OM844W3 - Northern Lights
Contents
1. 3 7 Bleeding the Fuel System 21 Injector SOEVIOG aite 22 23 LOCK OUT TAG OUT PROCEDURES 8 Injection Pump 23 Cooling System General 23 COMPONENT LOCATIONS Cooling System Flushing 24 M844W3 Marine Generator older baseframe 10 Heal Exchange u uuu uu tis ee 24 M844W3 Marine Generator new baseframe 11 Raw Water PUMP eds 24 M20CRW3 Commercial Generator 12 Generator BIS asset res t u u pha 24 Electrical System General 24 CONTROL PANELS 13 Glow Plug u RITTER 25 Booster D3tlerl6S u a aaa aaah 25 OPERATING PROCEDURES Battery dfe uuu 25 Break in Period orto te nre sins 14 PTO C c H 25 ROTEN TO 14 Winterizing Out of Service 25 uu ee O 14 Operalinp 14 TROUBLESHOOTING Oppia uuu nas 14 O Lun EON IU 26 Shutdowns and Alarms 15 S IT 27 29 Spare tenis ns a SRM NEA 15 WIRING DIAGRAMS SERVICING2. Wdy 0081 NYL 18 NVL 18 lt q O9cc e6z0c 569 G31V3 WdM 0051 198539 ZH ZH __ 35 43395 dW3l 3NIDN3 ano asvo H 90c vv8 iSi pee ow anong 30098 08 3r8 08 SONILIGS HOIIMS Q33dSN3AO Su NFS xov18 LOL 39018 3NISN3 lo er Map de edm J 3 S0Z VES A A A p T gt IMHO 335 o m a novia X GLIHM 26 Sue dis Seed O INA JONS lt 4 nae old Bea WNOLLdO SHE s xov18 81 8 A389 lt n u ue i P Lc mE AV13N 1V3H3Md J gt 3ION 335 09 dSO s ra 98 58 dod t 3 202 OLLJN VN rz z gu a O ONI 9v d Ead n 16 Z a AVI3M Nf 0 O QNO 3579 SL RM _____ 2 poc FT a Q L A385 UTEM xovi amp NWoNg L 96 PF pois nu 3NION3 D noo A _ ON _ Z S excede we Yo WNOILdO ON JONVYO yovig A339 66 SM3HIO AG 3NION3 ALON 335 SIOVINOO 39MVH2SIQ 33d Sg 98 HOLIMS w YJHSINONILXI 384 un lS aio P ME l was Td g EM E vos Avi3M NMOGLAHS m QlON310S lt 3Svo M wove 7384 Q
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5. qii NOLIVTIVISNI 3d Q3NINWSM3I3Q ONIZIS SYOLONGNOD 1 NOILV LIOX3 0000 xIS Qv31 aasnNa GYVOSIG SAOWSY 09vYXS 3HL NO LH9I3 SIWNINYSL OL 1 913 N3 A3S SQV31 193NNOO u gasdno3s LON SI 3SVLIOA N 1 NOILO3NNOO IVMLIQ3N 313134 310N 335 53002 1v201 _ 318vOllddv 3009 vOlMIO313 TVNOILVN SHL HLIM 5 10934 OL NI 38 OL SI3SN39 WIYLSNGNI NOIL3MOSIOG S YSWOLSND OV AINO YSWOLSNOD GSGNNOYS 38 OL SI3SN39 dQ310N SV 1 30 3 Q3QNVMIS OvAOO9 O GOL MLW 3dAL L 9MV 38 OL 34V SYOLONGNOD NOLLVTIVISNI TIV L u So UON EA MAL ZH 09 OVAOvZ OCI ZH 09 OVAOCI ovv9 OVAOVZ 007 ZH OS OVAOZZ OII ZH OS OVAOLL OL 193NNOO f 0000 dl Ln3N 531435 3MIM v l 13 3MIM v ALON 335 4 bre S 3 Z SALON 335 S Z SALON 335 3ounos Q3l93LlONd NEL ROME MUS AE SONDERN ih 2 NEZ GND I I N33u5 32018 9N3 N33u5 30018 9N3 Mel 068 l eran BS 3Nv33 N39 3Nv33 N39 anes A L NINE Ov LLYM O0l OVAOvZ Us VAN salvat od I S a O9VVZ1 OVA0Z1 001 s 308 08 31O31Oud d3sn Nv8 ANNT S31V9IONI OL 193NNOO A 0000 Bes MSLL 08 2VAOZL OLL TTT L lese n ZN OL 193NNOO 00007 IMs NEZ GND JTVNIWM3L OV LL
6. WARNING For servicing pneumatic and hydraulic equipment the following additional procedures must be implemented following completion of lock out tag out procedures for the unit to be serviced Shut off air water or supply valves at the equipment to be serviced Check the local bleed off point for completed release of pressurized air water or oil If shutting off of air water or other material cannot be achieved at the local supply valve shut off valves further back in the system and re check the bleed off point until complete shut off is achieved Affix a DO NOT OPERATE tag to each valve handle that requires shut off Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment Lock Out Tag Out Instructions Air Hose Connected Pneumatic Equipment Equipment connected to the compressed air system through an air hose with a detachable fitting must be shutdown and unplugged Excess air must be bled prior to removing the air hose prior to any maintenance or repair activities Affix a DO NOT OPERATE tag to the air hose near the detachable fitting Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment Check that the equipment cannot be operated by activating the ON switch Immediately after applying Lock Out or Tag Out devices ensure that all potentially hazardous stored or residual energy is relieved disconnected restra
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8. Align the top mark of the crank pulley with the top mark of the timing gear case Loosen the lock nut and adjust the clearance between the rocker arm and valve guide of both the intake and exhaust valves with the adjustment screw Figure 8 Clearance on both intake and exhaust valves should be 0 008 in 0 2 mm Repeat steps 3 and 4 for each cylinder Each set of valves must be adjusted individually Replace the rocker arm cover Tighten cover nuts to 5 8 ft Ibs 0 8 2 3 kg m OM844W3 11 13 19 Servicing FUELS GENERAL 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 and for all temperatures at an altitude of above 5 500 ft 1500 meters Use fuel having less that 1 sulphur preferably less that 0 5 The cetane number should be a minimum of 45 DO NOT use these unsuitable grades of fuel a Domestic heating oils all types Class B engine Class D domestic fuels Class E F G or H industrial or marine fuels ASTM D975 60T No 4 D and higher number fuels f Diesel fuel with engine oil mixed in CQ G Do not use any fuel additive other than an authorized diesel fuel biocide if fungus or bacteria cause fuel system problems Storing fuel a Keep dirt scale water an
9. OPERATOR S MANUAL A CALIFORNIA Proposition 65 Warning 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 Northern Lights 4420 14th Avenue N W Seattle WA 98107 Tel 206 789 3880 Fax 206 782 5455 Copyright 2013 Northern Lights Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Northern Lights Inc Printed in U S A PART NO OM844W3 11 13 ES NORTHERN LIGHTS OPERATOR S MANUAL for Models M844W3 M844DW3 M844LW3 and M20CRW3 Read this operator s manual thoroughly before starting to operate your equipment This manual contains information you will need to run and service your new unit Table of Contents INTRODUCTION 2 SERVICING continued Models Included u u uu u u uuu uu u usu 2 Changing Oil Filter 18 Model Numbers u uu 2 Til u 19 Serial Numbers 2 RAPI NS 19 Valve 19 WARRANTY _ 3 Fuels General 20 Fiel 20 SAFETY RULES
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11. Before servicing the pump check other possible causes a Check cleanliness of air filter b Check valve clearances c Clean and check injectors 3 Any repair which involves disassembly of the injection pump must be carried out by specially trained mechanics with the proper tools and test equipment NOTE All warranties on the engine become null and void if the injection pump seals are broken by unauthorized persons COOLING SYSTEM GENERAL NOTE Marine sets 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 to cool before working on the cooling system Open the filler cap carefully using protective clothing when the engine is warm WATER QUALITY 1 Distilled deionized soft water is preferred for use in cooling systems Bottled distilled water from a food store or water supplier is recommended Tap water often has a high mineral content Tap water should NEVER be put in a cooling system unless first tested by a water quality laboratory Do not use water made by the reverse osmosis method unless it has been PH neutralized OM844W3 11 13 23 revised 11 8 13 Servicing 2 Here are acceptable water quality specifications Grains per Gallon Parts per Million Contaminates Maximum Chlorides 40 2 5 Maximum Sul
