Northern Lights OM944W3 Operator's Manual
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Northern Lights OM944W3 Operator's Manual

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OPERATOR'S MANUAL
OPERATOR'S MANUAL
OM944W3
For Models: M944W3, M944W3G and M30CW3
www.northern-lights.com

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Summary of Contents for Northern Lights OM944W3

  • Page 1 OPERATOR’S MANUAL OPERATOR’S MANUAL OM944W3 For Models: M944W3, M944W3G and M30CW3 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.: OM944W3 01/23...

  • Page 3: Table Of Contents

    This publication is the property of Alaska Diesel Electric, 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 OM944W3 1/23...

  • Page 4: Introduction

    3 - US EPA Tier III compliant Northern Lights marine diesel generator set with M944W3 Northern Lights marine diesel generator set with a M30CW3 a 944 engine and a PX-332K2 series generator 944 engine and a PX-332K2 series generator end;...

  • 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 Check for any loose electrical connections or faulty grease, oil or debris. wiring. Disconnect battery ground cable (-) before making Look completely around engine to make sure that any adjustments or service work. everything is clear before starting. OM944W3 1/23...
  • Page 7 State of California to cause cancer and and open flame away from the top of battery. When reproductive harm. Wash hands after handling. checking battery electrolyte level, use a flashlight. OM944W3 1/23...
  • 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 Instructions

    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 OM944W3 1/23...

  • Page 12: Component Locations Generator Set

    10. Lube Oil Dipstick 17. Heat Exchanger Raw Water Intake Manifold 11. Fuel Manifold Drain and Zinc Lube Oil Fill 12. Oil Filter 23. Raw Water Pump 13. Fuel Primer Pump Air Filter Junction Box 14. Injection Pump OM944W3 1/23...
  • Page 13 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. Starter 22. Heat Exchanger 23. Raw Water Pump OM944W3 1/23...
  • Page 14 Intake Manifold 10. Lube Oil Dipstick Water Drain and Zinc 11. Intake Air Noise Reduction Tube 19. Vibration Isolating Mounts Lube Oil Fill Air Filter 12. Oil Filter 23. Raw Water Pump Junction Box 13. Fuel Primer Pump OM944W3 1/23...
  • Page 15 Figure 3: M944W3 Non-Service Side with PX-300K2 series generator end and new baseframe. 15. Lube Oil Drain 24. Belt Guard 18. AC Circuit Breaker 25. Oil Pan 20. Wet Exhaust Elbow 26. Alternator 21. Exhaust Manifold 27. Starter 22. Heat Exchanger 23. Raw Water Pump OM944W3 1/23...

  • 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 4-C: Series 4 Generator Control Panel OM944W3 1/23...

  • 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. OM944W3 1/23...

  • Page 18: Starting

    Once the engine starts, shut period. if off immediately and reinstall the impeller. Restart and check the exhaust overboard 3. Move the Engine Control switch to the STOP outlet for gushes of water. position until the engine stops completely. 4. Shut off seacock, fuel valve, and battery switch. OM944W3 1/23...

  • Page 19: Shutdowns And Alarms

    The parts are warning or shutdown system to the exclusion available from your local Northern Lights dealer. of careful gauge monitoring. Watching your Some marine models may already have “On-Board gauges can prevent damage to the unit and Kits,”...

  • Page 20: Servicing Schedule Chart

    2) Consult manufacturer’s maintenance schedule, note on chart. 1500 Hours: Fuel injectors are to be removed & injector tips cleaned. 3) Whenever necessary. 3000 Hours: Fuel injectors removed for adjustment, cleaning, & repair. 4) More often if necessary. 5) After first 50 hours. OM944W3 1/23...
  • Page 21 Check cooling system SP16 Change impeller in seawater pump SP20 Check condition of batteries with hydrometer 2000 HOURS or as required Check air cleaner SP12 Check fuel injection pump SP14 Flush cooling system SP15 Check and clean heat exchanger OM944W3 1/23...

  • Page 22: Servicing

    Dispose of waste oil in an approved manner. Never use a flushing oil. Loosen clamp on oil change tube. Remove cap. Drain oil. Replace cap and tube. Refill engine with recommended oil. 10. Engine capacity with new oil filter is: Model 944W3....10.5 qts. (10 liters) OM944W3 1/23...

  • Page 23: Changing Oil Filter

    If dirty, wash element in soapy water. Rinse and dry thoroughly before reinstalling. 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. OM944W3 1/23...

  • Page 24: Valve Clearances

    Insert a feeler gauge between the rocker arm and the valve stem cap. Adjust, while measuring the clearance, until the feeler gauge slides with a slight drag. Tighten the lock nut and recheck the clearance ( Figure 7 OM944W3 1/23...

  • Page 25: Fuels - General

    6. Storing fuel: a. Keep dirt, scale, water, and other foreign matter out of fuel. b. Avoid storing fuel for long periods of time. c. Fill the fuel tank at the end of each day’s operation. This will reduce condensation. OM944W3 1/23...

  • Page 26: Bleeding The Fuel System

    Then tighten the connections. can be seen in the fuel flowing from the air vent Do each line one-at-a-time. After the engine has plug hole. started, use a piece of cardboard to look for fuel leaks. OM944W3 1/23...

  • Page 27: Injector Service

    1. Injectors should be checked every 500 hours. This a. Take injectors to your Northern Lights dealer check should be made by a Northern Lights dealer or local injection repair station for testing and or local injection repair station. Expected service life service.

  • Page 28: Injection Pump

    Servicing SP-12. INJECTION PUMP f. Take the pump to your Northern Lights dealer or an injection repair station for testing and service. 1. Since operating conditions may vary considerably, it is difficult to give a definite interval for checking the injection pump.

  • Page 29: Cooling System

    Add used to make coolant solution. coolant as needed. NOTE: Be sure to open the sea-cock after working on the engine cooling system and starting the engine. OM944W3 1/23...

  • 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. OM944W3 1/23...

  • Page 31: Electrical System - General

    4. Remove the booster battery after starting the engine. engine is running. Alternator damage can result. 5. Sealed Batteries: 2. Do not reverse the polarity of the battery cables when See the manufacturer's charging and booster installing the battery. instructions. Figure 10: Booster Battery Connections OM944W3 1/23...

  • 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. OM944W3 1/23...

  • 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. OM944W3 1/23...

  • 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. OM944W3 1/23...
  • 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. OM944W3 1/23...
  • 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) OM944W3 1/23...

  • Page 37: Ac Wiring

    Updated 10-14-20 AC Wiring Diagram OM944W3 1/23...
  • Page 38 Updated 10-14-20 AC Wiring Diagram OM944W3 1/23...
  • Page 39 Updated 10-14-20 AC Wiring Diagram OM944W3 1/23...

  • Page 40: Dc Wiring

    Updated 10-14-20 DC Wiring Diagrams OM944W3 1/23...
  • Page 41 Updated 10-14-20 DC Wiring Diagrams OM944W3 1/23...
  • Page 42 Updated 10-14-20 DC Wiring Diagrams OM944W3 1/23...
  • Page 43 Updated 10-14-20 DC Wiring Diagram OM944W3 1/23...
  • Page 44 Updated 10-14-20 DC Wiring Diagram OM944W3 1/23...
  • Page 45 Updated 10-14-20 DC Wiring Diagram OM944W3 1/23...
  • Page 46 Updated 10-14-20 DC Wiring Diagram OM944W3 1/23...
  • Page 47 Updated 10-14-20 DC Wiring Diagram OM944W3 1/23...

  • Page 48: Panel Wiring

    Updated 10-14-20 Panel Wiring Diagrams OM944W3 1/23...
  • Page 49 Updated 10-14-20 Panel Wiring Diagrams OM944W3 1/23...
  • Page 50 Updated 10-14-20 Panel Wiring Diagrams OM944W3 1/23...
  • Page 51 Updated 10-14-20 Panel Wiring Diagrams OM944W3 1/23...

  • Page 52: Ac Wiring

    AC Wiring Diagram OM944W3 1/23...

  • Page 53: Dc Wiring

    DC Wiring Diagram OM944W3 1/23...
  • Page 54 DC Wiring Diagram OM944W3 1/23...
  • Page 55 DC Wiring Diagram OM944W3 1/23...
  • Page 56 DC Wiring Diagram OM944W3 1/23...

  • Page 57: Panel Diagrams

    Updated 6-22-12 Panel Wiring Diagram OM944W3 1/23...
  • Page 58 Updated 6-22-12 Panel Wiring Diagram OM944W3 1/23...
  • Page 59 Updated 6-22-12 Panel Wiring Diagram OM944W3 1/23...
  • Page 60 OM944W3 1/23...
  • Page 61 OM944W3 1/23...
  • Page 62 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. © 2023 All rights reserved. Litho USA.

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