Northern Lights M864W Operator's Manual
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Northern Lights M864W Operator's Manual

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OPERATOR'S MANUAL
OPERATOR'S MANUAL
OM864W
For Models: M864W, M864W3 and M864W3G
www.northern-lights.com

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  • Page 1 OPERATOR’S MANUAL OPERATOR’S MANUAL OM864W For Models: M864W, M864W3 and M864W3G www.northern-lights.com...
  • Page 2 4420 14th Avenue NW Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455 Copyright ©2018 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.: OM864W 10/18...

  • Page 3: Table Of Contents

    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 OM864W 10/18...

  • Page 4: Introduction

    86 mm G - GEM series base frame 3 - US EPA Tier III compliant M864W Northern Lights marine diesel generator set with an 864 engine and a PX-325K2 generator end M864W Northern Lights marine diesel generator set with an 864 engine and a PX-325K2 generator end,...

  • Page 5: Warranty

    Safety Rules 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 flash point of 43.3 Degrees C (110 Degrees F) or lower, such as Gasoline, Propane, Natural Gas or other similar fuel sources.
  • Page 6 Updated 4-12-17 Safety Rules (Continued) Handle Fuel Safely - Avoid Flames Wear Protective Clothing WARNING WARNING Diesel is highly flammable and should be treated with To prevent catching anything in moving machinery, care at all times. Do do not refuel while smoking or always wear close fitting clothes and safety when near sparks or open flame. equipment appropriate to the job. Prolonged exposure ALWAYS STOP ENGINE BEFORE FUELING to loud noise can MACHINE. Always fill cause hearing loss or portable fuel tank outdoors.
  • Page 7 Updated 4-12-17 Safety Rules (Continued) Never check battery charge Stay Clear of Rotating Drivelines by contacting the posts with DANGER a metal object. Use a volt- meter or hydrometer. Entanglement in rotating Frozen batteries may explode drivelines can cause serious if charged.
  • Page 8 Read and understand the MSDS for each chemical before Avoid High Pressure Fluids you start any job that includes it. Follow the procedures and use appropriate equipment exactly as recommended. WARNING Contact your Northern Lights dealer or Northern Lights Relieve pressure prior to factory for MSDS’s used on Northern Lights products. disconnecting pressurized lines. Escaping fluid under Work in Well Ventilated Areas...
  • Page 9 WARNING CAUTION Inhaling asbestos fibers may Disposing of waste improperly can threaten the cause lung cancer. Avoid environment and lead to unsafe working conditions. breathing any dust that may Potentially harmful waste used in Northern Lights be generated when handling equipment can include oil, fuel, coolant, filters and components containing asbestos batteries. fibers, including some gaskets. Use leakproof containers to drain fluid. Do not The asbestos used in these components is usually use food or beverage containers that may mislead found in a resin or otherwise sealed.
  • Page 10 Scope During maintenance, repairs or retooling of a Northern Lights generator set, simply turning the machine off or unplugging it while it is being worked on does not give enough protection to others who are not performing the maintenance or repair.
  • Page 11 This page left intentionally blank OM864W 10/18...

  • Page 12: M864 Generator Set

    Generator Component Locations Figure 2: M864 Service Side 1. DC Circuit Breaker Coolant Fill 15. DC Alternator 22. DC Panel Plug-In Air Filter 10. Expansion Tank 16. Lube Oil Drain 23. Heat Exchanger Fresh Intake Manifold 11. Heat Exchanger 17. Fuel Manifold Water Drain 4. Lube Oil Dipstick 12. Heat Exchanger Raw 18.
  • Page 13 Generator Component Locations Figure 3: M864 Non-Service Side Lube Oil Fill Heat Exchanger Raw Exhaust Manifold Water Drain and Zinc Coolant Fill Raw Water Pump Expansion Tank Oil Pan Heat Exchanger 10. Wet Exhaust Elbow 11. Manifold Drain OM864W 10/18...

  • Page 14: Control Panels

    Control Panels 1. PREHEAT/ SHUTDOWN BYPASS This switch serves two functions: a. Preheats engine before beginning the starting pro- cess. Press switch for 10-20 seconds before attempt- ing 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.

  • Page 15: Operating Procedures

    Operating Procedures BREAK-IN PERIOD BEFORE STARTING 1. The first 100 hours on a new or reconditioned 1. Check the water level by removing the engine are critical to its life and performance. pressure cap from the expansion tank. In order to give the cooling water an opportunity to expand, the 2.