12. 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 timing off See your dealer If you cannot correct problems with these procedures see your Northern Lights dealer OM844W3 11 13 29 revised 8 6 12 iagrams D iring W Or 16 g YAV MVACOL LSG Joyesaued pee ZMO0EXd weibeig OV Z SALON 335 ah le ray 4 310N 335 L 3LON 335 CMS y oo os 0383 THA CHA SMA 6 ALON 33S 9 CMS NIVO rav 4 AYdc 00L 1SA 39VLlOA O V SNOLVOlIddV OVAOZCL OOL 1d3OX3 S39VLIIOA TIV 404 NOILISOd OL 135 38 OL SI LMS HOLMS SNISN3S LNdNI NOLLV T IVLSNI G3NIN3313Q 38 OL ONIZIS SYOLONGNOD LAdLNO Q3193NNOO aanddns s3Wolsno 3lIVOIdNI SINN GSHSVG N3QQIH 53009 1v901 dl18vOllddv 3009 IVOI81943413 IVNOLLVN HLIM JONVGYOOOV NI 38 OL 38V 5135339 WIYLSNGNI NOIL3SOSIQ S YSWOLSND 1 5 GAGNNOYD 5135339 3NISVW AdVL 1vOlHIO313 A8 311051 LAN ANY N3HSVM 51901 1109 ONISN SNOILOANNOO S MOO1d WNINYSL WOMJ SQV31 d310344v 3AOW3M dalno3M 4l SYOLONGNOOD 39nv9 s39s3Vv1 31VQ
13. ethylene glycol antifreeze mix Antifreeze mixture is recommended as a good year round coolant 4 Check hoses and connections and repair any leak age SP15 HEAT EXCHANGER 1 Clean the heat exchanger core after 2500 hours of operation 2 Drain expansion tank and heat exchanger 3 Remove heat exchanger end covers and remove core 4 Clean the inside of exchanger core tubes using a metal rod Flush inspect and clean again if necessary 5 Reassemble Fill the cooling system start the engine and check for leaks SP17 RAW WATER PUMP 1 Change the seawater pump impeller every 1000 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 screwdrivers in order not to damage the pump housing If the impeller has broken into pieces remove front heat exchanger end cover and inspect for impeller pieces Clean inlet to heat exchanger bundle and reassemble 3 Clean the inside of the housing 4 Press in the new impeller and place the sealing washers in the outer end of the impeller center if this has not already been done 5 Replace the cover using a new gasket NOTE Make sure that there is always an extra impeller and cover gasket in reserve on board GENERATOR ENDS The maintenance and operation recommendations for the generator end are in a separate Owner s
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16. SCHEDULE CHART 16 AC Blecitieal uuu aa qasaqa 30 32 DC u a aan 33 40 SERVICING Lubrication General 18 Clip i E u E 18 Il RTT 18 Proprietary Information This publication 15 the property of Northern Lights Inc It may not be reproduced in whole or in part without the written permission of Northern Lights Inc O Northern Lights Inc All rights reserved Litho U S A Publication number OM844W3 11 13 OM844W3 11 13 1 Revised 11 8 13 Introduction 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 competent assistance Marine engines are taxed far more severely than auto or truck engines therefore maintenance schedules must be adhered to more strictly Failures can begin with minor problems that are overlooked and become amplified when not corrected during routine maintenance As operator it is your obligation to learn about your equipment and its proper maintenance This 15 not a comprehensive technical service manual Nor will it make the reader into an expert mechanic Its aim 15 to aid you in maintaining your unit properly Unit Identification MODELS INCLUDED This man
17. exhaust filter cleaning operations the engine will run at elevated temperatures for an extended period of time Exhaust parts and streams can reach high temperatures during operation leading to burns or other serious injury Avoid Harmful Asbestos Dust Inhaling asbestos fibers may cause 3 amp lung cancer Avoid breathing any dust that may be generated when handling components containing asbestos fibers including some gaskets The asbestos used In these components is usually found in a resin or otherwise sealed Normal handling of these components is not dangerous as long as airborne dust containing asbestos 15 not generated Avoid creating dust Never use compressed air for cleaning Avoid brushing or grinding materials containing asbestos When servicing wear an approved respirator A special vacuum cleaner is recommended to clean asbestos If this vacuum is not available apply a mist of oil or water on the material containing asbestos Keep all bystanders away from any area where asbestos dust may be generated Use Proper Lifting Equipment and Techniques Lifting heavy components incorrectly can cause severe injury or damage to machinery Avoid unbalanced loads Do not use lifting eyes Lift the generator set using lifting bars inserted through the lifting holes on the skid Follow all recommended removal and installation procedures in this and associated Northern Lights manuals U
18. if dirty wash element in soapy water Rinse and dry thoroughly before re installing Replace if necessary The element part number is M844W3 and M844LW3 24 23100 3 C Series sets the element cannot be cleaned Rocker Arm _ 4 1 0 008 in j 0 200 mm Replace it when necessary Part number is Figure 8 Valve Adjustment M20CRW3 71124 28401 4 NOTE Make absolutely sure no impurities enter the engine while changing the element Do NOT SP6 VALVE CLEARANCES run the engine with the air cleaner removed SP5 V BELTS 1 Check the tension and wear on the V belt daily 2 Use your thumb to press on the belt at the midpoint 3 between the crankshaft and alternator pulleys The tension Is correct if the belt can be depressed about 3 16 in 5 mm Arrangement 4 When No 1 cyl is at in compression With the crankshaft turned by 360 5 in normal direction from above Figure 7 844W3 and 844173 Valve sequence Adjust valve clearance after 1000 hours or as needed Valve adjustments should be done after the cylinder head bolts have been re tightened Engine should be cold and NOT running Watch the valves while turning the engine over by hand Turn until the inlet valve starts to open and the exhaust valve starts to close the valves are rocking Then turn the crankshaft one more full turn and adjust the clearance on both valves for this cylinder
19. lt 4349 4015 AOV IB LYVLS HOLIMS rd JOYINOD 3NI9N3 Q343 MOTT3A V lt SSJNeMHVH 109 73079 ONINOO OM844W3 11 13 41 4420 14th Ave NW Seattle WA 98107 Tel 206 789 3880 1 800 762 0165 www northern lights com Northern Lights and Lugger registered trademarks of Northern Lights Inc NORTHERN LIGHTS 2013 All rights reserved Litho USA
20. running the battery charging regulator could be ruined 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 1s not necessary if the engine 15 already warm 2 While holding the Shutdown Bypass Preheat switch in the ON position push the Engine Control switch to the START position 3 Assoon as the engine starts release both switches Do not crank the starter for more than 10 seconds consecutively If the engine fails to start with the first attempt be sure that it has stopped completely wait at least 30 seconds before re engaging NOTE Excessive cranking of the starter on Marine sets equipped with a water lift muffler can cause engine damage If the engine does not start after three 20 second cranks remove the impeller from the raw water pump This will prevent the muffler from filling with water and backfilling the exhaust line and engine Once the engine starts shut it off immediately and re install the impeller Re start the engine and check the exhaust overboard outlet for gushes of water 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 on Marine sets must be below 200 F 94 Normal coolant te
