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

Northern lights diesel generator set 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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  • 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 ©2007 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 09/07...

  • 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 09/07...

  • 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

    Warranty Warranty A warranty registration certifi cate is supplied NOTE: If the warranty is to apply, the with your set. It entitles the original purchaser of servicing instructions outlined in this manual our equipment to a warranty covering material or must be followed.

  • Page 6: Component Locations M864K Generator Set

    M864W Generator Component Locations Figure 2: M864W Service Side 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...
  • Page 7 M864W Generator Component Locations Figure 3: M864W Non-Service Side Heat Exchanger Raw Lube Oil Fill Water Drain and Zinc Exhaust Manifold Raw Water Pump Coolant Fill Oil Pan Expansion Tank 10. Wet Exhaust Elbow Heat Exchanger 11. Manifold Drain OM864W 09/07...

  • Page 8: 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 9: Operating Procedures

    Operating Procedures BEFORE STARTING BREAK-IN PERIOD 1. The fi rst 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 2.

  • Page 10: 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 11: 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 12: 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 13 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 14: Lubrication - General

    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 15: 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 16: 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 17: 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 18: 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 19: 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 20 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 21: 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 22: Cooling System

    Servicing SP15. 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 fi rst. CAUTION: The cooling water in the engine 2.

  • Page 23: 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 24: 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 25: 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 26: 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 09/07...

  • Page 27: 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 28 • 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 09/07...
  • Page 29 • 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 09/07...

  • Page 30: 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 31: Wiring Diagrams Dc Electrical

    DC Wiring Diagram OM864W 09/07...
  • Page 32 DC Wiring Diagram OM864W 09/07...
  • Page 33 DC Wiring Diagram OM864W 09/07...
  • Page 34 DC Wiring Diagram OM864W 09/07...

  • Page 35: Ac Electrical

    AC Wiring Diagram OM864W 09/07...
  • Page 36 Notes OM864W 09/07...
  • Page 37 OM864W 09/07...
  • Page 38 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. www.northern-lights.com © 2007 All rights reserved. Litho USA.

This manual is also suitable for:

M864w3

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