Cylinders Filtration marine generator set 94 mm Northern Lights marine diesel generator set with a 944 engine M944W3F and a PX-300K2 series generator end, 30 kW US EPA Tier III Final. Northern Lights commercial marine diesel generator set with a...
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.
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Revised 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.
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Revised 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.
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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.
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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.
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.
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.
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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 5/17...
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.
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.
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.
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.
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 cont.: Check oil level in engine Check air cleaner Check primary fuel filter...
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Service Record Service OPERATION HOURS/ DATE Point 50 HOURS Check V-belt tension SP21 Check electrolyte in batteries 250 HOURS Change engine oil Change lubricating oil filters Check air cleaner SP14 Check turbocharger SP20 Check zinc electrodes EVERY 500 HOURS Check valve clearances Change primary filter element SP10 Change secondary fuel filter...
Servicing LUBRICATION - GENERAL SP1. CHECKING OIL LEVEL 1. While the engine is stopped, check the oil 1. Use only clean, high quality lubricants level in the crankcase with the dipstick daily. stored in clean containers in a protected area. The oil level must be between the high and low marks on the stick.
Servicing SP3. CHANGING LUBE OIL FILTER SP5. 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.
Servicing SP7. 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.
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.
Servicing SP11. 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.
1. Injectors should be checked every 500 hours. This injector. Evenly tighten the injector retaining check should be made by a Northern Lights dealer nuts to 39.1 to 47.7 ft/lbs (53.0 to 64.7 N•m), or or local injection repair station.
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.
Servicing 3. If chlorides, sulfates or total dissolved solids are SP14. TURBOCHARGER higher than the above given specification, the water must be distilled, demineralized, or 1. Check for air leaks every 250 hours. Air leakage will deionized before it is used in a cooling system. lower engine output and may cause black exhaust 4.
Servicing SP20. ZINC ELECTRODES and then check the coolant level in the engine. Add coolant as needed. 1. A zinc electrode is installed in the heat exchanger cooling system to protect the engine from NOTE: Be sure to open the sea-cock after working electrolysis.
Servicing BOOSTER BATTERIES GENERATOR END CAUTION: Battery gas can explode. Keep all The maintenance and operation recommendations for flames and sparks away from batteries. the generator end are in a separate Owner's Manual. If you do not have one of these manuals, contact your 1.
Servicing SP21-22. BATTERY CARE 6. Cover the terminals and openings of the 1. Check the electrolyte level every 50 hours, or once starter and alternator with adhesive fabric a month. Add distilled water to the manufacturer's tape. Cover the starter and alternator with recommended level.
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 5/17...
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 •...
• 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. OM944F 5/17...
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Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) High Oil Consumption Break-in period • Oil consumption decreases after break in. Crankcase oil too light • Use proper viscosity oil. Oil leaks • Check for leaks in lines around gaskets and drain plug. Crankcase over full •...
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