21. then remove the cap slowly using protective clothing c Make repairs Restart your Marine set after the temperature gauge registers below 200 F 94 d Watch the temperature gauge regularly and turn off the unit if the temperature rises above 205 F 96 on units Repeat troubleshooting If shutdown 15 activated and the temperature gauge shows temperature within normal temperature range a Thisshutdown could have happened because ofa too high exhaust temperature This could have been caused by a damaged impeller or a partially blocked sea water strainer Check the sea water strainer first If it is clear then check the condition of the sea water pump impeller b Check the engine crankcase oil level c 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 does not show a normal reading 20 60 PSI after a few seconds of operation d If the oil level is normal DO NOT restart the engine Call your dealer for assistance SPARE PARTS 1 Northern Lights recommends that you keep the following spare parts on hand for field service The parts are available from your local Northern Lights dealer Some marine models already have On Board Kits a handy box that contains the most common parts 99 you will need All owners should have the following spares a Primary and secondary fuel filter elements Oil filters Air
22. 0 hours During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes first Change oil at the end of each season and the beginning of each season Change oil when engine is warm Dispose of waste oil in an approved manner Never use a flushing oil Loosen the clamp on the oil change tube Remove cap Drain oil Replace the cap and tube Refill engine with recommended oil for the season 10 Engine capacity with new oil filter 1s 844W3 844LW3 2 1 gallons 8 2 liters SP3 CHANGING LUBE OIL FILTER Change the lube oil filter every 250 hours Use a filter wrench to remove old filter Dispose of filter in approved manner Make sure the gasket from the old filter is removed and discarded Clean mount face Spread a thin film of engine oil on the rubber gasket on the new filter and screw it on nipple until gasket meets the sealing surface Using hands only no wrench tighten filter one half turn farther Overtightening can do damage to filter housing Fill engine with recommended oil Start engine and check for leakage Stop engine wait 3 minutes and check oil level Add additional oil if necessary Oil filter part number is 844W3 and 844LW3 24 03100 OM844W3 11 13 18 Servicing SP4 AIR CLEANER LL 14 Valve Adjustment Screw 1 Inspect air cleaner every 250 hours In dusty condi tions check more often 2 Marine sets
23. 1 13 16 Service Record Notes OM844W3 11 13 17 Servicing LUBRICATION GENERAL 1 Use only clean high lubricants stored in clean containers in a protected area 2 These lubricants are acceptable a API Service CC CD CE single viscosity oils b API Service CC CD SF multi viscosity oils 3 Use the proper weight oil for your average operation temperature Air Single Multi Temperature Viscosity Viscosity SAE30W SAE 15 40W 0 C 10 to 32 F 23 to 0 C SAE 10W SAE 10 30W Below 10 F 23 C SAE 5W SAE 5 20W Figure 4 Lube Oils 4 Some increase in oil consumption may be expected when SAE 5W and SAE 5 20W oils are used Check oil level frequently 5 Never put additives or flushing oil in crankcase 4 Maximum Level 4 Minimum Level Figure 5 Figure 6 SP1 CHECKING OIL LEVEL 1 Check the oil level in the crankcase with the dipstick Fig 5 The oil level must be in the area on the stick Never allow the level to go below this area Follow the lubrication recommendations above SP2 OIL CHANGES D d dev o 9 The set is delivered with special break in oil Change the engine oil and oil filter after 50 hours of operation Use Service CC 30 weight oil during the first 100 hours Change the oil and filter again at 100 hours using the oil recommended in the above diagram After this change oil and filter every 25
24. 100 mm 4 in from the area that will be affected by heat f paint cannot be removed wear an approved respirator f you sand or grind paint use an approved respirator f you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers from the area Allow at least 15 minutes for fumes to disperse before welding or heating Do not use a chlorinated solvent in an area where welding will occur Work only in areas that are well ventilated Dispose of paint and solvent properly Service Cooling System Safely Opening a pressurized cooling system can release explosive fluids and causing serious burns Before opening any pressurized cooling system make sure the engine has been shut off Do not remove a filler cap unless it is cool enough to comfortably grip with bare hands Slowly loosen cap to relieve pressure before opening fully Avoid High Pressure Fluids Relieve pressure prior to disconnecting pressurized lines Escaping fluid under pressure can penetrate the skin causing serious injury Always relieve pressure before disconnecting hydraulic or other pressurized lines Tighten all connections firmly before re applying pressure If searching for leaks use a piece of cardboard Always protect your hands and other body parts from high pressure fluids If an accident occurs see a doctor immediately Any hi
25. 14 S Or 48 MOLOW M3iMVIS XV L Say oig o 01 SSINYVH 90 07 11919 BOE e 4 NOIVN3N3O a OM844W3 11 13 39 added 9 19 11 Wiring Diagrams 2627 PUNOIE vc 104 weibeig 7 7 WOW SSVdAa 1 J lt OQ gt AALAWANOW AN PILING AO 2 ANON X OM844W3 11 13 40 added 9 19 11 gr6SZ v S SUEd O S S SWHO 022 S SWHO OZv 38 OL 540151535 2 SV 1 430 3 Q3QNVMIS 3 80 VL 38 OL 34V SYOLONGNOD NOLVTIVISNI TIV L 310N 33S lt NVL N3349 MON xovg 7 x xXov18 2v18 3nn8 oe oop 3 1dund S313WITOA T jonvo O 956 ama N33N95 O Bees a bova AM Jidund 7 S SS3NNVH xov18 xXov18 5v18 3n18 55 3ldund e 54 080 vy 39nv9 4 lt 3LIHM O HOLIMS SSVdA8 NMOGLOHS lt
26. 50 250 500 1000 2500 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours ENGINE Check oil level Change engine oil Change lube oil filters Check air cleaner Check V belt tension Check valve clearances FUEL SYSTEM Check primary filter Racor 2 3 Change primary filter element Racor 2 3 Change secondary fuel filter 1 3 Bleed the fuel system 3 Check injectors 1 3 6 7 Check fuel injection pump 7 COOLING SYSTEM Check coolant level Check and flush cooling system Check and clean heat exchanger Change impeller in raw water pump Inspect condition of exhaust elbow ELECTRICAL SYSTEM Check electrolyte level in batteries Check condition of batteries with hydrometer 1 4 DRIVEN EQUIPMENT SP20 19 Clutch and PTO service 2 OUT OF SERVICE SP21 19 Winterizing or out of service 3 6 Clean injection nozzles every 1500 hours Perform all maintenance once a year even if hour level has not been reached ads y 7 For EPA emission standards fuel nozzle needs to be cleaned every Consult manufacturer s maintenance schedule note on chart Whenever necessary More often if necessary 5 After first 50 hours then at 100 hours then at every 200 hours 1500 hours the fuel nozzle and fuel pump need to be cleaned adjusted or repaired every 3000 hours and the quality guarantee for these parts is 1500 hours or 2 years OM844W3 1
