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Northern Lights M1064D Operator's Manual

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OPERATOR'S
MANUAL
OM2-2
For Models:
M1064A, M1064D, M1064T1, M1064T2,
M1066A1, M1066A2, M1066A3, M1066T,
M40C2, M55C2, M65C2, & M99C2

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Summary of Contents for Northern Lights M1064D

  • Page 1 OPERATOR’S MANUAL OM2-2 For Models: M1064A, M1064D, M1064T1, M1064T2, M1066A1, M1066A2, M1066A3, M1066T, M40C2, M55C2, M65C2, & M99C2...
  • Page 2 4420 14th Avenue N.W. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455 Copyright ©2013 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.: OM2-2 1/17...

  • 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 OM2-2 1/17...

  • Page 4: Introduction

    II 6068 engine block and an electronically controlled fuel system controlled fuel system. Serial Numberss When referencing Northern Lights equipment by serial number, please refer only to the number stamped on the Northern Lights serial number plate. ® OM2-2 1/17...

  • Page 5: Warranty

    For replacement signs, ALWAYS STOP ENGINE proper placement of safety signs or clarification on any BEFORE FUELING safety issue, consult your Northern Lights dealer or the MACHINE. Always fill factory. portable fuel tank outdoors. There can be additional safety information contained Never fuel a hot engine.
  • Page 6 Revised 4-10-12 Safety Rules (Continued) Prevent accidental discharge of starting fluids by Operating equipment requires the full attention of storing all cans in a cool, safe place, away from sparks the operator. Do not use radio or music headphones or open flame. Store with cap securely on container. while operating machinery.
  • Page 7 Among the potentially hazardous with a metal object. Use a volt-meter or hydrometer. chemicals that may be used with Northern Lights Frozen batteries may explode if charged. Never products are lubricants, charge a battery that has not been allowed to warm to at least 16 o C (60 o F).
  • Page 8 Slowly loosen cap to relieve pressure before and use appropriate equipment exactly as recommended. opening fully. Contact your Northern Lights dealer or Northern Lights factory for MSDS’s used on Northern Lights products. Avoid High Pressure Fluids WARNING...
  • Page 9 Exhaust parts and streams can reach high Follow all recommended removal and installation temperatures during operation, leading to burns or procedures in this and associated Northern Lights other serious injury. manuals. Cleaning exhaust filters can also lead to exposure to...

  • Page 10: Lockout / Tag Out Procedures

    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 Notes OM2-2 1/17...

  • Page 12: Component Locations

    Component Locations Figures 1 & 2: M1064T1 (Mechanically Controlled Fuel System) 1. Junction Box 8. Coolant Fill 15. Lube Oil Drain 22. Injection Pump Drive 2. Exhaust Elbow 9. Alternator 16. Fuel Manifold Coupling Access Cover 3. Turbocharger 10. Raw Water Pump 17.
  • Page 13 Component Locations Figure 3 & 4: M1066T (Mechanically Controlled Fuel System) 1. Coolant Fill 9. Air Cleaner 17. Heat Exchanger Zinc (2) 24. Optional Governor Actuator 2. Expansion Tank 10. DC Circuit Breaker 18. Heat Exchanger Drain 25. Drive Belt Cover 3.
  • Page 14 Component Locations Figure 5 & 6: M40C2 (Mechanically Controlled Fuel System) 1. Junction Box 6. Coolant Fill 11. Lube Oil Drain 16. Exhaust Manifold 2. Fuel Filter 7. Expansion Tank 12. Lube Oil Filter 17. Injection Lines 3. Fuel Lift Pump 8.
  • Page 15 Northern Lights Control Panels 1. SHUTDOWN BYPASS SWITCH This switch bypasses the safety shutdown feature during the starting process. 2. ENGINE CONTROL SWITCH To start the engine, hold this switch in the START position until the engine is running. NOTE: Excessive cranking of marine sets equipped with water lift muffler systems can cause engine damage.
  • Page 16 Northern Lights Control Panel Figure 8: Series 4 B Generator Control Panel 7. AC VOLTMETER 1. SHUTDOWN BYPASS SWITCH This switch bypasses the safety shutdown feature The voltmeter shows the generator output during the starting process. voltage, phase to phase. If the voltage fluctuates greatly from the normal reading, shut 2.

