Northern Lights M864W User manual

OM864W
For Models: M864W and M864W3
OPERATOR’SMANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators

Diesel engine exhaust and some of its constitu-
ents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
— CALIFORNIA —
Proposition 65 Warning:
Northern Lights
4420 14th Avenue N.W.
Seattle, WA 98107
Tel: [phone]
Fax: [phone]
Copyright ©2007 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 09/07

OM864W 09/07
3
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 09/07
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.
OPERATOR'S MANUAL
for Northern Lights®M864W & M864W3 Diesel Generator Sets
INTRODUCTION
Models Included .....................................4
Model Numbers......................................4
Serial Numbers...............................................4
WARRANTY ................................................5
SAFETY RULES.........................................5
COMPONENT LOCATIONS
M864K Generator Set ......................6 - 7
CONTROL PANELS
Northern Lights Generator Sets..............8
OPERATING PROCEDURES
Break-in Period ......................................9
Before Starting........................................9
Starting................................................. 10
Operating ............................................. 10
Stopping................................................10
Shutdowns and Alarms .........................11
Spare Parts............................................11
SERVICING SCHEDULE CHART 12 - 13
SERVICING
Lubrication - General............................14
Checking Oil.........................................14
Oil Changes ..........................................14
Changing Oil Filter...............................15
Air Filter ...............................................15
Table of Contents
SERVICING (Continued)
V-Belts ...................................................15
Valve Clearances....................................16
Fuels - General.......................................17
Fuel Filters.............................................17
Bleeding the Fuel System......................18
Injector Service......................................19
Injection Pump...............................20 - 21
Cooling System .....................................22
Heat Exchanger......................................23
Raw Water Pump ...................................23
Zinc Electrodes......................................23
Electrical System - General...................24
Booster Batteries....................................24
Battery Care...........................................25
Winterizing / Out-of-Service .................25
TROUBLESHOOTING
Electrical................................................26
Engine............................................27 - 29
DATA SHEET
Specifications and Dimensions..............30
WIRING DIAGRAMS
DC Electrical .................................31 - 34
AC Electrical .........................................35

OM864W 09/07
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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 main-
tenance.
As operator, it is your obligation to learn about
your equipment and its proper maintenance. This is
not a comprehensive technical service manual. Nor
will it make the reader into an expert mechanic. Its
aim is to aid you in maintaining your unit properly.
Introduction
Introduction
M - Northern Lights marine generator set Model number of engine block
Bore Cylinders
86 mm 4
Serial Numbers
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:
+
Unit Identification
Northern Lights marine diesel generator set with
a 864 engine and a PX-325K2 series generator end.
M864W
M864
=
Your set has three serial numbers: 1an engine number
stamped on a plate attached to the valve cover, 2a
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 09/07
5
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.
CAUTION: Accident reports show that careless use of engines causes a high percentage of
accidents. You can avoid accidents by observing these safety rules. Study these rules carefully
and enforce them on the job.
• Use caution in handling fuel. Never refuel a
hot or running engine. Do not smoke while
filling fuel tank or servicing fuel system.
• Keep your hands, feet, hair and clothing
away from power-driven parts.
• Check for any loose electrical connections or
faulty wiring.
• Engines should be operated only by
knowledgeable, qualified personnel.
• Look completely around engine to make sure
that everything is clear before starting.
• Do not operate an engine that isn't in proper
working order. If an unsafe operating condition
is noted, tag the set and control panel so others
will also know about the problem.
• Provide first aid kits.
• Never leave engine without proper security.
• Turn the coolant tank cap slowly to relieve pres-
sure before removing. Add coolant only when the
engine is stopped and cool.
• Mount a fire extinguisher near engine.
• Always disconnect the battery ground strap
before making adjustments.
• Operate engines in properly ventilated areas.
• Keep trash and other objects away from engine.
• Escaping fluids under pressure can penetrate your
skin. Use a piece of cardboard or wood, not your
hands, to search for leaks.
• Avoid wearing loose clothing without a belt
when working around engines.
• Do not oil or grease engine while it is running.
Safety Rules
CAUTION: This symbol is used throughout
this book to alert you to possible danger areas.
Please take special notice of these sections.
Warranty
Warranty

