OPERATOR’S MANUAL OM864W For Models: M864W & M864W3 DANGER Northern Lights generator sets and /or any other diesel powered equipment provided by NLI is not provided with spark arresting or explosion proof components, and therefore is not to be installed in the presence of combustible gases having a flash point of 43.3 Degrees C (110 Degrees F) or lower, such as Gasoline, Propane, Natural Gas or other similar fuel sources. — 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 Copyright ©2017 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 6/17 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 SERVICING (Continued) V-Belts....................................................19 Valve Clearances.....................................20 Fuels - General........................................21 Fuel Filters..............................................21 Bleeding the Fuel System.......................22 Injector Service.......................................23 Injection Pump................................24 - 25 Cooling System ......................................26 Heat Exchanger.......................................27 Raw Water Pump....................................27 Zinc Electrodes.......................................27 Electrical System - General....................28 Booster Batteries.....................................28 Battery Care............................................29 Winterizing / Out-of-Service..................29 WARRANTY................................................ 3 SAFETY RULES................................... 3 - 8 COMPONENT LOCATIONS M864 Generator Set ...................... 10 - 11 CONTROL PANELS Northern Lights Generator Sets.............12 OPERATING PROCEDURES Break-in Period .....................................13 Before Starting.......................................13 Starting.................................................. 14 Operating.............................................. 14 Stopping.................................................15 Shutdowns and Alarms..........................15 Spare Parts.............................................15 SERVICING SCHEDULE CHART TROUBLESHOOTING Electrical.................................................30 Engine.............................................31 - 33 DATA SHEET Specifications and Dimensions...............34 .16 - 17 SERVICING Lubrication - General.............................18 Checking Oil..........................................18 Oil Changes...........................................18 Changing Oil Filter................................19 Air Filter................................................19 WIRING DIAGRAMS AC Electrical..................................35 - 36 DC Electrical..................................37 - 44 Panel Diagrams...............................45 - 51 Proprietary Information 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 6/17 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 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: 864 M M - Northern Lights marine generator set M864W = + Model number of engine block Bore Cylinders 86 mm 4 Northern Lights marine diesel generator set with a 864 engine and a PX-325K2 series generator end. Serial Numbers Your set has three serial numbers: 1 an engine number stamped on a plate attached to the valve cover, 2 a generator end serial number, and 3 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 6/17 2 Revised 4-12-17 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 DANGER: Northern Lights generator sets and /or any other diesel powered equipment provided by NLI is not provided with spark arresting or explosion proof components, and therefore is not to be installed in the presence of combustible gases having a flash point of 43.3 Degrees C (110 Degrees F) or lower, such as Gasoline, Propane, Natural Gas or other similar fuel sources. NOTICE: 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. repair parts include the current safety signs. For replacement signs, proper placement of safety signs or clarification 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. 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. 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. Recognize Safety Symbols and Instructions In addition to the information found in this section, this operator’s manual uses three different signal words to outline potential dangers of a specific nature. ! DANGER Prevent Bypass and Accidental Starting DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. ! WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. ! CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. ! WARNING Do not start engine by shorting across start terminal. Engine will start if normal circuitry is bypassed, creating a hazard by runaway machinery. 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 Start engine only from operator’s station. OM864W 6/17 3 Revised 4-12-17 Safety Rules (Continued) Handle Fuel Safely - Avoid Flames Wear Protective Clothing ! WARNING ! 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. To prevent catching anything in moving machinery, always wear close fitting 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. ALWAYS STOP ENGINE BEFORE FUELING MACHINE. Always fill portable fuel tank outdoors. Never fuel a hot engine. Prevent accidental discharge of starting fluids by storing all cans in a cool, safe place, away from sparks or open flame. Store with cap securely on container. Never incinerate or puncture a fuel container. Operating equipment requires the full attention of the operator. Do not use radio or music headphones while operating machinery. Practice Safe Maintenance Prevent fires 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. ! CAUTION Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency contact numbers for fire department, doctors, ambulance and hospital near the telephone. Understand all service procedures before starting work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is in operation. Service