Northern Lights M844W3, M844LW3, M20CRW3 Operator's Manual

OM844W3

For Models: M844W3, M844LW3, and M20CRW3

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.

Northern Lights

4420 14th Avenue N.W.
Seattle, WA 98107
Tel: [phone]
Fax: [phone]

Copyright ©2008 Alaska Diesel Electric, Inc.
All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Alaska Diesel Electric, Inc.

Printed in U.S.A.
PART NO.: OM844W3 01/08

OPERATOR'S MANUAL

for Models

M844W3, M844LW3, and M20CRW3

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

Models Included ...................................................4

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

Serial Numbers .....................................................5

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

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

COMPONENT LOCATIONS

M844W3 Marine Generator ................................. 6

M20CRW3 Commercial Generator ...................... 7

CONTROL PANELS ............................................... 8

OPERATING PROCEDURES

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

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

Starting .................................................................. 9

Operating ..............................................................9

Stopping ................................................................ 9

Shutdowns and Alarms ....................................... 10

Spare Parts ..........................................................10

SERVICING (continued)

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

Valve Clearances .................................................15

Fuels - General .................................................... 16

Fuel Filters .......................................................... 16

Bleeding the Fuel System ................................... 17

Injector Service ...........................................18 - 19

Injection Pump ....................................................19

Cooling System - General ................................... 19

Cooling System Flushing .................................... 20

Heat Exchanger ................................................... 20

Raw Water Pump ................................................20

Generator Ends ...................................................20

Electrical System - General ................................20

Glow Plugs .......................................................... 21

Booster Batteries ................................................. 21

Battery Care ........................................................ 21

PTO Care ............................................................21

Winterizing / Out-of-Service .............................. 21

TROUBLESHOOTING

Electrical ............................................................. 22

Engine ......................................................... 23 - 25

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

SERVICING

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

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

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

Changing Oil Filter ............................................. 14

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 OM844W3 01/08

OM844W3 01/08

WIRING DIAGRAMS

AC Electrical ......................................................26

DC Electrical ..............................................27 - 30

3

Introduction

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

Failures can begin with minor problems that are

overlooked and become amplied when not corrected

during routine maintenance.
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.

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:

M844W3 marine generator sets,

M844LW3 marine generator sets, and

M20CRW3 commercial generator sets.

NOTE: There are two versions of the 844W3 engine. The standard engine is designated 844W3. The long-stroke
engine is designated 844LW3. You will need to know which engine you have to use this manual and to order parts.

Fill in the model number of your unit in the blank space provided.

This will give you a reference whenever service or maintenance is required:

Model Numbers

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

M

M - Northern Lights marine generator set

M844W3

M844LW3

Northern Lights marine diesel generator set with

=

an 844 engine and a PX-316K2 generator end.

Northern Lights marine diesel generator set with

=

an 844L engine and a PX-320K2 generator end.

Model number of engine block

+

Bore Cylinders
84 mm 4

844

M20CRW3

My Northern Lights generator set MODEL number is:

W, L, C, 3

W - New winding

+

L - Long stroke version
C - Commercial version
3 - Tier 3

Northern Lights 20 kW (@ 60 Hz) commercial grade

=

marine generator set with a special generator end.

OM844W3 01/08

4

Generator set serial number plate.

Serial Numbers

Your set has three serial numbers: 1 an engine number stamped
on the block, 2 a generator plate, and

a generator set plate.

3

Use the serial number on the generator set plate when ordering parts
or in correspondence. The generator set plate is found on the service
side of the generator and resembles the drawing at left.

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

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.
in the Limited Warranty Statement. We recommend
that you study the statement carefully.

Safety Rules

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.

• 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.

• Provide rst aid kits.

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

• Use caution in handling fuel. Never refuel a hot

or running engine. Do not smoke while lling fuel

tank or servicing fuel system.

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

OM844W3 01/08

5

Marine Generator Component Locations

Service Side

5

Non-Service

Side

Figure 1A and 1B: M844W3

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

5

10. Oil Fill (Side)

11. Raw Water Pump

12. Raw Water Inlet

13. Vibration Mount

14. Oil Pressure Sender

15. Freshwater Block Drain

16. Fuel Inlet Line

17. Fuel Return Line

18. Oil Dipstick

19. Oil Filter

20. Lube Oil Drain

21. Fuel Lift Pump

22. Control Panel Plug-in

23. AC Circuit Breaker for
Automatic Voltage Regulator

24. Expansion Tank/Exhaust
Manifold/Heat Exch.Tank

OM844W3 01/08

6

25. Coolant Drain

26. Wet Exhaust Elbow

27. Junction Box

28. Starter

29. Alternator

30. Belt Guard

31. Coolant Thermostat (behind)

32. Water Temperature Sender

Commercial Generator Component Locations

Figure 2A and 2B: M20CRW3

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)

10. Raw Water Pump

11. Raw Water Inlet

12. Vibration Mount

13. Oil Pressure Sender

14. Freshwater Block Drain

15. Oil Dipstick

16. Oil Filter

17. Oil Drain

18. Fuel Lift Pump

19. Control Panel Plug-in

20. AC Circuit Breaker for
Automatic Voltage Regulator

21. Expansion Tank/Exhaust
Manifold/Heat Exch.Tank

22. Coolant Drain

23. Wet Exhaust Elbow

OM844W3 01/08

7

24. Junction Box

25. Starter

26. Alternator

27. Belt Guard

28. Coolant Thermostat (behind)

29. Water Temperature Sender

Control Panels

Figure 3-A: Series 1-B 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 engine safety

shutdown circuit. Hold switch in the ON position
10 - 20 seconds before starting the engine, and
continue holding on during engine cranking. Release

the switch as soon as the engine is running. Holding

the switch on too long can burn out the heater element.

2. ENGINE CONTROL SWITCH

To start the engine, hold this switch in the START

position until the engine is running.
NOTE: Excessive cranking of marine sets equipped

with water lift mufer systems can cause engine

damage. See page 7.

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 until the engine has
completely stopped.
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 3-B: Series 3 Generator Control Panel

4. OIL PRESSURE GAUGE

Shows the oil pressure in the engine lubricating system.

5. ENGINE TEMPERATURE GAUGE

Registers the temperature of the engine coolant.

6. D.C. VOLTMETER OR AMMETER

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
SWITCH

Used to check voltage and current of each phase.

Figure 3-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 (Item 9).

OM844W3 01/08

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. 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 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 or radiator. 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 dip-

stick. The oil level must be in the wafed area 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.

4. Close the sea-cock; check, clean, and reassemble the
sea strainer and re-open the sea-cock.

5. Place the battery switch in the ON position.

6. 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 regulator could be ruined.

STARTING

1. Hold the Shutdown Bypass-Preheat switch in the
ON position for 10 to 20 seconds before starting a
cold engine. Holding the switch too long can burn
out the glow plugs. This step is not necessary if the
engine is already warm.

2. While holding the Shutdown Bypass-Preheat 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 10 seconds

consecutively. If the engine fails to start with the rst

attempt, be sure that it has stopped completely (wait at
least 30 seconds) before re-engaging.

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 three 20-

second cranks, remove the impeller from the raw water

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

Once the engine starts, shut it off immediately and

re-install the impeller. Re-start the engine 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 on Marine sets must be
below 200°F (94°C). Normal coolant temperature
is 167° to 194°F (75°C to 90°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. Apply electrical load.

STOPPING

1. Remove electrical load from the generator set.

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 01/08

9