Northern Lights M944T3F, Operator'S Manual

Page 1: ...OM944F For Models M944W3 M944W3G M944W3F M944W3FG M944T3F M944T3FG M30CW3 M30C3F and M38C3F OPERATOR S MANUAL OPERATOR S MANUAL www northern lights com...

Page 2: ...to the outside Do not modify or tamper with the exhaust system Do not idle the engine except as necessary For more information go to www P65warnings ca gov diesel CALIFORNIA Proposition 65 Warning Nor...

Page 3: ...ING PROCEDURES Emissions Related Instructions 17 Break in Period 17 Before Starting 17 Starting 18 Operating 18 Stopping 18 Shutdowns and Alarms 19 Spare Parts 19 SERVICING SCHEDULE CHART 20 SERVICING...

Page 4: ...ot 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...

Page 5: ...EPA Tier III M944W3F Northern Lights commercial marine diesel generator set with a 944 engine and a PX 300K2 series generator end US EPA Tier III M30C3F Northern Lights marine diesel generator set wi...

Page 6: ...Keep signs in good and clean condition Replace missing or damaged signs Be sure new equipment components and repair parts include the current safety signs For replacement signs proper placement of sa...

Page 7: ...up of grease oil or debris Disconnect battery ground cable before making any adjustments or service work Handle Fuel Safely Avoid Flames WARNING Diesel is highly flammable and should be treated with...

Page 8: ...pen flame away from the top of battery When checking battery electrolyte level use a flashlight Safety Rules Continued Updated 4 12 17 Never check battery charge by contacting the posts with a metal o...

Page 9: ...flammable fluids Handle Chemical Products Safely WARNING Direct exposure to hazardous chemicals can cause serious injury Among the potentially hazardous chemicals that may be used with Northern Lights...

Page 10: ...drain fluid Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Do Not Open High Pressure F...

Page 11: ...aterial cannot be achieved at the local supply valve shut off valves further back in the system and re check the bleed off point until complete shut off is achieved Affix a DO NOT OPERATE tag to each...

Page 12: ...3 Rocker Arm Cover 4 Intake Manifold 5 Lube Oil Fill 6 Air Filter 7 Junction Box 8 Fuel Filter 9 Vibration Mounts 10 Lube Oil Dipstick 11 Fuel Manifold 12 Oil Filter 13 Fuel Primer Pump 14 Injection P...

Page 13: ...3 M944W3 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...

Page 14: ...4 Intake Manifold 5 Lube Oil Fills 6 Air Filter 7 Fuel Filter 8 Junction Box 9 Intake Air Noise Reduction Tube 10 Lube Oil Dipstick 11 Oil Filter 12 Fuel Supply Return Connections 13 Fuel Primer Pump...

Page 15: ...tor Set Component Locations 21 Exhaust Elbow 22 DPF and Exhaust Blanket 23 Exhaust Manifold 24 Alternator 25 Starter 26 Base Pan 22 23 21 25 26 Figure 5 M944W3F Non Service Side consult factory for de...

Page 16: ...4 Intake Manifold 5 Top Lube Oil Fill 6 Fuel Filter 7 Air Filter 8 Junction Box 9 Control Panel Plug 10 Vibration Isolation Mount 11 Lube Oil Dipstick 12 Oil Filter 13 Starter 14 Fuel Supply Return C...

Page 17: ...OM944F 5 21 15 M944W3F Generator Set Component Locations Figure 7 M944W3F Non Service Side consult factory for details...

Page 18: ...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...

Page 19: ...2 Operate engine under various conditions particularly heavy loading and minimal or no load conditions to help seat engine components properly 3 Constantly check the engine temperature and oil pressur...

Page 20: ...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...

Page 21: ...his could have been caused by a damaged impeller or a partially blocked sea water strainer Check the sea water strainer first If it is clear then check the condition of the sea water pump impeller b C...

Page 22: ...Check and clean heat exchanger Servicing Schedule Chart SERVICE 50 100 250 500 2000 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours ENGINE SP1 18 Check oil level SP2 18 Change engine oil 1 5...

