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Northern Lights M944W3F Operator's Manual

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OPERATOR'S MANUAL
OPERATOR'S MANUAL
OM944F
For Models: M944W3F, M944T3F, M30C3F
and M40C3F
www.northern-lights.com

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  • Page 1 OPERATOR’S MANUAL OPERATOR’S MANUAL OM944F For Models: M944W3F, M944T3F, M30C3F and M40C3F www.northern-lights.com...
  • Page 2 4420 14th Avenue NW Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455 Copyright ©2018 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.: OM944F 2/20...

  • Page 3: Table Of Contents

    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. © Northern Lights, Inc. All rights reserved. Litho U.S.A. Publication number OM944F 2/20...

  • Page 4: Introduction

    Unit Identification MODELS INCLUDED This manual covers the operating instructions for: • M944W3F and M30C3F marine and commercial generator sets, using the 944 engine block. • M944T3F and M40C3F marine and commercial generator sets, using the 944 engine block, turbocharged.

  • Page 5: Warranty

    Safety Rules NOTICE: Northern Lights generator sets and /or any other diesel powered equipment provided by NLI is not provided with spark arresting or explosion proof components, and therefore is not to be installed in the presence of combustible gasses having a flash point of 43.3 Degrees C (110 Degrees F) or lower, such as Gasoline, Propane, Natural Gas or other similar fuel sources.
  • Page 6 Updated 4-12-17 Safety Rules (Continued) Handle Fuel Safely - Avoid Flames Wear Protective Clothing WARNING WARNING Diesel is highly flammable and should be treated with care at all times. Do do not refuel while smoking or To prevent catching anything in moving machinery, when near sparks or open flame.
  • Page 7 Updated 4-12-17 Safety Rules (Continued) Never check battery charge Stay Clear of Rotating Drivelines by contacting the posts with DANGER a metal object. Use a volt- meter or hydrometer. Entanglement in rotating Frozen batteries may explode drivelines can cause serious if charged.
  • Page 8 Follow the procedures and use appropriate equipment exactly as recommended. WARNING Contact your Northern Lights dealer or Northern Lights Relieve pressure prior to factory for MSDS’s used on Northern Lights products. disconnecting pressurized lines.
  • Page 9 Disposing of waste improperly can threaten the cause lung cancer. Avoid environment and lead to unsafe working conditions. breathing any dust that may Potentially harmful waste used in Northern Lights be generated when handling equipment can include oil, fuel, coolant, filters and components containing asbestos batteries.

  • Page 10: Lock Out / Tag Out Procedures

    Scope 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.
  • Page 11 Notes OM944F 2/20...

  • Page 12: M944W3F Generator Set

    M944W3F Generator Set Component Locations Figure 2: M944W3F Service Side - consult factory for details on additional models. Expansion Tank Junction Box 14. Injection Pump Coolant Fill Intake Air Noise 15. Vibration Isolation Mount Rocker Arm Cover Reduction Tube 16. Lube Oil Drain 10.
  • Page 13 M944W3F Generator Set Component Locations Figure 2: M944W3F Non-Service Side - consult factory for details on additional models. 21. Exhaust Elbow 24. Alternator 22. Exhaust Blanket 25. Starter 23. Exhaust Manifold 26. Base Pan OM944F 2/20...

  • Page 14: Control Panels

    Control Panels 1. PREHEAT/ SHUTDOWN BYPASS This switch serves two functions: 1. Preheats air before beginning the starting process. Press switch for 10-20 seconds before attempting startup. 2. Bypasses the safety shutdown feature during the starting process. Keep switch engaged while starting engine, and for 2 to 3 seconds afterwards, allowing oil pressure to build beyond shutdown setpoint.

  • Page 15: Operating Procedures

    Emission-Related Installation Instructions Failing to follow these instructions when installing If you install the engine in a way that obscures the a certified engine in a vessel violates federal law (40 engine’s emission control information label during CFR 1068.105(b)), subject to fines or other penalties as normal engine maintenance, you must place a duplicate described in the Clean Air Act.

  • Page 16: Starting

    Updated 5-7-19 Operating Procedures STARTING OPERATING 1. Hold the Shutdown Bypass switch in the ON 1. Units with Series 3 and Series 4 Control Panels: position. check gauges often. Oil pressure must be above 15 PSI. The D.C. voltmeter should read between 2.

  • Page 17: Shutdowns And Alarms

    Check the engine crankcase oil level. *- For use with M944W, M944W3, M944W3F generator sets with heat exchangers. Consult your Northern Lights dealer for your unit’s b. If the oil level is low, fill with recommended specific spare parts requirements.

  • Page 18: Servicing Schedule Chart

    Updated 2-7-20 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 250 HOURS: Inspect for any signs of fluid leaking...
  • Page 19 Service Record Service OPERATION HOURS/ DATE Point 50 HOURS Check V-belt tension SP19 Check electrolyte in batteries 250 HOURS Change engine oil Change lubricating oil filters Check air cleaner SP13 Check turbocharger SP18 Check zinc electrodes EVERY 500 HOURS Check valve clearances Change primary filter element Change secondary fuel filter SP11...

  • Page 20: Servicing

    Updated 11-20-18 Servicing SP-1. CHECKING OIL LEVEL LUBRICATION - GENERAL 1. While the engine is stopped, check the oil level in 1. Use only clean, high quality lubricants stored in the crankcase with the dipstick daily. The oil level clean containers in a protected area. must be between the high and low marks on the stick.

  • Page 21: Changing Lube Oil Filter

    Servicing SP-3. CHANGING LUBE OIL FILTER SP-5. V-BELTS 1. Change the lube oil filter every 250 hours. 1. Check the tension and wear on the V-belt after every 50 hours. 2. Use a filter wrench to remove old filter. Dispose of filter in approved manner.

