Northern Lights Lugger 0844K Operator'S Manual Download Page 5

O844K  10/09

Serial Numbers

3

Safety Rules

CAUTIoN:  This symbol is used throughout

this book to alert you to possible danger areas.

Please take special notice of these sections.  

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.

NOTE:

 If the warranty is to apply, the servicing 

instructions outlined in this manual must be 

followed. If further information is needed, please con-

tact 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.

•  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.
•  Use caution in handling fuel. Never refuel a hot 

or running engine. Do not smoke while filling fuel 

tank or servicing fuel system.

Your set has three serial numbers: 

 an engine number stamped 

on the block, 

 a generator plate, and 

 a generator set plate. 

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 in 

Figure 1

Fill in the serial number of

your unit in the box provided.

Figure 1:  

Generator set serial number plate.

Warranty

•  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 work-

ing 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.

My Northern Lights generator set SERIAL number is:

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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