  • Page 17: Emission-Related Installation Instructions

    revised 3-19-13 Emission-Related Installation & Instructions Failing to follow these instructions when installing a turbocharged engine and 48” (1200 mm) for a non- a certified engine in a vessel violates federal law (40 turbocharged unit, measured at the engine exhaust elbow. CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.

  • Page 18: Break-In Period

    If the oil level was normal, DO NOT restart the engine. Call your Northern Lights or Lugger dealer for assistance. OM2-2 1/17...
  • Page 19 Revised 1-30-17 Service Schedule Chart, Mechanically Controlled Fuel System The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your marine generator set. More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’ column. DAILY: SP13 Check turbocharger air, oil &...
  • Page 20 Revised 9-16-15 Service Schedule Chart, Electronically Controlled Fuel System The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your marine generator set. More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’ column. EVERY 500 HOURS / YEARLY: DAILY: Replace air cleaner...

  • Page 21: Servicing

    Refill engine with recommended oil. not allow the engine to break-in properly. 4. Engine Lube Oil Capacity: Lubrication - General M1064D & T1 15.5 qts. 14.7 liters 1. Use only clean, high quality lubricants stored in M1064T2 (@60 Hz) 15.5 qts.

  • Page 22: Valve Clearances

    Servicing NOTE: Firing order is 1 - 3 - 4 - 2 SP6. VALVE CLEARANCES The following special tools will be needed: JDE 820 or JDE 83 Flywheel Turning Tool, JDE 81-4 Timing Pin. 1. Remove rocker arm cover with ventilator tube. 2.

  • Page 23: Fuels - General

    Servicing FUELS - GENERAL 2. Change secondary fuel filter every 500 hours. 1. Use only clean, high quality fuels of the following NOTE: The fuel filter on the engine is considered the specifications, as defined by ASTM designation D975 for “secondary fuel filter”.

  • Page 24: Bleeding The Fuel System

    Servicing SP8-10. FUEL FILTERS (Continued) 1. Whenever the fuel system has been opened for service, (lines disconnected, filter changed, etc.) it will be a. Turn off the fuel. necessary to bleed air from the system. b. Open the filter drain plug and drain (Figure 14-A) a.
  • Page 25 Servicing c. Do not bend the fuel delivery lines. When This coating will become discolored during normal loosening the fuel pressure lines, hold male union operation, but this is not harmful. Do not use a motor of nozzle line stationary with a backup wrench. driven brush to clean up nozzle body.
  • Page 26 Servicing Install injection nozzles (continued): DB4 AND DB2 INJECTION PUMPS – REMOVAL All Stanadyne DB2 and DB4 injection pumps will have a retained drive shaft (shaft stays in pump when pump is removed from engine). 1. Clean the fuel injection pump, lines, and area around the pump with cleaning solvent or a steam cleaner.

  • Page 27: Injection Pump

    Servicing NOTE: The injection pump drive gear fits snugly onto IMPORTANT: Injection pump mounting flange timing a tapered drive shaft and indexed by a hollow pin or mark (Figure 20-A ) and front plate timing mark Woodruff key installed in drive shaft. (Figure 20-B) presence and alignment MUST be 6.
  • Page 28 Servicing 5. Install pump mounting flange flush to engine front plate with drive gear held flush against front side of engine front plate. IMPORTANT: Do not use tightening force of pump mount- ing stud nuts to pull pump shaft into drive gear I.D. 6.

  • Page 29: Turbocharger

    Servicing SP13. TURBOCHARGER 2. Vapor bubbles are formed when the (Figure 25-C) 1. Check for air leaks every 100 hours. Air leakage piston's impact causes the liner walls to vibrate, will lower engine output and may cause black sending pressure waves into the coolant. exhaust smoke and soot.
  • Page 30 Run the engine for 2 hours and -37°C +109°C retest the coolant. Continue process until SCA Optimum -34°F +226°F concentration meets recommended levels. 3. SCA is available from your Northern Lights dealer -24°C +106°C Minimum -12°F +222°F in the following sizes. Pint - Part Number....20-00002 -52°C...

