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Northern Lights M944WF3 Operator's Manual

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OPERATOR'S
MANUAL
OM944F
For Models:
M944W3F, M944T3F,
M30CW3F & M40C3F

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Summary of Contents for Northern Lights M944WF3

  • Page 1 OPERATOR’S MANUAL OM944F For Models: M944W3F, M944T3F, M30CW3F & M40C3F...
  • Page 2 4420 14th Avenue NW Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455 Copyright ©2017 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.: OM944-f 5/17...

  • 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 5/17...

  • Page 4: Introduction

    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...

  • Page 5: 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 6 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.
  • Page 7 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.
  • 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 Notes OM944F 5/17...

  • Page 12: M944W3F Generator Set

    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.
  • Page 13 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...

  • Page 14: 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 15: Operating Procedures

    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.

  • Page 16: Starting

    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 17: 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 18: Servicing Schedule Chart

    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...
  • Page 19 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...

  • Page 20: Servicing

    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.

  • Page 21: Changing Oil Filter

    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.

  • Page 22: Valve Clearances

    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.

  • Page 23: 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 24: Bleeding The Fuel System

    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.

  • Page 25: Injector Service

    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.

  • Page 26: 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 27: Turbocharger

    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.

  • Page 28: Heat Exchanger

    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.

  • Page 29: Electrical System - General

    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.

  • Page 30: Battery Care

    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.

  • Page 31: 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 5/17...

  • Page 32: 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 33: Ac Electrical

    • 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...
  • Page 34 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 •...
  • Page 35 DC Wiring Diagram OM944F 5/17...
  • Page 36 DC Wiring Diagram OM944F 5/17...
  • Page 37 DC Wiring Diagram OM944F 5/17...
  • Page 38 DC Wiring Diagram OM944F 5/17...
  • Page 39 DC Wiring Diagram OM944F 5/17...
  • Page 40 DC Wiring Diagram OM944F 5/17...
  • Page 41 DC Wiring Diagram OM944F 5/17...
  • Page 42 DC Wiring Diagram OM944F 5/17...
  • Page 43 AC Wiring Diagram OM944F 5/17...
  • Page 44 AC Wiring Diagram OM944F 5/17...
  • Page 45 AC Wiring Diagram OM944F 5/17...
  • Page 46 AC Wiring Diagram OM944F 5/17...
  • Page 47 AC Wiring Diagram OM944F 5/17...

  • Page 48: Panel Diagrams

    S-1B Wiring Diagram OM944F 5/17...

  • Page 49: Wiring Diagrams

    S-3 Wiring Diagram OM944F 5/17...
  • Page 52 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. © 2017 All rights reserved. Litho USA.

This manual is also suitable for:

M944t3M30cw3fM40c3fM944t3f

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