Page 23: ...P13 Check turbocharger SP18 Check zinc electrodes EVERY 500 HOURS SP6 Check valve clearances SP8 Change primary filter element SP9 Change secondary fuel filter SP11 Check injectors SP15 Flush cooling...

Page 24: ...7 SP 2 OIL CHANGES 1 The set is delivered with special break in oil Change the engine oil and oil filter after 50 hours of operation Use diesel rated break in oil John Deere pre packaged or equivalent...

Page 25: ...lamp on the bracket and the hump hose to detach the air cleaner c Make sure the hump hose is clean inside and also that the new filter element is absolutely clean and installed properly 2 For naturall...

Page 26: ...ng the valve and one down opening the other valve The moment when the two rocker arms are exactly aligned with each other is when they rock Figure 11 Timing Mark 4 Measure the valve clearance for each...

Page 27: ...ng fuel a Keep dirt scale water and other foreign matter out of fuel b Avoid storing fuel for long periods of time c Fill the fuel tank at the end of each day s operation This will reduce condensation...

Page 28: ...cloth to prevent fuel from splashing b Turn the priming pump cap on the fuel feed pump counterclockwise to unlatch it Move the priming pump plunger 2 on Figure 10 up and down To close the pump turn t...

Page 29: ...e injector retaining nuts to 39 1 to 47 7 ft lbs 53 0 to 64 7 N m or 5 4 to 6 6 kgf m Do not overtighten b Reinstall the return line using new sealing washers Tighten bolts to 13 0 to 15 9 ft lbs 17 7...

Page 30: ...a around the pump with a cleaning solvent or steam cleaner NOTE Never steam clean or pour cold water on an injection pump while the engine is running or the pump is warm b Remove the injection lines f...

Page 31: ...2 Listen along air line while the engine is running A whistling or hissing sound could indicate leakage 3 Leakage on the pressure side between turbo and engine can be found by applying soapy water to...

Page 32: ...he engine Add coolant as needed NOTE Be sure to open the sea cock after working on the engine cooling system and starting the engine Servicing COOLING SYSTEM GENERAL NOTE Be sure to close the sea cock...

Page 33: ...re as needed 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 again if nece...

Page 34: ...END The maintenance and operation recommendations for the generator end are in a separate Owner s Manual OPX300K2 or OLXE check generator end part number for correct manual Megger generator end windi...

Page 35: ...hrough the engine Completely drain flush and fill the cooling system with pre mixed 50 50 conventional ethylene glycol heavy duty diesel engine coolant with SCAs Loosen alternator drive belt Completel...

Page 36: ...connection Low battery condition Check specific gravity of each battery Check electrolyte level of each battery Defective electrical system Repair or replace ground wire Starter Cranks Slowly Low bat...

Page 37: ...e Remove and check thermostat or Stalls Frequently Clogged primary Clean or replace filter element fuel filter element Clogged secondary Replace secondary filter element fuel filter element Water or d...

Page 38: ...engine temperature Check your thermostats Check water temperature to see if temperature gauge is working properly Faulty fuel injector Call your dealer Engine overheating See Engine Overheating secti...

Page 39: ...l Use correct fuel for temperature Fuel pump faulty See your dealer Injection nozzles dirty See your dealer Engine overloaded Reduce the electrical load Injection nozzles dirty See your dealer Injecti...

Page 40: ...38 OM944F 5 21 AC Wiring Diagram Updated 2 12 21 AC Wiring Diagram PX300K2 DST 100 2FAK B 9724J Drawings subject to change without notice...

Page 41: ...OM944F 5 21 39 AC Wiring Diagram AC Wiring Diagram 4 wire w circuit breaker PX300K2 DST 100 2FAK B 8459E Drawings subject to change without notice Updated 2 12 21...

Page 42: ...40 OM944F 5 21 AC Wiring Diagram Updated 2 12 21 AC Wiring Diagram M40C3F M40C3FR 4 wire MeccAlte DSR B 10606 Drawings subject to change without notice...

Page 43: ...OM944F 5 21 41 AC Wiring Diagram Updated 2 12 21 AC Wiring Diagram 12 wire PX300K2 DST 100 2FAK B 9723H Drawings subject to change without notice...