OM864W 09/07
6
Figure 2: M864W Service Side
1. DC Circuit Breaker
2. Air Filter
3. Intake Manifold
4. Lube Oil Dipstick
5. Secondary Fuel Filter
6. Lube Oil Fill
7. Fuel System Bleed Point
9. Coolant Fill
10. Expansion Tank
11. Heat Exchanger
12. Heat Exchanger Raw
Water Drain and Zinc
13. Raw Water Pump
14. Fuel Primer Pump
15. DC Alternator
16. Lube Oil Drain
17. Fuel Manifold
18. Oil Pan
19. Starter
20. Oil Filter
21. AC Generator
22. DC Panel Plug-In
23. Heat Exchanger Fresh
Water Drain
24. AC Circuit Breaker
M864W Generator Component Locations

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M864W Generator Component Locations
Figure 3: M864W Non-Service Side
2. Lube Oil Fill
3. Exhaust Manifold
4. Coolant Fill
5. Expansion Tank
6. Heat Exchanger
7. Heat Exchanger Raw
Water Drain and Zinc
8. Raw Water Pump
9. Oil Pan
10. Wet Exhaust Elbow
11. Manifold Drain

OM864W 09/07
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Figure 4-B: Series 3 Generator Control Panel
Figure 4-A: Series 1-B Generator Control Panel
1. PREHEAT/ SHUTDOWN BYPASS
This switch serves two functions:
a. Preheats engine before beginning the starting
process. Press switch for 10-20 seconds before
attempting startup.
b. Bypasses the safety shutdown feature during
the starting process. Keep switch engaged while
starting engine, and for 2 to 3 seconds afterwards,
allowing oil pressure to build beyond shutdown
setpoint.
2. ENGINE CONTROL SWITCH
To start the engine, hold this switch in the START
position until the engine is running. After the
engine starts, release the switch and it will return
to RUN position. To stop the engine, hold the
switch in the STOP position.
NOTE: The rocker switch is used on Series 1
panels only, and has a light that glows when
the set is running.
3. HOUR METER
Keeps track of engine running time.
4. OIL PRESSURE GAUGE
Shows the oil pressure in the engine lubricating
system.
5. WATER TEMPERATURE GAUGE
Registers the temperature of the cooling water.
6. D.C. VOLTMETER
When the engine is stopped, the voltmeter indi-
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
phase is selected with the Ammeter Selector
switch (#9).
Figure 4-C: Series 4 Generator Control Panel
Control Panels

OM864W 09/07
9
BEFORE STARTING
1. Check the water level by removing the
pressure cap from the expansion tank. In order
to give the cooling water an opportunity to
expand, the level should be about 1 in. (2.5
cm) below the filler cap sealing surface when
the engine is cold.
CAUTION: Use protective clothing
and open the filler cap carefully when the
engine is warm to prevent burns.
2. Check the oil level in the crankcase with the
dipstick. The oil level must be between high
and low marks on the stick. Never allow the
level to go below this area. Always add the
same viscosity of oil as is already in the
crankcase.
3. Check the fuel tank level and open any fuel
valves on the tank and at the secondary fuel
filter.
4. Close the sea-cock, check and clean the sea
strainer, and re-open the sea-cock.
5. Place the battery switch in the ON position.
NOTE: The battery switch must always be
keptONwhiletheengineisrunning.If
the switch is turned OFF while the
engineisrunning,thebatterycharging
alternator could be damaged.
BREAK-IN PERIOD
1. The first 100 hours on a new or reconditioned
engine are critical to its life and performance.
2. Constantly check the engine temperature and oil
pressure gauges.
3. Oil consumption is greater during break-in as
piston rings take time to seat.
4. Break-In Oil Changes: Change engine oil and
filter at 50 hours. Change oil and filter again at
100 hours (consult Lubricants section for oil
recommendation).
Operating Instructions:
Maintain at least a 75% load on your generator
set for the first 100 hours. If this is not possible,
maintain no less than a 50% load to ensure
proper seating of the piston rings. Vary the load
to help seat the rings.
Operating Procedures

OM864W 09/07
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OPERATING
1. Units with Series 3 and Series 4 Control
Panels:
Check gauges often. Oil pressure must be
above 15 PSI. The D.C. voltmeter should read
between 11 and 15 volts at 80° F (25° C) ambi-
ent temperature. The water temperature gauge
must be below 200° F (94° C). Check the A.C.
voltage and frequency meters (Series 4 panel).
If the gauges deviate from normal levels, shut
down the generator set and investigate.
2. Let the unit run unloaded for a three to five
minute warm-up period.
3. Add electrical load.
STOPPING
1. Remove electrical load from the generator set.
2. Run the engine for a three to five minute cool-
down period.
3. Move the Engine Control switch to the STOP
position until the engine stops completely.
4. Shut off seacock, fuel valve, and battery
switch.
STARTING
1. Hold the Shutdown Bypass switch in the ON
position for 10-20 seconds before starting.
NOTE: Holding the switch too long can burn
out the glow plugs.
2. While holding the Shutdown Bypass switch in
the ON position, push the Engine Control switch
to the START position.
3. As soon as the engine starts, release both
switches. Do not crank the starter for more than
20 seconds consecutively. If the engine fails
to start with the first attempt, be sure that it
has stopped completely before re-engaging the
starter.
NOTE: Excessive cranking of the starter on
marine sets equipped with a water lift
muffler can cause engine damage. If the
engine does not start after 3 consecutive 20-
second cranks, remove the impeller from the
seawater pump. This will prevent the
muffler from filling with water and
backfilling the exhaust line and engine. Once
the engine starts, shut it off immediately and
reinstall the impeller.
Restart and check the exhaust
overboard outlet for gushes of water.
Operating Procedures

