Northern Lights OM844W3 Manuel utilisateur

OM844W3

For Models: M844W3, M844LW3, and M20CRW3

OPERATOR’SMANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

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

the Northern Lights logo are trademarks of

Northern Lights, Inc.

Printed in U.S.A.

PART NO.: OM844W3 5/11

OM844W3 5/11

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.

Proprietary Information

This 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.

OPERATOR'S MANUAL

for Models

M844W3, M844LW3, and M20CRW3

Table of Contents

INTRODUCTION ......................................................2

Models Included ...................................................2

Model Numbers....................................................2

Serial Numbers .....................................................3

WARRANTY ............................................................3

SAFETY RULES....................................................3-7

COMPONENT LOCATIONS

M844W3 Marine Generator (older baseframe)....8

M844W3 Marine Generator (new baseframe)......9

M20CRW3 Commercial Generator....................10

CONTROL PANELS .............................................11

OPERATING PROCEDURES

Break-in Period...................................................12

Before Starting....................................................12

Starting................................................................12

Operating ............................................................12

Stopping..............................................................12

Shutdowns and Alarms.......................................13

Spare Parts..........................................................12

SERVICING SCHEDULE CHART.......................14

SERVICING

Lubrication - General..........................................16

Checking Oil.......................................................16

Oil Changes ........................................................16

Changing Oil Filter.............................................16

Air Filter .............................................................17

SERVICING (continued)

V-Belts................................................................17

Valve Clearances.................................................17

Fuels - General....................................................18

Fuel Filters..........................................................18

Bleeding the Fuel System...................................19

Injector Service............................................20- 21

Injection Pump....................................................21

Cooling System - General...................................21

Cooling System Flushing....................................22

Heat Exchanger...................................................22

Raw Water Pump ................................................22

Generator Ends ...................................................22

Electrical System - General................................22

Glow Plugs..........................................................23

Booster Batteries.................................................23

Battery Care........................................................23

PTO Care ............................................................23

Winterizing / Out-of-Service ..............................23

TROUBLESHOOTING

Electrical.............................................................24

Engine.........................................................25 - 27

WIRING DIAGRAMS

AC Electrical ......................................................28

DC Electrical ..............................................29 - 32

OM844W3 5/11

Introduction

Unit Identiﬁcation

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 is not a

comprehensive technical service manual. Nor will it

make the reader into an expert mechanic. Its aim is to

aid you in maintaining your unit properly.

W, L, C, 3

MODELS INCLUDED

This manual covers the operating instructions for:

M844W3 marine generator sets,

M844LW3 marine generator sets, and

M20CRW3 commercial generator sets.

NOTE: There are two versions of the 844W3 engine. The standard engine is designated 844W3. The long-stroke

engine is designated 844LW3. You will need to know which engine you have to use this manual and to order parts.

Fill in the model number of your unit in the blank space provided.

This will give you a reference whenever service or maintenance is required:

W - New winding

L - Long stroke version

C - Commercial version

3 - Tier 3

Northern Lights marine diesel generator set with

an 844 engine and a PX-316K2 generator end.

M 844

M844W3

Northern Lights marine diesel generator set with

an 844L engine and a PX-320K2 generator end.

M844LW3

Northern Lights 20 kW (@ 60 Hz) commercial grade

marine generator set with a special generator end.

M20CRW3

Model number of engine block

Bore Cylinders

84 mm 4

M - Northern Lights marine generator set

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:

My Northern Lights generator set MODEL number is:

OM844W3 5/11

Serial Numbers

Safety Rules

A warranty registration certiﬁcate is supplied

with your set. It entitles the original purchaser of our

equipment to a warranty covering material

or assembly faults. The extent of coverage is described

in the Limited Warranty Statement. We recommend

that you study the statement carefully.

NOTE: If the warranty is to apply, the servicing

instructions outlined in this manual must be

followed. If further information is needed, please

contact an authorized dealer or the factory.

CAUTION: Accident reports show that careless use of engines causes a high percentage of accidents.

You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.

Your set has three serial numbers: 1an engine number stamped

on the block, 2a generator plate, and 3a 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.

Generator set serial number plate.

Warranty

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 INSTRUCTIONS FOR FUTURE REFERENCE.

Recognize Safety Symbols and

Instructions

In addition to the information found in

this section, this operator’s manual will

use the CAUTION warning to outline

potential dangers of a speciﬁc nature.

CAUTION indicates the presence of a potential hazard

that can or will cause severe or minor property damage,

personal injury or death.

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

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.

Revised 5-13-11

OM844W3 5/11

Safety Rules

Revised 5-13-11

Keep you machine in proper working condition.

UNAUTHORIZED MODIFICATIONS TO THE

MACHINERY MAY IMPAIR ITS FUNCTION AND

SAFETY PARAMETERS.

Prevent Bypass andAccidental Starting

Do not start engine by shorting across

start terminal. Engine will start if

normal circuitry is bypassed, creating

a hazard by runaway machinery.

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.

Prevent accidental discharge

of starting ﬂuids by storing all

cans in a cool, safe place, away

from sparks or open ﬂame.