  • Page 16: Starting

    Operating Procedures STARTING OPERATING 1. Hold the Shutdown Bypass switch in the ON posi- 1. Units with Series 3 and Series 4 Control Panels: tion for 10-20 seconds before starting. Check gauges often. Oil pressure must be above 15 NOTE: Holding the switch too long can burn out PSI. The D.C. voltmeter should read between 11 and the glow plugs.

  • Page 17: Shutdowns And Alarms

    Generator sets have shutdown systems to stop the parts are available from your local Northern Lights engine. They have no warning horns. dealer. Some marine models may already have b. Other alarms and shutdowns are available as “On-Board Kits,” a handy box that contains the most...

  • Page 18: Servicing Schedule

    Servicing Schedule Chart The Servicing Schedule Chart below shows the service schedule 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: Check air cleaner Check oil level in engine Change primary fuel filter element Check primary fuel filter Change secondary fuel filter SP13 Check cooling water level SP17 Check zinc electrodes Check sea strainer EVERY 750 HOURS: AFTER FIRST 50 HOURS:...
  • Page 19 Service Record Service OPERATION HOURS/ DATE Point 50 HOURS Check V-belt tension SP18 Check electrolyte in batteries 200 HOURS Change engine oil Change lubricating oil filters Check air cleaner Change primary filter element (Racor) Change secondary fuel filter SP17 Check zinc electrodes EVERY 750 HOURS Check valve clearances SP11...

  • Page 20: Servicing

    Servicing LUBRICATION - GENERAL SP-1. CHECKING OIL LEVEL 1. Use only clean, high quality lubricants stored in 1. While the engine is stopped, check the oil level in clean containers in a protected area. the crankcase with the dipstick daily. The oil level must be between the high and low marks on the 2.

  • Page 21: Changing Oil Filter

    Servicing SP-3. CHANGING LUBE OIL FILTER SP-5. V-BELTS 1. Change the lube oil filter every 200 hours. 1. Check the tension and wear on the V-belt after every 50 hours. 2. Use a filter wrench to remove old filter. Dispose of filter in approved manner. 2. Use your thumb to press on the belt at the midpoint between the crankshaft and alternator pulleys. The 3. Make sure the gasket from the old filter is removed tension is correct if the belt can be depressed about and discarded.

  • Page 22: Valve Clearances

    Servicing SP-6. VALVE CLEARANCES 5. To adjust valve clearance, loosen the lock nut on the adjustment screw. Insert a feeler gauge between the 1. Readjust valve clearance after first 50 hours of rocker arm and the valve stem cap. Adjust until the operation. Adjust valves every 750 hours thereafter. feeler gauge slides with a slight drag.

  • Page 23: Fuels - General

    This will reduce condensation. temperatures above freezing 32° F (0° C). b. International fuel specifications: FUEL FILTERS ISO-8217-DMA BS 2869 Part 1 Class A1 1. Your generator set should have a primary fuel filter installed. We recommend the Northern Lights brand BS 2869 Part 2 Class A2 of fuel filter-water separators. 2. Use fuel having less that 1% sulphur (preferably less SP-7. PRIMARY FUEL FILTER than 0.5%). a. Check the primary fuel filter daily as 3. The cetane number should be a minimum of 45.

  • Page 24: Bleeding The Fuel System

    Servicing SP-10. BLEEDING THE FUEL SYSTEM 1. The fuel system is self-bleeding. However, any system may need manual bleeding when: CAUTION: Escaping diesel fuel under a. A new fuel filter is installed; pressure can penetrate skin causing serious b. The engine has run out of fuel; personal injury.

  • Page 25: Injector Service

    1. Injectors should be checked every 750 hours. This Remove all lines as an assembly; do not remove check should be made by a Northern Lights dealer or the spacers. Cover the ends of the lines, the injector local injection repair station.

  • Page 26: Injection Pump

    Servicing SP-12. INJECTION PUMP 3. Any repair which involves disassembly of the injec- tion pump must be carried out by specially trained 1. Since operating conditions may vary considerably, it mechanics with the proper tools and test equipment. is difficult to give a definite interval for checking the injection pump. But as a rule, pump settings, maxi- NOTE: All warranties on the engine become null mum speed, idle speed and exhaust smoke should be and void if the injection pump seals are...

  • Page 27: Injection Pump

    The crankshaft pulley notch mark for 13° Before front side. Top Dead Center (BTDC) should now align with e. Take the pump to your Northern Lights dealer or the timing pointer ( ). If it does not, the Figure 14 an injection repair station for testing and service. injection pump needs to be timed.

