Northern Lights M864W and M864W3 Operator's Manual
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Northern Lights M864W and M864W3 Operator's Manual

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OM864W
For Models: M864W and M864W3
OPERATOR'S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators

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Summary of Contents for Northern Lights M864W and M864W3

  • Page 1 OM864W For Models: M864W and M864W3 OPERATOR’S MANUAL Marine Generators | Marine Diesel Engines | Land-Based Generators...
  • 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.: OM864W 12/13...

  • 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 12/13...

  • Page 4: Introduction

    M864W3 marine generator sets, which use the 864 engine block. Model Numbers Model numbers give the unit's application, block model, aspiration, and RPM: Model number of engine block M - Northern Lights marine generator set Bore Cylinders 86 mm Northern Lights marine diesel generator set with M864W a 864 engine and a PX-325K2 series generator end.

  • Page 5: Warranty

    Northern Lights dealer or the factory. operated or maintained. To prevent accidents be aware of potential dangers and act safely.
  • Page 6 Added 11-21-11 Safety Rules ALWAYS STOP ENGINE BEFORE FUELING authorized hearing protection, such as earmuffs or MACHINE. Always fi ll plugs to protect against loud noises. portable fuel tank outdoors. Never fuel a hot engine. Operating equipment requires the full attention of the operator.
  • Page 7 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 coolants, paints and at least 16 o C (60 o F).
  • Page 8 Added 11-21-11 Safety Rules (Continued) Contact your Northern Lights dealer or Northern Slowly loosen cap to relieve pressure before opening Lights factory for MSDS’s used on Northern Lights fully. products. Avoid High Pressure Fluids Work in Well Ventilated Areas Relieve pressure prior to...

  • Page 9: Safety Rules

    Do not use US Avoid breathing any dust that may be generated measurement tools on metric fasteners, or vice versa. when handling Use only service parts that meet Northern Lights components containing specifi cations. asbestos fi bers, including some gaskets.

  • Page 10: Lock Out / 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 OM864W 12/13...

  • Page 12: Component Locations M864K Generator Set (W/ 2012 Baseframe)

    Added 11-21-11 M864W Generator Component Locations 2012 Baseframe Figure 2: M864W Service Side DC Circuit Breaker Coolant Fill 13. Lube Oil Fill 20. Starter AC Circuit Breaker Expansion Tank 14. Raw Water Pump 21. Lube Oil Dipstick Air Filter 10. Heat Exchanger 15.
  • Page 13 Added 11-21-11 M864W Generator Component Locations 2012 Baseframe Figure 3: M864W Non-Service Side Expansion Tank Oil Pan Coolant Fill Raw Water Pump Exhaust Manifold Heat Exchanger Raw Lube Oil Fill Water Drain and Zinc Wet Exhaust Elbow 10. Heat Exchanger Manifold Drain OM864W 12/13...
  • Page 14 Revised 11-21-11 M864W Generator Component Locations Pre-2012 Baseframe Figure 2: M864W Service Side DC Circuit Breaker Coolant Fill 13. Lube Oil Fill 20. Starter 2. AC Circuit Breaker Expansion Tank 14. Raw Water Pump 21. Lube Oil Dipstick 10. Heat Exchanger 15.
  • Page 15 Revised 11-21-11 M864W Generator Component Locations Pre-2012 Baseframe Figure 3: M864W Non-Service Side Expansion Tank Oil Pan Coolant Fill Raw Water Pump Lube Oil Fill Heat Exchanger Raw Exhaust Manifold Water Drain and Zinc 10. Heat Exchanger Wet Exhaust Elbow Manifold Drain OM864W 12/13...

  • Page 16: Control Panels

    Control Panels 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.

  • Page 17: Operating Procedures

    revised 12-26-13 Emission-Related Installation & Instructions Failing to follow these instructions when installing a turbocharged engine and 48” (1200 mm) for a non- a certifi ed engine in a vessel violates federal law (40 turbocharged unit, measured at the engine exhaust elbow. CFR 1068.105(b)), subject to fi...

  • Page 18: Starting

    Operating Procedures STARTING OPERATING 1. Hold the Shutdown Bypass switch in the ON 1. Units with Series 3 and Series 4 Control position for 10-20 seconds before starting. Panels: NOTE: Holding the switch too long can burn Check gauges often. Oil pressure must be out the glow plugs.

  • Page 19: Shutdowns And Alarms

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

  • Page 20: Servicing Schedule Chart

    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 fi...
  • Page 21 Service Record Service OPERATION HOURS/ DATE Point 50 HOURS Check V-belt tension SP19 Check electrolyte in batteries 200 HOURS Change engine oil Change lubricating oil fi lters Check air cleaner Change primary fi lter element (Racor) SP10 Change secondary fuel fi lter SP18 Check zinc electrodes EVERY 750 HOURS...

