Northern Lights Lugger 0844K Operator'S Manual Download Page 21

O844K  10/09

gLOW PLUgS

1.  Each cylinder is supplied with a glow plug which 

serves to heat the combustion chamber.

2.  To check the glow plugs, loosen the current 

  carrying flat wire between the plus-poles of the 

  glow plugs (

Figure 19

). Connect a D.C. test bulb 

between the plus-pole of the battery and the 

  plus-pole of the glow plug. If the bulb lights up, 

  the glow plug is functioning properly.

3.  Check all glow plugs and replace any faulty ones.

Figure 19:  

Glow plugs.

bOOSTER bATTERIES

CAUTIoN:  Battery gas can explode.  

 

Keep all flames and sparks away from batteries.

1.  Before changing or using booster batteries, check bat-

tery electrolyte level. Add distilled water if necessary.

2.  Booster and main batteries must have the same volt-

age rating.

3.  First, connect positive (+) terminal of booster bat-

tery to positive (+) terminal of main battery. Then, 

connect negative (-) terminal of booster battery to 

ground on the engine block (

see Figure 20

).

4.  Remove booster battery after starting engine.

5.  Sealed batteries:  See manufacturer charging and 

booster instructions. 

SP 18-19.  bATTERy CARE

1.  Check electrolyte level daily.  Add distilled water to 

manufacturer’s recommended level.

2.  Batteries, cables and cable terminals should 

  be checked and cleaned every 100 hours. 

  Clean corrosion with a water and baking soda 

  solution. Flush with clean water. Tighten terminals 

and grease them to inhibit corrosion.

3.  Check the battery condition with a hydrometer every 

250 hours.

SP20.  P.T.O.

1.  The electric clutch P.T.O. does not have any 

 

scheduled maintenance points. However, the 

 

equipment the P.T.O. powers may require 

 

maintenance. Consult the manufacturer of the driven 

equipment.

SP21.  WINTERIZINg / OUT-Of-SERvICE

1.  Marine sets:

  a.  Drain fresh water and seawater cooling systems 

    completely. Remember to shut off seacocks 

    before opening drain cocks.

  b.  Drain water supply lines and wet exhaust line.

  c.  Loosen the seawater pump cover and drain pump.

  d.  Change the crankcase oil and filter.

  e.  Loosen the alternator belt.

  f.  Disconnect and clean battery. Remove to warm 

    storage place if possible.

  g.  Clean outside of unit. Paint any scratched or 

    chipped surfaces. Put corrosion preventative on 

    all exposed metal surfaces.

19

Figure 20:

Battery connections.

Servicing

Summary of Contents for Lugger 0844K

Page 1: ...O844K For Models M844K M844LK M20CL and M20CR OPERATOR S MANUAL Marine Generators Marine Diesel Engines Land Based Generators...

Page 2: ...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 2009 Northern Lights Inc All rights reserve...

Page 3: ...Marine Generators 5 CONTROL Panels Northern Lights Generator Sets 6 Operating Procedures Break in Period 8 Before Starting 8 Starting 8 Operating 8 Stopping 8 Shutdowns and Alarms 9 Spare Parts 9 Serv...

Page 4: ...DED This manual covers the operating instructions for M844k marine generator sets M844Lk marine generator sets and M20CL commercial generator sets Note There are two versions of the 844 engine The sta...

Page 5: ...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 w...

Page 6: ...e 16 Crankcase Vent 17 Fuel Injector 18 Oil Fill Top 19 Fresh Water Pump 20 Injection Pump 21 Oil Fill Side 22 Raw Water Inlet 23 Oil Pressure Sender 24 Freshwater Block Drain 25 Fuel Return Line 26 F...

Page 7: ...el Inlet 22 Lube Oil Drain 23 Control Panel Plug in 24 Generator End 25 DC Circuit Breaker 26 Secondary Fuel Filter 27 Fuel Lift Pump 28 Fuel Return Line 29 Crankcase Vent 30 Oil Fill Top Figure 3A an...