  • Page 22: Valve Clearances

    Servicing SP-6. VALVE CLEARANCES 1. Readjust valve clearance after first 50 hours of operation. Check valves every 500 hours thereafter. 2. Check the valves when the engine is cold. 3. Rotate the crankshaft in a clockwise direction in the front 180 to bring each piston to the top dead center on the compression stroke.

  • Page 23: Fuels - General

    Servicing FUELS - GENERAL SP-7. PRIMARY FUEL FILTER a. Check the primary fuel filter daily as 1. Use only clean, high quality fuels of the following recommended by the filter manufacturer. specifications, as defined by ASTM designation SP-8. PRIMARY FUEL FILTER ELEMENT D975 for diesel fuels: b.

  • Page 24: Bleeding The Fuel System

    Servicing SP-10. BLEEDING THE FUEL SYSTEM CAUTION: Escaping diesel fuel under pressure can penetrate skin causing serious personal injury. Before disconnecting lines be sure to relieve all pressure. Before applying pressure, be sure all connections are tight and lines, pipes and hoses aren't damaged. Fuel escaping from a very small hole can be almost invisible.

  • Page 25: Injector Service

    4. Injector installation 1. Injectors should be checked every 500 hours. This a. Install new injector seal washer seat and check should be made by a Northern Lights dealer injector. Evenly tighten the injector retaining or local injection repair station.

  • Page 26: Injection Pump

    Remove the 4 mounting nuts. checked after every 2000 hours of operation. g. Take the pump to your Northern Lights dealer or Service of the fuel injection pump should only be an injection repair station for testing and service.

  • Page 27: Turbocharger

    Servicing SP-13. TURBOCHARGER 1. Check for air leaks every 250 hours. Air leakage will lower engine output and may cause black exhaust smoke and soot. 2. Listen along air line while the engine is running. A whistling or hissing sound could indicate leakage. 3.

  • Page 28: Cooling System - General

    Servicing COOLING SYSTEM - GENERAL SP-14. CHECKING COOLANT LEVEL NOTE: Be sure to close the sea-cock before working 1. Check the coolant level each day before starting the on the engine cooling system. engine. a. Check the water level by removing the pressure CAUTION: The cooling water in the engine cap from the expansion tank.

  • Page 29: Heat Exchanger

    Updated 2-7-20 Servicing SP-16. HEAT EXCHANGER SP-18. ZINC ELECTRODES 1. Clean the heat exchanger core as needed. 1. A zinc electrode is installed in the heat exchanger cooling system to protect the engine from 2. Drain the expansion tank and heat exchanger. electrolysis.

  • Page 30: Generator End

    Megger generator end windings every two years. Generator end bearings should be replaced every 10,000 hours. If you do not have one of these manuals, they can be obtained through the Northern Lights web site www.nothern-lights.com. Figure 12: Booster Battery Connections ELECTRICAL SYSTEM - GENERAL BATTERY CARE 1.

  • Page 31: Winterizing / Out-Of-Service

    Updated 10-23-18 Servicing SP-21. WINTERIZING / OUT-OF-SERVICE If the generator set will not be used for more than 3 months the following preparations should be taken for long term storage. • Change engine oil and filter, using API CJ or CK-4, 15W-40 oil.

  • Page 32: Troubleshooting

    Faulty connection • Clean and tighten battery and harness plug connections. Sulfated or worn out batteries • Check specific gravity and electrolyte level of each battery. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM944F 2/20...

  • Page 33: Engine

    Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) Engine Hard to Start Improper starting procedure • See starting section of this manual. Take or Will Not Start special note of Bypass Switch operation. No fuel • Check level of fuel in fuel tank. Low battery condition •...
  • Page 34 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) Lack of Engine Power Low compression pressure • Consult dealer. (continued) (worn piston rings, etc...) Engine Overheats Engine overloaded • Reduce the electrical load. Low coolant level • Fill tank or radiator to proper level. •...
  • Page 35 • Use proper viscosity of oil to ambient temperature. Excessive amount of engine oil • Maintain correct oil level. Fuel injection nozzles faulty • See your dealer. (uneven injection) If you cannot correct problems with these procedures, see your Northern Lights dealer. OM944F 2/20...
  • Page 36 AC Wiring Diagram OM944F 2/20...
  • Page 37 AC Wiring Diagram OM944F 2/20...
  • Page 38 AC Wiring Diagram OM944F 2/20...
  • Page 39 AC Wiring Diagram OM944F 2/20...
  • Page 40 AC Wiring Diagram OM944F 2/20...

  • Page 41: Dc Electrical

    Updated 2-11-20 DC Wiring Diagram OM944F 2/20...
  • Page 42 DC Wiring Diagram OM944F 2/20...
  • Page 43 Updated 2-11-20 DC Wiring Diagram OM944F 2/20...
  • Page 44 DC Wiring Diagram OM944F 2/20...
  • Page 45 Updated 2-11-20 DC Wiring Diagram OM944F 2/20...
  • Page 46 DC Wiring Diagram OM944F 2/20...
  • Page 47 Updated 2-11-20 DC Wiring Diagram OM944F 2/20...
  • Page 48 DC Wiring Diagram OM944F 2/20...

  • Page 49: Panel Diagrams

    S-1B Wiring Diagram OM944F 2/20...

  • Page 50: Wiring Diagrams

    S-3 Wiring Diagram OM944F 2/20...
  • Page 52 4420 14th Ave. NW., Seattle WA 98107 Tel: (206) 789-3880 • 1-800-762-0165 • www.northern-lights.com Northern Lights and Lugger are registered trademarks of Northern Lights, Inc. © 2020 All rights reserved. Litho USA.

This manual is also suitable for:

M944t3fM30c3fM40c3f

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