27. ION AND SAFETY PARAMETERS Prevent Bypass and Accidental Starting Do not start engine by shorting across start terminal Engine will start if normal circuitry is bypassed creating a hazard by runaway machinery 2 Start engine only from operator s station Handle Fuel Safely Avoid Flames Diesel is highly flammable and should be treated with care at all times Do do not refuel while smoking or when near sparks or open flame ALWAYS STOP ENGINE BEFORE FUELING MACHINE Always fill portable fuel tank outdoors Never fuel a hot engine S OM844W3 11 13 3 Revised 3 13 12 Safety Rules Prevent accidental discharge of starting fluids by Operating equipment requires the full attention of storing all cans in cool safe place away from sparks the operator Do not use radio or music headphones or open flame Store with cap securely on container while operating machinery Never incinerate or puncture a fuel container Prevent fires by keeping machine clean of accumulated Practice Safe Maintenance trash grease and debris Always clean any spilled fuel as swiftly as possible Do not store oily rags which CAUTION can ignite and burn spontaneously CAUTION Understand all service procedures Be prepared if a fire starts Keep first aid kit and fire before starting work Keep area clean and dry extinguisher handy Keep emergency contact numbers Never lubricate service or adjust machi
28. Manual If you do not have one of these manuals contact your local Northern Lights dealer ELECTRICAL SYSTEM GENERAL 1 Never switch battery switch off or break the circuit between the alternator and batteries while the engine is running Regulator damage can result OM844W3 11 13 24 revised 11 8 13 Servicing 2 Do NOT reverse the polarity of battery cables when installing the battery 3 If welding on the unit disconnect the regulator and bat tery Isolate the leads 4 Disconnect the battery cables when servicing the D C alternator 5 Never test with a screwdriver etc against any terminal to see if it emits sparks 6 Do not polarize the alternator or regulator 7 AD C circuit breaker protects your control panel and wiring harness It is located in the side of the generator junction box GLOW PLUGS 1 Each cylinder is supplied with glow plug which serves to heat the combustion chamber 2 check the glow plugs loosen the current 1 carrying flat wire between the plus poles of the glow plugs Figure 19 Connect a D C test bulb between the plus pole of the battery and the 2 plus pole of the glow plug If the bulb lights up the glow plug 15 functioning properly 3 Check all glow plugs and replace any faulty ones Figure 20 5 Sealed batteries See manufacturer charging and booster instructions Battery Booster Battery Battery connections SP 18 19 BATTERY CARE Check electro
29. NE PROBLEM POSSIBLE CAUSE RECOMMENDATION S High Fuel Consumption Fuel leakage mproper installation or tightening continued Excessive load on engine Check loads Below Normal Thermostat not working properly Check thermostat Engine Temperature Temperature gauge Check water temperature with thermometer not working properly Engine Malfunctions at High Output Range Fuel supply insufficient Air in fuel system or clogged fuel filter element Fuel injection amount between plungers uneven Check fuel injectors Valve clearance adjusted incorrectly Re adjust valve clearances Valve spring broken Replace valve spring Governor spring broken Replace governor spring Low Oil Pressure Low oil level Fill crankcase to proper level Improper type of oil Drain and fill crankcase with correct oil Partially plugged oil filter Replace filter Check bearings oil pump and relief valve for wear 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 Engine Emits Black Clogged or dirty air cleaner Service air cleaner or Gray Exhaust Smoke f Defective muffler Have dealer check back pressure back pressure too high Improper fuel Use correct fuel for temperature Injection nozzles dirty See your dealer Engine timing off See your dealer
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32. Placing any part of your body in a position where you could be caught by moving machinery Cleaning or oiling machinery when in operation Adjusting circuits chillers pumps air handlers valves circuit breakers or fans while in operation Working on piping or high pressure systems Lock Out Tag Out Instructions Electrical Equipment WARNING Be sure the equipment s ON OFF switch is in the OFF position and is unplugged from any electrical source before attempting to perform any type of work on the equipment Obtain an electrical plug cap cover with a lockset Secure the plug terminal end using the electrical plug lockout cap Lock the cap and retain the key If the equipment is directly wired into an electrical box with a shut off switch obtain a lock pad and or the appropriate colored tags and place the lock and tag through the shut off lever Retain the key until the repair is completed and the machine is safe to start Be certain the shut off lever is in the OFF position before restarting NEVER give a lock out key to unauthorized personnel If the equipment is directly wired into an electrical box without a shut off switch and lock out capability then a circuit breaker lock out will be required Obtain a circuit lock and tag set Install the lock onto the circuit breaker box Ensure the unit ON OFF switch is in the OFF position before restarting Lock Out Tag Out Instructions Pneumatic and Hydraulic Equipment
33. Re adjust valve clearance Engine Overheats Low coolant level Fill tank or radiator to proper level with proper mixture of coolant Check hoses for loose connections and leaks Air cleaner element clogged Clean or replace Keel cooling tubes Remove paint from tubes have been painted marine Cooling system interior dirty Flush cooling system Defective thermostat Remove and check thermostat Defective temperature gauge Check water temperature with thermometer and replace gauge if necessary Water pump impeller worn broken Check impeller and replace if necessary V belts slipping Fix belts to proper tension Engine Knocks Insufficient oil Call your dealer Injection pump out of time Call your dealer Below normal engine temperature Check your thermostats Check water temperature to see if temperature gauge is working properly Engine overheating See Engine Overheating 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 If you cannot correct problems with these procedures see your Northern Lights dealer OM844W3 11 13 28 Troubleshooting ENGI
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36. UCTIONS FOR FUTURE REFERENCE Recognize Safety Symbols and Instructions In addition to the information found in this section this operator s manual uses three different signal words to outline potential dangers of a specific nature ES Follow All Safety Instructions Carefully read and understand all safety messages in this manual and on your machine s safety signs Keep signs in good and clean condition Replace missing or damaged signs Be sure new equipment components and repair parts include the current safety signs For replacement signs proper placement of safety signs or clarification on any safety Issue consult your Northern Lights dealer or the factory There can be additional safety information contained DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a hazardous situation which 1f not avoided could result in minor or moderate injury on parts and components from outside suppliers that is not reproduced in this manual Consult the suppliers for additional safety information Learn how to operate the machine and how to use the controls properly Only trained personnel should operate machines or work on or around them Keep you machine in proper working condition UNAUTHORIZED MODIFICATIONS TO THE MACHINERY MAY IMPAIR ITS FUNCT
