Northern Lights OM944W3 User manual

OM944W3
For Models: M944W3, M944W3G and M30CW3
OPERATOR’S MANUAL
OPERATOR’S MANUAL
www.northern-lights.com

Breathing Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth
defects, and other reproductive harm.
* Always start and operate the engine in a well-ventilated area.
* If in an enclosed area, vent the exhaust 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:
Northern Lights
4420 14th Avenue NW
Seattle, WA 98107
Tel: [phone]
Fax: [phone]
Copyright ©2021 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.: OM944W3 01/23

OM944W3 1/23
1
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 Northern Lights, Inc.
© Northern Lights, Inc. All rights reserved. Litho U.S.A. Publication number OM944W3 1/23
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.
INTRODUCTION ..................................................2
Model Numbers ..................................................2
Serial Numbers ...................................................2
WARRANTY ...........................................................3
SAFETY RULES..............................................3 - 7
LOCK OUT / TAG OUT INSTRUCTIONS...........8
COMPONENT LOCATIONS
Generator Set ...........................................10 - 11
CONTROL PANELS
Northern Lights Generator Sets ...................... 14
OPERATING PROCEDURES
Break-in Period................................................ 15
Before Starting................................................. 15
Starting............................................................. 16
Operating ......................................................... 16
Stopping........................................................... 16
Shutdowns and Alarms .................................... 17
Spare Parts ....................................................... 17
SERVICING SCHEDULE CHART ......... 18 - 19
Table of Contents SERVICING
Lubrication - General....................................... 20
Checking Oil.................................................... 20
Oil Changes ..................................................... 20
Changing Oil Filter .......................................... 21
Air Filter .......................................................... 21
V-Belts ............................................................. 21
Valve Clearances.............................................. 22
Fuels - General................................................. 23
Fuel Filters ....................................................... 23
Bleeding the Fuel System ................................ 24
Injector Service................................................ 25
Injection Pump................................................. 26
Cooling System ............................................... 27
Heat Exchanger................................................ 28
Raw Water Pump ............................................. 28
Zinc Electrodes ................................................ 28
Electrical System - General ............................. 29
Booster Batteries.............................................. 29
Battery Care ..................................................... 30
Winterizing / Out-of-Service ........................... 30
TROUBLESHOOTING
Electrical .......................................................... 31
Engine ...................................................... 32 - 34
WIRING DIAGRAMS
AC Wiring...................................................35 - 37
DC Wiring...................................................38 - 45
Panel Wiring ...............................................46 - 49
APPENDIX (Non-Current Production Diagrams)
AC Wiring...........................................................50
DC Wiring...................................................51 - 54
Panel Diagrams...........................................55 - 57
OPERATOR'S MANUAL
for Models
M944W3, M944W3G and M30CW3

OM944W3 1/23
2
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 amplied 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:
M944 marine generator sets, which use the 944 engine block.
Model Numbers
Model numbers are based on the unit's application, block model, aspiration, and RPM:
+

Northern Lights marine diesel generator set with
a 944 engine and a PX-332K2 series generator
end with auxiliary winding. US EPA Tier III.
M944W3
M 944
=
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.
Northern Lights marine diesel generator set with a
944 engine and a PX-332K2 series generator end;
commercial unit, 30 kW, Tier III.
M30CW3 =
W, G, C, 3
W- Auxiliary winding in generator end
G- GEM series base frame
C - Commercial series
3 - US EPA Tier III compliant
Northern Lights marine diesel generator set with
a 944 engine and a PX-332K2 series generator
end with auxiliary winding on a Gem series base
frame. US EPA Tier III.
M944W3G =

