Northern Lights M864W,M864W3, M864W, M864W3 Owner's Manual
OM864W
For Models: M864W and M864W3
OPERATOR’S MANUAL
arine Generators | Marine Diesel Engines | Land-Based Generators
— CALIFORNIA —
Proposition 65 Warning:
Diesel engine exhaust and some of its constitu-
ents 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
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
OPERATOR'S MANUAL
for Northern Lights® M864W & M864W3 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 - 7
LOCK OUT / TAG OUT PROCEDURES .8
COMPONENT LOCATIONS
M864K Generator Set
M864K Generator Set
CONTROL PANELS
Northern Lights Generator Sets ............14
OPERATING PROCEDURES
Break-in Period ....................................15
Before Starting ......................................15
Starting ................................................. 16
Operating ............................................. 16
Stopping ................................................16
Shutdowns and Alarms .........................17
Spare Parts ............................................17
(w/ 2012 Baseframe) 10 - 11
(Pre-2012 Baseframe)
12 - 13
SERVICING
Lubrication - General ............................20
Checking Oil .........................................20
Oil Changes ..........................................20
Changing Oil Filter ...............................21
Air Filter ...............................................21
V-Belts ...................................................21
Valve Clearances ....................................22
Fuels - General .......................................23
Fuel Filters .............................................23
Bleeding the Fuel System ......................24
Injector Service ......................................25
Injection Pump ...............................26 - 27
Cooling System .....................................28
Heat Exchanger ......................................29
Raw Water Pump ...................................29
Zinc Electrodes ......................................29
Electrical System - General ...................30
Booster Batteries ....................................30
Battery Care ...........................................31
Winterizing / Out-of-Service .................31
TROUBLESHOOTING
Electrical ................................................32
Engine ............................................33 - 35
SERVICING SCHEDULE CHART 18 - 19
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
DATA SHEET
Specifi cations and Dimensions ..............36
WIRING DIAGRAMS
DC Electrical .................................37 - 43
AC Electrical .................................44 - 46
Proprietary Information
This publication is the property of Northern Lights, Inc.
OM864W 12/13
1
Introduction
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
amplifi ed when not corrected during routine main-
tenance.
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 Identifi cation
MODELS INCLUDED
This manual covers the operating instructions for:
M864W AND M864W3 marine generator sets, which use the 864 engine block.
Model Numbers
Model numbers give the unit's application, block model, aspiration, and RPM:
M
M - Northern Lights marine generator set
M864W
Northern Lights marine diesel generator set with
=
a 864 engine and a PX-325K2 series generator end.
Serial Numbers
864
Model number of engine block
+
Bore Cylinders
86 mm 4
Your set has three serial numbers:
an engine number
1
stamped on a plate attached to the valve cover, 2 a
generator end serial number, and
a generator set serial
3
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 12/13
2
Warranty
Revised 7-10-13
Warranty
A warranty registration certifi cate 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.
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.
IMPORTANT SAFETY INSTRUCTIONS.
Electromagnetic equipment, including generator sets
and their accessories, can cause bodily harm and
life threatening injuries when improperly installed,
operated or maintained. To prevent accidents be aware
of potential dangers and act safely.
READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUAL, PRIOR TO
THE INSTALLATION OF ANY GENERATOR SET
OR ACCESSORY. KEEP THESE INSTRUCTIONS
FOR FUTURE REFERENCE.
Recognize Safety Symbols and
Instructions
In addition to the information found
in this section, this operator’s manual
will use the CAUTION warning to
outline potential dangers of a specifi c nature.
CAUTION indicates the presence of a potential hazard
that can or will cause severe or minor property damage,
personal injury or death.
Follow All Safety Instructions
Carefully read and
understand all safety
messages in this manual
and on your machine’s
safety signs. Keep
signs in good and clean
condition. Replace
missing or damaged
signs. Be sure new equipment components and
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.
repair parts include the current safety signs. For
replacement signs, proper placement of safety signs
or clarifi cation 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 work on or around them.
Keep you machine in proper working condition.
UNAUTHORIZED MODIFICATIONS TO THE
MACHINERY MAY IMPAIR ITS FUNCTION
AND SAFETY PARAMETERS.
