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Northern Lights M864W, Operator'S Manual

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Northern Lights M864W Operator'S Manual Download Page 13

OM864W  10/18

11

Figure 3:  

M864 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

Generator Component Locations

Summary of Contents for M864W

Page 1: ...OM864W For Models M864W M864W3 and M864W3G OPERATOR S MANUAL OPERATOR S MANUAL www northern lights com ...

Page 2: ...to the outside Do not modify or tamper with the exhaust system Do not idle the engine except as necessary For more information go to www P65warnings ca gov diesel CALIFORNIA Proposition 65 Warning Northern Lights 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 o...

Page 3: ...LS Series 4 A 4 B and 4 C 12 OPERATING PROCEDURES Break in Period 13 Before Starting 13 Starting 14 Operating 14 Stopping 14 Shutdowns and Alarms 15 Spare Parts 15 SERVICING SCHEDULE 16 17 Table of Contents SERVICING Lubrication General 18 Checking Oil Level 18 Oil Changes 18 Changing Oil Filter 19 Air Cleaner 19 V Belts 19 Valve Clearances 20 Fuels General 21 Fuel Filters 21 Bleeding the Fuel Sys...

Page 4: ... the operating instructions for M864W marine generator sets M864W3 marine generator sets M864W3G marine generator sets Your set has three serial numbers 1 an engine number stamped on the block 2 a generator plate and 3 a generator set plate Use the serial number on the generator set plate when ordering parts or in correspondence The generator set plate is found on the service side of the generator...

Page 5: ...larification on any safety issue consult your Northern Lights dealer or the factory There can be additional safety information contained on parts and components from outside suppliers that is not reproduced in this manual Consult the suppliers for additional safety information Learn how to operate the machine and how to use the controls properly Only trained personnel should operate machines or wo...

Page 6: ...ld up of grease oil or debris Disconnect battery ground cable before making any adjustments or service work Handle Fuel Safely Avoid Flames WARNING Diesel is highly flammable and should be treated with care at all times Do do not refuel while smoking or when near sparks or open flame ALWAYS STOP ENGINE BEFORE FUELING MACHINE Always fill portable fuel tank outdoors Never fuel a hot engine Prevent a...

Page 7: ... open flame away from the top of battery When checking battery electrolyte level use a flashlight Never check battery charge by contacting the posts with a metal object Use a volt meter or hydrometer Frozen batteries may explode if charged Never charge a battery that has not been allowed to warm to at least 16oC 60oF Always remove grounded battery clamp first and replace ground clamp last Sulfuric...

Page 8: ...cts Safely WARNING Direct exposure to hazardous chemicals can cause serious injury Among the potentially hazardous chemicals that may be used with Northern Lights products are lubricants coolants paints and adhesives All potentially hazardous chemicals come with a Material Data Safety Sheet MSDS The MSDS provides specific details on chemical products including physical hazards safety procedures an...

Page 9: ...ge containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Do Not Open High Pressure Fuel System DANGER Many Northern Lights engines use high pressure fuel injection High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt any repair of fuel lines sensors or other components between...

Page 10: ...ot be achieved at the local supply valve shut off valves further back in the system and re check the bleed off point until complete shut off is achieved Affix a DO NOT OPERATE tag to each valve handle that requires shut off Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment Lock Out Tag Out Instructions Air Hose Connected Pneumatic Equipment Equip...

Page 11: ...OM864W 10 18 9 This page left intentionally blank ...

Page 12: ... 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 Generator Component Locations ...

Page 13: ... 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 Generator Component Locations ...

Page 14: ...on Series 1 panels only and has a light that glows when the set is run ning 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 indicates the condition of the battery When the engine is running the...

Page 15: ...an 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 kept ON while the engine is running If the switch is turned OFF while the engine is running the battery charging 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 chec...

Page 16: ...the Shutdown Bypass switch in the ON posi tion 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 sta...

Page 17: ... temperature gauge regularly and turn off the unit if the temperature rises above 205 F 96 C Repeat troubleshooting 3 If shutdown is activated and the temperature gauge shows temperature within normal temperature range a Check the engine crankcase oil level b If the oil level is low fill with recommended lubricating oil and restart Watch the oil pressure gauge carefully and shut off the engine if ...

Page 18: ...RVICE 50 100 200 750 1500 2400 3000 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours Hours Hours ENGINE SP1 18 Check oil level SP2 18 Change engine oil1 5 SP3 19 Change lube oil filters1 5 SP4 19 Check air cleaner1 4 SP5 19 Check V belt tension1 SP6 20 Check valve clearances5 FUEL SYSTEM SP7 21 Check primary filter2 SP8 21 Change primary filter element2 3 SP9 21 Change secondary fuel filte...

Page 19: ...rimary filter element Racor SP9 Change secondary fuel filter SP17 Check zinc electrodes EVERY 750 HOURS SP6 Check valve clearances SP11 Check injectors SP14 Check and flush cooling system SP16 Change impeller in seawater pump SP19 Check condition of batteries with hydrometer 1500 HOURS SP11 Check injectors clean tips 2400 HOURS SP12 Check fuel injection pump SP15 Check and clean heat exchanger 300...