Machines Safely Keep hands, feet and clothing away from powerdriven equipment. When shutting down an engine, disengage all power and operator controls. Allow the engine to cool completely before beginning any service work. ! DANGER 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. Securely support any machinery elements that must be raised for service work with support or lifting machinery specifically 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. Check for any loose electrical connections or faulty wiring. Disconnect battery ground cable (-) before making any adjustments or service work. Look completely around engine to make sure that everything is clear before starting. OM864W 6/17 4 Revised 4-12-17 Safety Rules (Continued) Never check battery charge by contacting the posts with a metal object. Use a voltmeter or hydrometer. Stay Clear of Rotating Drivelines ! DANGER 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. 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. Do not wear loose fitting 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. 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. Install all Safety Guards To Avoid 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. ! WARNING Direct contact with rotating fans, belts, pulley and drives can cause serious injury. Keep all guards in place at all times during engine operation. 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 Wear close-fitting 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 ! WARNING ! WARNING Prevent Battery Explosions Battery gas is highly flammable. Battery explosions can cause severe injury or death. To help prevent battery explosions, keep sparks, lighted matches and open flame away from the top of battery. When checking battery electrolyte level, use a flashlight. 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. OM864W 6/17 5 Revised 4-12-17 Safety Rules (Continued) Handle Chemical Products Safely 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. ! 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. Service Cooling System Safely ! WARNING 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 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. Contact your Northern Lights dealer or Northern Lights factory for MSDS’s used on Northern Lights products. Work in Well Ventilated Areas ! CAUTION 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. Opening a pressurized cooling system can release explosive fluids and causing serious burns. Before opening any pressurized cooling system, make sure the engine has been shut off. Do not remove a filler 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 ! WARNING Relieve pressure prior to disconnecting pressurized lines. Escaping fluid under pressure can penetrate the skin causing serious injury. Always relieve pressure before disconnecting hydraulic or other pressurized lines. Tighten all connections firmly before reapplying pressure. If searching for leaks, use a piece of cardboard. Always protect your hands and other body parts from high-pressure fluids. 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. Remove Paint Before Welding or Heating ! WARNING 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. Avoid Heating Near Pressurized Fluid Lines ! WARNING Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns and bodily injury. Pressurized lines can rupture when heat goes beyond the immediate flame area. Do not weld, solder or use a torch or open flame near pressurized lines or other flammable fluids. OM864W 6/17 6 Revised 4-12-17 Safety Rules (Continued) Do Not Open High-Pressure Fuel System ! 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. DANGER Many Northern Lights engines use highpressure 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 the high-pressure fuel pump and nozzles on engines with high pressure fuel systems. Use Proper Lifting Equipment and Techniques ! WARNING ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH PRESSURE FUEL INJECTION SYSTEMS. 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. Avoid Hot Exhaust ! WARNING 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. Use Proper Tools ! CAUTION Cleaning exhaust filters 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 filters. 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. During auto or manual/stationary exhaust filter 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. Do not use US measurement tools on metric fasteners, or vice versa. Use only service parts that meet Northern Lights specifications. Avoid Harmful Asbestos Dust Dispose of Waste Properly ! WARNING ! CAUTION Inhaling asbestos fibers may cause lung cancer. Avoid breathing any dust that may be generated when handling components containing asbestos fibers, including some gaskets. 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, filters and batteries. Use leakproof containers to drain fluid. Do not use food or beverage containers that may mislead someone into drinking from them. 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. Do not pour waste onto the ground, down a drain or into any water source. OM864W 6/17 7 Revised 4-12-17 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 off, 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. 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. 