OM944W3 1/23
3
A warranty registration certicate 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.
Safety Rules
Warranty
Updated 6-5-17
NOTICE: 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.
IMPORTANT SAFETY INSTRUCTIONS.
Electromagnetic equipment, including generator sets
and their accessories, can cause bodily harm and
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, this
operator’s manual uses three dierent signal words to
outline potential dangers of a specic nature.
Follow All Safety Instructions
Carefully read and understand
all safety messages in this
manual and on your machine’s
safety signs. 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 safety signs
or clarication on any safety issue, consult your
Northern Lights dealer or the factory.
There can be additional safety information contained
on parts and components from outside suppliers
that is not reproduced in this manual. Consult the
suppliers for additional safety information.
Learn how to operate the machine and how to use
the controls properly. Only trained personnel should
operate machines, or work on or around them.
Keep you machine in proper working condition.
UNAUTHORIZED MODIFICATIONS TO THE
MACHINERY MAY IMPAIR ITS FUNCTION
AND SAFETY PARAMETERS.
Prevent Bypass and Accidental
Starting
!
WARNING
Do not start engine by shorting across start terminal.
Engine will start if normal circuitry is bypassed,
creating a hazard by runaway machinery.
Start engine only from operator’s station.
!
DANGER
!
WARNING
!
CAUTION
DANGER indicates a hazardous situation which, if
not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if
not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation which,
if not avoided, could result in minor or moderate
injury.
DANGER: Northern Lights generator sets and /or any other diesel powered equipment provided by NLI is not provided
with spark arresting or explosion proof components, and therefore is not to be installed in the presence of combustible
gases having a ash point of 43.3 Degrees C (110 Degrees F) or lower, such as Gasoline, Propane, Natural Gas or other
similar fuel sources.

OM944W3 1/23
4
Safety Rules (Continued)
Wear Protective Clothing
!
WARNING
To prevent catching anything in moving machinery,
always wear close tting clothes and safety
equipment appropriate
to the job.
Prolonged exposure
to loud noise can
cause hearing loss or
impairment. Wear
suitable authorized
hearing protection,
such as earmus or plugs to protect against loud
noises.
Operating equipment requires the full attention of the
operator. Do not use radio or music headphones
while operating machinery.
Practice Safe Maintenance
!
CAUTION
Understand all service
procedures before starting work.
Keep area clean and dry. Never lubricate, service, or
adjust machine while it is in operation.
Keep hands, feet and clothing away from power-
driven equipment. When shutting down an engine,
disengage all power and operator controls. Allow
the engine to cool completely before beginning any
service work.
Securely support any machinery elements that must
be raised for service work with support or lifting
machinery specically intended for that purpose.
Keep all parts in good conditions and properly
installed. Fix damage immediately. Replace any
worn or broken parts. Remove any build 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 ammable and should be treated with
care at all times. Do do not refuel while smoking or
when near sparks or open ame.
ALWAYS STOP ENGINE BEFORE FUELING
MACHINE. Always ll
portable fuel tank outdoors.
Never fuel a hot engine.
Prevent accidental
discharge of starting uids
by storing all cans in a
cool, safe place, away
from sparks or open ame. Store with cap securely
on container. Never incinerate or puncture a fuel
container.
Prevent res by keeping machine clean of accumulated
trash, grease and debris. Always clean any spilled fuel
as swiftly as possible. Do not store oily rags, which
can ignite and burn spontaneously.
Be prepared if a re starts. Keep a rst aid kit and re
extinguisher handy. Keep emergency contact numbers
for re department, doctors, ambulance and hospital
near the telephone.
Service Machines Safely
!
DANGER
Do not wear a necktie, scarf, necklace, rings or other
jewelry, or any loose clothing
when working near moving
parts. Tie long hair 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.
Updated 4-12-17