  • Page 22: Servicing

    Servicing LUBRICATION - GENERAL SP1. 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 23: Changing Oil Filter

    Servicing SP3. CHANGING LUBE OIL FILTER SP5. V-BELTS 1. Change the lube oil fi lter every 200 hours. 1. Check the tension and wear on the V-belt after every 50 hours. 2. Use a fi lter wrench to remove old fi lter. Dispose of fi...

  • Page 24: Valve Clearances

    Servicing SP7. 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 fi rst 50 hours of rocker arm and the valve stem cap. Adjust until the operation.

  • Page 25: Fuels - General

    1. Use only clean, high quality fuels of the following 1. Your generator set should have a primary fuel fi lter specifi cations, as defi ned by ASTM designation installed. We recommend the Northern Lights brand D975 for diesel fuels: of fuel fi lter-water separators.

  • Page 26: Bleeding The Fuel System

    Servicing SP11. BLEEDING THE FUEL SYSTEM 1. The fuel system is self-bleeding. However, any CAUTION: Escaping diesel fuel under system may need manual bleeding when: pressure can penetrate skin causing serious a. A new fuel fi lter is installed; personal injury. Before disconnecting lines be b.

  • Page 27: Injector Service

    1. Injectors should be checked every 750 hours. This Figure 12-B disconnecting from injectors and injection pump. check should be made by a Northern Lights dealer or Remove all lines as an assembly; do not remove local injection repair station.

  • Page 28: Injection Pump

    Servicing SP13. INJECTION PUMP 3. Any repair which involves disassembly of the injec- 1. Since operating conditions may vary considerably, it tion pump must be carried out by specially trained is diffi cult to give a defi nite interval for checking the mechanics with the proper tools and test equipment.

  • Page 29: 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.

  • Page 30: Cooling System

    revised 11-8-13 Servicing COOLING SYSTEM - GENERAL SP14. CHECK THE COOLANT LEVEL NOTE: Be sure to close the sea-cock before working 1. Check the coolant level each day before starting the on the engine cooling system. engine. a. Check the water level by removing the pressure CAUTION: The cooling water in the engine cap from the radiator.

  • Page 31: Heat Exchanger

    Servicing SP16. HEAT EXCHANGER SP18. 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 32: Electrical System - General

    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 fl ames and sparks away from batteries. Manual. If you do not have one of these manuals, contact your local dealer.

  • Page 33: Battery Care

    Servicing SP19-20. BATTERY CARE 1. Check the electrolyte level every 50 hours, or once a month. Add distilled water to the manufacturer's recommended level. 2. Batteries, cables, and cable terminals should be checked and cleaned every 100 hours. Clean corrosion with a water and baking soda solution. Flush with clean water.

  • Page 34: Troubleshooting

    • Clean and tighten battery and harness plug connections. Sulfated or worn out batteries • Check specifi c gravity and electrolyte level of each battery. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM864W 12/13...

  • Page 35: 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 36 • Fill crankcase to proper level. Improper type of oil • Drain and fi ll crankcase with correct oil. Partially plugged oil fi lter • Replace fi lter. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM864W 12/13...

  • Page 37: Engine

    • Warm up engine to normal operating temperature. Defective thermostat • Remove and check thermostat. Engine out of time • See your dealer. Low Compression Pressure • See your dealer. If you cannot correct problems with these procedures, see your Northern Lights dealer. OM864W 12/13...

  • Page 38: Specifi Cations And Dimensions

    Specifi cations 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 39: Wiring Diagrams Dc Electrical

    Revised 11-21-11 DC Wiring Diagram OM864W 12/13...
  • Page 40 DC Wiring Diagram OM864W 12/13...
  • Page 41 Added 11-21-11 DC Wiring Diagram OM864W 12/13...
  • Page 42 Added 11-21-11 DC Wiring Diagram OM864W 12/13...
  • Page 43 Revised 7-9-11 DC Wiring Diagram OM864W 12/13...
  • Page 44 Revised 11-21-11 DC Wiring Diagram OM864W 12/13...
  • Page 45 Added 11-21-11 DC Wiring Diagram OM864W 12/13...

  • Page 46: Ac Electrical

    Added 11-21-11 DC Wiring Diagram OM864W 12/13...
  • Page 47 Revised 11-21-11 AC Wiring Diagram OM864W 12/13...
  • Page 48 Added 11-21-11 AC Wiring Diagram OM864W 12/13...
  • Page 49 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 Alaska Diesel Electric, Inc. © 2013 All rights reserved. Litho USA.

This manual is also suitable for:

M864wM864w3

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