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39. awater pump cover and drain pump Change the crankcase oil and filter Loosen the alternator belt Disconnect and clean battery Remove to warm storage place if possible Clean outside of unit Paint any scratched or chipped surfaces Put corrosion preventative on all exposed metal surfaces 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 battertes Check specific gravity of each battery Check electrolyte level of each battery Loose or defective alternator belt Adjust belt tension Replace belt Starter Inoperative Check DC circuit breaker If the breaker is tripped reset it Loose or corroded connections Clean and tighten loose battery and harness 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 f low fill cells with distilled water of each battery Crankcase oil too heavy Fill with oil of appropriate viscosity Loose or corroded connections Clean and tighten loose connections Entire Electrical System Check DC ci
40. d 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 day s operation This will reduce condensation and possible biological contamination d If biological contamination is detected or suspected contact your dealer for assistance SP7 9 FUEL FILTERS Part Numbers Complete Unit Fuel Filter Primary 24 50002 Element 24 50012 Figure 9 Primary Fuel Filter l 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 bowl as necessary Change the element as often as necessary or every 500 hours If the bowl fills with water change the primary and secondary element immediately Change secondary fuel filter every 500 hours NOTE The fuel filter on the engine is considered the secondary fuel filter a b Remove the spin on filter by turning it counterclockwise with a filter wrench Fill the new cartridge with fuel and install it after applying engine oil to gasket surface Screw on until the gasket surface comes into contact with sealing surface of filter base Then tighten it two thirds of a turn by hand Do not overtighten Fuel filter part number is 844W3 844LW3 24 52020 OM844W3 11 13 20 1 Serv
41. e NW Seattle WA 98107 Generator set serial number plate Your set has three serial numbers an engine number stamped on the block a generator plate and a generator set plate Use the serial number on the generator set plate when ordering parts or in correspondence The generator set plate is found on the service side of the generator and resembles the drawing at left OM844W3 11 13 Revised 3 13 12 Warranty A warranty registration certificate is supplied with your set The extent of coverage is described in the Limited Warranty Statement We recommend that you study the statement carefully NOTE If the warranty 15 to apply the servicing instructions outlined in this manual must be followed If further information 15 needed please contact an authorized dealer or the factory Safety Rules NOTICE Accident reports show that careless use of engines causes high percentage of accidents You can avoid accidents by observing these safety rules Study these rules carefully and enforce them on the job IMPORTANT SAFETY INSTRUCTIONS Electromagnetic equipment including generator sets and their accessories can cause bodily harm and life threatening injuries when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL PRIOR TO THE INSTALLATION OF ANY GENERATOR SET OR ACCESSORY KEEP THESE INSTR
42. e Circuit Breaker for 25 Starter 5 OilFill Top 14 Freshwater Block Drain 510190 101800 26 Alternator 6 Coolant Fill 15 Oil Dipstick eee 27 Belt Guard 7 Fresh Water Pump 16 Oil Filter Manifold Heat Exch Tank 28 Coolant Thermostat behind 8 Injection Pump 17 Oil Drain 22 Coolant Drain 29 Water Temperature Sender 9 Oil Fill Side 18 Fuel Lift Pump oras W OM844W3 11 13 12 PREHEAT amp SHUT DOWN BYPASS mel GENERATOR GENERATOR START HOURS u Hobbs o o 00E TOTAL HOURS Figure 3 B Series 3 Generator Control Panel Genera Voltage x Hertz mperes 60 Em 15 100 150 200 250 HEB n 30 45 50 f A C AMPERES 7 CYCLES PER SECONO 4 Series 4 A Generator Set Control Panel AC Ammeter amp Voltmeter Selector Switch L S Shutdown Bypass And Preheat Switch overcrank See Operators Figure 3 C Series 4 Generator Control Panel Control Panels 1 SHUTDOWN BYPASS PREHEAT SWITCH Two functions are built into this switch the preheat ing of the engine and bypassing of the engine safety shutdown circuit Hold switch in the ON position 10 20 seconds before starting the engine and continue holding on during engine cranking Release the switch as soon as the engine is running Holding the switch on too long can burn out the heater element 2 ENGINE CONTROL SWITCH To start the engine hold this switch in the START
43. e Regulator 31 Coolant Thermostat behind 24 Expansion Tank Exhaust Fresh Water Pump 17 Fuel Return Line if 32 Water Temperature Sender Injection Pump 18 Oil Dipstick Manifold Heat Exch Tank OM844W3 11 13 10 Non Service Side Figure and IB M844W3 ae Dr gt DC Circuit Breaker not visible Callout for approximate location Coolant Recovery Tank Secondary Fuel Filter Fuel Return Line Fuel Injector Oil Fill Top Coolant Fill Fresh Water Pump 4 added 3 28 11 Marine Generator Component Locations Injection Pump gt Service Side P Tu 1 o 2 13 Oil Fill Side 19 Oil Filter 25 Coolant Drain Raw Water Pump 20 Lube Oil Drain 26 Wet Exhaust Elbow Raw Water Inlet 21 Fuel Lift Pump 27 Junction Box Vibration Mount 22 Control Panel Plug in 28 Starter Oil Pressure Sender not visible Callout for a approximate location e uar ind 23 AC Circuit Breaker for 31 Coolant Thermostat behind Fuel Return Line Automatic Voltage Regulator 32 Water Temperature Sender Oil Dipstick 24 Expansion Tank Exhaust Manifold Heat Exch Tank OM844W3 11 13 11 Commercial Generator Component Locations Figure 2A and 2B M20CRW3 Raw Water Pump 26 12 1 DC Circuit Breaker 10 2 Secondary Fuel Filter 11 Raw Water Inlet 3 Fuel Return Line 12 Vibration Mount Control Plug in 24 Junction Box 4 Fuel Injector 13 Oil Pressure Sender
44. e engine has started use a piece of cardboard to look for fuel leaks OM844W3 11 13 21 Servicing For illustration purposes only your model is different Figure 13 Cover lines inlets and injection pump outlets Figure 17 Remove and replace copper sealing washer Figure 14 Remove return line nuts Figure 18 Reinstall injector Torque to proper tightness OM844W3 11 13 22 revised 11 8 13 Servicing SP11 INUECTOR SERVICE 1 Injectors should be checked every 1000 hours Check should be made by a Northern Lights dealer or local injection repair station Have your dealer check the fuel injection nozzle spray pattern with injection nozzle tester If the starting pressure is too high or the spray pattern is off abnormal fuel com bustion could take place causing low engine output and black exhaust smoke CAUTION Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury If injured by escaping diesel fuel see a doctor at once 2 Injector removal a Clean loose dirt from around the injectors and the fuel lines b Relieve high pressure in the fuel lines by loosening the delivery line flare nuts at each injector Figure 11 c Remove delivery lines by disconnecting from injectors and injection pump Figure 12 Remove all lines as an assembly do not remove the spacers Cover the ends of the lines the injector inlets and injection pump
45. eplace 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 nspect clamps and hoses on suction side of fuel pump for air leak Control lever adjusted incorrectly Adjust control lever Improper type of fuel Consult fuel supplier and use proper type of fuel for operating condition Uneven compression pressure Check cylinder compression pressure between cylinders Lack of Engine Power Intake air restriction Service air cleaner check proper ventilation Clogged primary Clean or replace filter element fuel filter element Clogged secondary Replace filter element fuel filter element Injection pump not getting fuel Have injection pump checked Improper type of fuel Consult fuel supplier and use proper type of fuel for operating conditions OM844W3 11 13 27 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION S Lack of Engine Power continued Overheated engine See Engine Overheats In next category Below normal engine temperature Remove and check thermostat Improper valve clearance Reset valves Best done by dealer Dirty or faulty injection nozzles Replace injectors Best done by dealer See your local dealer Poor cylinder compression pressure Check bore for wear or check alignment of nozzle holder