Page 8: ...t will return to RUN position To stop the engine hold the switch in the STOP position until the engine has com pletely stopped Note The rocker switch is used on Series 1 panels only and has a light th...

Page 9: ...O844K 10 09 7 Notes...

Page 10: ...ould 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 ste...

Page 11: ...perature rises above 205 F 96 C on Marine units Repeat troubleshooting 3 If shutdown is activated and the temperature gauge shows temperature within normal temperature range a Check the engine crankca...

Page 12: ...ntenance once a year even if hour level has not been reached 2 Consult manufacturer s maintenance schedule note on chart 3 Whenever necessary 4 More often if necessary 5 After first 50 hours then at 1...

Page 13: ...O844K 10 09 Service Record Notes 11...

Page 14: ...change oil every 100 hours or six weeks whichever comes first 4 Change oil at the end of each season and the begin ning of each season 5 Change oil when engine is warm 6 Dispose of waste oil in an app...

Page 15: ...CLEARANCES 1 Adjust valve clearance after first 50 hours of opera tion and every 1000 hours thereafter 2 Valve adjustments should be done after the cylinder head bolts have been re tightened Engine sh...

Page 16: ...ntamination d If biological contamination is detected or suspected contact your dealer for assistance SP7 9 FUEL FILTERS Figure 9 Primary Fuel Filter 1 Your generator set should have a primary fuel fi...

Page 17: ...System 1 The fuel system is self bleeding However any system may need manual bleeding when a A new fuel filter is installed b The engine has run out of fuel c The fuel lines injection pump or any oth...

Page 18: ...ery lines Figure 13 Cover lines inlets and injection pump outlets Figure 15 Remove return line Figure 16 Unscrew injector Figure 17 Remove and replace copper sealing washer Figure 18 Reinstall injecto...

Page 19: ...nd check for leaks using a piece of paper or cardboard DO NOT use hand to check for leaks SP12 Injection pump 1 Since operating conditions may vary considerably it is difficult to give a definite inte...

Page 20: ...ou remove all pieces of failed impeller NOTE Place some kind of protection under the screwdrivers in order not to damage the pump housing If the impeller has broken into pieces remove front heat excha...

Page 21: ...urer charging and booster instructions SP 18 19 BATTERY CARE 1 Check electrolyte level daily Add distilled water to manufacturer s recommended level 2 Batteries cables and cable terminals should be ch...

Page 22: ...lug connection Low battery output 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 23: ...ature 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...

Page 24: ...g section High Fuel Consumption Improper type of fuel Use correct fuel for temperature Clogged or dirty air cleaner Service air cleaner Improper valve clearance See your dealer Injection nozzles dirty...

Page 25: ...e too high Improper fuel Use correct fuel for temperature Injection nozzles dirty See your dealer Engine timing off See your dealer Engine Emits Improper fuel Use correct fuel for temperature White Sm...

Page 26: ...uction Head 39 in 990 mm 39 in 990 mm Keel Cooler TurboTube Length 4 feet 1 2 M 4 feet 1 2 M Keel Cooler Head Diameter 1 in 25 4 mm 1 in 25 4 mm Keel Cooler Water Hose ID 1 25 in 31 5 mm 1 25 in 31 5...

Page 27: ...uction Head 39 in 990 mm 39 in 990 mm Keel Cooler Turbo Tube Length 5 feet 1 5 M 5 feet 1 5 M Keel Cooler Head Diameter 1 in 25 4 mm 1 in 25 4 mm Keel Cooler Water Hose ID 1 25 in 31 5 mm 1 25 in 31 5...

Page 28: ...ad 39 in 990 mm 39 in 990 mm Keel Cooler Turbo Tube Length 5 feet 1 5 M 5 feet 1 5 M D C Electrical Minimum Battery Capacity 120 Amp Hour 120 Amp Hour Battery Cable Size 1 1 Starting Voltage Negative...

Page 29: ...O844K 10 09 27 Wiring Diagrams Engine Wiring Schematic 12V DC Drawing B 7998...

Page 30: ...O844K 10 09 Notes 28...

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