  • Page 28: Cooling System - General

    Servicing SP-14. COOLING SYSTEM FLUSHING COOLING SYSTEM - GENERAL NOTE: Be sure to close the sea-cock before working 1. Flush the cooling system every 750 hours or every on the engine cooling system. 12 months, whichever comes first. CAUTION: The cooling water in the engine 2. Remove fill cap and open drains on engine block.

  • Page 29: Heat Exchanger

    Servicing SP-15. HEAT EXCHANGER SP-17. ZINC ELECTRODES 1. Clean the heat exchanger core once a year or after 1. A zinc electrode is installed in the heat exchanger 2400 hours of operation. cooling system to protect the engine from electroly- sis.

  • Page 30: Generator End

    Servicing GENERATOR END BOOSTER BATTERIES The maintenance and operation recommendations CAUTION: Battery gas can explode. Keep all for the generator end are in a separate Owner's flames and sparks away from batteries. Manual. If you do not have one of these manuals, contact your local dealer.

  • Page 31: Battery Care

    Servicing SP-20. WINTERIZING / OUT-OF-SERVICE BATTERY CARE If the generator set will not be used for more than 3 SP-18. CHECK ELECTROLYTE LEVELS months the following preparations should be taken for 1. Check the electrolyte level every 50 hours, or once long term storage.

  • Page 32: Troubleshooting

    Entire Electrical System Check DC circuit breaker • If breaker is tripped, reset it. Does Not Function Faulty connection • Clean and tighten battery and harness plug connections. Sulfated or worn out batteries • Check specific gravity and electrolyte level of each battery. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM864W 10/18...

  • Page 33: Engine

    Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) Engine Hard to Start Improper starting procedure • See starting section of this manual. Take or Will Not Start special note of Bypass Switch operation. No fuel • Check level of fuel in fuel tank. Low battery condition •...
  • Page 34 • Check water temperature with thermometer. not working properly Low Oil Pressure Low oil level • Fill crankcase to proper level. Improper type of oil • Drain and fill crankcase with correct oil. Partially plugged oil filter • Replace filter. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM864W 10/18...

  • Page 35: Engine

    • Use correct fuel for temperature. White Smoke Cold engine • Warm up engine to normal operating temperature. Defective thermostat • Remove and check thermostat. Engine injection timing off • See your dealer. Low Compression Pressure • See your dealer. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM864W 10/18...

  • Page 36: Specifications And Dimensions

    Specifications and Dimensions Rated RPM/Frequency 1800/60 Hz 1500/50 Hz Kilowatt Rating 25 kW 20 kW General Information Cylinders In-line 4 In-line 4 Displacement 151.7 CID (2.49 151.7 CID (2.49 Cycle Bore x Stroke 3.39 in (86 mm) x 4.21 in (107 mm) 3.39 in (98 mm)x 4.21 in (107 mm) Rotation (Facing Flywheel) counterclockwise counterclockwise...

  • Page 37: Wiring Diagrams Ac Electrical

    Updated 6-29-17 AC Wiring Diagram OM864W 10/18...
  • Page 38 Updated 6-15-17 AC Wiring Diagram OM864W 10/18...

  • Page 39: Dc Electrical

    Updated 6-15-17 DC Wiring Diagram OM864W 10/18...
  • Page 40 Updated 6-15-17 DC Wiring Diagram OM864W 10/18...
  • Page 41 Updated 6-30-17 DC Wiring Diagram OM864W 10/18...
  • Page 42 Updated 6-15-17 DC Wiring Diagram OM864W 10/18...
  • Page 43 Updated 6-15-17 DC Wiring Diagram OM864W 10/18...
  • Page 44 Updated 6-15-17 DC Wiring Diagram OM864W 10/18...
  • Page 45 Updated 6-15-17 DC Wiring Diagram OM864W 10/18...
  • Page 46 Updated 6-15-17 DC Wiring Diagram OM864W 10/18...

  • Page 47: Panel Diagrams

    Updated 6-15-17 Panel Wiring Diagram OM864W 10/18...
  • Page 48 Updated 6-15-17 Panel Wiring Diagram OM864W 10/18...
  • Page 49 Updated 6-15-17 Panel Wiring Diagram OM864W 10/18...
  • Page 50 Updated 6-5-17 Panel Wiring Diagram OM864W 10/18...
  • Page 51 Updated 6-15-17 Panel Wiring Diagram OM864W 10/18...
  • Page 52 Updated 6-15-17 Panel Wiring Diagram OM864W 10/18...
  • Page 53 Updated 6-17-17 Panel Wiring Diagram OM864W 10/18...
  • Page 56 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. © 2018 All rights reserved. Litho USA.

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M864w3M864w3g

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