operator`s manual - Northern Lights Marine Generators

operator`s manual - Northern Lights Marine Generators
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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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