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 ! WARNING Lock Out/Tag Out Instructions Electrical Equipment Equipment connected to the compressed air system through an air hose with a detachable fitting must be shutdown and unplugged. Excess air must be bled prior ! WARNING to removing the air hose, prior to any maintenance or Be sure the equipment’s ON/OFF switch is in the OFF repair activities. position and is unplugged from any electrical source before attempting to perform any type of work on the equipment. Affix a DO NOT OPERATE tag to the air hose near the Obtain an electrical plug cap cover with a lockset. Secure detachable fitting. Each DO NOT OPERATE tag must be the plug terminal end using the electrical plug lockout cap. signed and dated by the authorized technician servicing Lock the cap and retain the key. the equipment. Check that the equipment cannot be operated by activating the ON switch. If the equipment is directly wired into an electrical box with a shut off switch, obtain a lock pad and/or the appropriate Stored Energy colored tags and place the lock and tag through the shut ! WARNING off lever. Retain the key until the repair is completed and the machine is safe to start. Be certain the shut off lever Immediately after applying Lock Out or Tag Out devices, is in the OFF position before restarting. NEVER give a ensure that all potentially hazardous stored or residual lock out key to unauthorized personnel. energy is relieved, disconnected, restrained and otherwise rendered safe. If the equipment is directly wired into an electrical box without a shut off switch and lock out capability, then a Verification of Isolation circuit breaker lock out will be required. Obtain a circuit ! CAUTION lock and tag set. Install the lock onto the circuit breaker box. Ensure the unit ON/OFF switch is in the OFF position Verify the machinery or equipment is actually isolated and before restarting. de-energized prior to beginning work on a machine or on equipment that has been locked out. Lock Out/Tag Out Instructions Pneumatic and Hydraulic Equipment Restarting Procedures ! WARNING 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. ! CAUTION 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 6/17 8 Notes OM864W 6/17 9 Generator Component Locations Figure 2: M864 Service Side 1. 2. 3. 4. 5. 6. 7. DC Circuit Breaker Air Filter Intake Manifold Lube Oil Dipstick Secondary Fuel Filter Lube Oil Fill Fuel System Bleed Point 9. 10. 11. 12. 15. 16. 17. 18. 19. 20. 21. Coolant Fill Expansion Tank Heat Exchanger Heat Exchanger Raw Water Drain and Zinc 13. Raw Water Pump 14. Fuel Primer Pump OM864W 6/17 10 DC Alternator Lube Oil Drain Fuel Manifold Oil Pan Starter Oil Filter AC Generator 22. DC Panel Plug-In 23. Heat Exchanger Fresh Water Drain 24. AC Circuit Breaker Generator Component Locations Figure 3: M864 Non-Service Side 2. 3. 4. 5. 6. Lube Oil Fill Exhaust Manifold Coolant Fill Expansion Tank Heat Exchanger 7. Heat Exchanger Raw Water Drain and Zinc 8. Raw Water Pump 9. Oil Pan 10. Wet Exhaust Elbow 11. Manifold Drain OM864W 6/17 11 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. 2. ENGINE CONTROL SWITCH To start the engine, hold this switch in the START Figure 4-A: Series 1-B Generator Control Panel 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 indi- Figure 4-B: Series 3 Generator Control Panel cates 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 Figure 4-C: Series 4 Generator Control Panel phase is selected with the Ammeter Selector switch (#9). OM864W 6/17 12 Operating Procedures BREAK-IN PERIOD BEFORE STARTING 1. The first 100 hours on a new or reconditioned engine are critical to its life and performance. 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. 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. CAUTION: Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns. 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). 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. 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. 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 6/17 13 Operating Procedures STARTING OPERATING 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. 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. 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. 2. Let the unit run unloaded for a three to five minute warm-up period. 3. Add electrical load. 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. 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. OM864W 6/17 14 Operating Procedures SHUTDOWNS AND ALARMS SPARE PARTS 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. 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. 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. 2. If your set is operating a long distance from a servicing dealer, add the following: 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. 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 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. OM864W 6/17 15 a. b. c. d. Complete set of injectors Copper washers for injector change Compelete set of glow plugs Fuel lift pump 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 SP8 SP14 SP4 SP9 SP10 SP18 Check oil level in engine Check primary fuel filter Check cooling water level Check sea strainer Check air cleaner Change primary fuel filter element Change secondary fuel filter Check zinc electrodes 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 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 50 HOURS: SP5 Check V-belt tension SP19 Check electrolyte level in batteries EVERY 1500 HOURS: SP12 Check injectors, clean tips AFTER FIRST 100 HOURS: SP2/3 Change engine oil and filter EVERY 2400 HOURS: SP13 Check fuel injection pump SP16 Check and clean heat exchanger EVERY 200 HOURS: SP2/3 Change engine oil and filter EVERY 3000 HOURS: SP12 Remove injectors for adjustment, clean & repair SERVICE POINT PAGE OPERATION DAILY ENGINE: SP1 SP2 SP3 SP4 SP5 SP7 12 12 13 13 13 14 50 Hours • Check oil level Change engine oil1, 5 Change lube oil filters1, 5 Check air cleaner1, 4 Check V-belt tension1 Check valve clearances5 • • • FUEL SYSTEM: • SP8 SP9 SP10 SP11 SP12 SP13 15 15 15 16 17 18 Check primary filter2 Change primary filter element2, 3 Change secondary fuel filter1, 3 Bleed the fuel system3 Check injectors1, 6 Check fuel injection pump SP14 SP15 SP16 SP17 SP18 20 20 21 21 21 Check cooling water level Check and flush cooling system Check and clean heat exchanger Change impeller in raw water pump1, 3 Check zinc electrodes4 SP19 SP20 23 23 Check electrolyte level in batteries1, 4 Check condition of batteries with hydrometer1 SP23 23 Winterizing or out-of-service3 100 200 Hours Hours 750 Hours • • • • • • ELECTRICAL SYSTEM: • OUT OF SERVICE: 1) Perform all maintenance once a year even if hour level has not been reached. 2) Consult manufacturer's maintenance schedule, note on chart. 3) Whenever necessary. 4) More often if necessary. 5) After first 50 hours. • • • • • • 6) To insure that your engine stays in compliance with applicable EPA & CARB emission standards, the following additional maintenance procedures & intervals must be maintained. 1500 Hours: Fuel injectors are to be removed & injector tips cleaned. 3000 Hours: Fuel injectors removed for adjustment, cleaning, & repair. OM864W 6/17 16 3000 Hours • • • • COOLING SYSTEM: 1500 2400 Hours Hours Service Record Service Point OPERATION HOURS/ DATE 50 HOURS SP5 Check V-belt tension SP19 Check electrolyte in batteries 200 HOURS SP2 Change engine oil SP3 Change lubricating oil filters SP4 Check air cleaner SP8 Change primary filter element (Racor) 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 in seawater pump SP20 Check condition of batteries with hydrometer 1500 HOURS SP12 Check injectors, clean tips 2400 HOURS SP13 Check fuel injection pump SP16 Check and clean heat exchanger SP22 Check and clean oil cooler on reverse gear 3000 HOURS \\ SP12 Clean and repair injectors OM864W 6/17 17 Servicing LUBRICATION - GENERAL SP1. CHECKING OIL LEVEL 1. Use only clean, high quality lubricants stored in clean containers in a protected area. 2. These lubricants are acceptable: a. API Service CC/CD/CE single viscosity oils. b. API Service CC/CD/SF multi-viscosity oils. 1. While the engine is stopped, check the oil level in the crankcase with the dipstick daily. The oil level must be between the high and low marks on the stick. Fill with the recommended oil, and fill only to the high mark on the dipstick. Follow the lubrication recommendations in Figure 5. 3. Use the proper weight oil for your average operation temperature. SP2. OIL CHANGES Air Temperature Single Viscosity MultiViscosity Above 32° F (0° C) SAE 30W SAE 15-40W -10° to 32° F (-23° to 0° C) SAE 10W SAE 10-30W Figure 5: Lube Oils 4. Never put additives or flushing oil in crankcase. 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 this, change oil and filter every 200 hours. 3. During intermittent cold weather operation, change oil every 100 hours or six weeks, whichever comes first. 4. Change oil at any seasonal change in temperature when a new viscosity of oil is required. 5. Change oil when engine is warm but not hot. 6. Dispose of waste oil in an approved manner. 7. Never use a flushing oil. 8. Remove cap. Drain oil. Replace cap and tube. 9. Refill engine with recommended oil. 10.Engine capacity with new oil filter is: Model 864W & W3..........................7.8 qts. (7.4 liters) OM864W 6/17 18 Servicing SP3. CHANGING LUBE OIL FILTER SP5. V-BELTS 1. Change the lube oil filter every 200 hours. 1. Check the tension and wear on the V-belt after every 50 hours. 2. Use a filter wrench to remove old filter. Dispose of filter in approved manner. 2. Use your thumb to press on the belt at the midpoint between the crankshaft and alternator pulleys. The tension is correct if the belt can be depressed about 3/8 in. (10 - 15 mm) with 22 lbs. (10 kg) force. 3. Make sure the gasket from the old filter is removed and discarded. Clean mount face. 4. Spread a thin film of engine oil on the rubber gasket on the new filter and screw it on nipple until gasket meets the 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. SP4. AIR CLEANER 1. Visually inspect air cleaner every 200 hours. In dusty conditions, check more often. 2. Remove the plate on the side of the air intake manifold. Remove and inspect the foam element. If dirty, wash element in soapy water. Rinse and dry thoroughly before reinstalling. NOTE:Make absolutely sure no impurities enter the engine while changing the element, and do not run the engine with the air cleaner removed. Do not clean the filter with diesel fuel, solvent, or gasoline. Serious engine damage can result. OM864W 6/17 19 Servicing SP7. VALVE CLEARANCES 1. Readjust valve clearance after first 50 hours of operation. Adjust valves every 750 hours thereafter. 2. Warm up the engine to 167° F - 185° F (75° C - 85° C). Shut off fuel and battery. 3. Rotate the crankshaft in a clockwise direction to set cylinder No. 1 to the top dead center. Top dead center (TDC) is when notch “TDC” on the pulley aligns with the pointer and the two valves on cylinder No. 4 “rock”. Rocking is when the rocker arms (for the two valves on a given cylinder) are moving in opposite directions, one up closing the valve and one down opening the other valve. The moment when the two rocker arms are exactly aligned with each other is when they “rock”. 5. To adjust valve clearance, loosen the lock nut on the adjustment screw. Insert a feeler gauge between the rocker arm and the valve stem cap. Adjust until the feeler gauge slides with a slight drag. Tighten the lock nut and recheck the clearance (Figure 8). Figure 8: Valve Adjustment 6. Rotate the crankshaft in clockwise direction one full turn to set cylinder No. 4 to top dead center (TDC). Adjust the remaining valves (shown as in Figure 7). 7. Replace the rocker arm cover. 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 OM864W 6/17 20 Servicing FUELS - GENERAL 6. Storing fuel: a. Keep dirt, scale, water, and other foreign matter out of fuel. b. Avoid storing fuel for long periods of time. c. Fill the fuel tank at the end of each day’s operation. This will reduce condensation. 1. Use only clean, high quality fuels of the following specifications, as defined by ASTM designation D975 for diesel fuels: a. Use grade No. 2 diesel at ambient temperatures above freezing 32° F (0° C). b. International fuel specifications: ISO-8217-DMA BS 2869 Part 1 Class A1 BS 2869 Part 2 Class 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 or SP8-10. FUEL FILTERS 1. Your generator set should have a primary fuel filter installed. We recommend the Northern Lights brand of fuel filter-water separators. a. Check the primary fuel filter daily as recommended by the filter manufacturer. Empty the collection bowl as necessary. b. Change the element as often as necessary or every 200 hours. c. If the bowl fills with water, change the primary and secondary element immediately. animal fats. It can involve animal fats, yellow greases (used greases), cotton seed, sunflower seed, coconut oil, or sesame seed, but mainly in the US soybean methyl ester is used (SME). In Europe mainly rapeseed (canola) methyl ester is made (RME), and in Asia palm methyl ester (PME) is made. 100% biodiesel (B100) is made in compliance with ASTM D6751 or EN14214 (EU) specifications. Biodiesel may be used in a 5% blend (5% biodiesel/ 95% diesel) from a BQ-9000 accredited producer. 20% biodiesel blends (20% biodiesel/ 80% diesel) can only be used if they meet ASTM D6751 or EN14214 (EU) specifications. A 2% reduction in power and a 3% reduction in fuel economy can be expected if a 20% blend is used. With a 20% biodiesel blend, an approved fuel conditioner is recommended. The petroleum part of the biodiesel blend must meet ASTM D975 or EN590 (EU) specifications. Biodiesel blends must be used within 90 days of their manufacture. When biodiesel blends are used the oil level must be checked daily and storage, leaking, possible microbial growth, plugging, and components degradation must all be checked more frequently. Note: Using raw pressed or partially refined vegetable oils or recycled greases as fuel (which have not been through transesterification) could cause engine failure. Request a certificate of analysis from an approved biodiesel fuel distributor to make sure the biodiesel blend meets specifications. Figure 9: Primary Fuel Filter 2. Change secondary fuel filter every 200 hours. NOTE: The fuel filter on the engine is considered the “secondary fuel filter”. a. Remove the spin-on filter by turning it counter clockwise with a filter wrench. Fill the new cartridge with fuel and install it after applying engine oil to the gasket surface. Screw on the filter until the gasket surface comes into contact with the sealing surface of the filter base. Then, tighten it two-thirds of a turn by hand. Do not overtighten. b. Fuel filter part number is: Model 864W & W3............................... #24-52020 OM864W 6/17 21 Servicing SP11. BLEEDING THE 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. CAUTION: Escaping diesel fuel under pressure can penetrate skin causing serious personal injury. Before disconnecting lines be sure to relieve all pressure. Before applying pressure, be sure all connections are tight and lines, pipes and hoses aren't damaged. Fuel escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks. If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if proper medical treatment isn't administered immediately. 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 bubbles) escapes from the bleed nipple (Figure 10-I). Tighten bleed nipple. 3. If the engine does not start after this bleeding process, loosen a fuel line at the injector (Figure 10-F) while cranking the engine with the starter motor until pure fuel escapes. Then tighten the connection. Do each line one-at-a-time. 4. After the engine has started, use a piece of cardboard to look for fuel leaks. Figure 10: Fuel System OM864W 6/17 22 Servicing SP12. INJECTOR SERVICE c. Remove delivery lines (Figure 12-B) by disconnecting from injectors and injection pump. Remove all lines as an assembly; do not remove the spacers. Cover the ends of the lines, the injector 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. 1. Injectors should be checked every 750 hours. This check should be made by a Northern Lights dealer or local injection repair station. To insure that your engine stays in compliance with applicable EPA and CARB emission standards, the following maintenance procedures and intervals must be maintained. 1500 Hours: Fuel injectors are to be removed and injector tips cleaned. 3000 Hours: Fuel injectors removed for adjustment, cleaning, and repaired. NOTE: Do not use pry bars to remove injectors from the cylinder head. CAUTION: Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury. If injured by escaping fuel, see a doctor at once. 3. Injector Repair and Cleaning a. Take injectors to your Northern Lights dealer or local injection repair station for testing and service. 2. Injector Removal: a. Clean loose dirt from around the injectors and the fuel lines. b. Relieve high pressure in the fuel lines by loosening the delivery line flare nuts at each injector. 4. Injector Installation: a. Install new injector seal washer seat and injector. Tighten the injector (Figure 11-1) to 42 - 50 ft/lbs. (5.8 - 6.9 k/gm). Do not overtighten. b. Reinstall the return line (Figure 11-4) using new sealing washers (Figure 11-2). Tighten bolts (Figure 11-3) to 18 - 25 ft/lbs (2.5 - 3.5 k/gm). NOTE: Overtightening can damage injectors. Figure 11: Injectors OM864W 6/17 23 c. Reinstall injection lines (Figure 12-B). Tighten flare nuts (Figure 12-K) at injection pump to 18.2 - 25.3 ft/lbs (2.5 - 3.5 k/gm). Leave the lines loose at injectors for bleeding. d. Bleed the injection lines (Figure 12-B). Crank the engine to fill the lines. Tighten flare nuts at injectors to 18.2 - 25.3 ft/lbs (2.5 - 3.5 k/gm). e. Start the engine and check for leaks using a piece of paper or cardboard. Do not use your hand to check for leaks. Servicing SP13. INJECTION PUMP 3. Any repair which involves disassembly of the injection pump must be carried out by specially trained mechanics with the proper tools and test equipment. 1. Since operating conditions may vary considerably, it is difficult to give a definite interval for checking the injection pump. But as a rule, pump settings, maximum speed, idle speed and exhaust smoke should be checked after every 2400 hours of operation. Service of the fuel injection pump should only be done if checks indicate pump malfunction. NOTE: All warranties on the engine become null and void if the injection pump seals are broken by unauthorized persons. 2. Black smoke can be an indication of pump malfunction. Before servicing the pump, check other possible causes: a. Check cleanliness of the air filter. b. Check valve clearances. c. Clean and check injectors. Figure 12: Fuel System A. B. C. Injection Line Clamps Fuel Injection Lines Fuel Feed Line D. E. F. G. Throttle Lever H. Hand Priming Pump I. Air Vent Point Timing Mark Plug Fuel Return Line Injector (4) OM864W 6/17 24 J. K. (4) Mounting Bolts Flare Nuts Servicing 4. Injection Pump Removal: INJECTION PUMP TIMING CAUTION: Escaping diesel fuel under pressure can have sufficient force to penetrate the skin, causing serious personal injury. If injured by escaping diesel fuel, see a doctor at once. 1. The injection pump is timed at the factory and the pump body and mounting flange are marked. If pump timing is questionable, follow the procedure below. a. Clean the injection pump, hoses, and area around the pump with a cleaning solvent or steam cleaner. 2. Check Injection Pump Timing: a. Bleed air from the fuel system (see page 16). b. Remove the fuel injection line from the No. 1 fuel delivery valve on the injection pump (Figure 13). NOTE: Never steam clean or pour cold water on an injection pump while the engine is running or the pump is warm. b. Remove the injection lines (Figure 12-B) from the pump and injectors. Remove all lines as an assembly. Do not remove the spacers. Cover the ends of the lines, the injector inlets, and the injection pump outlets to keep dirt out of the injectors, lines, and pump. c. Remove the plug (Figure 12-D) from the timing case cover. Use an indelible marker to put a mark on the injection pump gear through the plug hole. You will use this mark to align the pump during reassembly. Do not rotate the crankshaft after marking. d. Remove the 4 mounting 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). Figure 13: Fuel Injection Lines c. Pressurize the system with the hand primer pump (Figure 12-H). d. Slowly rotate the crankshaft by hand in clockwise direction until fuel just begins to rise in the No. 1 delivery valve. e. The crankshaft pulley notch mark for 13° Before Top Dead Center (BTDC) should now align with the timing pointer (Figure 14). If it does not, the injection pump needs to be timed. Figure 14: Timing Marks OM864W 6/17 25 Servicing COOLING SYSTEM - GENERAL SP15. COOLING SYSTEM FLUSHING NOTE: Be sure to close the sea-cock before working on the engine cooling system. 1. Flush the cooling system every 750 hours or every 12 months, whichever comes first. CAUTION: The cooling water in the engine reaches extremely high temperatures. You must use extreme caution when working on hot engines to avoid burns. Allow the engine to cool before working on the cooling system. Open the filler cap carefully, using protective clothing when the engine is warm. 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 clean water into the engine until water coming from engine is clear of discoloration. Close drains and refill the engine with recommended coolant mixture. SP14. CHECK THE COOLANT LEVEL 4. Use 50% water / 50% ethylene glycol antifreeze mix. Antifreeze mixture is recommended as a good year-round coolant. 1. Check the coolant level each day before starting the engine. a. Check the water level by removing the pressure cap from the radiator. 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. b. The pressure valve in the filler cap releases when the pressure is approximately 7 PSI (0.5 kg/cm2). Use a cap pressure tester to check cap if you suspect it is faulty. 5. Check hoses and connections and repair any leakage. 6. Start the engine and check for leaks. Run the engine for five minutes, then shut it down. Let engine cool, and then check the coolant level in the engine. Add coolant as needed. NOTE: Be sure to open the sea-cock after working on the engine cooling system and starting the engine. OM864W 6/17 26 Servicing SP16. HEAT EXCHANGER SP18. ZINC ELECTRODES 1. Clean the heat exchanger core once a year or after 2400 hours of operation. 1. A zinc electrode is installed in the heat exchanger cooling system to protect the engine from electrolysis. Check it faithfully every 200 hours. If you are in warm saltwater, or where electrolysis is a known problem, check it more often. 2. Drain the expansion tank and heat exchanger. 3. Remove the heat exchanger end covers. 2. Remove the zinc holder from the bottom of the exchanger (Figure 2-12). This will drain raw water from the exchanger. 4. Clean the inside of the exchanger core tubes using a metal rod. Flush, inspect, and clean again if necessary. 3. Scrape or steel brush the zinc electrode clean. If more than 50% of the electrode is corroded away, replace it with a new zinc. The electrode screws out of the holder. 5. Reassemble the heat exchanger. Fill the cooling system. Start the engine and check for leaks. SP17. RAW WATER PUMP 4. Reinstall the zinc holders. Be sure the threads are clean for good metal-to-metal contact. Do not use thread sealant. 1. Change the raw water pump impeller every 750 hours, or as needed. 5. Refill the cooling system. Start the engine and check for leaks. 2. Remove the pump cover. Pry out the impeller using needle-nose pliers or two screwdrivers. Be sure to remove all pieces of the failed impeller. PTO Check the manufacturer’s manual for servicing requirements for the Optional PTO with electric clutch. NOTE: Place some kind of protection under the screwdrivers in order to not damage the pump housing. 3. Clean the inside of the housing. 4. Press in the new impeller and place the sealing plug in the outer 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. Figure 15: Optional PTO with electic clutch OM864W 6/17 27 Servicing GENERATOR END BOOSTER BATTERIES The maintenance and operation recommendations for the generator end are in a separate Owner's Manual. If you do not have one of these manuals, contact your local dealer. 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. ELECTRICAL SYSTEM - GENERAL 2. Booster and main batteries must have the same voltage rating. 1. Never switch the battery switch off or break the circuit between the alternator and the batteries while the engine is running. Alternator damage can result. 3. First, connect the positive (+) terminal of the booster battery to the positive (+) terminal of the main battery. Then, connect the negative (–) terminal of the booster battery to ground on the engine block (Figure 16). 2. Do not reverse the polarity of the battery cables when installing the battery. 4. Remove the booster battery after starting the engine. 5. Sealed Batteries: See the manufacturer's charging and booster instructions. Figure 16: Booster Battery Connections OM864W 6/17 28 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. Tighten terminals and grease them to inhibit future corrosion. 3. Check the battery condition with a hydrometer every 750 hours. SP23. WINTERIZING / OUT-OF-SERVICE NOTE: Remember to close the sea-cock before opening drain cocks. 1. Change the crankcase oil and filter. 2. Drain fresh water and seawater cooling systems completely. Flush fresh water systems and refill with the proper antifreeze mixture. 3. Drain the water supply lines and wet exhaust line. 4. Loosen the seawater pump cover and drain the pump. 5. Loosen the alternator belt. 6. Disconnect and clean the battery. Remove the battery to a warm storage place if possible. 7. Clean the outside of the unit. Paint any scratched or chipped surfaces. Put corrosion preventative on all exposed metal surfaces. OM864W 6/17 29 Troubleshooting DC ELECTRICAL SYSTEM PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) Battery Will Not Charge Loose or corroded connections • Clean and tighten battery connections. Sulfated or worn out batteries • Check specific gravity of each battery. • Check electrolyte level of each battery. Loose or defective alternator belt • Adjust belt tension. • Replace belt. Check DC circuit breaker • If the breaker is tripped, reset it. Loose or corroded connections • Clean and tighten loose battery and harness plug connection. Low battery condition • Check specific gravity of each battery. • Check electrolyte level of each battery. Defective electrical system ground wire: • Repair or replace. Low battery condition • Battery is too small. • Battery cables are too small. Check specific gravity of each battery • Replace battery if necessary. Check electrolyte level of each battery • If low, fill cells with distilled water. Crankcase oil too heavy • Fill with oil of appropriate viscosity. Loose or corroded connections • Clean and tighten loose connections. Check DC circuit breaker • If breaker is tripped, reset it. Faulty connection • Clean and tighten battery and harness plug connections. Sulfated or worn out batteries • Check specific gravity and electrolyte level of each battery. Starter Inoperative Starter Cranks Slowly Entire Electrical System Does Not Function If you cannot correct problems with these procedures, see your Northern Lights dealer. OM864W 6/17 30 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) Engine Hard to Start or Will Not Start Improper starting procedure • See starting section of this manual. Take special note of Bypass Switch operation. No fuel • Check level of fuel in fuel tank. Low battery condition • Check electrolyte level and condition. Excessive resistance in starting circuit • Clean and tighten all battery connections. Crankcase oil too heavy • Use oil of proper viscosity. Improper type of fuel • Consult fuel supplier and use proper type of fuel for operating condition. Water, dirt or air in fuel system • Drain, flush, fill and bleed system. Clogged primary fuel filter element • Clean or replace filter element. Clogged secondary fuel filter element • Replace filter element. Dirty or faulty injection nozzles • Have your dealer check injection nozzles. Below normal engine temperature • Remove and check thermostat. Clogged primary fuel filter element • Clean or replace filter element. Clogged secondary fuel filter element • Replace secondary 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 type of fuel • Consult fuel supplier and use proper type of fuel for operating condition. Engine overloaded • Reduce the load. Intake air restriction • Service air cleaner. Clogged primary fuel filter element • Clean or replace filter element. Clogged secondary fuel filter element • Replace filter element. Improper type of fuel • Consult fuel supplier and use proper type of fuel for operating conditions. Overheated engine • See “Engine Overheats” in next category. Below normal engine temperature • Remove and check thermostat. Improper valve clearance • Reset valves. Best done by dealer. Dirty or faulty injection nozzles • Replace injectors. Best done by dealer. • See your local dealer. Engine Runs Irregularly or Stalls Frequently Lack of Engine Power OM864W 6/17 31 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) Engine Overheats Engine overloaded • Reduce the electrical load. Low coolant level • Fill tank or radiator to proper level. • Check hoses for loose connections and leaks. Keel cooling tubes (marine sets) have been painted • Remove paint from tubes. Cooling system needs flushing • Flush cooling system. Defective thermostat • Remove and check thermostat. Defective temperature gauge • Check water temperature with thermometer and replace gauge if necessary. Water pump impeller worn or broken • Check the impeller and replace if necessary. Insufficient oil • Call your dealer. Injection pump out of time • Call your dealer. Below normal engine temperature • Check your thermostats. • Check water temperature to see if temperature gauge is working properly. Faulty fuel injector • Call your dealer. Engine overheating • See “Engine Overheating” section. 