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Northern Lights OM844W3 Operator's Manual

For models: m844w3; m844lw3; m20crw3
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OM844W3
For Models: M844W3, 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, 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 ©2011 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 5/11...

  • 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 5/11...

  • Page 4: Introduction

    Northern Lights marine diesel generator set with M844W M20CRW3 Northern Lights 20 kW (@ 60 Hz) commercial grade an 844 engine and a PX-316K2 generator end. marine generator set with a special generator end. Northern Lights marine diesel generator set with M844LW an 844L engine and a PX-320K2 generator end.

  • Page 5: Serial Numbers

    Learn how to operate the machine and how to use CAUTION indicates the presence of a potential hazard the controls properly. Only trained personnel should that can or will cause severe or minor property damage, operate machines, or work on or around them. personal injury or death. OM844W3 5/11...
  • Page 6 Check for any loose electrical Entanglement in rotating connections or faulty wiring. drivelines can cause serious injury or death. Look completely around engine to Keep shields in place make sure that everything is clear at all times. Make before starting. OM844W3 5/11...
  • Page 7 Among the potentially hazardous Never check battery charge by contacting the posts chemicals that may be used with a metal object. Use a volt-meter or hydrometer. with Northern Lights products are lubricants, Frozen batteries may explode if charged. Never coolants, paints and charge a battery that has not been allowed to warm to adhesives.
  • Page 8 Follow the procedures disconnecting pressurized and use appropriate equipment exactly as recommended. lines. Escaping fl uid under Contact your Northern Lights dealer or Northern Lights pressure can penetrate the factory for MSDS’s used on Northern Lights products. skin causing serious injury.
  • Page 9 The asbestos used in these environment and lead to unsafe working conditions. components is usually Potentially harmful waste used in Northern Lights found in a resin or otherwise equipment can include oil, fuel, coolant, fi lters and sealed. Normal handling of these components is not batteries.

  • Page 10: Component Locations M844W3 Marine Generator (Older Baseframe)

    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 5/11...

  • Page 11: M844W3 Marine Generator (New Baseframe)

    Fuel Injector Freshwater Block Drain 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 5/11...

  • Page 12: 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 5/11...

  • Page 13: 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 ( Item 9 Figure 3-C: Series 4 Generator Control Panel OM844W3 5/11...

  • Page 14: Operating Procedures

    2. Run the engine for a 3 to 5 minute cool down period. battery charging regulator could be ruined. 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 5/11...

  • Page 15: Shutdowns And Alarms

    SPARE PARTS 1. Your unit is fi tted 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 fi eld service. The a.

  • Page 16: 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 fi rst 50 hours, then at 100 hours, then at every 250 hours. OM844W3 5/11...
  • Page 17 Service Record Notes OM844W3 5/11...

  • Page 18: 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 fi lter part number is: 844W3 and 844LW3 – #24-03100 Figure 6 OM844W3 5/11...

  • Page 19: Air Filter

    5. Repeat steps 3 and 4 for each cylinder. Each set of 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 5/11...

  • Page 20: Fuels - General

    fi lter base. Then, tighten it two-thirds of a turn by hand. Do not overtighten. b. Fuel fi lter part number is: 844W3 and 844LW3 – #24-52020 OM844W3 5/11...

  • Page 21: Bleeding The Fuel System

    fi lter. 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 5/11...
  • Page 22 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 5/11...

  • Page 23: 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 24: Cooling System Flushing

    Manual. If you do not have one of these manuals, 5. Reassemble. Fill the cooling system, start the engine contact your local Northern Lights dealer. and check for leaks. ELECTRICAL SYSTEM - GENERAL 1. Never switch battery switch off or break the circuit between the alternator and batteries while the engine is running.

  • Page 25: Glow Plugs

    (-) terminal of booster battery to ground on the engine block ( see Figure 20 4. Remove booster battery after starting engine. 5. Sealed batteries: See manufacturer charging and booster instructions. Figure 20: Battery connections. OM844W3 5/11...

  • Page 26: 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. OM844W3 5/11...

  • Page 27: Engine

    Clogged secondary • Replace fi lter element. fuel fi lter 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 5/11...
  • Page 28 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 5/11...
  • Page 29 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 5/11...

  • Page 30: Wiring Diagrams

    Wiring Diagrams OM844W3 5/11...

  • Page 31: Dc Electrical

    Wiring Diagrams OM844W3 5/11...
  • Page 32 Wiring Diagrams OM844W3 5/11...
  • Page 33 Wiring Diagrams OM844W3 5/11...
  • Page 34 Wiring Diagrams OM844W3 5/11...
  • Page 35 OM844W3 5/11...
  • Page 36 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 © 2011 All rights reserved. Litho USA.

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