Store with cap securely on

container. Never incinerate or puncture a fuel container.

Prevent ﬁres by keeping machine clean of accumulated

trash, grease and debris. Always clean any spilled fuel

as swiftly as possible. Do not store oily rags, which can

ignite and burn spontaneously.

Be prepared if a ﬁre starts. Keep a ﬁrst aid kit and ﬁre

extinguisher handy. Keep emergency contact numbers

for ﬁre department, doctors, ambulance and hospital near

the telephone.

Service Machines Safely

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 items get caught

in moving machinery, severe injury or death could result.

Check for any loose electrical

connections or faulty wiring.

Look completely around engine to

make sure that everything is

clear

before starting.

Wear Protective Clothing

To prevent catching anything in moving machinery,

always wear close ﬁtting clothes and safety equipment

appropriate to the job.

Prolonged exposure

to loud noise can

cause hearing loss

or impairment.

Wear suitable

authorized hearing

protection, such as

earmuffs or plugs to

protect against loud noises.

Operating equipment requires the full attention of the

operator. Do not use radio or music headphones while

operating machinery.

Practice Safe Maintenance

Understand all service procedures before starting work.

Keep area clean and dry. Never lubricate, service, or

adjust machine while it is in operation.

Keep hands, feet and clothing

away from power-driven

equipment. When shutting

down an engine, disengage

all power and operator

controls. Allow the engine

to cool completely before

beginning any service work.

Securely support any machinery elements that must

be raised for service work with support or lifting

machinery speciﬁcally intended for that purpose.

Keep all parts in good conditions and properly installed.

Fix damage immediately. Replace any worn or broken

parts. Remove any build up of grease, oil or debris.

Disconnect battery ground cable (-) before making any

adjustments or service work.

Stay Clear of Rotating

Drivelines

Entanglement in rotating

drivelines can cause

serious injury or death.

Keep shields in place

at all times. Make

OM844W3 5/11

Safety Rules (Continued)

Revised 5-13-11

sure that rotating shields turn freely in pace with the

drivelines.

Do not wear loose ﬁtting equipment around rotating

drivelines. Stop the engine and make sure that

all moving parts have stopped before making any

adjustments, connections, or performing any other type

of service to the engine or other driven equipment.

Install all 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 is highly

ﬂammable. Battery

explosions can cause

severe injury or death.

To help prevent battery explosions, keep sparks,

lighted matches and open ﬂame 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 16oC (60oF).

Always remove grounded (-) battery clamp ﬁrst and

replace ground clamp last.

Sulfuric acid in battery electrolyte is 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

WARNING: Battery posts, terminals, and related

accessories can contain lead and lead compounds,

chemicals known to the State of California to cause

cancer and reproductive harm. Wash hands after

handling.

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause

serious injury. Among the potentially hazardous

chemicals that may be used

with Northern Lights

products are lubricants,

coolants, paints and

adhesives.

OM844W3 5/11

Safety Rules (Continued)

Revised 5-13-11

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 high

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

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 components between

the high-pressure fuel pump and nozzles on engines with

high pressure fuel systems.

ONLYAUTHORIZED TECHNICIANS CAN

PERFORM REPAIRS ON AN HIGH PRESSURE FUEL

INJECTION SYSTEMS.

All potentially hazardous chemicals come with a Material

Data Safety Sheet (MSDS). The MSDS provides speciﬁc

details on chemical products, including physical hazards,

safety procedures and emergency response techniques

Read and understand the MSDS for each chemical before

you start any job that includes it. 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

potentially toxic fumes and dust, remove paint before

heating.

• Remove paint a

minimum of 100 mm

(4 in.) from the area

that will be affected by

heat.

•

If paint cannot be

removed, wear an

approved respirator.

•

If you sand or grind paint, use an approved respirator.

• If 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

OM844W3 5/11

Safety Rules (Continued)

Revised 5-13-11

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.

Use 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.

Avoid Hot Exhaust

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 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 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

is 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.

OM844W3 5/11

1. DC Circuit Breaker

2. Coolant Recovery Tank

3. Secondary Fuel Filter

4. Fuel Return Line

5. Fuel Injector

6. Oil Fill (Top)

7. Coolant Fill

8. Fresh Water Pump

9. Injection Pump

Marine Generator Component Locations

19. Oil Filter

20. Lube Oil Drain

21. Fuel Lift Pump

22. Control Panel Plug-in

23. AC Circuit Breaker for

Automatic Voltage Regulator

24. Expansion Tank/Exhaust

Manifold/Heat Exch.Tank

Service Side



Non-Service

Side



Figure 1A and 1B: M844W3

25. Coolant Drain

26. Wet Exhaust Elbow

27. Junction Box

28. Starter

29. Alternator

30. Belt Guard

31. Coolant Thermostat (behind)

32. Water Temperature Sender

10. Oil Fill (Side)

11. Raw Water Pump

12. Raw Water Inlet

13. Vibration Mount

14. Oil Pressure Sender

15. Freshwater Block Drain

16. Fuel Inlet Line

17. Fuel Return Line

18. Oil Dipstick

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