Northern Lights Lugger 0844K User manual

O844K
For Models: M844K, M844LK, M20CL, and M20CR
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: [phone]
Fax: [phone]
Copyright ©2009 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.: O844K 10/09

O844K 10/09
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.
1
Proprietary Information
This publication is the property of Northern Lights, 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 O844K 10/09
OPERATOR'S MANUAL
for Models
M844k, M844Lk, M20CL, and M20CR
Table of Contents
INTRODUCTION ...................................................... 2
Models Included ................................................... 2
Model Numbers .................................................... 2
Serial Numbers ..................................................... 3
WARRANTY ............................................................ 3
SAFETY RULES ...................................................... 3
COMPONENT LOCATIONS
M844kand M844LkMarine Generators.............. 4
M20CL 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
SERVICING SCHEDULE CHART ............... 10 - 11
SERVICING
Lubrication - General..........................................12
Checking Oil.......................................................12
Oil Changes ........................................................12
Changing Oil Filter .............................................12
Air Filter .............................................................13
SERVICING (continued)
V-Belts ................................................................13
Retightening Cylinder Head Bolts......................13
Valve Clearances.................................................13
Fuels - General....................................................14
Fuel Filters ..........................................................14
Bleeding the Fuel System ...................................15
Injector Service...........................................16 - 17
Injection Pump....................................................17
Cooling System - General...................................17
Cooling System Flushing....................................18
Heat Exchanger (Marine) ...................................18
Raw Water Pump ................................................18
Generator Ends ...................................................18
Electrical System - General ................................18
Glow Plugs..........................................................19
Booster Batteries.................................................19
Battery Care ........................................................ 19
PTO Care ............................................................19
Winterizing / Out-of-Service ..............................19
TROUBLESHOOTING
Electrical .............................................................20
Engine .........................................................21 - 23
DATA SHEETS
M844k.................................................................24
M844Lk..............................................................25
M20CL................................................................26
WIRING DIAGRAMS
DC Electrical ......................................................27

O844K 10/09
Introduction
2
Unit Identication
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 can begin with minor problems that are over-
looked 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.
L, C
MODELS INCLUDED
This manual covers the operating instructions for:
M844kmarine generator sets,
M844Lkmarine generator sets, and
M20CL commercial generator sets.
NOTE: There are two versions of the 844 engine. The standard engine is designated 844. The long-stroke engine
is designated 844L. 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 space provided.
This will give you a reference whenever service or maintenance is required:
L - Long stroke version
C - Commercial version
++
Northern Lights marine diesel generator set with
an 844 engine and a PX-300K generator end.
M 844
=
M844k
Northern Lights marine diesel generator set with
an 844L engine and a PX-300K generator end.
=
M844Lk
Northern Lights 20 kW (@ 60 Hz) commercial grade
marine generator set with a special generator end.
=
M20CL
Model number of engine block
Bore Cylinders
84 mm 4
M - Northern Lights marine generator set
Model Numbers
Model numbers give the unit's application, block model, aspiration, and RPM:
My Northern Lights generator set MODEL number is:

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 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 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 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.
• Use caution in handling fuel. Never refuel a hot
or running engine. Do not smoke while lling 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,
qualied 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 rst aid kits.
My Northern Lights generator set SERIAL number is: