Northern Lights M864K Operator's Manual
OPERATOR’S
OPERATOR’S
MANUAL
MANUAL
M864K
— CALIFORNIA —
Proposition 65 Warning:
Diesel engine exhaust and some of its constituents
are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
Alaska Diesel Electric, Inc.
4420 14th Avenue N.W.
P.O. Box 70543
Seattle, WA 98107
Tel: (206) 789-3880
Fax: (206) 782-5455
Copyright ©2002 Alaska Diesel Electric, Inc.
All rights reserved. Alaska Diesel Electric™,
the Alaska Diesel Electric logo, Northern Lights™,
and the Northern Lights logo are all trademarks
of Alaska Diesel Electric, Inc.
Printed in U.S.A.
PART NO.: OM864K 04/02
OPERATOR'S MANUAL
for Northern Lights® M864K Diesel Generator Sets
Read this operator's manual thoroughly before starting to operate your equipment.
This manual contains information you will need to run and service your new unit.
Table of Contents
INTRODUCTION ................................................... 2
Models Included ................................................ 2
Model Numbers................................................. 2
Serial Numbers .................................................. 2
WARRANTY ........................................................... 3
SAFETY RULES .................................................... 3
COMPONENT LOCATIONS
M864K Generator Set ..................................4 - 5
CONTROL PANELS
Northern Lights Generator Sets......................... 6
OPERATING PROCEDURES
Break-in Period ................................................. 7
Before Starting .................................................. 7
Starting .............................................................. 8
Operating ........................................................... 8
Stopping ............................................................ 8
Shutdowns and Alarms...................................... 9
Spare Parts......................................................... 9
SERVICING (Continued)
V-Belts ............................................................ 13
Valve Clearances............................................. 14
Fuels - General ................................................ 15
Fuel Filters....................................................... 15
Bleeding the Fuel System................................ 16
Injector Service ............................................... 17
Injection Pump ........................................ 18 - 19
Cooling System ............................................... 20
Heat Exchanger ............................................... 21
Raw Water Pump ............................................ 21
Zinc Electrodes................................................ 21
Electrical System - General............................. 22
Booster Batteries ............................................. 22
Battery Care..................................................... 23
Winterizing / Out-of-Service........................... 23
TROUBLESHOOTING
Electrical.......................................................... 24
Engine...................................................... 25 - 27
DATA SHEET
Specifications and Dimensions ....................... 28
SERVICING SCHEDULE CHART ............ 10 - 11
SERVICING
Lubrication - General ...................................... 12
Checking Oil ................................................... 12
Oil Changes .....................................................12
Changing Oil Filter.......................................... 13
Air Filter .......................................................... 13
This publication is the property of Alaska Diesel Electric, Inc.
It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc.
© Alaska Diesel Electric, Inc. All rights reserved. Litho U.S.A. Publication number OM864K 04/02
WIRING DIAGRAMS
DC Electrical ................................................... 29
AC Electrical ................................................... 30
Proprietary Information
OM864K 04/02
1
Introduction
The servicing of marine engines and generator sets
presents unique problems. In many cases, boats cannot be
moved to a repair facility. Marine engines cannot be
compared to the servicing of automobiles, trucks, or
even farm equipment. Failures often occur in remote
areas far from competent assistance. Marine engines are
taxed far more severely than auto or truck engines;
therefore, maintenance schedules must be adhered
Unit Identification
MODELS INCLUDED
This manual covers the operating instructions for:
M864K marine generator sets, which use the 864 engine block.
Model Numbers
to more strictly. Failures begin with minor problems that
are overlooked and become amplified when not corrected
during routine maintenance.
As operator, it is your obligation to learn about your
equipment and its proper maintenance. This is not a
comprehensive technical service manual. Nor will it make
the reader into an expert mechanic. Its aim is to aid you in
maintaining your unit properly.
Model numbers give the unit's application, block model, aspiration, and RPM:
M
M- Northern Lights marine generator set
M864K
Northern Lights marine diesel generator set with
=
a 864 engine and a PX-325K series generator end.
Model number of engine block
+
Bore Cylinders
86 mm 4
864
Serial Numbers
Your set has three serial numbers: ➀ an engine number stamped on
a plate attached to the valve cover, ➁ a generator end serial number,
and ➂ a generator set serial number.
