Northern Lights OM844W3 Operator's Manual
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Northern Lights OM844W3 Operator's Manual

Marine/commercial generator sets
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OM844W3
For Models: M844W3, M844DW3, M844LW3,
and M20CRW3
OPERATOR'S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators

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Summary of Contents for Northern Lights OM844W3

  • Page 1 OM844W3 For Models: M844W3, M844DW3, M844LW3, and M20CRW3 OPERATOR’S MANUAL Marine Generators | Marine Diesel Engines | Land-Based Generators...
  • Page 2 4420 14th Avenue N.W. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455 Copyright ©2013 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.: OM844W3 11/13...

  • 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 OM844W3 11/13...

  • Page 4: Introduction

    844L engine and a PX-320K2 generator end. M844DW Northern Lights 16 kW marine diesel generator set M20CRW3 Northern Lights 20 kW (@ 60 Hz) commercial grade with an 844L engine and a PX-320K2 generator end. marine generator set with a special generator end. 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. OM844W3 11/13...
  • 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 and use appropriate equipment exactly as recommended. 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: Safety Rules

    Exhaust parts and streams can reach high Follow all recommended removal and installation temperatures during operation, leading to burns or procedures in this and associated Northern Lights other serious injury. manuals. Cleaning exhaust filters can also lead to exposure to...

  • 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 OM844W3 11/13...
  • Page 12 AC Circuit Breaker for Oil Fill (Top) Freshwater Block Drain Belt Guard Automatic Voltage Regulator Coolant Fill Fuel Inlet Line Coolant Thermostat (behind) Expansion Tank/Exhaust Fresh Water Pump Fuel Return Line Water Temperature Sender Manifold/Heat Exch.Tank Injection Pump Oil Dipstick OM844W3 11/13...

  • Page 13: M844W3 Marine Generator (New Baseframe)

    Freshwater Block Drain approximate location) Coolant Thermostat (behind) AC Circuit Breaker for Oil Fill (Top) Fuel Inlet Line Water Temperature Sender Automatic Voltage Regulator Coolant Fill Fuel Return Line Expansion Tank/Exhaust Fresh Water Pump Oil Dipstick Manifold/Heat Exch.Tank OM844W3 11/13...

  • Page 14: M20Crw3 Commercial Generator

    Freshwater Block Drain Expansion Tank/Exhaust Belt Guard Coolant Fill Oil Dipstick Manifold/Heat Exch.Tank Coolant Thermostat (behind) Fresh Water Pump Oil Filter Coolant Drain Water Temperature Sender Injection Pump Oil Drain Wet Exhaust Elbow Oil Fill (Side) Fuel Lift Pump OM844W3 11/13...

  • Page 15: Control Panels

    Used to check voltage and current of each phase. 10. A.C. AMMETER Shows the generator load on each phase. The phase is selected with the Ammeter Selector switch ( Figure 3-C: Series 4 Generator Control Panel Item 9 OM844W3 11/13...

  • Page 16: Operating Procedures

    2. Run the engine for a 3 to 5 minute cool down period. 3. Hold the Engine Control switch to the STOP position until the engine comes to a complete stop. 4. Shut off the seacock, fuel valve, and battery switch. OM844W3 11/13...

  • Page 17: Shutdowns And Alarms

    SHUTDOWNS AND ALARMS SPARE PARTS 1. Your unit is fitted with a system to protect it from 1. Northern Lights recommends that you keep the high water temperature or low oil pressure. following spare parts on hand for field service. The a.

  • Page 18: Servicing Schedule Chart

    3000 hours, and the quality guarantee for 4) More often if necessary. these parts is 1500 hours or 2 years. 5) After first 50 hours, then at 100 hours, then at every 200 hours. OM844W3 11/13...
  • Page 19 Service Record Notes OM844W3 11/13...

  • Page 20: Servicing

    6. Fill engine with recommended oil. Start engine and check for leakage. Stop engine, wait 3 minutes, and check oil level. Add additional oil if necessary. 7. Oil filter part number is: 844W3 and 844LW3 – #24-03100 Figure 6 OM844W3 11/13...