46. fates 100 5 9 Maximum Dissolved Solids 340 20 0 Maximum Total Hardness 170 10 0 PH Level 5 5 to 9 0 3 If chlorides sulfates or total dissolved solids higher than the above given specification the water must be distilled demineralized or deionized before it is used in a cooling system 4 Iftotal hardness is higher than 170 ppm and all other parameters are within the given specifications the water must be softened before it 1s used to make coolant solution SP13 CHECK THE COOLANT LEVEL 1 Check the coolant level each day before starting the engine 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 2 The pressure valve in the filler cap releases when the pressure is approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it 1s faulty SP14 COOLING SYSTEM FLUSHING 1 Flush the cooling system every 2500 hours 2 Marine sets a Remove expansion tank cap and drain engine block b Open block drain cock Remove hose from bottom of heat exchanger tank c Pour clean water into expansion tank until water coming from drains is free of discoloration and sediment Let water drain completely Close drains and refill with recommended mixture 3 Coolant Specifications Use 50 distilled water 50
47. filter Alternator belt Thermostat and gaskets Seawater pump impeller amp gaskets Glow plug Injector and washer Em go OS If your set is operating a long distance from a servicing dealer add the following a Complete set of injectors b Copper washers for injector change c Complete set of glow plugs d Fuel lift pump OM844W3 11 13 15 Servicing Schedule Chart 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 EVERY 500 HOURS SP1 Check oil level in engine SP8 Change primary fuel filter element SP5 Check V belt tension SP9 Change secondary fuel filter SP7 Check primary fuel filter SP22 Inspect condition of exhaust elbow SP13 Check coolant level Check sea strainer EVERY 1000 HOURS Check raw water pump for leaks SP4 Change air cleaner element SP18 Check electrolyte in batteries SP6 Check valve clearances SP11 Check injectors AFTER FIRST 50 HOURS SP17 Change impeller SP2 3 Change engine oil and filter SP6 Adjust valves EVERY 2500 HOURS SP12 Check fuel injection pump AFTER FIRST 100 HOURS SP14 Check and flush cooling system SP2 3 Change engine oil and filter SP15 Check and clean heat exchanger EVERY 250 HOURS SP2 3 Change engine oil and filter SP4 Check air cleaner SP19 Check state of charge of batteries SERVICE
48. gh pressure spray injected into the skin must be removed within a few hours to prevent the risk of gangrene or other infection Avoid Heating Near Pressurized Fluid Lines p Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns and bodily injury Pressurized lines can rupture when heat goes beyond the immediate flame area Do not weld solder or use a torch or open flame near pressurized lines or other flammable fluids Do Not Open High Pressure Fuel System Many Northern Lights engines use high pressure fuel injection High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt any repair of fuel lines sensors or other OM844W3 11 13 6 Revised 3 13 12 Safety Rules Continued components between the high pressure fuel pump and nozzles on engines with high pressure fuel systems ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH PRESSURE FUEL INJECTION SYSTEMS Avoid Hot Exhaust Mdh pe Avoid exposure to and physical contact with hot exhaust gases Exhaust parts and streams can reach high temperatures during operation leading to burns or other serious injury Cleaning exhaust filters can also lead to exposure to hot exhaust gas and the injury risk associated with it Avoid exposure to and physical contact with hot exhaust gases when cleaning exhaust filters During auto or manual stationary
49. icing SP10 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 are not damaged Fuel escaping from a very small hole can be almost invisible Use a piece of cardboard or wood rather than hands to search for suspected leaks If injured by escaping fuel see a doctor at once Serious infection or reaction can develop if proper medical treatment is not administered immediately Figure 10 Fuel System The fuel system 15 self bleeding However any system may need manual bleeding when a A new fuel filter 1s 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 Loosen bleed bolt A Figure 10 on top of the filter Pump hand primer B on fuel lift pump until pure fuel no bubbles escapes from bleed bolt A Tighten bleed screw A 3 Loosen bleed screw C Pump hand primer B until pure fuel no bubbles escapes Then tighten bleed screw C 4 Ifthe engine does not start after the above bleed ing process loosen a fuel line at the injector while cranking the engine with the starter motor until pure fuel escapes Then tighten the connection Do each line one at a time 5 After th
50. ined and otherwise rendered safe x 44 CAUTION x Verify the machinery or equipment is actually isolated and de energized prior to beginning work on a machine or on equipment that has been locked out x CAUTION x Follow the procedures below prior to restoring energy Ensure that all machinery or equipment is properly reassembled Inspect the machinery or equipment to verify non essential items have been removed Ensure that all are safely outside danger zones Notify personnel that lock out tag out devices have been removed and energy will be reapplied Only authorized personnel may remove lock out tag out devices or notices OM844W3 11 13 8 Notes OM844W3 11 13 9 UI Marine Generator Component Locations gt Service Side LL adis NT Non Service lt Side gt Figure and 1B MS44W3 1 DC Circuit 10 Oil Fill Side 19 Oil Filter 25 Coolant Drain Coolant Recovery 11 Raw Water Pump 20 Lube Oil Drain 26 Wet Exhaust Elbow Secondary Fuel Filter 12 Raw Water Inlet 21 Fuel Lift P 27 Junction Box Fuel Return Line 13 Vibration Mount Fuel Lift Pump 28 Start Fil Ini i 22 Control Panel Plug in arter jector 14 Oil Pressure Sender 29 Alt t Oil Fill To 23 AC Circuit Breaker for ernator p 15 Freshwater Block Drain I 30 Belt Guard Coolant Fill 16 Fuel Inlet Line Automatic Voltag
51. lyte level every 50 hours or once per month Add distilled water to manufacturer s recommended level Batteries cables and cable terminals should be checked and cleaned every 100 hours Clean corrosion with a water and baking soda solution Flush with clean water Tighten terminals and grease them to inhibit corrosion 3 Check the battery condition with a hydrometer every 250 hours SP20 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 Figure 19 Glow plugs SP21 WINTERIZING OUT OF SERVICE BOOSTER BATTERIES 1 a CAUTION Battery gas can explode Keep all flames and sparks away from batteries b 1 Before changing or using booster batteries check battery C electrolyte level Add distilled water if necessary d 2 Booster and main batteries must have the same voltage e rating f 3 First connect positive terminal of booster battery to positive terminal of main battery Then connect g negative terminal of booster battery to ground on the engine block see Figure 20 4 Remove booster battery after starting engine OM844W3 11 13 25 Marine sets Drain fresh water and seawater cooling systems completely Remember to shut off seacocks before opening drain cocks Drain water supply lines and wet exhaust line Loosen the se