NOTE: Always use the generator set serial number when ordering parts
or in correspondence. The generator set serial number plate is found on
the service side of the generator and resembles the drawing in Figure 1.
Figure 1: Generator set serial number plate.
OM864K 04/02
2
Warranty
A warranty registration certificate is supplied with your
set. It entitles the original purchaser of our equipment to
a warranty covering material or assembly faults. The
extent of coverage is described in the Limited Warranty
Statement. We recommend that you study the statement
carefully.
NOTE: If the warranty is to apply, the servicing
instructions outlined in this manual must be followed.
If further information is needed, please contact an
authorized dealer or the factory.
Safety Rules
CAUTION: Accident reports show that careless use of engines causes a high percentage of accidents.
You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.
• Never leave engine without proper security.
• Turn the coolant tank cap slowly to relieve pressure
before removing. Add coolant only when the engine
is stopped and cool.
• Mount a fire extinguisher near engine.
• Always disconnect the battery ground strap before
making adjustments.
• Operate engines in properly ventilated areas.
• Keep trash and other objects away from engine.
• Escaping fluids under pressure can penetrate your
skin. Use a piece of cardboard or wood, not your
hands, to search for leaks.
• Avoid wearing loose clothing without a belt when
working around engines.
• Do not oil or grease engine while it is running.
• Use caution in handling fuel. Never refuel a hot or
running engine. Do not smoke while filling fuel tank
or servicing fuel system.
• Keep your hands, feet, hair and clothing away from
power-driven parts.
• Check for any loose electrical connections or faulty
wiring.
• Engines should be operated only by knowledgeable,
qualified personnel.
• Look completely around engine to make sure that
everything is clear before starting.
• Do not operate an engine that isn't in proper working
order. If an unsafe operating condition is noted, tag the
set and control panel so others will also know about the
problem.
• Provide first aid kits.
CAUTION: This symbol is used throughout
this book to alert you to possible danger areas.
Please take special notice of these sections.
OM864K 04/02
3
M864K Generator Component Locations
Figure 2: M864K Service Side with PXK generator end.
1. DC Circuit Breaker
2. Air Filter
3. Intake Manifold
4. Lube Oil Dipstick
5. Secondary Fuel Filter
6. Lube Oil Fill
7. Fuel System Bleed Point
8. Exhaust Manifold
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
OM864K 04/02
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21. AC Generator
22. DC Panel Plug-In
23. Heat Exchanger Fresh
Water Drain
24. AC Circuit Breaker
M864K Generator Component Locations
Figure 3: M864K Non-Service Side with PXK generator end.
1. Intake Manifold
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
OM864K 04/02
5
Control Panels
Figure 4-A: Series 1-B Generator Control Panel
1. SHUTDOWN BYPASS
This switch bypasses the safety shutdown feature
during the starting process.
NOTE: Three position Engine Control switches must
be in the RUN position during preheating.
Shutdown Bypass switch must be held in
ON position during starting.
2. ENGINE CONTROL SWITCH
To start the engine, hold this switch in the START
position until the engine is running. After the engine
starts, release the switch and it will return to RUN
position. To stop the engine, hold the switch in the
STOP position.
NOTE: The rocker switch is used on Series 1 panels
only, and has a light that glows when the set is
running.
3. HOUR METER
Keeps track of engine running time.
Figure 4-B: Series 3 Generator Control Panel
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
voltmeter indicates the voltage output of the alternator.
For Series 4 Control Panels only:
7. A.C. VOLTMETER
Shows the generator output voltage.
8. FREQUENCY METER (Hertz)
The frequency meter indicates alternating current
frequency: 60 Hz (1800 rpm) or 50 Hz (1500 rpm).
9. AMMETER/VOLTMETER SELECTOR
Used to check the voltage and current of each phase.
Return to “Amps Off” position when not monitoring.
Figure 4-C: Series 4 Generator Control Panel
10. A.C. AMMETER
OM864K 04/02
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Shows the generator load on each phase. The phase is
selected with the Ammeter Selector switch (
#9).
Operating Procedures
BREAK-IN PERIOD
1. The first 100 hours on a new or reconditioned
engine are critical to its life and performance.
2. Constantly check the engine temperature and oil
pressure gauges.
3. Oil consumption is greater during break-in as
piston rings take time to seat.
