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Summary of Contents for Northern Lights OM944T
- Page 1 OPERATOR’S MANUAL OPERATOR’S MANUAL OM944T For Models: M944T and M38CR2 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.: OM944T3 5/19...
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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 OM944T 5/19... -
Page 4: Introduction
Northern Lights marine diesel generator set with M944T a 944 engine and a LX-E 34E series generator end. Northern Lights commercial marine diesel generator set with M38CR2 a 944 engine and a Newage series generator end, 38 kW. Serial Numbers... -
Page 5: Warranty
For replacement signs, ALWAYS STOP ENGINE proper placement of safety signs or clarification on any BEFORE FUELING safety issue, consult your Northern Lights dealer or the MACHINE. Always fill factory. portable fuel tank outdoors. There can be additional safety information contained Never fuel a hot engine. - Page 6 Wear suitable authorized moving parts have stopped hearing protection, such before making any adjustments, as earmuffs or plugs to connections, or performing protect against loud noises. any other type of service to the engine or other driven equipment. OM944T 5/19...
- Page 7 Among the potentially hazardous with a metal object. Use a volt-meter or hydrometer. chemicals that may be used with Northern Lights Frozen batteries may explode if charged. Never products are lubricants, charge a battery that has not been allowed to warm to at least 16 o C (60 o F).
- Page 8 Slowly loosen cap to relieve pressure before opening fully. Contact your Northern Lights dealer or Northern Lights factory for MSDS’s used on Northern Lights products. Avoid High Pressure Fluids WARNING...
- 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.
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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 Updated 12-12-12 Notes OM944T 5/19...
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Page 12: M944T Generator Set
11. Lube Oil Dipstick 18. Raw Water Pump Lube Oil Fill 12. Oil Filter 19. Heat Exchanger Raw Water Intake Manifold 13. Vibration Mounts Drain and Zinc Fuel Filter 14. Fuel Supply & 20. Heat Exchanger Return Connections OM944T 5/19... - Page 13 Updated 9/28/12 M944T Generator Set Component Locations Figure 3: M944T Non-Service Side 24. Starter 19. Turbocharger 20. Wet Exhaust Elbow 25. Oil Pan 21. Exhaust Manifold 22. Alternator 23. Belt Guard OM944T 5/19...
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Page 14: M38Cr2 Generator Set
Expansion Tank Harness Plug Coolant Fill Lube Oil Dipstick Thermostat Housing 10. Fuel Manifold (optional) 11. Oil Filter Fuel Filter 12. Fuel Primer Pump Intake Manifold Air Cleaner 13. Injection Pump Junction Box 14. A.C. Coolant Heater (optional) OM944T 5/19... - Page 15 M38CR2 Generator Set Component Locations Figure 5: M38CR2 Non-Service Side (Representative only - early production) 19. Turbocharger 23. Oil Pan 20. Exhaust Manifold 24. Starter 21. Alternator 22. Belt Guard OM944T 5/19...
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Page 16: Control Panels
Used to check the voltage and current of each phase. Return to “Amps Off” position when not monitoring. 10. A.C. AMMETER Shows the generator load on each phase. The phase is selected with the Ammeter Selector switch ( Figure 6-C: Series 4 Generator Control Panel OM944T 5/19... -
Page 17: Operating Procedures
5. 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 running, the battery charging alternator could be damaged. OM944T 5/19... -
Page 18: Starting
3. Move the Engine Control switch to the STOP line and engine. Once the engine starts, shut position. if off immediately and reinstall the impeller. Restart and check the exhaust overboard outlet for gushes of water. OM944T 5/19... -
Page 19: Shutdowns And Alarms
The parts are a. Generator sets have shutdown systems to stop available from your local Northern Lights dealer. the engine. They have no warning horns. Some marine models may already have “On-Board b. -
Page 20: Servicing Schedule Chart
2) Consult manufacturer's maintenance schedule, note on chart. 6) Fuel inj. valve opening pressure: 11.77 MPa (120 kgf/cm ) 1710 PSI. 3) Or Whenever necessary. 7) Or every 2 years. 4) Change at 1000 hours. 8) Valve clearance = .25 mm (0.0098”). OM944T 5/19... - Page 21 Change secondary fuel filter SP12 Check injectors SP19 Change impeller in seawater pump SP22 Check condition of batteries with hydrometer 1000 HOURS or as required SP13 Check fuel injection pump SP18 Check and clean heat exchanger Service Notes: OM944T 5/19...
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Page 22: Lubrication - General
7. Never use a flushing oil. 8. Loosen clamp on oil change tube. Remove cap. Drain oil. Replace cap and tube. 9. Refill engine with recommended oil. 10. Engine capacity with new oil filter is: ....2.64 gallons (10 liters) OM944T 5/19... -
Page 23: Changing Oil Filter
Note: Make absolutely sure no impurities enter the engine while changing the element, and do not run the engine with the air cleaner removed. Do not clean the filter with diesel fuel, solvent, or gasoline. Serious engine damage can result. OM944T 5/19... -
Page 24: Valve Clearances
17 bolts total, Tightening Torque: measuring the clearance, until the feeler gauge slides 113 to 123 N•m (11.5 to 12.5 kgf•m) with a slight drag. Tighten the lock nut and recheck [83.2 to 90.4 lbf•ft] the clearance ( Figure 9 OM944T 5/19... -
Page 25: Fuels - General
1. Use only clean, high quality fuels of the following 1. Your generator set should have a primary fuel filter specifications, as defined by ASTM designation installed. We recommend the Northern Lights brand D975 for diesel fuels: of fuel filters. -
Page 26: Bleeding The Fuel System
Then tighten the connections. plug hole. Do each line one-at-a-time. After the engine has started, use a piece of cardboard to look for fuel leaks. OM944T 5/19... -
Page 27: Injector Service
SP12. INJECTOR SERVICE 1. Injectors should be checked every 500 hours. This 3. Injector repair and cleaning: check should be made by a Northern Lights dealer a. Take injectors to your Northern Lights dealer or local injection repair station. or local injection repair station for testing and service. -
Page 28: Injection Pump
Service of the fuel injection pump should only be f. Remove the 4 mounting nuts. done if checks indicate pump malfunction. g. Take the pump to your Northern Lights dealer or an injection repair station for testing and service. 2. Black smoke can be an indication of pump malfunction. -
Page 29: Turbocharger
6. Check hoses and connections and repair any Maximum Sulfates leakage. Maximum Dissolved Solids 20.0 Maximum Total Hardness 10.0 7. Start the engine and check for leaks. Run the engine for five minutes, then shut it down. Let engine cool, PH Level 5.5 to 9.0 OM944T 5/19... -
Page 30: Heat Exchanger
4. Press in the new impeller and place the sealing plug in the outer end of the impeller center if this has not already been done. NOTE: Make sure that there is always an extra impeller and cover gasket in reserve on board. OM944T 5/19... -
Page 31: Electrical System - General
Figure 10 4. Remove the booster battery after starting the engine. 5. Sealed Batteries: See the manufacturer's charging and booster instructions. Figure 12: Booster Battery Connections OM944T 5/19... -
Page 32: Battery Care
3. Drain the water supply lines and wet exhaust line. Cover the intake and exhaust ports with adhesive fabric tape. 4. Loosen the seawater pump cover and drain the pump. 5. Loosen the alternator belt. OM944T 5/19... -
Page 33: 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. OM944T 5/19... -
Page 34: 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. OM944T 5/19... - Page 35 • Fill crankcase to proper level. Improper type of oil • Drain and fill crankcase with correct oil. Partially plugged oil filter • Replace filter. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM944T 5/19...
- Page 36 Low Compression Pressure • See your dealer. Low engine oil viscosity • 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) OM944T 5/19...
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Page 37: Wiring Diagrams Ac Electrical
AC Wiring Diagram OM944T 5/19... -
Page 38: Dc Electrical
DC Wiring Diagram OM944T 5/19... - Page 39 DC Wiring Diagram OM944T 5/19...
- Page 40 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. © 2019 All rights reserved. Litho USA.
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