  • Page 31: Heat Exchanger Cleaning

    If applicable, open the cooling system EGC (antifreeze). air vent on top of turbocharger. 3. Test kits are available through your Northern Lights or 4. Open the drains on the exhaust manifold and engine Lugger Dealer. block. Drain the fresh water system (see Component 4 Pack - Part Number.......20-00005...

  • Page 32: Raw Water Pump

    Manual. If you do not have one of these manuals, 3. Reinstall the zinc holders. Be sure the threads are contact your local Northern Lights dealer. clean and have good metal to metal contact. ELECTRICAL SYSTEM - GENERAL SP20.

  • Page 33: Booster Batteries

    Servicing BOOSTER BATTERIES 1. Change the engine oil and replace the filter. Service the air cleaner. CAUTION: Battery Gas Can Explode. Keep all 2. Drain, flush, and refill the cooling system. flames and sparks away from batteries. 3. Crank the engine a few times with a starter, without starting the engine.

  • Page 34: Troubleshooting

    Troubleshooting If you cannot correct problems with these procedures, see your Lugger or Northern Lights dealer. DC ELECTRICAL SYSTEM Crankcase oil too heavy: Battery Will Not Charge • Fill with oil of appropriate viscosity. Loose or corroded connections: Loose or corroded connections: •...
  • Page 35 Troubleshooting If you cannot correct problems with these procedures, see your Lugger or Northern Lights dealer. Engine Runs Irregularly or Stalls Dirty or faulty injection nozzles: Frequently • Replace injectors. Best done by dealer. Below normal engine temperature: • See your local dealer.
  • Page 36 Troubleshooting If you cannot correct problems with these procedures, see your Lugger or Northern Lights dealer. High Fuel Consumption Improper fuel: Engine overloaded. • Use correct fuel for temperature. • Reduce load. Engine overloaded. Air in fuel system: • Reduce load.
  • Page 37 Revised 4-10-12 AC Wiring Diagram OM2-2 1/17...

  • Page 38: Wiring Diagrams

    Revised 7-9-12 A.C. Wiring Diagram OM2-2 1/17...
  • Page 39 Added 4-10-12 A.C. Wiring Diagram OM2-2 1/17...
  • Page 40 D.C. Wiring Diagram OM2-2 1/17...
  • Page 41 Revised 4-10-12 D.C. Wiring Diagram OM2-2 1/17...
  • Page 42 Revised 4-10-12 D.C. Wiring Diagram OM2-2 1/17...
  • Page 43 D.C. Wiring Diagram OM2-2 1/17...
  • Page 44 Revised 4-10-12 D.C. Wiring Diagram OM2-2 1/17...
  • Page 45 Revised 4-10-12 D.C. Wiring Diagram OM2-2 1/17...
  • Page 46 Revised 4-10-12 D.C. Wiring Diagram OM2-2 1/17...
  • Page 47 Added 4-10-12 D.C. Wiring Diagram OM2-2 1/17...
  • Page 48 Added 4-10-12 Notes OM2-2 1/17...
  • Page 49 D.C. Wiring - 12 Volt Standard Ground for M1066A2 and M1066A3 Drawing D-3769B OM2-2 01/17...
  • Page 50 D.C. Wiring - 24 Volt Isolated Ground for M1066A2 and M1066A3 Drawing D-3772C OM2-2 01/17...

  • Page 51: Panel Wiring

    Added 4-10-12 Panel Wiring Diagram OM2-2 1/17...
  • Page 52 Added 4-10-12 Panel Wiring Diagram OM2-2 1/17...
  • Page 53 Added 4-10-12 Panel Wiring Diagram OM2-2 1/17...

  • Page 54: On-Board Spare Parts

    On Board Spare Parts Safety at sea depends on careful preparation, product knowledge, and having the right tools and parts. Below is a list of parts Northern Lights, Inc. recommends you carry onboard at all times. Onboard Parts Kits are available from your dealer.
  • Page 57 4420 14th Ave. NW., Seattle WA 98107 Tel: (206) 789-3880 • 1-800-762-0165 • www.northern-lights.com Northern Lights and Lugger are registered trademarks of Northern Lights, Inc. © 2017 All rights reserved. Litho USA.

This manual is also suitable for:

M1064t2M1064aM1064t1M1066a2M1066tM1066a3 ... Show all

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