Northern Lights M864W Operator's Manual

OPERATOR’S

MANUAL

M864W

— 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.

NORTHERN LIGHTS

4420 14th Avenue N.W.

Seattle, WA 98107

Tel: (206) 789-3880

Fax: (206) 782-5455

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.: OM864W 10/04

OPERATOR'S MANUAL

for Northern Lights® M864W 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
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 SCHEDULE CHART 10 - 11
SERVICING
Lubrication - General ..........................	12
Checking Oil .......................................	12
Oil Changes .........................................	12
Changing Oil Filter ..............................	13
Air Filter ..............................................	13

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
WIRING DIAGRAMS
DC Electrical ................................	29 - 32
AC Electrical ........................................	33

Proprietary Information

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 OM864W 10/04

OM864W 10/04

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 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.

Unit Identification

MODELS INCLUDED

This manual covers the operating instructions for:

M864W marine generator sets, which use the 864 engine block.

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:

864

M - Northern Lights marine generator set

Model number of engine block

Bore

Cylinders

86 mm

Northern Lights marine diesel generator set with

M864W

a 864 engine and a PX-325K2 series generator end.

Serial Numbers

Your set has three serial numbers: an engine number stamped on a plate attached to the valve cover, a generator end serial number, and 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.

OM864W 10/04

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.

OM864W 10/04

M864W Generator Component Locations

Figure 2: M864W Service Side

1.	DC Circuit Breaker	9.	Coolant Fill	15.	DC Alternator	22.	DC Panel Plug-In
2.	Air Filter	10.	Expansion Tank	16.	Lube Oil Drain	23.	Heat Exchanger Fresh
3.	Intake Manifold	11.	Heat Exchanger	17.	Fuel Manifold		Water Drain
4.	Lube Oil Dipstick	12.	Heat Exchanger Raw	18.	Oil Pan	24.	AC Circuit Breaker
5.	Secondary Fuel Filter		Water Drain and Zinc	19.	Starter
6.	Lube Oil Fill	13.	Raw Water Pump	20.	Oil Filter
7.	Fuel System Bleed Point	14.	Fuel Primer Pump	21.	AC Generator

OM864W 10/04

M864W Generator Component Locations

Figure 3: M864W Non-Service Side

2.	Lube Oil Fill	7.	Heat Exchanger Raw
			Water Drain and Zinc
3.	Exhaust Manifold	8.
4.	Coolant Fill		Raw Water Pump
		9.	Oil Pan
5.	Expansion Tank
		10.	Wet Exhaust Elbow
6.	Heat Exchanger
		11.	Manifold Drain

OM864W 10/04

Control Panels

Figure 4-A: Series 1-B Generator Control Panel

Figure 4-B: Series 3 Generator Control Panel

Figure 4-C: Series 4 Generator Control Panel

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.

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.

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.

10.A.C. AMMETER

Shows the generator load on each phase. The phase is selected with the Ammeter Selector switch (#9).

OM864W 10/04

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.

Operating Procedures

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 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.

OM864W 10/04

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 20second 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 it 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 cooldown 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.

OM864W 10/04

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.

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.

Operating Procedures

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,”

ahandy 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

aservicing 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

OM864W 10/04

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:

SP1 Check oil level in engine SP8 Check primary fuel filter SP14 Check cooling water level Check sea strainer

AFTER FIRST 50 HOURS:

SP2/3 Change engine oil and filter SP5 Check V-belt tension

SP7 Adjust valves

SP19 Check electrolyte level in batteries

EVERY 50 HOURS:

SP5 Check V-belt tension

SP19 Check electrolyte level in batteries

AFTER FIRST 100 HOURS:

SP2/3 Change engine oil and filter

EVERY 200 HOURS:

SP2/3 Change engine oil and filter

SP4 Check air cleaner

SP9 Change primary fuel filter element

SP10 Change secondary fuel filter

SP18 Check zinc electrodes

EVERY 750 HOURS:

SP7 Check valve clearances SP12 Check injectors

SP15 Check and flush cooling system SP17 Change impeller

SP20 Check state of charge of batteries

EVERY 1500 HOURS:

SP12 Check injectors, clean tips

EVERY 2400 HOURS:

SP13 Check fuel injection pump

SP16 Check and clean heat exchanger

EVERY 3000 HOURS:

SP12 Remove injectors for adjustment, clean & repair

SERVICE				50	100	200	750	1500	2400	3000
POINT	PAGE	OPERATION	DAILY	Hours	Hours	Hours	Hours	Hours	Hours	Hours

ENGINE:

SP1

Check oil level

●

SP2

Change engine oil1, 5

●

SP3

Change lube oil filters1, 5

●

SP4

Check air cleaner1, 4

●

SP5

Check V-belt tension1

●

SP7

Check valve clearances5

●

FUEL

SYSTEM:

SP8

Check primary filter2

●

SP9

Change primary filter element2, 3

●

SP10

Change secondary fuel filter1, 3

●

SP11

Bleed the fuel system3

SP12

Check injectors1, 6

●

SP13

Check fuel injection pump

●

COOLING SYSTEM:

SP14

Check cooling water level

●

SP15

Check and flush cooling system

●

SP16

Check and clean heat exchanger

●

SP17

Change impeller in raw water pump1, 3

●

SP18

Check zinc electrodes4

●

ELECTRICAL SYSTEM:

SP19

Check electrolyte level in batteries1, 4

●

SP20

Check condition of batteries with hydrometer1

●

OUT OF

SERVICE:

SP23

Winterizing or out-of-service3

1) Perform all maintenance once a year even if hour level has not been reached.

6) To insure that your engine stays in compliance with applicable EPA

2) Consult manufacturer's maintenance schedule, note on chart.

& CARB emission standards, the following additional maintenance

3) Whenever necessary.

procedures & intervals must be maintained.

4) More often if necessary.

1500 Hours: Fuel injectors are to be removed & injector tips cleaned.

5) After first 50 hours.

3000 Hours: Fuel injectors removed for adjustment, cleaning, & repair.

OM864W 10/04

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