Northern Lights M944W, M30CW Operator's Manual

OM944W

For Models: M944W and M30CW

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

— CALIFORNIA —

Proposition 65 Warning:

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.

www.northern-lights.com

4420 14th Ave. NW., Seattle WA 98107

Tel: [phone] • 1-800-762-0165

• Fax: [phone]

Northern Lights and Lugger are registered

trademarks of Alaska Diesel Electric, Inc.

© 2006 All rights reserved. Litho USA.

OPERATOR'S MANUAL

for Northern Lights® M944W and M30CW Diesel Generator Sets

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.

Table of Contents

INTRODUCTION ....................................................4

Model Numbers ..................................................4

Serial Numbers ...................................................4

WARRANTY ............................................................5

SAFETY RULES .....................................................5

COMPONENT LOCATIONS

M944W Generator Set .................................6 - 7

CONTROL PANELS

Northern Lights Generator Sets .........................8

OPERATING PROCEDURES

Break-in Period ...................................................9

Before Starting ....................................................9

Starting ............................................................. 10

Operating ......................................................... 10

Stopping ........................................................... 10

Shutdowns and Alarms .....................................11

Spare Parts ........................................................11

SERVICING SCHEDULE CHART ............ 12 - 13

SERVICING (Continued)

V-Belts ............................................................. 15

Valve Clearances .............................................. 16

Fuels - General ................................................. 17

Fuel Filters ....................................................... 17

Bleeding the Fuel System ................................ 18

Injector Service ................................................ 19

Injection Pump ................................................. 20

Cooling System ............................................... 21

Heat Exchanger ................................................ 22

Raw Water Pump ............................................. 22

Zinc Electrodes ................................................ 22

Electrical System - General ............................. 23

Booster Batteries .............................................. 23

Battery Care ..................................................... 24

Winterizing / Out-of-Service ........................... 24

TROUBLESHOOTING

Electrical .......................................................... 25

Engine ...................................................... 26 - 28

WIRING DIAGRAMS

AC Electrical ................................................... 29

DC Electrical ........................................... 30 - 33

SERVICING

Lubrication - General ....................................... 14

Checking Oil .................................................... 14

Oil Changes ..................................................... 14

Changing Oil Filter .......................................... 15

Air Filter .......................................................... 15

Proprietary Information

This publication is the property of Alaska Diesel Electric, Inc.

It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc.

© Alaska Diesel Electric, Inc. All rights reserved. Litho U.S.A. Publication number OM944W 06/06

OM944W 06/06

3

Introduction

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 competent assistance. Marine engines are
taxed far more severely than auto or truck engines;
therefore, maintenance schedules must be adhered to

more strictly. Failures begin with minor problems that

are overlooked and become amplied when not corrected

during routine maintenance.
As operator, it is your obligation to learn about your
equipment and its proper maintenance. This is not a
comprehensive technical service manual. Nor will it make
the reader into an expert mechanic. Its aim is to aid you in
maintaining your unit properly.

Unit Identication

MODELS INCLUDED

This manual covers the operating instructions for:

M944W marine generator sets, which use the 944 engine block.

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:

M 944

M - Northern Lights marine generator set

Northern Lights marine diesel generator set with

M944W

M30CW

=

a 944 engine and a PX-332K2 series generator end.

Northern Lights marine diesel generator set with a 944 engine and a

=

PX-332K2 series generator end; commercial unit, 30 kW.

Serial Numbers

Figure 1: Generator set
serial number plate.

+

Model number of engine block

Bore Cylinders
94 mm 4

Your set has three serial numbers: 1 an engine number stamped on
a plate attached to the valve cover, 2 a generator end serial number,
and 3 a generator set serial number.

NOTE: Always use the generator set serial number when ordering parts
or in correspondence. The generator set serial number plate is found on
the service side of the generator and resembles the drawing in Figure 1.

OM944W 06/06

4

Warranty

A warranty registration certi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 you study the statement
carefully.

CAUTION: Accident reports show that careless use of engines causes a high percentage
of accidents. You can avoid accidents by observing these safety rules. Study these rules carefully
and enforce them on the job.

• Never leave engine without proper security.

• Turn the coolant tank cap slowly to relieve pressure
before removing. Add coolant only when the engine
is stopped and cool.

• Mount a re extinguisher near engine.

• Always disconnect the battery ground strap before
making adjustments.

• Operate engines in properly ventilated areas.

• Keep trash and other objects away from engine.