Prevent Bypass and Accidental Starting
Do not start engine by shorting across start terminal.
Engine will start if normal
circuitry is bypassed, creating a
hazard by runaway machinery.
Start engine only from operator’s
station.
Handle Fuel Safely - Avoid Flames
Diesel is highly fl ammable and should be treated
with care at all times. Do not refuel while smoking
or when near sparks or open fl ame.
OM864W 12/13
3
Added 11-21-11
Safety Rules
ALWAYS STOP ENGINE BEFORE FUELING
MACHINE. Always fi ll
portable fuel tank outdoors.
Never fuel a hot engine.
Prevent accidental discharge
of starting fl uids by storing
all cans in a cool, safe place,
away from sparks or open fl ame. Store with cap
securely on container. Never incinerate or puncture a
fuel container.
Prevent fi res by keeping machine clean of accumulated
trash, grease and debris. Always clean any spilled fuel
as swiftly as possible. Do not store oily rags, which
can ignite and burn spontaneously.
Be prepared if a fi re starts. Keep a fi rst aid kit and fi re
extinguisher handy. Keep emergency contact numbers
for fi re department, doctors, ambulance and hospital
near the telephone.
Service Machines Safely
Do not wear a necktie, scarf,
necklace, rings or other
jewelry, or any loose clothing
when working near moving
parts. Tie long hair behind
your head. If any of these
items get caught in moving
machinery, severe injury or death could result.
Check for any loose electrical connections or faulty
wiring.
Look completely around engine to make sure that
everything is clear before starting.
Wear Protective Clothing
To prevent catching anything in moving machinery,
always wear close fi tting clothes and safety equipment
appropriate to the
job.
Prolonged exposure
to loud noise can
cause hearing loss
or impairment.
Wear suitable
authorized hearing protection, such as earmuffs or
plugs to protect against loud noises.
Operating equipment requires the full attention of
the operator. Do not use radio or music headphones
while operating machinery.
Practice Safe Maintenance
Understand all service procedures before starting
work. Keep area clean and dry. Never lubricate,
service, or adjust machine while it is in operation.
Keep hands, feet and
clothing away from
power-driven equipment.
When shutting down
an engine, disengage
all power and operator
controls. Allow the
engine to cool completely before beginning any
service work.
Securely support any machinery elements that must
be raised for service work with support or lifting
machinery specifi cally intended for that purpose.
Keep all parts in good conditions and properly
installed. Fix damage immediately. Replace any
worn or broken parts. Remove any build up of
grease, oil or debris.
Disconnect battery ground cable (-) before making
any adjustments or service work.
Stay Clear of Rotating Drivelines
Entanglement in
rotating drivelines
can cause serious
injury or death.
Keep shields in
place at all times.
Make sure that
rotating shields turn
freely in pace with the drivelines.
Do not wear loose fi tting equipment around rotating
drivelines. Stop the engine and make sure that
all moving parts have stopped before making any
adjustments, connections, or performing any other type
of service to the engine or other driven equipment.
OM864W 12/13
4
Revised 7-9-12
Safety Rules (Continued)
Install all Safety Guards
Direct contact with rotating fans, belts, pulley and
drives can cause serious injury.
Keep all guards in place at all times during engine
operation.
Wear close-fi tting clothes.
Stop the engine and be sure all
fans, belts, pulleys and drives
are stopped before making
adjustments, connections, or
cleaning near fans and their
components.
Do not allow anything on your person to dangle into
or come in contact with a moving fan, belt, pulley or
drive. Fans can act as vacuums and pull materials
up from below, so avoid that area as well while in
service.
Safe Battery Handling
Prevent Battery Explosions
Battery gas is highly
fl ammable. Battery
explosions can cause severe
injury or death. To help
prevent battery explosions,
keep sparks, lighted matches
and open fl ame away from
the top of battery. When
checking battery electrolyte level, use a fl ashlight.
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).
T o A void Hazards:
• Fill batteries only in well-ventilated areas.
• Wear appropriate eye protection and rubber gloves.
• Never use air pressure to clean batteries.
• Wear appropriate ventilation equipment to avoid
inhaling fumes when adding electrolyte.
• Do not spill or drip electrolyte.
• Use correct jump-start procedure if required.
If acid is spilled on skin or in eyes:
1. Flush skin with water.
2. Apply baking soda or lime to
help neutralize acid.
3. Flush eyes with water for
15-30 minutes.
4. Get medical attention
immediately.
If acid is swallowed:
1. DO NOT induce vomiting.
2. Drink large amounts of
water or milk, without
exceeding 2 liters
(2 quarts)
3. Get medical attention immediately
WARNING: Battery posts, terminals, and related
accessories can contain lead and lead compounds,
chemicals known to the State of California to cause
cancer and reproductive harm. Wash hands after
handling.
Handle Chemical Products Safely
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.
Always remove grounded (-) battery clamp fi rst and
replace ground clamp last.
Sulfuric acid in battery electrolyte is poisonous and
strong enough to burn skin, eat holes into clothing
and other materials, and cause blindness if splashed
into eyes.
All potentially hazardous
chemicals come with a Material Safety Data Sheet
(MSDS). The MSDS provides specifi c details on
chemical products, including physical hazards, safety
procedures and emergency response techniques
.
Read and understand the MSDS for each chemical before
you start any job that includes it. Follow the procedures
and use appropriate equipment exactly as recommended.
OM864W 12/13
5
Added 11-21-11
Safety Rules (Continued)
Contact your Northern Lights dealer or Northern
Lights factory for MSDS’s used on Northern Lights
products.
Work in Well Ventilated Areas
Exhaust fumes from engines contain carbon
monoxide and can cause sickness or death. Work in
well ventilated areas to avoid prolonged exposure
to engine fumes. If it is necessary to run an engine
in an enclosed area, route the exhaust fumes out of
the area with an approved, leak proof exhaust pipe
extension.
Remove Paint Before Welding or Heating
Hazardous fumes can be generated when paint is
heated by welding, soldering or using a torch. To
avoid potentially toxic fumes and dust, remove paint
before heating.
• Remove paint a
minimum of 100 mm
(4 in.) from the area
that will be affected by
heat.
• If paint cannot be
removed, wear an
approved respirator.
• If you sand or grind
paint, use an approved respirator.
• If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove
solvent or paint stripper containers from the area.
• Allow at least 15 minutes for fumes to disperse
before welding or heating.
Do not use a chlorinated solvent in an area where
welding will occur. Work only in areas that are well
ventilated. Dispose of paint and solvent properly.
Service Cooling System Safely
Opening a pressurized cooling
system can release explosive
fl uids and causing serious burns.
Before opening any pressurized
cooling system, make sure the
engine has been shut off. Do
not remove a fi ller cap unless
it
is cool enough to comfortably grip with bare hands.
Slowly loosen cap to relieve pressure before opening
fully.
Avoid High Pressure Fluids
Relieve pressure prior to
disconnecting pressurized
lines. Escaping fl uid
under pressure can
penetrate the skin causing
serious injury. Always
relieve pressure before
disconnecting hydraulic or other pressurized lines.
Tighten all connections fi rmly before re-applying
pressure.
If searching for leaks, use a piece of cardboard.
Always protect your hands and other body parts
from high-pressure fl uids.
If an accident occurs, see a doctor immediately. Any
high pressure spray injected into the skin must be
removed within a few hours to prevent the risk of
gangrene or other infection.
Avoid Heating Near Pressurized Fluid Lines
Flammable spray can be
generated by heating near
pressurized fl uid lines,
resulting in severe burns and
bodily injury. Pressurized
lines can rupture when heat
goes beyond the immediate
fl ame area. Do not weld,
solder or use a torch or open fl ame near pressurized
lines or other fl ammable fl uids.
Do Not Open High-Pressure Fuel System
Many Northern Lights engines use high-pressure
fuel injection. High-pressure fl uid remaining in fuel
lines can cause serious injury. Do not disconnect
or attempt any repair of fuel lines, sensors, or other
components between the high-pressure fuel pump
and nozzles on engines with high pressure fuel
systems.
ONL Y AUTHORIZED TECHNICIANS CAN
PERFORM REPAIRS ON AN HIGH PRESSURE
FUEL INJECTION SYSTEMS.
OM864W 12/13
6
Added 11-21-11
Safety Rules (Continued)
Avoid Hot Exhaust
Avoid exposure to and physical contact with hot
exhaust gases. Exhaust parts and streams can reach
high temperatures during operation, leading to burns
or other serious injury.
Cleaning exhaust fi lters can
also lead to exposure to hot
exhaust gas and the injury
risk associated with it. Avoid
exposure to and physical
contact with hot exhaust gases
when cleaning exhaust fi lters.
During auto or manual/stationary exhaust fi lter
cleaning operations, the engine will run at
elevated temperatures for an extended period of
time. Exhaust parts and streams can reach high
temperatures during operation, leading to burns or
other serious injury.
Avoid Harmful Asbestos Dust
Inhaling asbestos fi bers may cause lung cancer.
Avoid breathing any dust that may be generated
when handling
components containing
asbestos fi bers, including
some gaskets.
The asbestos used in
these components is
usually found in a resin
or otherwise sealed.
Normal handling of these
components is not dangerous, as long as airborne
dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding materials
containing asbestos. When servicing, wear an
approved respirator. A special vacuum cleaner is
recommended to clean asbestos. If this vacuum is
not available, apply a mist of oil or water on the
material containing asbestos. Keep all bystanders
away from any area where asbestos dust may be
generated.
Use Proper Lifting Equipment
and Techniques
Lifting heavy components
incorrectly can cause severe injury
or damage to machinery. Avoid
unbalanced loads. Do not use
lifting eyes. Lift the generator set
using lifting bars inserted through the lifting holes
on the skid. Follow all recommended removal and
installation procedures in this and associated Northern
Lights manuals.
Use Proper Tools
Makeshift tools
and procedures
can create safety
hazards. Always use
appropriate tools for
the job.
Use power tools only to loosen threaded parts and
fasteners. For loosening and tightening hardware,
always use the correct sized tools. Do not use US
measurement tools on metric fasteners, or vice versa.
Use only service parts that meet Northern Lights
specifi cations.
Dispose of Waste Properly
Disposing of waste improperly can threaten the
environment and lead to unsafe working conditions.
Potentially harmful waste used in Northern Lights
equipment can include oil, fuel, coolant, fi lters and
batteries.
Use leakproof containers to drain fl uid. Do not
use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain or
into any water source.
OM864W 12/13
7
Added 7-9-12
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. Many serious accidents happen when someone thought the machine was turned of f, or all of its energy was
safely blocked or released.
General Policy
!
CAUTION
To avoid dangerous or hazardous situations, refrain from
any of the following:
• Removing or bypassing a guard or other safety device
• Placing any part of your body in a position where you
could be caught by moving machinery.
• Cleaning or oiling machinery when in operation.
• Adjusting circuits, chillers, pumps, air handlers, valves,
circuit breakers or fans while in operation.
• Working on piping or high pressure systems.
Lock Out/Tag Out Instructions Electrical Equipment
!
W ARNING
Be sure the equipment’s ON/OFF switch is in the OFF
position and is unplugged from any electrical source before
attempting to perform any type of work on the equipment.
Obtain an electrical plug cap cover with a lockset. Secure
the plug terminal end using the electrical plug lockout cap.
Lock the cap and retain the key.
If the equipment is directly wired into an electrical box with
a shut off switch, obtain a lock pad and/or the appropriate
colored tags and place the lock and tag through the shut
off lever . Retain the key until the repair is completed and
the machine is safe to start. Be certain the shut off lever
is in the OFF position before restarting. NEVER give a
lock out key to unauthorized personnel.
If the equipment is directly wired into an electrical box
without a shut off switch and lock out capability, then a
circuit breaker lock out will be required. Obtain a circuit
lock and tag set. Install the lock onto the circuit breaker
box. Ensure the unit ON/OFF switch is in the OFF position
before restarting.
Lock Out/Tag Out Instructions Pneumatic and Hydraulic Equipment
If shutting off of air, water or other material cannot 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.
Affi x 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
!
W ARNING
Equipment connected to the compressed air system
through an air hose with a detachable fi tting must be
shutdown and unplugged. Excess air must be bled prior
to removing the air hose, prior to any maintenance or
repair activities.
Affi x a DO NOT OPERATE tag to the air hose near the
detachable fi tting. Each DO NOT OPERA TE tag must be
signed and dated by the authorized technician servicing
the equipment. Check that the equipment cannot be
operated by activating the ON switch.
Stored Energy
!
W ARNING
Immediately after applying Lock Out or Tag Out devices,
ensure that all potentially hazardous stored or residual
energy is relieved, disconnected, restrained and otherwise
rendered safe.
Verifi cation of Isolation
!
CAUTION
Verify the machinery or equipment is actually isolated and
de-energized prior to beginning work on a machine or on
equipment that has been locked out.
Restarting Procedures
!
W ARNING
For servicing pneumatic and hydraulic equipment, the
following additional procedures must be implemented,
following completion of lock out/tag out procedures for
the unit to be serviced:
Shut off air, water or supply valves at the equipment to
be serviced.
Check the local bleed-off point for completed release of
pressurized air, water or oil.
!
Follow the procedures below prior to restoring energy:
• Ensure that all machinery or equipment is properly
reassembled. Inspect the machinery or equipment to
verify non-essential items have been removed.
• Ensure that all personnel are safely outside danger
zones. Notify personnel that lock out/tag out devices have
been removed and energy will be reapplied.
• Only authorized personnel may remove lock out/tag out
devices or notices.
OM864W 12/13
8
CAUTION
Notes
OM864W 12/13
9
Added 11-21-11
M864W Generator Component Locations
2012 Baseframe
24
23
6
4
1
3
5
7
8
9
2
10
11
12
13
14
15
21
22
20
Figure 2: M864W Service Side
1. DC Circuit Breaker
2. AC Circuit Breaker
3. Air Filter
4. Secondary Fuel Filter
5. Fuel System Bleed Point
6. Lube Oil Fill
7. Intake Manifold
8. Coolant Fill
9. Expansion Tank
10. Heat Exchanger
11. Heat Exchanger Raw
Water Drain and Zinc
12. Heat Exchanger Fresh
Water Drain
19
18
OM864W 12/13
10
17
13. Lube Oil Fill
14. Raw Water Pump
15. Fuel Primer Pump
16. Lube Oil Drain
17. DC Alternator
18. Oil Pan
19. Fuel Manifold
16
20. Starter
21. Lube Oil Dipstick
22. Oil Filter
23. AC Generator
24. DC Panel Plug-In
Added 11-21-11
M864W Generator Component Locations
2012 Baseframe
10
2
1
4
5
3
9
8
Figure 3: M864W Non-Service Side
1. Expansion Tank
2. Coolant Fill
3. Exhaust Manifold
4. Lube Oil Fill
5. Wet Exhaust Elbow
6. Manifold Drain
7
6
7. Oil Pan
8. Raw Water Pump
9. Heat Exchanger Raw
Water Drain and Zinc
10. Heat Exchanger
OM864W 12/13
11
Revised 11-21-11
M864W Generator Component Locations
Pre-2012 Baseframe
Figure 2: M864W Service Side
1. DC Circuit Breaker
2. AC Circuit Breaker
3. Air Filter
4. Secondary Fuel Filter
5. Fuel System Bleed Point
6. Lube Oil Fill
7. Intake Manifold
8. Coolant Fill
9. Expansion Tank
10. Heat Exchanger
11. Heat Exchanger Raw
Water Drain and Zinc
12. Heat Exchanger Fresh
Water Drain
OM864W 12/13
12
13. Lube Oil Fill
14. Raw Water Pump
15. Fuel Primer Pump
16. DC Alternator
17. Lube Oil Drain
18. Oil Pan
19. Fuel Manifold
20. Starter
21. Lube Oil Dipstick
22. Oil Filter
23. AC Generator
24. DC Panel Plug-In
Revised 11-21-11
M864W Generator Component Locations
Pre-2012 Baseframe
Figure 3: M864W Non-Service Side
1. Expansion Tank
2. Coolant Fill
3. Lube Oil Fill
4. Exhaust Manifold
5. Wet Exhaust Elbow
6. Manifold Drain
7. Oil Pan
8. Raw Water Pump
9. Heat Exchanger Raw
Water Drain and Zinc
10. Heat Exchanger
OM864W 12/13
13
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