  • Page 21: Servicing (Continued)

    360 in normal valves must be adjusted individually. direction from above 6. Replace the rocker arm cover. Tighten cover nuts to 5 - 8 ft/lbs (0.8 - 2.3 kg/m). Figure 7: 844W3 and 844LW3 Valve sequence OM844W3 11/13...

  • Page 22: Fuels - General

    Screw on until the gasket surface comes into contact with sealing surface of filter base. Then, tighten it two-thirds of a turn by hand. Do not overtighten. b. Fuel filter part number is: 844W3 and 844LW3 – #24-52020 OM844W3 11/13...

  • Page 23: Bleeding The Fuel System

    Pump hand primer “B” on fuel lift pump until 5. After the engine has started, use a piece of cardboard pure fuel (no bubbles) escapes from bleed bolt “A”. to look for fuel leaks. Tighten bleed screw “A”. OM844W3 11/13...
  • Page 24 Figure 12: Remove delivery lines. Figure 16: Unscrew injector. Figure 13: Cover lines, inlets and injection pump outlets. Figure 17: Remove and replace copper sealing washer. Figure 14: Remove return line nuts. Figure 18: Reinstall injector. Torque to proper tightness. OM844W3 11/13...

  • Page 25: Injector Service

    DO NOT use hand to check for leaks. 1. Injectors should be checked every 1000 hours. Check should be made by a Northern Lights dealer SP12. INJECTION PUMP or local injection repair station. Have your dealer 1.

  • Page 26: Cooling System Flushing

    Pour clean water into expansion tank until water Manual. If you do not have one of these manuals, coming from drains is free of discoloration and contact your local Northern Lights dealer. sediment. Let water drain completely. Close drains and refill with recommended mixture.

  • Page 27: Glow Plugs

    Clean outside of unit. Paint any scratched or negative (-) terminal of booster battery to ground on chipped surfaces. Put corrosion preventative on the engine block ( see Figure 20 all exposed metal surfaces. 4. Remove booster battery after starting engine. OM844W3 11/13...

  • Page 28: 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. OM844W3 11/13...

  • Page 29: Engine

    Clogged secondary • Replace filter element. fuel filter element Injection pump not getting fuel • Have injection pump checked. Improper type of fuel • Consult fuel supplier and use proper type of fuel for operating conditions. OM844W3 11/13...

  • Page 30: Engine Knocks

    Injection pump out of time • See your dealer. Engine not at proper temperature • Check your thermostats. • Check water temperature with thermometer and replace gauge if necessary. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM844W3 11/13...

  • Page 31: Engine

    White Smoke Cold engine • Warm up engine to normal operating temperature. Defective thermostat • Remove and check thermostat. Engine timing off • See your dealer. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM844W3 11/13...

  • Page 32: Wiring Diagrams

    8/6/12 Wiring Diagrams OM844W3 11/13...
  • Page 33 9-19-11 Wiring Diagrams OM844W3 11/13...
  • Page 34 Revised 6/8/12 Wiring Diagrams OM844W3 11/13...

  • Page 35: Dc Electrical

    9-19-11 Wiring Diagrams OM844W3 11/13...
  • Page 36 Wiring Diagrams OM844W3 11/13...
  • Page 37 9-19-11 Wiring Diagrams OM844W3 11/13...
  • Page 38 9-19-11 Wiring Diagrams OM844W3 11/13...
  • Page 39 6/8/12 Wiring Diagrams OM844W3 11/13...
  • Page 40 Revised 6/8/12 Wiring Diagrams OM844W3 11/13...
  • Page 41 6/8/12 Wiring Diagrams OM844W3 11/13...
  • Page 42 9-19-11 Wiring Diagrams OM844W3 11/13...
  • Page 43 9-19-11 Wiring Diagrams OM844W3 11/13...
  • Page 45 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. © 2013 All rights reserved. Litho USA.

This manual is also suitable for:

M844w3M844dw3M844lw3M20crw3

Table of Contents