OM944W3 1/23
5
Stay Clear of Rotating Drivelines
!
DANGER
Entanglement in rotating
drivelines can cause serious
injury or death. Keep
shields in place at all times. Make sure that rotating
shields turn freely in pace with the drivelines.
Do not wear loose tting equipment around rotating
drivelines. Stop the engine and make sure that
all moving parts have stopped before making any
adjustments, connections, or performing any other type
of service to the engine or other driven equipment.
Install all Safety Guards
!
WARNING
Direct contact with rotating
fans, belts, pulley and drives
can cause serious injury.
Keep all guards in place
at all times during engine
operation.
Wear close-tting clothes. Stop the engine and be
sure all fans, belts, pulleys and drives are stopped
before making adjustments, connections, or cleaning
near fans and their components.
Do not allow anything on your person to dangle into
or come in contact with a moving fan, belt, pulley or
drive. Fans can act as vacuums and pull materials
up from below, so avoid that area as well while in
service.
Safe Battery Handling
!
WARNING
Prevent Battery Explosions
Battery gas is highly ammable. Battery explosions
can cause severe injury or death. To help prevent
battery explosions, keep sparks, lighted matches
and open ame away from the top of battery. When
checking battery electrolyte level, use a ashlight.
Safety Rules (Continued)
Never check battery charge
by contacting the posts with
a metal 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 rst and
replace ground clamp last.
S ulfuric 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.
To Avoid Hazards:
• Fill batteries only in well-ventilated areas.
• Wear appropriate eye protection and rubber gloves.
• Never use air pressure to clean batteries.
• Wear appropriate ventilation equipment to avoid
inhaling fumes when adding electrolyte.
• Do not spill or drip electrolyte.
• Use correct jump-start procedure if required.
If acid is spilled on skin or in eyes:
1. Flush skin with water.
2. Apply baking soda or lime to
help neutralize acid.
3. Flush eyes with water for
15-30 minutes.
4. Get medical attention
immediately.
If acid is swallowed:
1. DO NOT induce vomiting.
2. Drink large amounts of
water or milk, without
exceeding 2 liters
(2 quarts)
3. Get medical attention
immediately
Battery posts, terminals, and related accessories
can contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
!
WARNING
Updated 4-12-17

OM944W3 1/23
6
Safety Rules (Continued)
Do not use a chlorinated solvent in an area where
welding will occur. Work only in areas that are well
ventilated. Dispose of paint and solvent properly.
Service Cooling System Safely
!
WARNING
Opening a pressurized cooling
system can release explosive uids
and causing serious burns.
Before opening any pressurized
cooling system, make sure the
engine has been shut o. Do
not remove a ller cap unless it is cool enough to
comfortably grip with bare hands. Slowly loosen cap to
relieve pressure before opening fully.
Avoid High Pressure Fluids
!
WARNING
Relieve pressure prior to
disconnecting pressurized
lines. Escaping uid under
pressure can penetrate the
skin causing serious injury.
Always relieve pressure before disconnecting
hydraulic or other pressurized lines. Tighten all
connections rmly before re-applying pressure.
If searching for leaks, use a piece of cardboard.
Always protect your hands and other body parts from
high-pressure uids.
If an accident occurs, see a doctor immediately. Any
high pressure spray injected into the skin must be
removed within a few hours to prevent the risk of
gangrene or other infection.
Avoid Heating Near Pressurized Fluid Lines
!
WARNING
Flammable spray can be generated
by heating near pressurized uid
lines, resulting in severe burns and
bodily injury. Pressurized lines
can rupture when heat goes beyond
the immediate ame area. Do not weld, solder or use
a torch or open ame near pressurized lines or other
ammable uids.
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
products are lubricants, coolants,
paints and adhesives.
All potentially hazardous chemicals come with a Material
Data Safety Sheet (MSDS). The MSDS provides specic
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.
Contact your Northern Lights dealer or Northern Lights
factory for MSDS’s used on Northern Lights products.
Work in Well Ventilated Areas
!
CAUTION
Exhaust fumes from engines contain carbon monoxide
and can cause sickness or death. Work in well ventilated
areas to avoid prolonged exposure to engine fumes. If it
is necessary to run an engine in an enclosed area, route
the exhaust fumes out of the area with an approved, leak
proof exhaust pipe extension.
Remove Paint Before Welding or Heating
!
WARNING
Hazardous fumes can be
generated when paint is heated
by welding, soldering or using a
torch. To avoid potentially toxic
fumes and dust, remove paint
before heating.
• Remove paint a minimum of 100 mm (4 in.) from the
area that will be aected by heat.
• If paint cannot be removed, wear an approved respirator.
• If you sand or grind paint, use an approved respirator.
• If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove
solvent or paint stripper containers from the area.
• Allow at least 15 minutes for fumes to disperse
before welding or heating.
Updated 4-12-17

