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  4. L944D, M944W, NL944D2, M30CW, M944T, NL944T2, and M38CR2
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Northern Lights L944D, M944W, NL944D2, M30CW, M944T, NL944T2, and M38CR2 Operator's Manual

Other manuals for L944D, M944W, NL944D2, M30CW, M944T, NL944T2, and M38CR2: Parts Manual

Summary of L944D, M944W, NL944D2, M30CW, M944T, NL944T2, and M38CR2

  • Page 2

    Diesel engine exhaust and some of its constitu- ents are known to the state of california to cause cancer, birth defects, and other reproductive harm. — california — proposition 65 warning: northern lights 4420 14th avenue n.W. Seattle, wa 98107 tel: (206) 789-3880 fax: (206) 782-5455 copyright ©201...

  • Page 3: Operator'S Manual

    Ol944d 11/13 3 proprietary information 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 ol944d 11/13 read this op...

  • Page 4

    4 ol944d 11/13 the servicing of marine engines and generator sets presents unique problems. In many cases, boats cannot be moved to a repair facility. Marine engines cannot be compared to the servicing of automobiles, trucks, or even farm equipment. Failures often occur in remote areas far from comp...

  • Page 5

    Ol944d 11/13 5 a warranty registration certificate is supplied with your engine. It entitles the original purchaser of our equipment to a warranty covering material or assembly faults. The extent of coverage is described in the limited warranty statement. We recommend that you study the statement ca...

  • Page 6

    6 ol944d 11/13 figure 2: l944d service side l944d component locations 1. Expansion tank 2. Coolant fill 3. Rocker arm cover 4. Fuel filter 5. Relay board cover 6. Air filter 7. Transmission gear 8. Oil pan 9. Lube oil dipstick 10. Oil filter 11. Fuel primer pump 12. Injection pump 13. Lube oil fill ...

  • Page 7

    Ol944d 11/13 7 l944d component locations figure 3: l944d non-service side 15. Wet exhaust elbow 16. Exhaust manifold 17. Heat exchanger 18. Raw water pump 19. Pto housing 20. Belt guard 25. Oil pan 21. Alternator 22. Starter 15 16 13 1 17 18 19 8 20 2 21 22 7 14.

  • Page 8

    8 ol944d 11/13 instrument panel figure 4: lugger main instrument control panel 1. Tachometer the tachometer shows the engine speed in revolutions per minute. (rpm). Numbers are multiples of 100. 2. Hour meter keeps track of the engine running time. 3. D.C. Voltmeter when the engine is stopped, the v...

  • Page 9

    Ol944d 11/13 9 operating procedures before starting 1. Check the water level by removing the pressure cap from the expansion tank. In order to give the cooling water an opportunity to expand, the level should be about 1 in. (2.5 cm) below the filler cap sealing surface when the engine is cold. Cauti...

  • Page 10

    10 ol944d 11/13 5. If the proper propeller is used, the engine should reach its appropriate maximum rpm’s at full throttle (2500 rpm). If the maximum rated rpm’s for your engine application are exceeded at full throttle, then your propeller is too small. If you cannot reach your maximum rated rpm’s ...

  • Page 11

    Ol944d 11/13 11 alarms (continued) 2. If the alarm system is activated: a. Check the temperature gauge, if the temperature is above 205 0 f (97 0 c) shut the engine off immediately. B. Use the trouble shooting guide on page 25 to isolate the cause of the overheat. Caution: do not remove the water fi...

  • Page 12

    12 ol944d 11/13 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: sp1 check oil level in engine sp8 check primary fuel filter ...

  • Page 13

    Ol944d 11/13 13 service point hours/ date service record operation 50 hours sp5 check v-belt tension sp19 check electrolyte in batteries 250 hours sp2 change engine oil sp3 change lubricating oil filters sp4 check air cleaner sp18 check zinc electrodes every 500 hours sp7 check valve clearances sp8 ...

  • Page 14

    14 ol944d 11/13 servicing lubrication - general 1. Use only clean, high quality lubricants stored in clean containers in a protected area. 2. These lubricants are acceptable: a. Api service cd, ce, and cf-4 single viscosity oils. B. Api service cd, ce, and cf-4 multi-viscosity oils. 3. Use the prope...