• Escaping uids under pressure can penetrate your

skin. Use a piece of cardboard or wood, not your
hands, to search for leaks.

• Avoid wearing loose clothing without a belt when
working around engines.

NOTE: If the warranty is to apply, the servicing
instructions outlined in this manual must be followed.
If further information is needed, please contact an
authorized dealer or the factory.

Safety Rules

• Use caution in handling fuel. Never refuel a hot or

running engine. Do not smoke while lling fuel tank

or servicing fuel system.

• Keep your hands, feet, hair and clothing away from
power-driven parts.

• Check for any loose electrical connections or faulty
wiring.

• Engines should be operated only by knowledgeable,

qualied personnel.

• Look completely around engine to make sure that
everything is clear before starting.

• Do not operate an engine that isn't in proper working
order. If an unsafe operating condition is noted, tag the
set and control panel so others will also know about the
problem.

• Do not oil or grease engine while it is running.

• Remove the negative (-) battery terminal cable before
servicing electrical components or welding.

CAUTION: This symbol is used throughout
this book to alert you to possible danger areas.
Please take special notice of these sections.

OM944W 06/06

• Provide rst aid kits.

5

M944W Generator Set Component Locations

17

1

16

2

3

4

5

6

7

8

1415

Figure 2: M944W Service Side with PX-300K2 series generator end.

1. Expansion Tank

2. Coolant Fill

3. Rocker Arm Cover

4. Intake Manifold

5. Lube Oil Fill

6. Air Filter

7. Junction Box

13

12

8. Fuel Filter

9. Vibration Mounts

10. Lube Oil Dipstick

11. Fuel Manifold

12. Oil Filter

13. Fuel Primer Pump

14. Injection Pump

OM944W 06/06

6

9

1011

15. Lube Oil Drain

16. Thermostat Housing

17. Heat Exchanger Raw Water

Drain and Zinc

M944W Generator Set Component Locations

18

19

20

21

22

23

24

25

27

Figure 3: M944W Non-Service Side with PX-300K2 series generator end.

18. AC Circuit Breaker

19. DC Circuit Breaker

20. Wet Exhaust Elbow

21. Exhaust Manifold

22. Heat Exchanger

23.

Raw Water Pump

24. Belt Guard

25. Oil Pan

26. Alternator

27. Starter

OM944W 06/06

7

26

Control Panels

Figure 4-A: Series 1-B Generator Control Panel

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.

2. ENGINE CONTROL SWITCH

To start the engine, hold this switch in the START

position until the engine is running. After the engine

starts, release the switch and it will return to RUN

position. To stop the engine, hold the switch in the

STOP position.

NOTE: The rocker switch is used on Series 1 panels
only, and has a light that glows when the set is
running.

3. HOUR METER

Keeps track of engine running time.

Figure 4-B: Series 3 Generator Control Panel

4. OIL PRESSURE GAUGE

Shows the oil pressure in the engine lubricating system.

5. WATER TEMPERATURE GAUGE

Registers the temperature of the cooling water.

6. D.C. VOLTMETER

When the engine is stopped, the voltmeter indicates the

condition of the battery. When the engine is running,
the voltmeter indicates the voltage output of the alterna­tor.

For Series 4 Control Panels only:

7. A.C. VOLTMETER

Shows the generator output voltage.

8. FREQUENCY METER (Hertz)

The frequency meter indicates alternating current

frequency: 60 Hz (1800 rpm) or 50 Hz (1500 rpm).

9. AMMETER/VOLTMETER SELECTOR

Used to check the voltage and current of each phase.

Return to “Amps Off” position when not monitoring.

Figure 4-C: Series 4 Generator Control Panel

10. A.C. AMMETER

Shows the generator load on each phase. The phase is

selected with the Ammeter Selector switch (#9).

OM944W 06/06

8

Operating Procedures

BREAK-IN PERIOD

1. The rst 100 hours on a new or reconditioned

engine are critical to its life and performance.

2. Constantly check the engine temperature and oil
pressure gauges.

3. Oil consumption is greater during break-in as

piston rings take time to seat.

4. Break-In Oil Changes: Change engine oil and

lter at 50 hours. Change oil and lter again at

100 hours (consult Lubricants section for oil
recommendation).

Operating Instructions:

Maintain at least a 75% load on your generator

set for the rst 100 hours. If this is not possible,

maintain no less than a 50% load to ensure proper
seating of the piston rings. Vary the load to help

seat the rings.