52. me away from the top of battery When checking battery electrolyte level use a flashlight Never check battery charge by contacting the posts with a metal object Use a volt meter or hydrometer Frozen batteries may explode if charged Never charge a battery that has not been allowed to warm to at least 169 C 60 F Always remove grounded battery clamp first and replace ground clamp last Sulfuric acid in battery electrolyte 15 poisonous and strong enough to burn skin eat holes into clothing and other materials and cause blindness if splashed into eyes To Avoid Hazards Fill batteries only in well ventilated areas Wear appropriate eye protection and rubber gloves Never use air pressure to clean batteries Wear appropriate ventilation equipment to avoid inhaling fumes when adding electrolyte Do not spill or drip electrolyte Use correct jump start procedure if required If acid is spilled on skin or in eyes 1 Flush skin with water 2 Apply baking soda or lime to help neutralize acid 3 Flush eyes with water for 15 30 minutes 4 Get medical attention immediately If acid is swallowed 1 DO NOT induce vomiting 2 Drink large amounts of water or milk without exceeding 2 liters 2 quarts 3 Get medical attention immediately Battery posts terminals and related accessories can contain lead and lead compounds chemicals known to the State of California to cause cancer and re
53. mperature is 167 to 194 F 75 C to 90 C Check the A C voltage and frequency meters Series 4 panel If the gauges deviate from normal levels shut down the generator set and investigate 2 Letthe unit run unloaded for a three to five minute warm up period 3 Apply electrical load STOPPING 1 Remove electrical load from the generator set 2 Run the engine for a 3 to 5 minute cool down period 3 Hold the Engine Control switch to the STOP position until the engine comes to a complete stop 4 Shut off the seacock fuel valve and battery switch OM844W3 11 13 14 Operating Procedures SHUTDOWNS AND ALARMS l 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 Do not rely on your warning to the exclusion of careful gauge monitoring Watching your gauges can prevent damage to the unit and dangerous power losses Do the following when your warning or shutdown system is activated a Engage the preheat switch to check the temperature gauge b If above 205 F 96 C use the Trouble Shooting Guide on page 20 to isolate the cause of the overheat CAUTION Do not remove the water fill cap of an overheated engine Escaping high temperature steam can cause severe burns Allow the engine to cool and
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55. ne while it is for fire department doctors ambulance and hospital in operation near the telephone Keep hands feet and clothing away from power driven equipment When shutting down an engine Service Machines Safely disengage all power and operator controls Allow the engine to cool completely before beginning any service work Do not wear a necktie scarf necklace rings or other jewelry or any loose clothing when working near moving parts Tie long hair behind your head If any of these Keep all parts in good conditions and properly items get caught in moving machinery severe injury or installed Fix damage immediately Replace any death could result worn or broken parts Remove any build up of grease oil or debris Securely support any machinery elements that must be raised for service work with support or lifting machinery specifically intended for that purpose ec G Check for any loose electrical connections or faulty wiring Disconnect battery ground cable before making any adjustments or service work Look completely around engine to make sure that everything 1s clear before starting Stay Clear of Rotating Drivelines Wear Protective Clothing AN G R 1 WARNING Entanglement In rotating drivelines can cause sertous injury or death Keep shields in place at all times To prevent catching anything in moving machinery Make sure that rotating shields turn freely in pace always wear cl
56. ose fitting clothes and safety equipment with the drivelines appropriate to the job Prolonged exposure to loud noise can cause hearing Do not wear loose fitting equipment around rotating loss or impairment Wear suitable authorized ay hearing protection such as earmuffs or plugs to protect against loud noises gs Qrivelines Stop the engine and make sure that all moving parts have stopped w before making any adjustments connections or performing AN any other type of service to p o l the engine or other driven w equipment Co OM844W3 11 13 4 Revised 3 13 12 Safety Rules Continued Installall Safety Guards Direct contact with rotating fans belts pulley and drives can cause serious injury Keep all guards in place at all times during engine operation Wear close fitting clothes Stop the engine and be sure all fans belts pulleys and drives are stopped before making adjustments connections or cleaning near fans and their components Do not allow anything on your person to dangle into or come in contact with a moving fan belt pulley or drive Fans can act as vacuums and pull materials up from below so avoid that area as well while in service Safe Battery Handling Prevent Battery Explosions Battery gas 15 highly flammable Battery explosions can cause severe injury or death To help prevent battery explosions keep sparks lighted matches and open fla
57. outlets to keep dirt out Figure 13 d Remove the return line retaining bolts Figure 14 Remove the return line Figure 15 e Unscrew and remove the injectors Figure 16 NOTE Do not use pry bars to remove injectors from cylinder head f After removing the injectors discard the copper sealing washers from the injector hole in the head Figure 17 Cover holes to prevent dirt and debris from entering the cylinders Injector installation a Install a new copper sealing washer in each injector hole Figure 17 b Screw in injector and tighten to 44 51 ft Ibs 6 to 7 kgm Figure 18 NOTE Overtightening can damage injector c Install return line using a new sealing washer below each connection Tighten return line retaining bolts to 22 30 ft Ibs d Install delivery lines Leave loose at injectors for bleeding e Crank engine to fill lines Tighten lines at injectors to 11 18 ft Ibs Start engine 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 2500 hours of operation Service of the fuel injection pump should only be done if checks indicate pump malfunction 2 Black smoke can be an indication of pump malfunction
58. position until the engine is running NOTE Excessive cranking of marine sets equipped with water lift muffler systems can cause engine damage See page 7 After the engine starts release the switch and 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 temperature of the engine coolant 6 D C VOLTMETER OR AMMETER When the engine is stopped the voltmeter indicates the condition of the battery When the engine is running the voltmeter indicates the voltage output of the alternator For Series 4 Control Panels Only 7 A C VOLTMETER Shows the generator output voltage 8 FREQUENCY METER Hertz The frequency meter indicates alternating current frequency 60 Hz 1800 RPM or 50 Hz 1500 RPM 9 AMMETER VOLTMETER SELECTOR SWITCH Used to check voltage and current of each phase 10 A C AMMETER Shows the generator load on each phase The phase is selected with the Ammeter Selector switch Item 9 OM844W3 11 13 13 updated page 1 9 13 Operating Procedures BREAK IN PERIOD The first 100 hours on a new or reconditioned engine are critical
