improper contact, or otherdamage is noticed. Replace the thrust washer also ifany damage is noticed or if the thickness exceeds theservice limit.2. Measure the oil clearance with a plasti-gauge, of thecrankshaft center journal and metal. If the oil clearanceexceeds the service limit, replace the metal and/ or thecrankshaft.Crankshaft center journal finishing o (mm):67.957 - 67.970W844-2 01/0615W844piston-connrodClearance between crankshaft center journaland metal (oil clearance) (mm)Standard Assembly valueService limit0.044- 0.1020.2Rear bearing holder thickness (mm)Standard Assembly value Service limit2.95- 3.002.8
SECTION 2 – INSPECTION PROCEDURESEngine Main Parts InspectionF. Bearing Holder, Thrust Washer (continued)1. Re-assemble the bearing holder with theidentification cutting mark at the center andthe bearing holder with the thrust washer atthe flywheel side, facing the stepped sidetowards the front. Install the thrust washerfacing the oil groove to the crankshaft thrustsurface.Bearing Holder Tightening Torque: 49- 54 N m(5.0 - 5.5 kgf m) [36 - 39.8 ft. lbs.]Install the metal with the oil groove to theupper side and the one without the oil grooveto the lower side.Note: Be sure that the oil holes of thebearing holder and and cylinder block arealigned.W844bearingholderG. Crankshaft Bearing1. Check the bearing and if peeling, melting,improper contact, or other damage is noticed,replace the bearing.2. Using a cylinder gauge and a micrometer,measure the oil clearance of the bearing andthe crankshaft journal. If the oil clearanceexceeds the service limit, replace the bearingand/ or the crankshaft.W844cylgaugeClearance between crankshaft journal andbearing (Oil clearance) (mm)Standard assembly valueService limit0.044 - 0.1160.23. Measure the dimensions in the A and Bdirections at the positions 1 and 2 (at figure atright) making sure to avoid the oil hole of thebearing. Calculate the difference from themaximum value of the crankshaft journal, theoil clearance.4. To replace the bearing, push it up using apress or something similar. Align the oil holesand push it up until the bearing end surfacebecomes level with the outside machinedsurface of the cylinder block (C on fig. at right).W844crankshaftjournalCrankshaft journal outside diameter finishingdimension o (mm): 67.957 - 67.970W844-2 01/0616
SECTION 2 – INSPECTION PROCEDURESEngine Main Parts InspectionH. Crankshaft1. Measure the run-out of the crankshaft byfirst supporting the crankshaft with a V block(as shown in figure on right). Put a dial gauge inthe crankshaft center journal and read thedial gauge while rotating the shaft one turn,gently. If the service limit is exceeded, repairor replace the crankshaft.W844crankshaftmeas2. Check the crankshaft oil seal for damageor wear on the contact surfaces, and checkfor clogging in the oil hole.3
seat is corrected according to the valve guide. Use seat cutter of 15 , 45 , and 75 to correct the seat to the standard assembling values. Valve Seat Contact Width (mm) Standard assembly value Repair value Intake 1.77-1.19 2.5 Exhaust 1.87-2.09 2.5 W844valveseatwidth 6. Replace the cylinder head if the seat
WELCOME TO THE NORTHERN LIGHTS CONFERENCE CENTER. The space to bring people together, and the tools to make it productive! INNONLAKESUPERIOR.COM FOR MORE INFORMATION CALL 218.625.0406 PAGE 4. Northern Lights Ballroom Northern Lights 1 Northern Lights 2 Copper Harbor Room Rock Harbor Room Eagle Harbor Room s ft,,40,40 770 770 8. banuet .
WELCOME TO THE NORTHERN LIGHTS CONFERENCE CENTER. The space to bring people together, and the tools to make it productive! INNONLAKESUPERIOR.COM FOR MORE INFORMATION CALL 218.625.0406 PAGE 4. Northern Lights Ballroom Northern Lights 1 Northern Lights 2 Copper Harbor Room Rock Harbor Room Eagle Harbor Room s ft. 3,136 1,540 1,540 770 770 .
XSEDE HPC Monthly Workshop Schedule January 21 HPC Monthly Workshop: OpenMP February 19-20 HPC Monthly Workshop: Big Data March 3 HPC Monthly Workshop: OpenACC April 7-8 HPC Monthly Workshop: Big Data May 5-6 HPC Monthly Workshop: MPI June 2-5 Summer Boot Camp August 4-5 HPC Monthly Workshop: Big Data September 1-2 HPC Monthly Workshop: MPI October 6-7 HPC Monthly Workshop: Big Data
143-18 Grommet for 64 mm lights, recessed w/ open back, PC 144-18 Grommet for 64 mm lights, recessed w/ closed back, PC 2594 Cam-on surface mount bracket for 64 mm lights 146-18 Mounting grommet for 51 mm lights, open back, FLUSH 146-182 Mounting grommet for 51 mm lights, closed back, PC 146-184 Mounting grommet for 51 mm lights, open back, PC
parking lights and dashboard lights are lighted up. “ ”:in this position, the backlights, parking lights and dashboard lights are lighted up. “ · ”: in this position, the headlights, backlights, parking lights and dashboard lights are powered off. ENGINE BUTTO
Ct Northern Lights North Star Peace Region Ct Northern Lights Tilley Peace Region Ct Northern Sunrise Cadotte Lake Peace Region . Municipalities, Locations and Corresponding Alberta Transportation Regions September 20, 2018 7 Municipality Location/Commissions Region Ct Northern Sunrise Ct Northern Sunrise Peace Region .
Jun 14, 2017 · Turbocharger Starter Relay. 38 - 41 GROUP 6 - GASKETS GROUP 3 - COOLING SYSTEM Engine . with a John Deere 4045 engine, 55 kW. Northern Lights Tier III marine diesel generator set with a John Deere 4045 engine, 65 kW. Northern Lights Tier III turbocharged marine diesel generator set with a John Deere 404
Northern Lights marine diesel generator set with a 753 engine, PXK generator end, and an AVR. Northern Lights industrial generator set with a 753 engine, PXK generator end, and and AVR. M 753K M / NL 753 NL Your set has three serial numbers: 1 an engine number stamped on the block, 2 a generator plate, and 3 a generator set plate.
