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Northern Lights Lugger OM944W Operator's Manual

Marine generators | marine diesel engines | land-based generators
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OM944W
For Models: M944W and M30CW
OPERATOR'S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators

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Summary of Contents for Northern Lights Lugger OM944W

  • Page 1 OM944W For Models: M944W and M30CW OPERATOR’S MANUAL Marine Generators | Marine Diesel Engines | Land-Based Generators...
  • Page 2 4420 14th Ave. NW., Seattle WA 98107 Tel: (206) 789-3880 • 1-800-762-0165 • Fax: (206) 782-5455 Northern Lights and Lugger are registered trademarks of Northern Lights, Inc. © 2006 All rights reserved. Litho USA.

  • 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 OM944W 06/06...

  • Page 4: Introduction

    Northern Lights marine diesel generator set with M944W a 944 engine and a PX-332K2 series generator end. Northern Lights marine diesel generator set with a 944 engine and a M30CW PX-332K2 series generator end; commercial unit, 30 kW. Serial Numbers...

  • Page 5: Warranty

    Warranty A warranty registration certifi cate is supplied with your NOTE: If the warranty is to apply, the servicing set. It entitles the original purchaser of our equipment instructions outlined in this manual must be followed. to a warranty covering material or assembly faults. The If further information is needed, please contact an extent of coverage is described in the Limited Warranty authorized dealer or the factory.

  • Page 6: M944W Generator Set

    M944W Generator Set Component Locations Figure 2: M944W Service Side with PX-300K2 series generator end. Expansion Tank Fuel Filter 15. Lube Oil Drain Coolant Fill Vibration Mounts 16. Thermostat Housing 10. Lube Oil Dipstick 17. Heat Exchanger Raw Water Rocker Arm Cover 11.
  • Page 7 M944W Generator Set Component Locations 18 19 Figure 3: M944W Non-Service Side with PX-300K2 series generator end. 18. AC Circuit Breaker 24. Belt Guard 25. Oil Pan 19. DC Circuit Breaker 20. Wet Exhaust Elbow 26. Alternator 21. Exhaust Manifold 27.

  • Page 8: 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 9: Operating Procedures

    Operating Procedures BREAK-IN PERIOD BEFORE STARTING 1. The fi rst 100 hours on a new or reconditioned 1. Check the water level by removing the pressure engine are critical to its life and performance. cap from the expansion tank. In order to give the cooling water an opportunity to expand, the level 2.

  • Page 10: 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 11: Shutdowns And Alarms

    1. Your unit is fi tted with a system to protect it from high water temperature or low oil pressure. parts on hand for fi eld service. The parts are available from your local Northern Lights dealer. a. Generator sets have shutdown systems to stop the engine. They have no warning horns.

  • Page 12: 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: Check oil level in engine SP2/3 Change engine oil and fi...
  • Page 13 Service Record Service OPERATION HOURS/ DATE Point 50 HOURS Check V-belt tension SP19 Check electrolyte in batteries 250 HOURS Change engine oil Change lubricating oil fi lters Check air cleaner SP18 Check zinc electrodes EVERY 500 HOURS Check valve clearances Change primary fi...

  • Page 14: Lubrication - General

    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 15: Changing Oil Filter

    Servicing SP3. CHANGING LUBE OIL FILTER SP5. V-BELTS 1. Change the lube oil fi lter every 250 hours. 1. Check the tension and wear on the V-belt after every 50 hours. 2. Use a fi lter wrench to remove old fi lter. Dispose of fi...

  • Page 16: Valve Clearances

    Servicing SP7. VALVE CLEARANCES 1. Readjust valve clearance after fi rst 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 17: Fuels - General

    1. Use only clean, high quality fuels of the following 1. Your generator set should have a fuel fi lter installed. specifi cations, as defi ned by ASTM designation We recommend the Northern Lights brand of fuel D975 for diesel fuels: fi lters.

  • Page 18: 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 19: 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 20: Injection Pump

    Servicing SP13. 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 diffi cult to give a defi nite interval for checking the injection pump.

  • Page 21: Cooling System

    Servicing COOLING SYSTEM - GENERAL SP15. COOLING SYSTEM FLUSHING NOTE: Be sure to close the sea-cock before working 1. Flush the cooling system every 2000 hours or every on the engine cooling system. 12 months, whichever comes fi rst. CAUTION: The cooling water in the engine 2.

  • Page 22: Heat Exchanger

    Servicing SP18. ZINC ELECTRODES SP16. HEAT EXCHANGER 1. A zinc electrode is installed in the heat exchanger 1. Clean the heat exchanger core once a year or after cooling system to protect the engine from 2000 hours of operation. electrolysis. Check it faithfully every 250 hours. If you are in warm saltwater, or where electrolysis is a 2.

  • Page 23: Electrical System - General

    Servicing BOOSTER BATTERIES GENERATOR END CAUTION: Battery gas can explode. Keep all The maintenance and operation recommendations for fl ames 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 24: Battery Care

    Servicing SP19-20. 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 25: Troubleshooting

    • Clean and tighten battery and harness plug connections. Sulfated or worn out batteries • Check specifi c gravity and electrolyte level of each battery. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM944W 06/06...

  • Page 26: 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 27 • Fill crankcase to proper level. Improper type of oil • Drain and fi ll crankcase with correct oil. Partially plugged oil fi lter • Replace fi lter. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM944W 06/06...
  • Page 28 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 29: Wiring Diagrams Ac Electrical

    AC Wiring Diagram OM944W 06/06...

  • Page 30: Dc Electrical

    DC Wiring Diagram OM944W 06/06...
  • Page 31 DC Wiring Diagram OM944W 06/06...
  • Page 32 DC Wiring Diagram OM944W 06/06...
  • Page 33 DC Wiring Diagram OM944W 06/06...
  • Page 34 OM944W 06/06...
  • Page 35 4420 14th Ave. NW., Seattle WA 98107 Tel: (206) 789-3880 • 1-800-762-0165 • Fax: (206) 782-5455 Northern Lights and Lugger are registered trademarks of Northern Lights, Inc. www.northern-lights.com © 2006 All rights reserved. Litho USA.

This manual is also suitable for:

Lugger m944wLugger m30cw

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