  • Page 15

    Ol944d 11/13 15 sp3. Changing lube oil filter 1. Change the lube oil filter every 250 hours. 2. Use a filter wrench to remove old filter. Dispose of filter in approved manner. 3. Make sure the gasket from the old filter is removed and discarded. Clean mount face. 4. Spread a thin film of engine oil ...

  • Page 16

    16 ol944d 11/13 servicing sp7. Valve clearances 1. Readjust valve clearance after first 50 hours of opera- tion. Check valves every 500 hours thereafter. 2. Check the valves when the engine is cold. 3. Rotate the crankshaft in a clockwise direction, using a turning socket, from the front of the engi...

  • Page 17

    Ol944d 11/13 17 fuels - general 1. Use only clean, high quality fuels of the following specifications, as defined by astm designation d975 for diesel fuels: a. Use grade no. 2 diesel at ambient temperatures above freezing 32° f (0° c). B. Use grade no. 1 at ambient temperatures below freezing. C. In...

  • Page 18

    18 ol944d 11/13 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 da...

  • Page 19

    Ol944d 11/13 19 servicing sp12. Injector service 1. Injectors should be checked every 500 hours. This check should be made by a northern lights dealer or local injection repair station. Caution: escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious perso...

  • Page 20

    20 ol944d 11/13 sp13. Injection pump 1. Since operating conditions may vary considerably, it is difficult to give a definite interval for checking the injection pump. But as a rule, pump settings, maximum speed, idle speed and exhaust smoke should be checked after every 2000 hours of operation. Serv...

  • Page 21

    Ol944d 11/13 21 servicing cooling system - general note: be sure to close the sea-cock before working on the engine cooling system. Caution: the cooling water in the engine reaches extremely high temperatures. You must use extreme caution when working on hot engines to avoid burns. Allow the engine ...

  • Page 22

    22 ol944d 11/13 sp16. Heat exchanger 1. Clean the heat exchanger core once a year or after 2000 hours of operation. 2. Drain the expansion tank and heat exchanger. 3. Remove the heat exchanger end covers. 4. Clean the inside of the exchanger core tubes using a metal rod. Flush, inspect, and clean ag...

  • Page 23

    Ol944d 11/13 23 electrical system - general 1. Never switch the battery switch off or break the circuit between the alternator and the batteries while the engine is running. Alternator damage can result. 2. Do not reverse the polarity of the battery cables when installing the battery. 3. When weldin...

  • Page 24

    24 ol944d 11/13 sp19-20. Battery care 1. Check the electrolyte level every 50 hours, or once a month. Add distilled water to the manufacturer's recommended level. 2. Batteries, cables, and cable terminals should be checked and cleaned every 100 hours. Clean corrosion with a water and baking soda sol...

  • Page 25

    Ol944d 11/13 25 if you cannot correct problems with these procedures, see your northern lights dealer. Troubleshooting dc electrical system problem possible cause recommendation(s) battery will not charge loose or corroded connections • clean and tighten battery connections. Sulfated or worn out bat...

  • Page 26

    26 ol944d 11/13 troubleshooting engine problem possible cause recommendation(s) engine hard to start improper starting procedure • see starting section of this manual. Or will not start no fuel • check level of fuel in fuel tank. Low battery condition • check electrolyte level and condition. Excessi...

  • Page 27

    Ol944d 11/13 27 troubleshooting engine problem possible cause recommendation(s) lack of engine power low compression pressure • consult dealer. (continued) (worn piston rings, etc...) engine overheats engine overloaded • check propeller size or pitch. Low coolant level • fill tank to proper level. •...

  • Page 28

    28 ol944d 11/13 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 • remove excess...

  • Page 29

    Ol944d 11/13 29 65 hp hp/ rpm 2500 rpm general information engine type cylinders inline 4 displacement 203 in 3 (3.33 liters) cycles 4 bore x stroke 3.7 x 4.72 in (94 x 120 mm) rotation (facing flywheel) counter-clockwise crankcase capacity including oil filter 11 qts (10 liter) aspiration natural f...

  • Page 30

    30 ol944d 11/13 northern lights dc wiring diagram – model l944d 12 v olt standard ground drawing c-6359 dc wiring diagram.

  • Page 31

    Ol944d 11/13 31 northern lights dc wiring diagram – model l944d 24 v olt standard ground drawing c-6360 dc wiring diagram.

  • Page 32

    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..