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Northern Lights OM844W3 Operator's Manual

Other manuals for OM844W3: Operator's Manual
Manual is about: M844W3; M844DW3; M844LW3; M20CRW3

Summary of OM844W3

  • 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

    Om844w3 5/11 1 read this operator's manual thoroughly before starting to operate your equipment. This manual contains information you will need to run and service your new unit. Proprietary information this publication is the property of northern lights, inc. It may not be reproduced in whole or in ...

  • Page 4

    Om844w3 5/11 2 introduction unit identifi cation 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 i...

  • Page 5

    Om844w3 5/11 3 serial numbers safety rules a warranty registration certifi cate is supplied with your set. 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 ...

  • Page 6

    Om844w3 5/11 4 safety rules revised 5-13-11 keep you machine in proper working condition. Unauthorized modifications to the machinery may impair its function and safety parameters. Prevent bypass and accidental starting do not start engine by shorting across start terminal. Engine will start if norm...

  • Page 7

    Om844w3 5/11 5 safety rules (continued) revised 5-13-11 sure that rotating shields turn freely in pace with the drivelines. Do not wear loose fi tting equipment around rotating drivelines. Stop the engine and make sure that all moving parts have stopped before making any adjustments, connections, or...

  • Page 8

    Om844w3 5/11 6 safety rules (continued) revised 5-13-11 engine has been shut off. Do not remove a fi ller cap unless it is cool enough to comfortably grip with bare hands. Slowly loosen cap to relieve pressure before opening fully. Avoid high pressure fluids relieve pressure prior to disconnecting p...

  • Page 9

    Om844w3 5/11 7 safety rules (continued) revised 5-13-11 use proper lifting equipment and techniques lifting heavy components incorrectly can cause severe injury or damage to machinery. Avoid unbalanced loads. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lif...

  • Page 10

    Om844w3 5/11 8 1. Dc circuit breaker 2. Coolant recovery tank 3. Secondary fuel filter 4. Fuel return line 5. Fuel injector 6. Oil fill (top) 7. Coolant fill 8. Fresh water pump 9. Injection pump marine generator component locations 19. Oil filter 20. Lube oil drain 21. Fuel lift pump 22. Control pa...

  • Page 11

    Om844w3 5/11 9 1. Dc circuit breaker (not visible. Callout for approximate location) 2. Coolant r ecovery tank 3. Secondary fuel filter 4. Fuel return line 5. Fuel injector 6. Oil fill (top) 7. Coolant fill 8. Fresh water pump marine generator component locations 19. Oil filter 20. Lube oil drain 21...

  • Page 12

    Om844w3 5/11 10 commercial generator component locations 1. Dc circuit breaker 2. Secondary fuel filter 3. Fuel return line 4. Fuel injector 5. Oil fill (top) 6. Coolant fill 7. Fresh water pump 8. Injection pump 9. Oil fill (side) 19. Control panel plug-in 20. Ac circuit breaker for automatic volta...

  • Page 13

    Om844w3 5/11 11 control panels figure 3-b: series 3 generator control panel figure 3-a: series 1-b generator control panel figure 3-c: series 4 generator control panel 1. Shutdown bypass-preheat switch two functions are built into this switch: the preheat- ing of the engine, and bypassing of the eng...

  • Page 14

    Om844w3 5/11 12 break-in period 1. The fi rst 100 hours on a new or reconditioned engine are critical to its life and performance. 2. Frequently check the engine temperature and oil pressure gauges (sets with series 3 or 4 panels). 3. Oil consumption is greater during break-in as piston rings take t...

  • Page 15

    Om844w3 5/11 13 shutdowns and alarms 1. Your unit is fi tted with a system to protect it from high water temperature or low oil pressure. A. Generator sets have shutdown systems to stop the engine. They have no warning horns. B. Other alarms and shutdowns are available as optional equipment. Note: d...

  • Page 16

    Om844w3 5/11 14 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 sp5 check v-belt tension sp7 c...