59. productive harm Wash hands after handling Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injur Among the potentially hazardous chemicals that may be used with Northern Lights products are lubricants coolants paints and adhesives All potentially hazardous chemicals come with a Material safety Data Sheet MSDS The MSDS provides specific details on chemical products including physical hazards safety procedures and emergency response techniques OM844W3 11 13 5 Revised 3 13 12 Safety Rules Continued Read and understand the MSDS for each chemical before you start any Job that Includes tt Follow the procedures and use appropriate equipment exactly as recommended Contact your Northern Lights dealer or Northern Lights factory for MSDS s used on Northern Lights products Work in Well Ventilated Areas Exhaust fumes from engines contain carbon monoxide and can cause sickness or death Work in well ventilated areas to avoid prolonged exposure to engine fumes If it is necessary to run an engine in an enclosed area route the exhaust fumes out of the area with an approved leak proof exhaust pipe extension Remove Paint Before Welding or Heating Hazardous fumes can be generated when paint is heated by welding soldering or using a torch To avoid amp potentially toxic fumes and dust remove paint before heating Remove paint a minimum of
60. rcuit breaker If breaker is tripped reset it Does Not Function Faulty connection Clean and tighten battery and harness plug connections Sulfated or worn out battertes Check specific gravity and electrolyte level of each battery If you cannot correct problems with these procedures see your Northern Lights dealer OM844W3 11 13 26 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 output Check electrolyte level and condition Excessive resistance Clean and tighten all battery connections in starting circuit Crankcase oil too heavy Use oil of proper viscosity Improper type of fuel Consult fuel supplier and use proper type of fuel for operating condition Water dirt or air in fuel system Drain flush fill and bleed system Clogged primary Clean or replace filter element fuel filter element Lift pump malfunction Repair lift pump Clogged secondary Replace filter element fuel filter element Dirty or faulty injection nozzles Have your dealer check injection nozzles Engine Runs Irregularly Below normal engine temperature Remove and check thermostat or Stalls Frequently Clogged primary Clean or replace filter element fuel filter element Clogged secondary R
61. se Proper Tools Makeshift tools and procedures can create safety hazards Always use appropriate tools for the job Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware always use the correct sized tools Do not use US measurement tools on metric fasteners or vice versa Use only service parts that meet Northern Lights specifications Dispose of Waste Properly Disposing of waste improperly can threaten the environment and lead to unsafe working conditions Potentially harmful waste used in Northern Lights equipment can include oil fuel coolant filters and batteries Use leakproof containers to drain fluid Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source OM844W3 11 13 Added 3 13 12 Lock Out Tag Out Procedures During maintenance repairs or retooling of a Northern Lights generator set simply turning the machine off or unplugging it while it is being worked on does not give enough protection to others who are not performing the maintenance or repair Many serious accidents happen when someone thought the machine was turned off or all of its energy was safely blocked or released General Policy A CAUTION To avoid dangerous or hazardous situations refrain from any of the following Removing or bypassing a guard or other safety device
62. to its life and performance Operate the engine under various conditions particularly heavy loades with minimal idling to help seat engine components properly Frequently check the engine temperature and oil pressure gauges sets with Series 3 or 4 panels Oil consumption 15 greater during break in as piston rings take time to seat Break In Oil Changes Change engine oil and filter at 50 hours Change oil and filter again at 100 hours consult Lubricants section for oil recommendation then at every 250 hours BEFORE STARTING Check the water level by removing the pressure cap from the expansion tank or radiator In order to give the cooling water an opportunity to expand the level should be about 1 in 2 5 em below the filler cap sealing surface when the engine 15 cold CAUTION Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns Check the oil level in the crankcase with the dipstick The oil level must be in the waffled area on the stick Never allow the level to go below this area Always add the same viscosity of oil as 15 already in the crankcase Check the fuel tank level and open any fuel valves Close the sea cock check clean and reassemble the sea strainer and re open the sea cock 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 is turned OFF while the engine is
63. ual covers the operating instructions for M844W3 marine generator sets M844DW3 marine generator sets M844LW3 marine generator sets and M20CRW3 commercial 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 15 required NOTE There are two versions of the 844W3 engine The standard engine is designated 8441 3 The long stroke engine is designated 644LW3 You will need to know which engine you have to use this manual and to order parts My Northern Lights generator set MODEL number is Model Numbers Model numbers give the unit s application block model aspiration and RPM M Northern Lights marine generator set 4 M844W3 Northern Lights marine diesel generator set with an 844 engine and a PX 316K2 generator end M844DW3 Northern Lights 16 kW marine diesel generator set with an 844L engine and a PX 320K2 generator end Model number of engine block 844 W D L C 3 W New winding D Series Designation Cylinders 4 L Long stroke version C Commercial version 3 Tier 3 M844LW3 Northern Lights marine diesel generator set with an 844L engine and a PX 320K2 generator end M20CRW3 f Northern Lights 20 kW 60 Hz commercial grade marine generator set with a special generator end Serial Numbers NORTHERN LIGHTS Serial No Model No Northern Lights 4420 14th Av
64. vis 2 ___ __1 9 yvig 1 _ 2 Og 0 8 5 CE F awa tena Pn L 22 m E ISd Sl HOLIMS yds MYY qa lt o MES WNOILdO SC 3oNVHO 31dund 4 e SM3HIO I 66 SIOVINO2 394 510 3 Jovia pi eun Suid NOILSO Sg 98 yas b lt 3Ov18 ZF A AVEO 66 MT lt TT wea Uis i mM awnoss 35 2 ves 105 F 9 310N 335 ERO Move 1315 s Z am Covet L 96 1 ves MOVIE 01 HOLIMS Wav pe A A A EX NV SNM 1304 A J auHM 1HW 940 c 0t 22 FO qaq oi X X Mor SER 01 vc 939 01 Sg 98 lt 9 HILMO 8 q3H MOTI3A Z Old 1019313 NOlLdO o ime OL SF o qas oig LE YS OL ad 27 of E GEMS 001 aay old e i qup 88 m g 5 ol quc 32018 3NION3 gt E y a xy WIZ LZ GAZ NONI OY HINS T TANIO NO INnOM Nada gt MO ONW 3lMV S n8vo 1 SMV 78 eee Oy 2 Jovia oig oig SS3NMVH JOIVNHJLIV lies NIS IV19ld TVNOILdO E z d E lt XO8 YOLVYINIAD J3NVd OM844W3 11 13 34 added 9 19 11 Wiring Diagrams
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