Northern Lights M844W3 Operator's Manual
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Northern Lights M844W3 Operator's Manual

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OPERATOR'S MANUAL
OPERATOR'S MANUAL
OM844W3
For Models: M844W3, M844DW3, M844DW3G
M844LW3, M844LW3G, M20CRW3
www.northern-lights.com

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  • Page 1 OPERATOR’S MANUAL OPERATOR’S MANUAL OM844W3 For Models: M844W3, M844DW3, M844DW3G M844LW3, M844LW3G, M20CRW3 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.: OM844W3 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 OM844W3 5/21...

  • Page 4: Introduction

    Gem series base frame. US EPA TIer III. M844LW3 Northern Lights marine diesel generator set with M20CRW3 Northern Lights 20 kW (@ 60 Hz) commercial grade an 844L engine and a PX-320K2 generator end. marine generator set with a special generator end. US EPA TIer III.

  • Page 5: Warranty

    Safety Rules DANGER: 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 gases 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: Component Locations M844W3 Marine Generator (Gem Series Base Frame)

    Updated 10-11-19 Marine Generator Component Locations Figure 1C and 2C: M844LW3G Gem series (s/n: 8442-56160 and above) DC Circuit Breaker Raw Water Pump Coolant Recovery Tank Raw Water Inlet Fuel Filter Vibration Mount Fuel Return Line Fuel Inlet Line Fuel Injector Fuel Return Line Lube Oil Fill, Top Oil Dipstick...

  • Page 12: M844W3 Marine Generator (2011 Base Frame)

    Updated 3-17-21 Marine Generator Component Locations Service Side Non-Service Side Figure 1B and 2B: M844W3 with 2011 base frame DC Circuit Breaker Injection Pump Oil Filter Junction Box Oil Fill (Side) (not visible. Callout for Lube Oil Drain Starter Raw Water Pump...

  • Page 13: M20Crw3 Commercial Generator

    Marine Generator Component Locations Figure 2A and 2B: M20CRW3 DC Circuit Breaker Raw Water Pump Secondary Fuel Filter Raw Water Inlet Junction Box Control Panel Plug-in Fuel Return Line Vibration Mount Starter AC Circuit Breaker for Fuel Injector Oil Pressure Sender Alternator Automatic Voltage Regulator Oil Fill (Top)

  • Page 14: Control Panels

    Updated 10-11-19 Control Panels 1. SHUTDOWN BYPASS-PREHEAT SWITCH There are two functions built into this switch: 1. Preheats the fuel before beginning the starting process. Press switch 10 seconds before attempting start-up. 2. Bypasses the safety shutdown feature during starting process.

  • Page 15: Operating Procedures

    Updated 10-11-19 Operating Procedures BREAK-IN PERIOD STARTING 1. The first 100 hours on a new or reconditioned engine 1. Hold the Shutdown Bypass-Preheat switch in the are critical to its life and performance. ON position for 10 seconds before starting a cold 2.

  • Page 16: Shutdowns And Alarms

    (20-60 PSI) after a *- For use with M844DW3/G and M844LW3/G generator sets with heat exchangers. Consult your Northern Lights dealer for your unit’s few seconds of operation. specific spare parts requirements.

  • Page 17: Servicing Schedule Chart

    Updated 10-11-19 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: Check oil level in engine...

  • Page 18: Servicing

    Never allow the level to go below this 2. Use the most current API service category diesel rated area. Follow the lubrication recommendations above. oil. Northern Lights recommends the use of multi- viscosity oil. SP-2. OIL CHANGES 3.

  • Page 19: Air Cleaner

    Updated 10-11-19 Servicing SP-4. AIR CLEANER 1. Inspect air cleaner every 250 hours. In dusty condi- tions, check more often. 2. Marine sets: if dirty, wash element in soapy water. Rinse and dry thoroughly before re-installing. Replace if necessary. The element part number is: M844DW3 and M844LW3 –...

  • Page 20: Valve Clearances

    Servicing SP-6. VALVE CLEARANCES Cylinder No. 1 No. 2 No. 3 No. 4 Valve Arrangement 1. Adjust valve clearance after 1000 hours or as needed. When No. 1 2. To bring the No. 1 cylinder to top dead center in the cyl.

  • Page 21: Fuels - General

    Updated 10-11-19 Servicing FUELS - GENERAL Primary Fuel Filter 1. 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 Part Numbers above freezing 32°F (0°C).

  • Page 22: Injector Service

    1. Since operating conditions may vary considerably, it whenever necessary. Check should be made by a is difficult to give a definite interval for checking the Northern Lights dealer or local injection repair injection pump. But as a rule, pump settings, station.
  • Page 23 Updated 11-8-13 Servicing For illustration purposes only, your specific model may not be shown Figure 11: Remove delivery line flare nuts. Figure 15: Remove return line. Figure 12: Remove delivery lines. Figure 16: Unscrew injector. Figure 13: Cover lines, inlets and injection pump outlets. Figure 17: Remove and replace copper sealing washer.

  • Page 24: Cooling System - General

    Updated 11-8-13 Servicing SP-12. CHECK THE COOLANT LEVEL COOLING SYSTEM - GENERAL 1. Check the coolant level each day before starting the NOTE: Marine sets – be sure to close the sea-cock engine. Check the water level by removing the before working on the engine cooling system.

  • Page 25: Heat Exchanger

    OPX300K-2, included with your manual kit. Contact 2. Drain expansion tank and heat exchanger. 3. Remove heat exchanger end covers and remove core. your Authorized Northern Lights dealer or factory representative for additional copies. 4. Clean the inside of exchanger core tubes using a metal rod.

  • Page 26: Booster Batteries

    Updated 10-11-19 Servicing POWER TAKE-OFF BOOSTER BATTERIES The optional electric clutch P.T.O. does not have CAUTION: Battery gas can explode. any scheduled maintenance points. However, the Keep all flames and sparks away from batteries. equipment that the P.T.O. powers may require Battery electrolyte is sulfuric acid diluted, which maintenance.

  • Page 27: 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. OM844W3 5/21...

  • Page 28: Engine

    Updated 2-10-20 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 •...
  • Page 29 • Service air cleaner. Improper valve clearance • See your dealer. Injection nozzles dirty • See your dealer. Injection pump out of time • See your dealer. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM844W3 5/21...
  • Page 30 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) High Fuel Consumption Engine not at proper temperature • Check your thermostats. • Check water temperature with thermometer (continued) and replace gauge if necessary. Fuel leakage • Improper installation or tightening. Excessive load on engine •...
  • Page 31 This Page Left Intentionally Blank OM844W3 5/21...

  • Page 32: Wiring Diagrams Ac Electrical

    Updated 5-7-21 AC Wiring Diagram OM844W3 5/21...
  • Page 33 Updated 5-7-21 AC Wiring Diagram OM844W3 5/21...
  • Page 34 Updated 4-15-21 AC Wiring Diagram OM844W3 5/21...

  • Page 35: Dc Electrical

    Updated 5-19-21 DC Wiring Diagram OM844W3 5/21...
  • Page 36 Updated 4-15-21 DC Wiring Diagram OM844W3 5/21...
  • Page 37 Updated 4-15-21 DC Wiring Diagram OM844W3 5/21...
  • Page 38 Updated 4-15-21 DC Wiring Diagram OM844W3 5/21...
  • Page 39 Updated 4-15-21 DC Wiring Diagram OM844W3 5/21...
  • Page 40 Updated 5-7-21 DC Wiring Diagram OM844W3 5/21...
  • Page 41 Updated 5-7-21 DC Wiring Diagram OM844W3 5/21...
  • Page 42 Updated 5-7-21 DC Wiring Diagram OM844W3 5/21...
  • Page 43 Updated 5-7-21 DC Wiring Diagram OM844W3 5/21...

  • Page 44: Panel Diagrams

    Updated 5-7-21 Panel Wiring Diagram OM844W3 5/21...
  • Page 45 Updated 5-7-21 Panel Wiring Diagram OM844W3 5/21...
  • Page 46 Updated 5-7-21 Panel Wiring Diagram OM844W3 5/21...
  • Page 47 Updated 5-7-21 Panel Wiring Diagram OM844W3 5/21...

  • Page 48: Appendix (Non-Current Production Diagrams) Dc Electrical

    Updated 9-19-11 DC Wiring Diagrams OM844W3 5/21...
  • Page 49 DC Wiring Diagrams OM844W3 5/21...
  • Page 50 Updated 6-8-12 DC Wiring Diagrams OM844W3 5/21...
  • Page 51 Updated 6-8-12 DC Wiring Diagrams OM844W3 5/21...

  • Page 52: Panel Diagrams

    Updated 9-19-11 Panel Wiring Diagrams OM844W3 5/21...
  • Page 53 Updated 9-19-11 Panel Wiring Diagrams OM844W3 5/21...
  • Page 54 Updated 6-8-12 Panel Wiring Diagrams OM844W3 5/21...
  • Page 55 Updated 9-19-11 Panel Wiring Diagrams OM844W3 5/21...
  • Page 56 Updated 9-19-11 Panel Wiring Diagrams OM844W3 5/21...
  • Page 58 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.

This manual is also suitable for:

M844dw3M844dw3gM844lw3M844lw3gM20crw3

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