OM944W3 1/23
7
Safety Rules (Continued)
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding materials
containing asbestos. When servicing, wear an
approved respirator. A special vacuum cleaner is
recommended to clean asbestos. If this vacuum is not
available, apply a mist of oil or water on the material
containing asbestos. Keep all bystanders away from
any area where asbestos dust may be generated.
Use Proper Lifting Equipment and Techniques
!
WARNING
Lifting heavy components incorrectly
can cause severe injury or damage
to machinery. Avoid unbalanced
loads. Do not use lifting eyes. Lift
the generator set using lifting bars inserted through
the lifting holes on the skid. Follow all recommended
removal and installation procedures in this and
associated Northern Lights manuals.
Use Proper Tools
!
CAUTION
Makeshift tools and procedures
can create safety hazards.
Always use appropriate tools for the job.
Use power tools only to loosen threaded parts and
fasteners. For loosening and tightening hardware,
always use the correct sized tools.
Do not use US measurement tools on metric
fasteners, or vice versa. Use only service parts that
meet Northern Lights specications.
Dispose of Waste Properly
!
CAUTION
Disposing of waste improperly can threaten the
environment and lead to unsafe working conditions.
Potentially harmful waste used in Northern Lights
equipment can include oil, fuel, coolant, lters and
batteries.
Use leakproof containers to drain uid. 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 Fuel System
!
DANGER
Many Northern Lights engines use high-
pressure fuel injection. High-pressure uid
remaining in fuel lines can cause serious
injury. Do not disconnect or attempt
any repair of fuel lines, sensors, or other
components between the high-pressure fuel pump
and nozzles on engines with high pressure fuel
systems.
ONLY AUTHORIZED TECHNICIANS CAN
PERFORM REPAIRS ON AN HIGH PRESSURE
FUEL INJECTION SYSTEMS.
Avoid Hot Exhaust
!
WARNING
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 lters 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 lters.
During auto or manual/stationary exhaust lter
cleaning operations, the engine will run at
elevated temperatures for an extended period of
time. Exhaust parts and streams can reach high
temperatures during operation, leading to burns or
other serious injury.
Avoid Harmful Asbestos Dust
!
WARNING
Inhaling asbestos bers may
cause lung cancer. Avoid
breathing any dust that may
be generated when handling
components containing asbestos
bers, including some gaskets.
The asbestos used in these components is usually
found in a resin or otherwise sealed. Normal
handling of these components is not dangerous,
as long as airborne dust containing asbestos is not
generated.
Updated 4-12-17