Page 44: ...42 OM944F 5 21 AC Wiring Diagram Updated 2 12 21 AC Wiring Diagram M944T3F 12 wire LX E 34E DST 100 2FAK B 9582H Drawings subject to change without notice...

Page 45: ...OM944F 5 21 43 AC Wiring Diagram AC Wiring Diagram M944T3F 12 wire ZigZag w circuit breaker LX E 34E DST 100 2FAK B 10597A Drawings subject to change without notice...

Page 46: ...44 OM944F 5 21 AC Wiring Diagram AC Wiring Diagram M40C3F M40C3FR three phase 12 wire Mecc Alte ECP32 3L 4B 3 DSR B 10539A Drawings subject to change without notice...

Page 47: ...OM944F 5 21 45 AC Wiring Diagram Updated 2 12 21 AC Wiring Diagram 12 wire Mecc Alte ECP32 1L4C DSR B 11861 Drawings subject to change without notice...

Page 48: ...46 OM944F 5 21 AC Wiring Diagram M944T3F AC Stamford SX460 B 10180A Drawings subject to change without notice AC Wiring Diagram Updated 2 12 21...

Page 49: ...OM944F 5 21 47 AC Wiring Diagram AC Wiring Diagram M40C3F M40C3FR Marathon AVC63 12B1 w PMG B 7429Q Drawings subject to change without notice...

Page 50: ...48 OM944F 5 21 DC Wiring Diagram Updated 2 12 21 DC Wiring Diagram M944W3F M30C3F 12 VDC Standard Ground C 7213C Drawings subject to change without notice...

Page 51: ...OM944F 5 21 49 DC Wiring Diagram Updated 2 12 21 DC Wiring Diagram M944W3F M30C3F 12 VDC Isolated Ground C 7264C Drawings subject to change without notice...

Page 52: ...50 OM944F 5 21 DC Wiring Diagram DC Wiring Diagram M944W3F M30C3F 24 VDC Standard Ground C 7263B Drawings subject to change without notice Updated 2 12 21...

Page 53: ...OM944F 5 21 51 DC Wiring Diagram DC Wiring Diagram M944W3F M30C3F 24 VDC Isolated Ground C 7262D Drawings subject to change without notice Updated 2 12 21...

Page 54: ...52 OM944F 5 21 DC Wiring Diagram DC Wiring Diagram M944W3FG 12 VDC Standard Ground C 7514A Drawings subject to change without notice Updated 2 12 21...

Page 55: ...OM944F 5 21 53 DC Wiring Diagram DC Wiring Diagram M944W3FG 12 VDC Isolated Ground C 7452A Drawings subject to change without notice Updated 2 12 21...

Page 56: ...54 OM944F 5 21 DC Wiring Diagram DC Wiring Diagram M944W3FG 24 VDC Standard Ground C 7453A Drawings subject to change without notice Updated 2 12 21...

Page 57: ...OM944F 5 21 55 DC Wiring Diagram DC Wiring Diagram M944W3FG 24 VDC Isolated Ground C 7454B Drawings subject to change without notice Updated 2 12 21...

Page 58: ...56 OM944F 5 21 DC Wiring Diagram DC Wiring Diagram M944T3F 12 VDC Standard Ground C 7214H Drawings subject to change without notice Updated 2 12 21...

Page 59: ...OM944F 5 21 57 DC Wiring Diagram DC Wiring Diagram M944T3F 12 VDC Isolated Ground C 7266E Drawings subject to change without notice Updated 2 12 21...

Page 60: ...58 OM944F 5 21 DC Wiring Diagram DC Wiring Diagram M944T3F 24 VDC Standard Ground C 7265C Drawings subject to change without notice Updated 2 12 21...

Page 61: ...OM944F 5 21 59 DC Wiring Diagram DC Wiring Diagram M944T3F 24 VDC Isolated Ground C 7234F Drawings subject to change without notice Updated 2 12 21...

Page 62: ...60 OM944F 5 21 DC Wiring Diagram DC Wiring Diagram M944T3FG 12 VDC Standard Ground C 7441B Drawings subject to change without notice Updated 2 12 21...