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 your dealer. Engine not at proper temperature • Check your thermostats. • Check water temperature with thermometer and replace gauge if necessary. Below Normal Engine Temperature Thermostats not working properly • Check thermostats. Temperature gauge not working properly • Check water temperature with thermometer. Low Oil Pressure Low oil level • Fill crankcase to proper level. Improper type of oil • Drain and fill crankcase with correct oil. Partially plugged oil filter • Replace filter. Engine Knocks High Fuel Consumption If you cannot correct problems with these procedures, see your Northern Lights dealer. OM864W 6/17 32 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) High Oil Consumption Break-in period • Oil consumption decreases after break in. Crankcase oil too light • Use proper viscosity oil. Oil leaks • Check for leaks in lines around gaskets and drain plug. Crankcase over full • Remove excess oil. Clogged or dirty air cleaner • Service air cleaner. Defective muffler (back pressure too high) • Have dealer check back pressure. 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. Improper fuel • Use correct fuel for temperature. Cold engine • Warm up engine to normal operating temperature. Defective thermostat • Remove and check thermostat. Engine injection timing off • See your dealer. Low Compression Pressure • See your dealer. Engine Emits Black or Gray Exhaust Smoke Engine Emits White Smoke If you cannot correct problems with these procedures, see your Northern Lights dealer. OM864W 6/17 33 Specifications and Dimensions Rated RPM/Frequency Kilowatt Rating 1800/60 Hz 25 kW 1500/50 Hz 20 kW In-line 4 151.7 CID (2.49 l) 4 3.39 in (86 mm) x 4.21 in (107 mm) counterclockwise 21.5:1 7.8 qts. (7.4 l) Natural SAE 4 SAE C-110 In-line 4 151.7 CID (2.49 l) 4 3.39 in (98 mm)x 4.21 in (107 mm) counterclockwise 21.5:1 7.8 qts. (7.4 l) Natural SAE 4 SAE C-110 3 - 980 lbs., 1 - 965 lbs. 26.88 in (683 mm) 20.75 in (527 mm) 47.0 in (1194 mm) 3 - 980 lbs., 1 - 965 lbs. 26.88 in (683 mm) 20.75 in (527 mm) 47.0 in (1194 mm) 2.2 gal (8.3 ltr) .75 in (19 mm) .75 in (19 mm) .75 in (19 mm) 1788 BTU/min 11.5 gal/min (43.5 l/m) 39 in (1 m) 8 ft (2.44 m) 1.25 in (32 mm) 1.5 in (38 mm) 2.2 gal (8.3 ltr) .75 in (19 mm) .75 in (19 mm) .75 in (19 mm) 1400 BTU/min 9.5 gal/min (36 l/m) 39 in (1 m) 8 ft (2.44 m) 1.25 in (32 mm) 1.5 in (38 mm) 220 Amp/hour - 640 CCA #1/0 up to 10 ft (3 m) 20 ft (6.1 m) 12 VDC 220 Amp/hour - 640 CCA #1/0 up to 10 ft (3 m) 20 ft (6.1 m) 12 VDC 292 cfm (8.3 m3/m) 67.2 cfm (1.89 m3/m) 39 sq in (193 cm2) 48 in. H2O (1219 mm H2O) 3 in (75 mm) 225 cfm (6.4 m3/m) 54 cfm (1.53 m3/m) 39 sq in (193 cm2) 48 in. H2O (1219 mm H2O) 3 in (75 mm) 3/8 in (10 mm) 3/8 in (10 mm) 39 in (100 mm) 0.414 lbs/hp/hr 2.3 gal/h (8.7 l/hr) 3/8 in (10 mm) 3/8 in (10 mm) 39 in (100 mm) 0.409 lbs/hp/hr 1.8 gal/h (6.8 l/hr) General Information Cylinders Displacement Cycle Bore x Stroke Rotation (Facing Flywheel) Compression Ratio Crankcase Capacity (Including Oil Filter) Aspiration Flywheel Housing Size Flywheel Drive Size Dry Weight Complete Unit with Heat Exchanger Cooling Height Width Length Cooling System Approximate Cooling System Capacity with Heat Exchanger Minimum Through-Hull Diameter Sea Water Pump Inlet Hose (Inside Diameter) Minimum Sea Water Discharge Heat Rejection to Jacket Water Fresh Water Pump Capacity Maximum Sea Water Pump Suction Head Keel Cooler Tube Length (Turbo Tube) Keel Cooler Head Diameter Keel Cooler Water Hose ID Discharge and Suction Electrical Minimum Battery Capacity Battery Cable Size Instrument Harness Length Starting Voltage, Negative Ground Air Generator Cooling Air Flow, 3 & 1 Air Consumption Maximum Engine Room Vent Maximum Exhaust Back Pressure Wet Exhaust Elbow OD Fuel Minimum Suction Line Minimum Return Line Maximum Fuel Transfer Pump Suction Specific Fuel Consumption at Maximum Load Approximate Fuel Rate at Maximum Load NOTE: Specifications are subject to change without notice. OM864W 6/17 34 Northern Lights AC Wiring Diagram – Taiyo PX300K2 4 Lead Generator with DST-100-2FAK AVR Drawing B-9724E revised 6-29-17 AC Wiring Diagram OM864W 6/17 35 Northern Lights AC Wiring Diagram – Taiyo PX300K2 12 Lead Generator with DST-100-2FAK AVR Drawing B-9723D revised 6-15-17 AC Wiring Diagram OM864W 6/17 36 Northern Lights DC Wiring Diagram – M864W/M864W3 12 VDC Standard Ground B+ Control Drawing B-10770C added 6-15-17 DC Wiring Diagram OM864W 6/17 37 Northern Lights DC Wiring Diagram – M864W/M864W3 12 VDC Isolated Ground B+ Control Drawing B-10844 added 6-15-17 DC Wiring Diagram OM864W 6/17 38 Northern Lights DC Wiring Diagram – M864W/M864W3 24 VDC Standard Ground B+ Control Drawing B-10818F added 6-30-17 DC Wiring Diagram OM864W 6/17 39 Northern Lights DC Wiring Diagram – M864W/M864W3 24 VDC Isolated Ground B+ Control Drawing B-10843 added 6-15-17 DC Wiring Diagram OM864W 6/17 40 Northern Lights DC Wiring Diagram – M864W3 12V Standard Ground Drawing B-9956B revised 6-15-17 DC Wiring Diagram OM864W 6/17 41 Northern Lights DC Wiring Diagram – M864W 12V Isolated Ground Drawing B-9969 revised 6-15-17 DC Wiring Diagram OM864W 6/17 42 Northern Lights DC Wiring Diagram – M864W3 24V Standard Ground Drawing B-9878D revised 6-15-17 DC Wiring Diagram OM864W 6/17 43 Northern Lights DC Wiring Diagram – M864W 24V Isolated Ground Drawing B-9901D revised 6-15-17 DC Wiring Diagram OM864W 6/17 44 S-1 Panel, B+ Deutsch A-12798 Panel Wiring Diagram revised 6-15-17 Wiring Diagrams OM864W 6/17 45 S-1B Panel, B+ A-12791B Panel Wiring Diagram Added 6-5-17 Wiring Diagrams OM864W 6/17 46 S-3B Panel, Viewline B+ A-12799A Panel Wiring Diagram Added 6-5-17 Wiring Diagrams OM864W 6/17 47 S-3C Panel, Viewline B+ A-12790A Panel Wiring Diagram Added 6-5-17 Wiring Diagrams OM864W 6/17 48 OM864W 6/17 49 Drawing A-12667A S-1B Control Panel Panel Wiring Diagram added 6-15-17 Wiring Diagrams Panel Wiring Diagram S-3B / S-3C Oceanline / Viewline Panels 12V A-12574A added 6-15-17 Wiring Diagrams OM864W 6/17 50 Panel Wiring Diagram S-3C control Panel, Viewline A-12645B added 6-16-17 Wiring Diagrams OM864W 6/17 51 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. © 2017 All rights reserved. Litho USA.
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