OM944W3 1/23
8
General Policy
To avoid dangerous or hazardous situations, refrain from
any of the following:
• Removing or bypassing a guard or other safety device
• Placing any part of your body in a position where you
could be caught by moving machinery.
• Cleaning or oiling machinery when in operation.
• Adjusting circuits, chillers, pumps, air handlers, valves,
circuit breakers or fans while in operation.
• Working on piping or high pressure systems.
Lock Out/Tag Out Instructions -
Electrical Equipment
Be sure the equipment’s ON/OFF switch is in the OFF
position and is unplugged from any electrical source before
attempting to perform any type of work on the equipment.
Obtain an electrical plug cap cover with a lockset. Secure
the plug terminal end using the electrical plug lockout cap.
Lock the cap and retain the key.
If the equipment is directly wired into an electrical box with
a shut o󰀨 switch, obtain a lock pad and/or the appropriate
colored tags and place the lock and tag through the shut
o󰀨 lever. Retain the key until the repair is completed and
the machine is safe to start. Be certain the shut o󰀨 lever
is in the OFF position before restarting. NEVER give a
lock out key to unauthorized personnel.
If the equipment is directly wired into an electrical box
without a shut o󰀨 switch and lock out capability, then a
circuit breaker lock out will be required. Obtain a circuit
lock and tag set. Install the lock onto the circuit breaker
box. Ensure the unit ON/OFF switch is in the OFF position
before restarting.
Lock Out/Tag Out Instructions -
Pneumatic and Hydraulic Equipment
For servicing pneumatic and hydraulic equipment, the
following additional procedures must be implemented,
following completion of lock out/tag out procedures for
the unit to be serviced:
Shut o󰀨 air, water or supply valves at the equipment to
be serviced.
Check the local bleed-o󰀨 point for completed release of
pressurized air, water or oil.
If shutting o󰀨 of air, water or other material cannot be
achieved at the local supply valve, shut o󰀨 valves further
back in the system and re-check the bleed-o󰀨 point until
complete shut-o󰀨 is achieved.
A󰀩x a DO NOT OPERATE tag to each valve handle that
requires shut o󰀨. Each DO NOT OPERATE tag must be
signed and dated by the authorized technician servicing
the equipment.
Lock Out/Tag Out Instructions -
Air Hose Connected Pneumatic Equipment
Equipment connected to the compressed air system
through an air hose with a detachable tting must be
shutdown and unplugged. Excess air must be bled prior
to removing the air hose, prior to any maintenance or
repair activities.
A󰀩x a DO NOT OPERATE tag to the air hose near the
detachable tting. Each DO NOT OPERATE tag must be
signed and dated by the authorized technician servicing
the equipment. Check that the equipment cannot be
operated by activating the ON switch.
Stored Energy
Immediately after applying Lock Out or Tag Out devices,
ensure that all potentially hazardous stored or residual
energy is relieved, disconnected, restrained and otherwise
rendered safe.
Verication of Isolation
Verify the machinery or equipment is actually isolated and
de-energized prior to beginning work on a machine or on
equipment that has been locked out.
Restarting Procedures
Follow the procedures below prior to restoring energy:
• Ensure that all machinery or equipment is properly
reassembled. Inspect the machinery or equipment to
verify non-essential items have been removed.
• Ensure that all personnel are safely outside danger
zones. Notify personnel that lock out/tag out devices have
been removed and energy will be reapplied.
• Only authorized personnel may remove lock out/tag out
devices or notices.
Scope
During maintenance, repairs or retooling of a Northern Lights generator set, simply turning the machine o󰀨 or unplugging
it while it is being worked on does not give enough protection to others who are not performing the maintenance or
repair. Many serious accidents happen when someone thought the machine was turned o󰀨, or all of its energy was
safely blocked or released.
!
CAUTION
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
CAUTION
!
CAUTION
Lock Out / Tag Out Procedures
Updated 4-12-17

OM944W3 1/23
9
Notes

OM944W3 1/23
10
Figure 2: M944W3 Service Side with PX-300K2 series generator end.
M944W3 Generator Set Component Locations
1. Expansion Tank
2. Coolant Fill
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 Pump
15. Lube Oil Drain
16. Thermostat Housing
17. Heat Exchanger Raw Water
Drain and Zinc
23. Raw Water Pump
1234567
8
9
1011
13 12
1415
16
17
23
5

OM944W3 1/23
11
M944W3 Generator Set Component Locations
Figure 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. Oil Pan
26. Alternator
27. Starter
18 19 20 21
22
24
25
26
27
23

OM944W3 1/23
12
123
4
567
8
9
10
11
13
12
14
15
16
17
23
5
Figure 2: M944W3 Service Side with PX-300K2 series generator end and new baseframe.
M944W3 Generator Set Component Locations
1. Expansion Tank
2. Coolant Fill
3. Rocker Arm Cover
4. Intake Manifold
5. Lube Oil Fill
6. Air Filter
7. Junction Box
8. Fuel Filter
9. Fuel Supply &
Return Connections
10. Lube Oil Dipstick
11. Intake Air Noise Reduction Tube
12. Oil Filter
13. Fuel Primer Pump
14. Injection Pump
16. Thermostat Housing
17. Heat Exchanger with Raw
Water Drain and Zinc
19. Vibration Isolating Mounts
23. Raw Water Pump
Updated 9-24-12