  • Page 17

    Om844w3 5/11 15 service record notes.

  • Page 18

    Om844w3 5/11 16 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 cc/cd/ce single viscosity oils. B. Api service cc/cd/sf multi-viscosity oils. 3. Use the proper weight oil for...

  • Page 19

    Om844w3 5/11 17 sp4. Air cleaner 1. Inspect air cleaner every 250 hours. In dusty condi- tions, check more often. 2. Marine sets: if dirty, wash element in soapy water. Rinse and dry thoroughly before re-installing. Replace if necessary. The element part number is: m844 w3 and m844 lw3 – #24-23100 3...

  • Page 20

    Om844w3 5/11 18 servicing fuels - general 1. Use only clean, high quality fuels of the following specifi cations, as defi ned 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 freez...

  • Page 21

    Om844w3 5/11 19 servicing sp10. 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...

  • Page 22

    Om844w3 5/11 20 figure 11: remove delivery line fl are nuts. Figure 12: remove delivery lines. Figure 13: cover lines, inlets and injection pump outlets. Figure 15: remove return line. Figure 16: unscrew injector. Figure 17: remove and replace copper sealing washer. Figure 18: reinstall injector. To...

  • Page 23

    Om844w3 5/11 21 sp11. Injector service 1. Injectors should be checked every 1000 hours. Check should be made by a northern lights dealer or local injection repair station. Have your dealer check the fuel injection nozzle spray pattern with injection nozzle tester. If the starting pressure is too hig...

  • Page 24

    Om844w3 5/11 22 servicing sp14. Cooling system flushing 1. Flush the cooling system every 2500 hours. 2. Marine sets: a. Remove expansion tank cap and drain engine block. B. Open block drain cock. Remove hose from bottom of heat exchanger tank. C. Pour clean water into expansion tank until water com...

  • Page 25

    Om844w3 5/11 23 glow plugs 1. Each cylinder is supplied with a glow plug which serves to heat the combustion chamber. 2. To check the glow plugs, loosen the current carrying fl at wire between the plus-poles of the glow plugs ( figure 19 ). Connect a d.C. Test bulb between the plus-pole of the batte...

  • Page 26

    Om844w3 5/11 24 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 27

    Om844w3 5/11 25 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 output • che...

  • Page 28

    Om844w3 5/11 26 troubleshooting engine problem possible cause recommendation(s) lack of engine power (continued) overheated engine • see “engine overheats” in next category. Below normal engine temperature • remove and check thermostat. Improper valve clearance • reset valves. Best done by dealer. D...

  • Page 29

    Om844w3 5/11 27 troubleshooting engine problem possible cause recommendation(s) high fuel consumption fuel leakage • improper installation or tightening. (continued) excessive load on engine • check loads. Below normal thermostat not working properly • check thermostat. Engine temperature temperatur...

  • Page 30

    Om844w3 5/11 28 wiring diagrams ac w iring diagram m844w2, m844l w2, m20cr w2, for 12 & 4 lead generators with a vr dst -100-2f ak drawing b-8280e.

  • Page 31

    Om844w3 5/11 29 wiring diagrams dc w iring diagram m844w3, m844l w3, m20cr w3 for 12 vdc standard ground drawing b-8394b.

  • Page 32

    Om844w3 5/11 30 wiring diagrams dc w iring diagram m844w3, m844l w3, m20cr w3 for 24 vdc standard ground drawing b-8534a.

  • Page 33

    Om844w3 5/11 31 wiring diagrams dc w iring diagram m844w3, m844l w3, m20cr w3 for 12 vdc isolated ground drawing b-8533a.

  • Page 34

    Om844w3 5/11 32 wiring diagrams dc w iring diagram m844w3, m844l w3, m20cr w3 for 24 vdc isolated ground drawing b-8535a.

  • Page 35

    Om844w3 5/11 33.

  • Page 36

    Www.Northern-lights.Com 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. © 2011 all rights reserved. Litho usa..