Page 20: ...recommended oil and fill only to the high mark on the dipstick Follow the lubrication recommendations in Figure 5 SP 2 OIL CHANGES 1 The set is delivered with special break in oil Change the engine oil and oil filter after 50 hours of operation Use Service CC 30 weight oil during the first 100 hours 2 Change the oil and filter again at 100 hours using the oil recommended in the above diagram After...

Page 21: ...e sealing surface 5 Using hands only no wrench tighten filter one half turn farther Overtightening can do damage to filter housing 6 Fill engine with recommended oil Start engine and check for leakage Stop engine wait 3 minutes and check oil level Add additional oil if necessary 7 Oil filter part number is Model 864W W3 24 08701 SP 4 AIR CLEANER 1 Visually inspect air cleaner every 200 hours In du...

Page 22: ...ent when the two rocker arms are exactly aligned with each other is when they rock Figure 6 Timing Marks 4 Measure the valve clearance for each of the valves shown as in Figure 7 Standard valve clearances for a hot engine are Intake IN 0 007 0 009 in 0 18 0 22 mm Exhaust EX 0 013 0 015 in 0 33 0 37 mm Figure 7 Valve Sequence 5 To adjust valve clearance loosen the lock nut on the adjustment screw I...

Page 23: ... A2 2 Use fuel having less that 1 sulphur preferably less than 0 5 3 The cetane number should be a minimum of 45 4 DO NOT use these unsuitable grades of fuel a Domestic heating oils all types b Class B engine c Class D domestic fuels d Class E F G or H industrial or marine fuels e ASTM D975 60T No 4 D and higher number fuels 5 Biodiesel Biodiesel involves the transesterification of vegetable oils ...

Page 24: ...y Figure 10 Fuel System 1 The fuel system is self bleeding However any system may need manual bleeding when a A new fuel filter is installed b The engine has run out of fuel c The fuel lines injection pump or any other fuel system component has been removed and installed 2 Loosen bleed nipple Figure 10 I on top of the fuel filter Pump hand primer Figure 10 H on fuel lift pump until pure fuel no bu...

Page 25: ...njector inlets and injection pump outlets to keep dirt out d Remove the return line retaining nuts washers and return line e Loosen the injector Figure 12 I Remove the injector f Remove the injector seat Cover the holes to prevent debris from entering the cylinders NOTE Do not use pry bars to remove injectors from the cylinder head 3 Injector Repair and Cleaning a Take injectors to your Northern L...

Page 26: ... servicing the pump check other possible causes a Check cleanliness of the air filter b Check valve clearances c Clean and check injectors 3 Any repair which involves disassembly of the injec tion pump must be carried out by specially trained mechanics with the proper tools and test equipment NOTE All warranties on the engine become null and void if the injection pump seals are broken by unauthori...

Page 27: ...g nuts Figure 12 J One 1 is found on the back side of the injection pump and three 3 are found on the front side e Take the pump to your Northern Lights dealer or an injection repair station for testing and service 5 Injection Pump Installation a Reverse the removal process b Make sure the mark on the gear shows through the plug hole c Torque mounting bolts to 12 18 ft lbs 1 7 2 5 k gm INJECTION P...

Page 28: ...s approximately 7 PSI 0 5 kg cm2 Use a cap pressure tester to check cap if you suspect it is faulty SP 14 COOLING SYSTEM FLUSHING 1 Flush the cooling system every 750 hours or every 12 months whichever comes first 2 Remove fill cap and open drains on engine block The hex headed engine block drain is on the service side of the engine below the intake manifold next to the flywheel housing 3 Pour cle...

Page 29: ... end of the impeller center if this has not already been done NOTE Make sure that there is always an extra impeller and cover gasket in reserve on board SP 17 ZINC ELECTRODES 1 A zinc electrode is installed in the heat exchanger cooling system to protect the engine from electroly sis Check it faithfully every 200 hours If you are in warm saltwater or where electrolysis is a known problem check it ...

Page 30: ...y BOOSTER BATTERIES CAUTION Battery gas can explode Keep all flames and sparks away from batteries 1 Before changing or using booster batteries check the battery electrolyte level Add distilled water if necessary 2 Booster and main batteries must have the same volt age rating 3 First connect the positive terminal of the booster battery to the positive terminal of the main bat tery Then connect the...

Page 31: ... flush and fill the cooling system with pre mixed 50 50 conventional ethylene glycol heavy duty diesel engine coolant with SCAs Loosen alternator drive belt Completely seal off intake and exhaust openings with heavy plastic bags and duct tape Cover entire engine in large plastic bag and tape closed at bottom of bag place several moisture absorbing desiccant packs inside plastic bag Store engine in...

Page 32: ...ug connection Low battery condition Check specific gravity of each battery Check electrolyte level of each battery Defective electrical system Repair or replace ground wire Starter Cranks Slowly Low battery condition Battery is too small Battery cables are too small Check specific gravity Replace battery if necessary of each battery Check electrolyte level If low fill cells with distilled water of...