OM944W3 1/23
13
M944W3 Generator Set Component Locations
Figure 3: M944W3 Non-Service Side with PX-300K2 series generator end and new baseframe.
15. Lube Oil Drain
18. AC Circuit Breaker
20. Wet Exhaust Elbow
21. Exhaust Manifold
22. Heat Exchanger
23. Raw Water Pump
24. Belt Guard
25. Oil Pan
26. Alternator
27. Starter
18
20 21
22
24
25
15
26
27
23
Updated 9-24-12

OM944W3 1/23
14
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
alternator.
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 O” 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

OM944W3 1/23
15
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. Operate the engine under various conditions,
particularly heavy loads with minimal idling, to help
seat engine components properly.
3. Constantly check the engine temperature and oil
pressure gauges.
4. Oil consumption is greater during break-in as
piston rings take time to seat.
5. 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).
Updated 1-9-13

OM944W3 1/23
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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. Let the unit run unloaded for a three to ve minute
warm-up period.
3. Add electrical load.
STOPPING
1. Remove electrical load from the generator set.
2. Run the engine for a three to ve minute cool-down
period.
3. Move the Engine Control switch to the STOP
position until the engine stops completely.
4. Shut o seacock, fuel valve, and battery switch.
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 the start switch
and continue to hold the bypass/preheat switch for an
additional ve seconds. 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.
NOTE: Excessive cranking of the starter on marine
   setsequippedwithawaterliftmuercan
cause engine damage. If the engine does not
start after 3 consecutive 20-second cranks,
remove the impeller from the seawater
   pump.Thiswillpreventthemuerfrom
   llingwithwaterandbackllingtheexhaust
line and engine. Once the engine starts, shut
   ifoimmediatelyandreinstalltheimpeller.
Restart and check the exhaust overboard
outlet for gushes of water.
Updated 5-7-19

OM944W3 1/23
17
SHUTDOWNS AND ALARMS
1. Your unit is tted with a system to protect it from
high water temperature, low oil pressure, and high
exhaust temperature.
a. Generator sets have shutdown systems to stop
the engine. They have no warning horns.
b. Other alarms and shutdowns are available as
optional equipment.
NOTE: If your unit is equipped with optional
shutdowns and alarms, do not rely on your
warning or shutdown system to the exclusion
of careful gauge monitoring. Watching your
gauges can prevent damage to the unit and
dangerous power losses.
2. Do the following when your warning or shutdown
system is activated:
a. Engage the preheat switch to check the
temperature gauge.
b. If above 205°F (96°C), use the Troubleshooting
Guide on page 25 to isolate the cause of the over-
heat.
CAUTION: Do not remove the water ll
cap of an overheated engine. Escaping high
temperature steam can cause severe burns. Allow
the engine to cool and then remove the cap slowly
using protective clothing.
c. Make repairs and restart after the temperature
gauge registers below 200° F (94° C).
d. Watch the temperature gauge regularly and
turn o the unit if the temperature rises above
205° F (96° C). Repeat troubleshooting.
3. If shutdown is activated and the temperature gauge
shows temperature within normal temperature range:
a. This shutdown could have happened because
of a 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 rst. If it is clear, then check the
condition of the sea water pump impeller.
b. Check the engine crankcase oil level.
Operating Procedures
c. If the oil level is low, ll with recommended
lubricating oil and restart. Watch the oil pressure
gauge carefully and shut o the engine if it does
not show a normal reading (20-60 PSI) after a
few seconds of operation.
d. If the oil level is normal, DO NOT restart the
engine. Call your dealer for assistance.
SPARE PARTS
1. ADE recommends that you keep the following spare
parts on hand for eld service. The parts are
available from your local Northern Lights dealer.
Some marine models may already have “On-Board
Kits,” a handy box that contains the most common
parts you will need.
a. Primary and secondary fuel lter elements
b. Oil lters
c. Air lter elements
d. Alternator belt
e. Thermostat and gaskets
f. Seawater pump impeller and gaskets
g. Glow plugs
h. Injector and washer
2. If your set is operating a long distance from a
servicing dealer, add the following:
a. Complete set of injectors
b. Copper washers for injector change
c. Complete set of glow plugs
d. Fuel lift pump
Updated 8-27-09