4. Break-In Oil Changes: Change engine oil and
filter at 50 hours. Change oil and filter again at
100 hours (consult Lubricants section for oil
recommendation).
Operating Instructions:
Maintain at least a 75% load on your generator
set for the first 100 hours. If this is not possible,
maintain no less than a 50% load to ensure proper
seating of the piston rings. Vary the load to help
seat the rings.
BEFORE STARTING
1. Check the water level by removing the pressure
cap from the expansion tank. In order to give the
cooling water an opportunity to expand, the level
should be about 1 in. (2.5 cm) below the filler cap
sealing surface when the engine is cold.
CAUTION: Use protective clothing and open the
filler cap carefully when the engine is warm to
prevent burns.
2. Check the oil level in the crankcase with the
dipstick. The oil level must be between high and low
marks on the stick. Never allow the level to go
below this area. Always add the same viscosity of oil
as is already in the crankcase.
3. Check the fuel tank level and open any fuel valves
on the tank and at the secondary fuel filter.
4. Close the sea-cock, check and clean the sea strainer,
and reopen the sea-cock.
5. Marine Sets: 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.
OM864K 04/02
7
Operating Procedures
STARTING
1. Hold the Shutdown Bypass switch in the ON
position 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 start with the
first attempt, be sure that it has stopped completely
before re-engaging the starter.
NOTE: Excessive cranking of the starter on marine
sets equipped with a water lift muffler can
cause engine damage. If the engine does not
start after 3 consecutive 20-second cranks,
remove the impeller from the seawater
pump. This will prevent the muffler from
filling with water and backfilling the exhaust
line and engine. Once the engine starts, shut
if off immediately and reinstall the impeller.
Restart and check the exhaust overboard
outlet for gushes of water.
OPERATING
1. Units with Series 3 and Series 4 Control Panels:
check gauges often. Oil pressure must be above
15 PSI. The D.C. voltmeter should read between
11 and 15 volts at 80° F (25° C) ambient temperature.
The water temperature gauge must be below 200° F
(94° C). Check the A.C. voltage and frequency
meters (Series 4 panel). If the gauges deviate from
normal levels, shut down the generator set and
investigate.
2. Let the unit run unloaded for a three to five minute
warm-up period.
3. Add electrical load.
STOPPING
1. Remove electrical load from the generator set.
2. Run the engine for a three to five minute cool-down
period.
3. Move the Engine Control switch to the STOP
position until the engine stops completely.
4. Shut off seacock, fuel valve, and battery switch.
OM864K 04/02
8
Operating Procedures
SHUTDOWNS AND ALARMS
1. Your unit is fitted with a system to protect it from
high water temperature or low oil pressure.
a. Generator sets have shutdown systems to stop the
engine. They have no warning horns.
b. Other alarms and shutdowns are available as
optional equipment.
NOTE: If your unit is equipped with optional
shutdowns and alarms, do not rely on the
warning or shutdown system to the exclusion
of careful gauge monitoring. Watching your
gauges can prevent damage to the unit and
dangerous power losses.
2. Do the following when your warning or shutdown
system is activated:
a. Check the temperature gauge. If above 205° F
(96° C), shut off the engine immediately.
b. Use the Trouble Shooting Guide on page 26 to
isolate the cause of the overheat.
CAUTION: Do not remove the water fill
cap of an overheated engine. Escaping high
temperature steam can cause severe burns.
Allow the engine to cool and then remove the
cap slowly using protective clothing.
SPARE PARTS
1. ADE recommends that you keep the following spare
parts on hand for field service. The parts are
available from your local Northern Lights dealer.
Some marine models may already have “On-Board
Kits,” a handy box that contains the most common
parts you will need.
a. Primary and secondary fuel filter elements
b. Oil filters
c. Air filter elements
d. Alternator belt
e. Thermostat and gaskets
f. Seawater pump impeller and gaskets
g. Glow plugs
h. Injector and washer
2. If your set is operating a long distance from a
servicing dealer, add the following:
a. Complete set of injectors
b. Copper washers for injector change
c. Compelete set of glow plugs
d. Fuel lift pump
c. Make repairs and restart after the temperature
gauge registers below 200° F (94° C).
d. Watch the 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 it does
not show a normal reading (20-60 PSI) after a
few seconds of operation.
c. If the oil level is normal, DO NOT restart the
engine. Call your dealer for assistance.
OM864K 04/02
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