Northern Lights M944W3 Operator's Manual
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Northern Lights M944W3 Operator's Manual

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OPERATOR'S MANUAL
OPERATOR'S MANUAL
OM944F
For Models: M944W3, M944W3G, M944W3F,
M944W3FG, M944T3F, M944T3FG, M30CW3,
M30C3F and M38C3F
www.northern-lights.com

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  • Page 1 OPERATOR’S MANUAL OPERATOR’S MANUAL OM944F For Models: M944W3, M944W3G, M944W3F, M944W3FG, M944T3F, M944T3FG, M30CW3, M30C3F and M38C3F www.northern-lights.com...
  • Page 2 4420 14th Avenue NW Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455 Copyright © 2021 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 5/21...

  • 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 • 5/21...

  • Page 4: Introduction

    Unit Identification MODELS INCLUDED This manual covers the operating instructions for: • M944W3, M944W3G, M944W3F and M944W3FG marine generator sets, using the 944 engine block. • M944T3F and M944T3FG turbocharged marine generator sets, using the 944 engine block. • M30CW3, M30C3F and M38C3F commercial marine generator sets, using the 944 engine block.

  • Page 5: Model Numbers

    G - Gem series base frame T - Turbocharged C - Commercial series 3 - US EPA Tier III compliant Northern Lights marine diesel generator set with a Northern Lights marine diesel generator set with a M944W3 944 engine and a PX-332K2 series generator end 944 engine and a PX-332K2 series generator end;...

  • Page 6: 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 7 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 To prevent catching anything in moving machinery, care at all times. Do do not refuel while smoking or always wear close fitting clothes and safety when near sparks or open flame.
  • Page 8 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 9 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 10 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 11: 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 12: M944W3 Generator Set

    M944W3 Generator Set Component Locations Figure 2: M944W3 Service Side with PX-300K2 series generator end. Expansion Tank Fuel Filter 15. Lube Oil Drain Coolant Fill Vibration Mounts 16. Thermostat Housing Rocker Arm Cover 10. Lube Oil Dipstick 17. Heat Exchanger Raw Water Intake Manifold 11.
  • Page 13 M944W3 Generator Set Component Locations 18 19 Figure 3: M944W3 Non-Service Side with PX-300K2 series generator end. 24. Belt Guard 18. AC Circuit Breaker 19. DC Circuit Breaker 25. Oil Pan 20. Wet Exhaust Elbow 26. Alternator 21. Exhaust Manifold 27.

  • Page 14: M944W3F Generator Set

    M944W3F Generator Set Component Locations Figure 4: 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 15 M944W3F Generator Set Component Locations Figure 5: M944W3F Non-Service Side - consult factory for details on additional models. 21. Exhaust Elbow 24. Alternator 22. DPF and Exhaust Blanket 25. Starter 23. Exhaust Manifold 26. Base Pan OM944F 5/21...

  • Page 16: M944W3Fg Generator Set

    Updated 3-22-21 M944T3FG Generator Set Component Locations Figure 6: M944W3FG Service Side - consult factory for details on additional models. Expansion Tank Control Panel Plug 15. Fuel Primer Pump Coolant Fill 10. Vibration Isolation 16. Belt Guard Rocker Arm Cover Mount 17.
  • Page 17 M944W3F Generator Set Component Locations Figure 7: M944W3F Non-Service Side - consult factory for details OM944F 5/21...

  • Page 18: 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 19: Operating Procedures

    Updated 11-10-20 Emission-Related Installation Instructions (For “F” Series Models) 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 20: Starting

    Updated 11-10-20 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 21: Shutdowns And Alarms

    Workshop manual b. 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 specific spare parts requirements.

  • Page 22: Servicing Schedule Chart

    Updated 11-10-20 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 23: Servicing Record

    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 24: Lubrication - General

    Updated 11-10-20 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 25: Changing Lube Oil Filter

    Updated 11-10-20 Servicing Note: Make absolutely sure no impurities enter SP-3. CHANGING LUBE OIL FILTER the engine while changing the element, and do not run the engine with the air cleaner 1. Change the lube oil filter every 250 hours. removed.

  • Page 26: 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 27: 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 28: 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 29: 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 30: 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 31: 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 32: 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 33: 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 34: Generator End

    If you do not have one of these manuals, they can be 3. First, connect the positive (+) terminal of the booster obtained through the Northern Lights web site battery to the positive (+) terminal of the main www.nothern-lights.com.

  • Page 35: Battery Care

    Updated 11-10-20 Servicing BATTERY CARE SP-21. WINTERIZING / OUT-OF-SERVICE SP-19. CHECK ELECTROLYTE LEVELS If the generator set will not be used for more than 3 1. Check the electrolyte level every 50 hours, or once months the following preparations should be taken for a month.

  • Page 36: 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 5/21...

  • Page 37: 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 38 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 39 • 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 5/21...

  • Page 40: Ac Wiring

    Updated 2-12-21 AC Wiring Diagram OM944F 5/21...
  • Page 41 Updated 2-12-21 AC Wiring Diagram OM944F 5/21...
  • Page 42 Updated 2-12-21 AC Wiring Diagram OM944F 5/21...
  • Page 43 Updated 2-12-21 AC Wiring Diagram OM944F 5/21...
  • Page 44 Updated 2-12-21 AC Wiring Diagram OM944F 5/21...
  • Page 45 AC Wiring Diagram OM944F 5/21...
  • Page 46 AC Wiring Diagram OM944F 5/21...
  • Page 47 Updated 2-12-21 AC Wiring Diagram OM944F 5/21...
  • Page 48 Updated 2-12-21 AC Wiring Diagram OM944F 5/21...
  • Page 49 AC Wiring Diagram OM944F 5/21...

  • Page 50: Dc Wiring

    Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 51 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 52 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 53 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 54 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 55 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 56 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 57 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 58 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 59 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 60 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 61 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 62 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 63 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 64 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 65 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 66 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 67 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 68 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...
  • Page 69 Updated 2-12-21 DC Wiring Diagram OM944F 5/21...

  • Page 70: Panel Wiring

    Updated 10-16-20 Panel Wiring Diagram OM944F 5/21...
  • Page 71 Panel Wiring Diagram OM944F 5/21...
  • Page 72 Panel Wiring Diagram OM944F 5/21...
  • Page 73 Updated 3-31-21 Panel Wiring Diagram OM944F 5/21...

  • Page 74: Panel Diagrams

    AC Wiring Diagram OM944F 5/21...
  • Page 75 AC Wiring Diagram OM944F 5/21...
  • Page 76 DC Wiring Diagram OM944F 5/21...
  • Page 77 DC Wiring Diagram OM944F 5/21...
  • Page 78 DC Wiring Diagram OM944F 5/21...
  • Page 79 DC Wiring Diagram OM944F 5/21...
  • Page 80 Updated 6-22-12 Panel Wiring Diagram OM944F 5/21...
  • Page 81 Updated 6-22-12 Panel Wiring Diagram OM944F 5/21...
  • Page 82 Updated 6-22-12 Panel Wiring Diagram OM944F 5/21...
  • Page 84 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. © 2021 All rights reserved. Litho USA. OM944F 5/21...

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