OM944W3 1/23
18
Servicing Schedule Chart
After Every Every Every Every Every Every Every
SERVICE 50 + 100 6 50 100 250 500 600 2000
POINT PAGE OPERATION DAILY Hours Months Hours Hours Hours Hours Hours Hours
ENGINE:
SP1 20 Check oil level •
SP2 20 Change engine oil 1) •• • • •
SP3 21 Change lube oil lters 1) •• • • •
SP4 21 Check or change air cleaner 2) • •
SP5 21 Check V-belt tension 3) ••
SP6 22 Check valve clearance 2) 4) •
FUEL SYSTEM:
SP7 23 Check primary lter (Racor) 4) 5) •
SP8 23 Change primary lter element 2) 4) 5) •
SP9 23 Change secondary lter element 2) 4) 5) •
SP10 24 Bleed the fuel system 3) •
SP11 25 Check injectors 2) 5) 6) • •
SP12 26 Check fuel injection pump 7) •
COOLING SYSTEM:
SP13 27 Check cooling water level •
SP14 27 Check and ush cooling system •
SP15 28 Check and clean heat exchanger •
SP16 28 Change impeller in raw water pump
2) 5)     •
SP17 28 Service/clean siphon break ••
SP18 28 Check zinc electrodes 4) •
ELECTRICAL SYSTEM:
SP19 29 Check electrolyte level in batteries 2) • • •
SP20 29 Check condition of batteries 2) •
OUT OF SERVICE:
SP22 30 Winterizing or out-of-service 3)
The Servicing Schedule Chart below shows the intervals required for proper maintenance of your generator set. More
detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’ column.
DAILY:
Inspect for any signs of fuel leaking
SP1 Check oil level in engine
SP7 Check primary fuel lter
SP13 Check cooling water level
Check sea water strainer
AFTER FIRST 50 HOURS:
SP2/3 Change engine oil and lter
SP5 Check V-belt tension
SP19 Check electrolyte level in batteries
AFTER FIRST 100 HOURS:
SP2/3 Change engine oil and lter
EVERY SIX MONTHS:
SP2/3 Change engine oil and lter
SP17 Service/clean siphon break
(if equipped)
EVERY 50 HOURS:
SP5 Check V-belt tension
SP20 Check electrolyte level in batteries
EVERY 100 HOURS:
SP2/3 Change engine oil and lter
SP5 Check V-belt tension
SP20 Check electrolyte level in batteries
EVERY 250 HOURS:
SP2/3 Change engine oil and lter
SP4 Check air cleaner
SP9 Change secondary fuel lter
SP18 Check zinc electrodes
1) Perform oil changes every six months, 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 rst 50 hours.
6) To insure that your engine stays in compliance with applicable EPA
& CARB emission standards, the following additional maintenance proce-
dures & intervals must be maintained.
1500 Hours: Fuel injectors are to be removed & injector tips cleaned.
3000 Hours: Fuel injectors removed for adjustment, cleaning, & repair.
EVERY 500 HOURS:
SP6 Check valve clearances
SP8 Change primary fuel lter element
SP10 Bleed fuel system
SP11 Check injectors
SP14 Check and ush cooling system
SP16 Change impeller
SP20 Check state of charge of batteries
EVERY 2000 HOURS or as needed:
SP4 Change air cleaner
SP12 Check fuel injection pump
SP14 Check and ush cooling system
SP15 Check and clean heat exchanger
Updated 1-6-23