Northern Lights M864W User manual

OM864W

For Models: M864W and M864W3

OPERATOR’SMANUAL

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: (206) 789-3880

Fax: (206) 782-5455

the Northern Lights logo are trademarks of

Northern Lights, Inc.

Printed in U.S.A.

PART NO.: OM864W 09/07

OM864W 09/07

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.

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.

OPERATOR'S MANUAL

for Northern Lights®M864W & M864W3 Diesel Generator Sets

INTRODUCTION

Models Included .....................................4

Model Numbers......................................4

Serial Numbers...............................................4

WARRANTY ................................................5

SAFETY RULES.........................................5

COMPONENT LOCATIONS

M864K Generator Set ......................6 - 7

CONTROL PANELS

Northern Lights Generator Sets..............8

OPERATING PROCEDURES

Break-in Period ......................................9

Before Starting........................................9

Starting................................................. 10

Operating ............................................. 10

Stopping................................................10

Shutdowns and Alarms .........................11

Spare Parts............................................11

SERVICING SCHEDULE CHART 12 - 13

SERVICING

Lubrication - General............................14

Checking Oil.........................................14

Oil Changes ..........................................14

Changing Oil Filter...............................15

Air Filter ...............................................15

Table of Contents

SERVICING (Continued)

V-Belts ...................................................15

Valve Clearances....................................16

Fuels - General.......................................17

Fuel Filters.............................................17

Bleeding the Fuel System......................18

Injector Service......................................19

Injection Pump...............................20 - 21

Cooling System .....................................22

Heat Exchanger......................................23

Raw Water Pump ...................................23

Zinc Electrodes......................................23

Electrical System - General...................24

Booster Batteries....................................24

Battery Care...........................................25

Winterizing / Out-of-Service .................25

TROUBLESHOOTING

Electrical................................................26

Engine............................................27 - 29

DATA SHEET

Speciﬁcations and Dimensions..............30

WIRING DIAGRAMS

DC Electrical .................................31 - 34

AC Electrical .........................................35

OM864W 09/07

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

ampliﬁed when not corrected during routine main-

tenance.

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

86 mm 4

Serial Numbers

MODELS INCLUDED

This manual covers the operating instructions for:

M864W AND M864W3 marine generator sets, which use the 864 engine block.

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:

Unit Identiﬁcation

Northern Lights marine diesel generator set with

a 864 engine and a PX-325K2 series generator end.

M864W

M864

Your set has three serial numbers: 1an engine number

stamped on a plate attached to the valve cover, 2a

generator end serial number, and 3a 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.

OM864W 09/07

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

contact 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.

• Use caution in handling fuel. Never refuel a

hot or running engine. Do not smoke while

ﬁlling fuel tank or servicing fuel system.

• 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

working 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.

• Never leave engine without proper security.

• Turn the coolant tank cap slowly to relieve pres-

sure 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.

Safety Rules

CAUTION: This symbol is used throughout

this book to alert you to possible danger areas.

Please take special notice of these sections.

Warranty

OM864W 09/07

Figure 2: M864W Service Side

1. DC Circuit Breaker

2. Air Filter

3. Intake Manifold

4. Lube Oil Dipstick

5. Secondary Fuel Filter

6. Lube Oil Fill

7. Fuel System Bleed Point

9. Coolant Fill

10. Expansion Tank

11. Heat Exchanger

12. Heat Exchanger Raw

Water Drain and Zinc

13. Raw Water Pump

14. Fuel Primer Pump

15. DC Alternator

16. Lube Oil Drain

17. Fuel Manifold

18. Oil Pan

19. Starter

20. Oil Filter

21. AC Generator

22. DC Panel Plug-In

23. Heat Exchanger Fresh

Water Drain

24. AC Circuit Breaker

M864W Generator Component Locations

OM864W 09/07

M864W Generator Component Locations

Figure 3: M864W Non-Service Side

2. Lube Oil Fill

3. Exhaust Manifold

4. Coolant Fill

5. Expansion Tank

6. Heat Exchanger

7. Heat Exchanger Raw

Water Drain and Zinc

8. Raw Water Pump

9. Oil Pan

10. Wet Exhaust Elbow

11. Manifold Drain

OM864W 09/07

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:

a. Preheats engine before beginning the starting

process. Press switch for 10-20 seconds before

attempting startup.

b. 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 indi-

cates 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 Off” 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

Control Panels

OM864W 09/07

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 ﬁller cap sealing surface when

the engine is cold.

CAUTION: Use protective clothing

and open the ﬁller 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

ﬁlter.

4. Close the sea-cock, check and clean the sea

strainer, and re-open the sea-cock.

5. Place the battery switch in the ON position.

NOTE: The battery switch must always be

keptONwhiletheengineisrunning.If

the switch is turned OFF while the

engineisrunning,thebatterycharging

alternator could be damaged.

BREAK-IN PERIOD

1. The ﬁrst 100 hours on a new or reconditioned

engine are critical to its life and performance.

2. Constantly check the engine temperature and oil

pressure gauges.

3. Oil consumption is greater during break-in as

piston rings take time to seat.

4. Break-In Oil Changes: Change engine oil and

ﬁlter at 50 hours. Change oil and ﬁlter again at

100 hours (consult Lubricants section for oil

recommendation).

Operating Instructions:

Maintain at least a 75% load on your generator

set for the ﬁrst 100 hours. If this is not possible,

maintain no less than a 50% load to ensure

proper seating of the piston rings. Vary the load

to help seat the rings.

Operating Procedures

OM864W 09/07

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) ambi-

ent 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 ﬁve

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 ﬁve minute cool-

down period.

3. Move the Engine Control switch to the STOP

position until the engine stops completely.

4. Shut off seacock, fuel valve, and battery

switch.

STARTING

1. Hold the Shutdown Bypass switch in the ON

position for 10-20 seconds before starting.

NOTE: Holding the switch too long can burn

out the glow plugs.

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 both

switches. Do not crank the starter for more than

20 seconds consecutively. If the engine fails

to start with the ﬁrst attempt, be sure that it

has stopped completely before re-engaging the

starter.

NOTE: Excessive cranking of the starter on

marine sets equipped with a water lift

mufﬂer 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

mufﬂer from ﬁlling with water and

backﬁlling the exhaust line and engine. Once

the engine starts, shut it off immediately and

reinstall the impeller.

Restart and check the exhaust

overboard outlet for gushes of water.

Operating Procedures

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