Northern Lights OM844W3 Operator'S Manual Download | Manualshive

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OM844W3

For Models: M844W3, M844LW3, and M20CRW3

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

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Summary of Contents for OM844W3

Page 1: ...OM844W3 For Models M844W3 M844LW3 and M20CRW3 OPERATOR S MANUAL Marine Generators Marine Diesel Engines Land Based Generators ...

Page 2: ...d 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 2011 Northern Lights Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Northern Lights Inc Printed in U S A PART NO OM844W3 5 11 ...

Page 3: ...r older baseframe 8 M844W3 Marine Generator new baseframe 9 M20CRW3 Commercial Generator 10 CONTROL PANELS 11 OPERATING PROCEDURES Break in Period 12 Before Starting 12 Starting 12 Operating 12 Stopping 12 Shutdowns and Alarms 13 Spare Parts 12 SERVICING SCHEDULE CHART 14 SERVICING Lubrication General 16 Checking Oil 16 Oil Changes 16 Changing Oil Filter 16 Air Filter 17 SERVICING continued V Belt...

Page 4: ...covers the operating instructions for M844W3 marine generator sets M844LW3 marine generator sets and M20CRW3 commercial generator sets NOTE There are two versions of the 844W3 engine The standard engine is designated 844W3 The long stroke engine is designated 844LW3 You will need to know which engine you have to use this manual and to order parts Fill in the model number of your unit in the blank ...

Page 5: ... life threatening injuries when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL PRIOR TO THE INSTALLATION OF ANY GENERATOR SET OR ACCESSORY KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE Recognize Safety Symbols and Instructions In addition to the information found in this section thi...

Page 6: ...r behind your head If any of these items get caught in moving machinery severe injury or death could result Check for any loose electrical connections or faulty wiring Look completely around engine to make sure that everything is clear before starting Wear Protective Clothing To prevent catching anything in moving machinery always wear close fitting clothes and safety equipment appropriate to the ...

Page 7: ...l object Use a volt meter or hydrometer Frozen batteries may explode if charged Never charge a battery that has not been allowed to warm to at least 16oC 60oF Always remove grounded battery clamp first and replace ground clamp last Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin eat holes into clothing and other materials and cause blindness if splashed into eyes T...

Page 8: ...NJECTION SYSTEMS All potentially hazardous chemicals come with a Material Data Safety Sheet MSDS The MSDS provides specific details on chemical products including physical hazards safety procedures and emergency response techniques Read and understand the MSDS for each chemical before you start any job that includes it Follow the procedures and use appropriate equipment exactly as recommended Cont...

Page 9: ... Avoid Hot Exhaust Avoid exposure to and physical contact with hot exhaust gases Exhaust parts and streams can reach high temperatures during operation leading to burns or other serious injury Cleaning exhaust filters can also lead to exposure to hot exhaust gas and the injury risk associated with it Avoid exposure to and physical contact with hot exhaust gases when cleaning exhaust filters During...

Page 10: ...lug in 23 AC Circuit Breaker for Automatic Voltage Regulator 24 Expansion Tank Exhaust Manifold Heat Exch Tank Service Side Non Service Side Figure 1A and 1B M844W3 25 Coolant Drain 26 Wet Exhaust Elbow 27 Junction Box 28 Starter 29 Alternator 30 Belt Guard 31 Coolant Thermostat behind 32 Water Temperature Sender 10 Oil Fill Side 11 Raw Water Pump 12 Raw Water Inlet 13 Vibration Mount 14 Oil Press...

Page 11: ...er for Automatic Voltage Regulator 24 Expansion Tank Exhaust Manifold Heat Exch Tank Service Side Non Service Side Figure 1A and 1B M844W3 2 1 22 4 5 8 9 7 6 3 11 12 13 14 10 15 18 16 17 19 20 21 22 25 Coolant Drain 26 Wet Exhaust Elbow 27 Junction Box 28 Starter 29 Alternator 30 Belt Guard 31 Coolant Thermostat behind 32 Water Temperature Sender 7 11 31 32 24 27 28 13 29 30 26 25 9 Injection Pump...

Page 12: ... 20 AC Circuit Breaker for Automatic Voltage Regulator 21 Expansion Tank Exhaust Manifold Heat Exch Tank 22 Coolant Drain 23 Wet Exhaust Elbow Figure 2A and 2B M20CRW3 24 Junction Box 25 Starter 26 Alternator 27 Belt Guard 28 Coolant Thermostat behind 29 Water Temperature Sender 10 Raw Water Pump 11 Raw Water Inlet 12 Vibration Mount 13 Oil Pressure Sender 14 Freshwater Block Drain 15 Oil Dipstick...

Page 13: ... it will return to RUN position To stop the engine hold the switch in the STOP position until the engine has completely stopped 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 ENGINE TEMPERATURE GAUGE Registers the ...

Page 14: ...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 step is not necessary if the engine is already warm 2 While holding the Shutdown Bypass Preheat 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...

Page 15: ...ure within normal temperature range a Thisshutdowncouldhavehappenedbecauseofa too high exhaust temperature This 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 Check the engine crankcase oil level c If the oil level is low fill with recommended lubricat...

Page 16: ...e on chart 3 Whenever necessary 4 More often if necessary 5 After first 50 hours then at 100 hours then at every 250 hours Servicing Schedule Chart SERVICE 50 250 500 1000 2500 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours ENGINE SP1 12 Check oil level SP2 12 Change engine oil 1 5 SP3 12 Change lube oil filters 1 5 SP4 13 Check air cleaner 1 4 SP5 13 Check V belt tension SP6 13 Check va...

Page 17: ...OM844W3 5 11 15 Service Record Notes ...

Page 18: ...ge oil every 100 hours or six weeks whichever comes first 4 Change oil at the end of each season and the beginning of each season 5 Change oil when engine is warm 6 Dispose of waste oil in an approved manner 7 Never use a flushing oil 8 Loosen the clamp on the oil change tube Remove cap Drain oil Replace the cap and tube 9 Refill engine with recommended oil for the season 10 Engine capacity with n...

Page 19: ...justments should be done after the cylinder head bolts have been re tightened Engine should be cold and NOT running 3 Watch the valves while turning the engine over by hand Turn until the inlet valve starts to open and the exhaust valve starts to close the valves are rocking Then turn the crankshaft one more full turn and adjust the clearance on both valves for this cylinder Align the top mark of ...

Page 20: ...nd of each day s operation This will reduce condensation and possible biological contamination 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 filter installed We recommend the Racor brand of fuel filter water separators a Check the primary fuel filter daily as ...

Page 21: ...m 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 other fuel system component has been removed and installed 2 Loosen bleed bolt A Figure 10 on top of the filter Pump hand primer B on fuel lift pump until pure fuel no bubbles escapes from bleed bolt A Tighten...

Page 22: ...er 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 injector Torque to proper tightness Servicing Figure 14 Remove return line nuts For illustration purposes only your model is different ...

Page 23: ... lines Leave loose at injectors for bleeding e Crank engine to fill lines Tighten lines at injectors to 11 18 ft lbs Start engine and 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 interval for checking the injection pump But as a rule pump settings maxi...

Page 24: ...TE 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 exchanger end cover and inspect for impeller pieces Clean inlet to heat exchanger bundle and reassemble 3 Clean the inside of the housing 4 Press in the new impeller and place the sealing washers in the outer end of the impeller center if this has...

Page 25: ...ing and booster instructions SP 18 19 BATTERY CARE 1 Check electrolyte level every 50 hours or once per month 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 batte...

Page 26: ... plug 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 battery output Battery is too small Battery cables are too small Check specific gravity Replace battery if necessary of each battery Check electrolyte level If low fill cells with distilled water of ea...

Page 27: ... Runs Irregularly Below normal engine temperature 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 dirt in the fuel system Drain flush fill and bleed system Dirty or faulty injection nozzles Have your dealer check injection nozzles Air in fuel system I...

Page 28: ...ystem Defective thermostat Remove and check thermostat Defective temperature gauge Check water temperature with thermometer and replace gauge if necessary Water pump impeller worn broken Check impeller and replace if necessary V belts slipping Fix belts to proper tension Engine Knocks Insufficient oil Call your dealer Injection pump out of time Call your dealer Below normal engine temperature Chec...

Page 29: ...proper level Improper type of oil Drain and fill crankcase with correct oil Partially plugged oil filter Replace filter Check bearings oil pump and relief valve for wear High Oil Consumption Break in period Oil consumption decreases after break in Crankcase oil too light Use proper viscosity oil Oil leaks Check for leaks in lines around gaskets and drain plug Engine Emits Black Clogged or dirty ai...

Page 30: ...OM844W3 5 11 28 Wiring Diagrams AC Wiring Diagram M844W2 M844LW2 M20CRW2 for 12 4 lead generators with AVR DST 100 2FAK Drawing B 8280E ...

Page 31: ...OM844W3 5 11 29 Wiring Diagrams DC Wiring Diagram M844W3 M844LW3 M20CRW3 for 12 VDC Standard Ground Drawing B 8394B ...

Page 32: ...OM844W3 5 11 30 Wiring Diagrams DC Wiring Diagram M844W3 M844LW3 M20CRW3 for 24 VDC Standard Ground Drawing B 8534A ...

Page 33: ...OM844W3 5 11 31 Wiring Diagrams DC Wiring Diagram M844W3 M844LW3 M20CRW3 for 12 VDC Isolated Ground Drawing B 8533A ...

Page 34: ...OM844W3 5 11 32 Wiring Diagrams DC Wiring Diagram M844W3 M844LW3 M20CRW3 for 24 VDC Isolated Ground Drawing B 8535A ...

Page 35: ...OM844W3 5 11 33 ...

Page 36: ...hern lights com 4420 14th Ave NW Seattle WA 98107 Tel 206 789 3880 1 800 762 0165 Fax 206 782 5455 Northern Lights and Lugger are registered trademarks of Northern Lights Inc 2011 All rights reserved Litho USA ...

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