Northern Lights M944W3, M30CW3 Operator's Manual

OM944W3

For Models: M944W3 and M30CW3

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constituents 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: (206) 789-3880

Fax: (206) 782-5455

Printed in U.S.A.

PART NO.: OM944W3 01/08

OPERATOR'S MANUAL

for Northern Lights® M944W3 and M30CW3 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
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
Lubrication - General.......................................	14
Checking Oil.....................................................	14
Oil Changes......................................................	14
Changing Oil Filter...........................................	15
Air Filter...........................................................	15

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

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 OM944W3 01/08

OM944W3 01/08

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 amplified 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 Identification

ModelS INCLUDED

This manual covers the operating instructions for:

M944W3 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		+	Model number of engine block
			Bore	Cylinders
			94 mm	4

M944W3

M30CW3

=Northern Lights marine diesel generator set with a 944 engine and a PX-332K2 series generator end, Tier III.

=Northern Lights marine diesel generator set with a 944 engine and a PX-332K2 series generator end; commercial unit, 30 kW, Tier III.

Serial Numbers

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

an engine number stamped on a generator end 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.

Figure 1: Generator set serial number plate.

OM944W3 01/08

A warranty registration certificate 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.

Warranty

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

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 fire 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 fluids 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.

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

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

•Use caution in handling fuel. Never refuel a hot or running engine. Do not smoke while filling 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, qualified 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 first aid kits.

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

OM944W3 01/08

Northern Lights M944W3, M30CW3 Operator's Manual

M944W3 Generator Set Component Locations

5 16

Figure 2: M944W3 Service Side with PX-300K2 series generator end.

1.	Expansion Tank	8.	Fuel Filter	15.	Lube Oil Drain
2.	Coolant Fill	9.	Vibration Mounts	16.	Thermostat Housing
3.	Rocker Arm Cover	10.	Lube Oil Dipstick	17.	Heat Exchanger Raw Water
4.	Intake Manifold	11.	Fuel Manifold	23.	Drain and Zinc
5.	Lube Oil Fill	12.	Oil Filter	23.	Raw Water Pump
6.	Air Filter	13.	Fuel Primer Pump
7.	Junction Box	14.	Injection Pump

OM944W3 01/08

M944W3 Generator Set Component Locations

18 19

Figure 3: M944W3 Non-Service Side with PX-300K2 series generator end.

18.	AC Circuit Breaker	24.	Belt Guard
19.	DC Circuit Breaker	25.	Oil Pan
20.	Wet Exhaust Elbow	26.	Alternator
21.	Exhaust Manifold	27.	Starter

22.Heat Exchanger

23.Raw Water Pump

OM944W3 01/08

Control Panels

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

Figure 4-B: Series 3 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.

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.

10.A.C. AMMETER

Shows the generator load on each phase. The phase is selected with the Ammeter Selector switch (#9).

Figure 4-C: Series 4 Generator Control Panel

OM944W3 01/08

BREAK-IN PERIOD

1.The first 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 filter at 50 hours. Change oil and filter again at

100 hours (consult Lubricants section for oil recommendation).

Operating Instructions:

Maintain at least a 75% load on your generator set for the first 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.

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.

CAUTION: Use protective clothing and open the filler 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 filter.

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.

OM944W3 01/08

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 first 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 muffler 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 muffler from filling with water and backfilling 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 five 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 five 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.

OM944W3 01/08

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