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 ller cap

sealing surface when the engine is cold.

CAUTION: Use protective clothing and open

the ller cap carefully when the engine is warm

to prevent burns.

2. Check the oil level in the crankcase with the
dipstick. The oil level must be between high and
low marks on the stick. Never allow the level to go
below this area. Always add the same viscosity of

oil as is already in the crankcase.

3. Check the fuel tank level and open any fuel valves

on the tank and at the secondary fuel lter.

4. Close the sea-cock, check and clean the sea strainer,
and reopen the sea-cock.

5. Place the battery switch in the ON position.

NOTE: The battery switch must always be kept ON
while the engine is running. If the switch is
turned OFF while the engine is running,
the battery charging alternator could be
damaged.

OM944W 06/06

9

Operating Procedures

STARTING

1. Hold the Shutdown Bypass switch in the ON
position.

2. While holding the Shutdown Bypass switch in the
ON position, push the Engine Control switch to the
START position.

3. As soon as the engine starts, release both switches.
Do not crank the starter for more than 20 seconds
consecutively. If the engine fails to start with the

rst attempt, be sure that it has stopped completely

before re-engaging the starter.

NOTE: Excessive cranking of the starter on marine

   setsequippedwithawaterliftmufercan

cause engine damage. If the engine does not
start after 3 consecutive 20-second cranks,
remove the impeller from the seawater

   pump.Thiswillpreventthemuferfrom
   llingwithwaterandbackllingtheexhaust

line and engine. Once the engine starts, shut
if off immediately and reinstall the impeller.
Restart and check the exhaust overboard
outlet for gushes of water.

OPERATING

1. Units with Series 3 and Series 4 Control Panels:
check gauges often. Oil pressure must be above
15 PSI. The D.C. voltmeter should read between
11 and 15 volts at 80° F (25° C) ambient temperature.

The water temperature gauge must be below 200°
F (94° C). Check the A.C. voltage and frequency
meters (Series 4 panel). If the gauges deviate from
normal levels, shut down the generator set and

investigate.

2. Let the unit run unloaded for a three to ve minute

warm-up period.

3. Add electrical load.

STOPPING

1. Remove electrical load from the generator set.

2. Run the engine for a three to ve minute cool-down

period.

3. Move the Engine Control switch to the STOP
position until the engine stops completely.

4. Shut off seacock, fuel valve, and battery switch.

OM944W 06/06

10

Operating Procedures

SHUTDOWNS AND ALARMS

1. Your unit is 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: If your unit is equipped with optional
shutdowns and alarms, do not rely on your
warning or shutdown system to the exclusion
of careful gauge monitoring. Watching your
gauges can prevent damage to the unit and
dangerous power losses.

2. Do the following when your warning or shutdown

system is activated:
a. Check the temperature gauge. If above 205° F
(96° C), shut off the engine immediately.
b. Use the Trouble Shooting Guide on page 25 to
isolate the cause of the overheat.

CAUTION: Do not remove the water ll

cap of an overheated engine. Escaping high
temperature steam can cause severe burns. Allow
the engine to cool and then remove the cap slowly
using protective clothing.

SPARE PARTS

1. ADE recommends that you keep the following spare

parts on hand for eld service. The parts are

available from your local Northern Lights dealer.

Some marine models may already have “On-Board
Kits,” a handy box that contains the most common
parts you will need.

a. Primary and secondary fuel lter elements
b. Oil lters
c. Air lter elements

d. Alternator belt
e. Thermostat and gaskets
f. Seawater pump impeller and gaskets
g. Glow plugs
h. Injector and washer

2. If your set is operating a long distance from a
servicing dealer, add the following:

a. Complete set of injectors
b. Copper washers for injector change
c. Complete set of glow plugs
d. Fuel lift pump

c. Make repairs and restart after the temperature
gauge registers below 200° F (94° C).
d. Watch the temperature gauge regularly and
turn off the unit if the temperature rises above
205° F (96° C). Repeat troubleshooting.

3. If shutdown is activated and the temperature gauge

shows temperature within normal temperature range:
a. Check the engine crankcase oil level.

b. If the oil level is low, ll with recommended

lubricating oil and restart. Watch the oil pressure
gauge carefully and shut off the engine if it does
not show a normal reading (20-60 PSI) after a
few seconds of operation.
c. If the oil level is normal, DO NOT restart the
engine. Call your dealer for assistance.

OM944W 06/06

11