Page 63: ...OM944F 5 21 61 DC Wiring Diagram DC Wiring Diagram M944T3FG 12 VDC Isolated Ground C 7443A Drawings subject to change without notice Updated 2 12 21...

Page 64: ...62 OM944F 5 21 DC Wiring Diagram DC Wiring Diagram M944T3FG 24 VDC Standard Ground C 7442B Drawings subject to change without notice Updated 2 12 21...

Page 65: ...OM944F 5 21 63 DC Wiring Diagram DC Wiring Diagram M944T3FG 24 VDC Isolated Ground C 7444A Drawings subject to change without notice Updated 2 12 21...

Page 66: ...64 OM944F 5 21 DC Wiring Diagram M38C3F 12 VDC Standard Ground C 7491 Drawings subject to change without notice Updated 2 12 21 DC Wiring Diagram...

Page 67: ...OM944F 5 21 65 DC Wiring Diagram M38C3F 12 VDC Isolated Ground C 7492 Drawings subject to change without notice Updated 2 12 21 DC Wiring Diagram...

Page 68: ...66 OM944F 5 21 DC Wiring Diagram M38C3F 24 VDC Standard Ground C 7493 Drawings subject to change without notice Updated 2 12 21 DC Wiring Diagram...

Page 69: ...OM944F 5 21 67 DC Wiring Diagram M38C3F 24 VDC Isolated Ground C 7494 Drawings subject to change without notice Updated 2 12 21 DC Wiring Diagram...

Page 70: ...68 OM944F 5 21 Panel Wiring Diagram Panel Wiring Diagram S 1 Panel B A 12798B Updated 10 16 20...

Page 71: ...OM944F 5 21 69 NORTHERN LIGHTS Panel Wiring Diagram Panel Wiring Diagram S 1B B Deutsch A 12791C...

Page 72: ...70 OM944F 5 21 NORTHERN LIGHTS Panel Wiring Diagram Panel Wiring Diagram S 3B S 3C Panel B A 12790D...

Page 73: ...OM944F 5 21 71 Panel Wiring Diagram S 3A B Deutsch B 10854D Panel Wiring Diagram Updated 3 31 21...

Page 74: ...72 OM944F 5 21 NORTHERN LIGHTS AC Wiring Diagram AC Wiring Diagram 4 wire PX300K2 w DST 100 2FAK AVR B 9724 NON CURRENT MODEL...

Page 75: ...OM944F 5 21 73 NON CURRENT MODEL AC Wiring Diagram AC Wiring Diagram M944W3 and M30CW3 12 wire B 9723D...

Page 76: ...74 OM944F 5 21 DC Wiring Diagram DC Wiring Diagram M944W3 and M30CW3 12 VDC Standard Ground C 6855A NON CURRENT MODEL...

Page 77: ...OM944F 5 21 75 DC Wiring Diagram M944W3 and M30CW3 12 VDC Standard Ground C 6839A DC Wiring Diagram NON CURRENT MODEL...

Page 78: ...76 OM944F 5 21 DC Wiring Diagram DC Wiring Diagram M944W3 and M30C3 24 VDC Standard Ground C 6870A NON CURRENT MODEL...

Page 79: ...OM944F 5 21 77 DC Wiring Diagram DC Wiring Diagram M944W3 24 VDC Isolated Ground C 6871A NON CURRENT MODEL...

Page 80: ...78 OM944F 5 21 Panel Wiring Diagram Panel Wiring Diagram S 1B 12 Volt Drawing A 3170 Updated 6 22 12 NON CURRENT MODEL...

Page 81: ...OM944F 5 21 79 Panel Wiring Diagram Panel Wiring Diagram S 3C Drawing A 12645A Updated 6 22 12 NON CURRENT MODEL...

Page 82: ...80 OM944F 5 21 Panel Wiring Diagram Panel Wiring Diagram S 1B 24Volt Drawing A 4792 Updated 6 22 12 NON CURRENT MODEL...

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Page 84: ...F 5 21 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 2021 All rights reserved Li...