Northern Lights M944T User manual
OM944T
For Models: M944T & M38CR2
OPERATOR’S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators
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 ©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.: OM944T 10/08
OM944T 10/08
3
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 OM944T 10/08
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.
OPERATOR'S MANUAL
for Northern Lights®M944T & M38CR2 Diesel Generator Sets
INTRODUCTION ....................................................4
Model Numbers ..................................................4
Serial Numbers ...................................................4
WARRANTY ............................................................5
SAFETY RULES .....................................................5
COMPONENT LOCATIONS
M944T 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
Table of Contents
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 - 31
4
OM944T 10/08
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 amplied 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.
Introduction
M - Northern Lights marine generator set Model number of engine block
Bore Cylinders
94 mm 4
Serial Numbers
MODELS INCLUDED
This manual covers the operating instructions for:
M944T& M38CR2 marine generator sets, which use the 944 engine block.
Model Numbers
Model numbers give the unit's application, block model, aspiration, and RPM:
+
Unit Identication
Northern Lights marine diesel generator set with
a 944 engine and a LX-E 34E series generator end.
M944T
M944
=
Your set has three serial numbers: 1an engine number stamped on
a plate attached to the valve cover, 2a generator end serial number,
and 3a 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.
Figure 1: Generator set
serial number plate.
T - Turbocharged
C- Commercial
T, C
+
Northern Lights commercial diesel generator set with
a 944 engine and a UCI224 Stamford generator end.
M38CR2 =
OM944T 10/08
5
A warranty registration certicate 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.
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.
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.
• 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,
qualied 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.
• 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.
• Do not oil or grease engine while it is running.
• Remove the negative (-) battery terminal cable before
servicing electrical components or welding.
Safety Rules
CAUTION: This symbol is used throughout
this book to alert you to possible danger areas.
Please take special notice of these sections.
Warranty
6
OM944T 10/08
Figure 2: M944TService Side
M944T Generator Set Component Locations
1. Expansion Tank
2. Coolant Fill
3. Thermostat Housing
4. Rocker Arm Cover
5. Lube Oil Fill
6. Intake Manifold
7. Fuel Filter
8. Air Cleaner
9. Junction Box
10. Lube Oil Dipstick
11. Oil Filter
12. Vibration Mounts
13. Fuel Manifold
14. Fuel Primer Pump
15. Injection Pump
16. Lube Oil Drain
17. Raw Water Pump
18. Heat Exchanger Raw Water
Drain and Zinc
19. Heat Exchanger
12345 6 789
12
10
13
11
1415
16
17
18
19
OM944T 10/08
7
M944T Generator Set Component Locations
Figure 3: M944TNon-Service Side
19. Turbocharger
20. Wet Exhaust Elbow
21. Exhaust Manifold
22. Alternator
23. Belt Guard
24. Starter
25. Oil Pan
19 20
22
23
24
25
21
8
OM944T 10/08
Control Panels
Figure 4-B: Series 3 Generator Control Panel
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.
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 alterna-
tor.
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
OM944T 10/08
9
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 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.
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.
10
OM944T 10/08
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. Add electrical load.
STOPPING
1. Remove electrical load from the generator set.
2. Run the engine for a two to three minute cool-down
period.
3. Move the Engine Control switch to the STOP
position.
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 10 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
setsequippedwithawaterliftmufercan
cause engine damage. If the engine does not
start after 3 consecutive 10-second cranks,
remove the impeller from the seawater
pump.Thiswillpreventthemuferfrom
llingwithwaterandbackllingtheexhaust
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.
This manual suits for next models
1
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