Page 33: ...tat or Stalls Frequently Clogged primary Clean or replace filter element fuel filter element Clogged secondary Replace secondary filter element fuel filter element Water or dirt in the fuel system Drain flush fill and bleed system Dirty or faulty injection nozzles Have your dealer check injection nozzles Air in fuel system Inspect clamps and hoses on suction side of fuel pump for air leak Improper...

Page 34: ... gauge is working properly Faulty fuel injector Call your dealer Engine overheating See Engine Overheating section High Fuel Consumption Improper type of fuel Use correct fuel for temperature Clogged or dirty air cleaner Service air cleaner Engine overloaded Reduce the electrical load Improper valve clearance See your dealer Injection nozzles dirty See your dealer Injection pump out of time See yo...

Page 35: ...er Have dealer check back pressure back pressure too high Improper fuel Use correct fuel for temperature Engine overloaded Reduce the electrical load Injection nozzles dirty See your dealer Engine injection timing off See your dealer Engine Emits Improper fuel Use correct fuel for temperature White Smoke Cold engine Warm up engine to normal operating temperature Defective thermostat Remove and che...

Page 36: ...ion to Jacket Water 1788 BTU min 1400 BTU min Fresh Water Pump Capacity 11 5 gal min 43 5 l m 9 5 gal min 36 l m Maximum Sea Water Pump Suction Head 39 in 1 m 39 in 1 m Keel Cooler Tube Length Turbo Tube 8 ft 2 44 m 8 ft 2 44 m Keel Cooler Head Diameter 1 25 in 32 mm 1 25 in 32 mm Keel Cooler Water Hose ID Discharge and Suction 1 5 in 38 mm 1 5 in 38 mm Electrical Minimum Battery Capacity 220 Amp ...

Page 37: ...OM864W 10 18 35 AC Wiring Diagram Updated 6 29 17 Northern Lights AC Wiring Diagram Taiyo PX300K2 4 Lead Generator with DST 100 2FAK AVR Drawing B 9724E ...

Page 38: ...OM864W 10 18 36 AC Wiring Diagram Northern Lights AC Wiring Diagram Taiyo PX300K2 12 Lead Generator with DST 100 2FAK AVR Drawing B 9723D Updated 6 15 17 ...

Page 39: ...OM864W 10 18 37 DC Wiring Diagram Northern Lights DC Wiring Diagram M864W M864W3 12 VDC Standard Ground B Control Drawing B 10770C Updated 6 15 17 ...

Page 40: ...OM864W 10 18 38 Northern Lights DC Wiring Diagram M864W M864W3 12 VDC Isolated Ground B Control Drawing B 10844 DC Wiring Diagram Updated 6 15 17 ...

Page 41: ...OM864W 10 18 39 Northern Lights DC Wiring Diagram M864W M864W3 24 VDC Standard Ground B Control Drawing B 10818F DC Wiring Diagram Updated 6 30 17 ...

Page 42: ...OM864W 10 18 40 Northern Lights DC Wiring Diagram M864W M864W3 24 VDC Isolated Ground B Control Drawing B 10843 DC Wiring Diagram Updated 6 15 17 ...

Page 43: ...OM864W 10 18 41 Northern Lights DC Wiring Diagram M864W3 12V Standard Ground Drawing B 9956B DC Wiring Diagram Updated 6 15 17 ...

Page 44: ...OM864W 10 18 42 Northern Lights DC Wiring Diagram M864W 12V Isolated Ground Drawing B 9969 DC Wiring Diagram Updated 6 15 17 ...

Page 45: ...OM864W 10 18 43 Northern Lights DC Wiring Diagram M864W3 24V Standard Ground Drawing B 9878D DC Wiring Diagram Updated 6 15 17 ...

Page 46: ...OM864W 10 18 44 Northern Lights DC Wiring Diagram M864W 24V Isolated Ground Drawing B 9901D DC Wiring Diagram Updated 6 15 17 ...

Page 47: ...OM864W 10 18 45 Panel Wiring Diagram S 1 Panel B Deutsch A 12798 Panel Wiring Diagram Updated 6 15 17 ...

Page 48: ...OM864W 10 18 46 Panel Wiring Diagram S 1B Panel B A 12791B Panel Wiring Diagram Updated 6 15 17 ...

Page 49: ...OM864W 10 18 47 Panel Wiring Diagram S 3B Panel Viewline B A 12799A Panel Wiring Diagram Updated 6 15 17 ...

Page 50: ...OM864W 10 18 48 Panel Wiring Diagram S 3C Panel Viewline B A 12790A Panel Wiring Diagram Updated 6 5 17 ...

Page 51: ...OM864W 10 18 49 Panel Wiring Diagram S 1B Control Panel Drawing A 12667A Panel Wiring Diagram Updated 6 15 17 ...

Page 52: ...OM864W 10 18 50 Panel Wiring Diagram S 3B S 3C Oceanline Viewline Panels 12V A 12574A Panel Wiring Diagram Updated 6 15 17 ...

Page 53: ...OM864W 10 18 51 Panel Wiring Diagram S 3C control Panel Viewline A 12645B Panel Wiring Diagram Updated 6 17 17 ...

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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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