OM864W 09/07
11
SHUTDOWNS AND ALARMS
1. Your unit is fitted with a system to protect it from
high water temperature or low oil pressure.
a. Generator sets have shutdown systems to stop the
engine. They have no warning horns.
b. Other alarms and shutdowns are available as
optional equipment.
NOTE: If your unit is equipped with optional
shutdowns and alarms, do not rely on the
warning or shutdown system to the exclusion
of careful gauge monitoring. Watching your
gauges can prevent damage to the unit and
dangerous power losses.
2. Do the following when your warning or shutdown
system is activated:
a. Check the temperature gauge. If above 205° F
(96° C), shut off the engine immediately.
b. Use the Trouble Shooting Guide on page 26 to
isolate the cause of the overheat.
CAUTION: Do not remove the water fill
cap of an overheated engine. Escaping high
temperature steam can cause severe burns.
Allow the engine to cool and then remove the
cap slowly using protective clothing.
c. Make repairs and restart after the temperature
gauge registers below 200° F (94° C).
d. Watch the temperature gauge regularly and
turn off the unit if the temperature rises above
205° F (96° C). Repeat troubleshooting.
3. If shutdown is activated and the temperature gauge
shows temperature within normal temperature range:
a. Check the engine crankcase oil level.
b. If the oil level is low, fill with recommended
lubricating oil and restart. Watch the oil pressure
gauge carefully and shut off the engine if it does
not show a normal reading (20-60 PSI) after a
few seconds of operation.
c. If the oil level is normal, DO NOT restart the
engine. Call your dealer for assistance.
SPARE PARTS
1. ADE recommends that you keep the
following spare parts on hand for field
service. The parts are available from your
local Northern Lights dealer. Some marine
models may already have “On-Board Kits,”
a handy box that contains the most common
parts you will need.
a. Primary and secondary fuel filter
elements
b. Oil filters
c. Air filter elements
d. Alternator belt
e. Thermostat and gaskets
f. Seawater pump impeller and gaskets
g. Glow plugs
h. Injector and washer
2. If your set is operating a long distance from
a servicing dealer, add the following:
a. Complete set of injectors
b. Copper washers for injector change
c. Compelete set of glow plugs
d. Fuel lift pump
Operating Procedures

OM864W 09/07
12
The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your generator set.
More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’column.
DAILY:
SP1 Check oil level in engine
SP8 Check primary fuel filter
SP14 Check cooling water level
Check sea strainer
AFTER FIRST 50 HOURS:
SP2/3 Change engine oil and filter
SP5 Check V-belt tension
SP7 Adjust valves
SP19 Check electrolyte level in batteries
EVERY 50 HOURS:
SP5 Check V-belt tension
SP19 Check electrolyte level in batteries
AFTER FIRST 100 HOURS:
SP2/3 Change engine oil and filter
EVERY 200 HOURS:
SP2/3 Change engine oil and filter
SP4 Check air cleaner
SP9 Change primary fuel filter element
SP10 Change secondary fuel filter
SP18 Check zinc electrodes
EVERY 750 HOURS:
SP7 Check valve clearances
SP12 Check injectors
SP15 Check and flush cooling system
SP17 Change impeller
SP20 Check state of charge of batteries
EVERY 1500 HOURS:
SP12 Check injectors, clean tips
EVERY 2400 HOURS:
SP13 Check fuel injection pump
SP16 Check and clean heat exchanger
EVERY 3000 HOURS:
SP12 Remove injectors for adjustment, clean & repair
Servicing Schedule Chart
SERVICE 50 100 200 750 1500 2400 3000
POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours Hours Hours
ENGINE:
SP1 12 Check oil level •
SP2 12 Change engine oil1, 5 ••
SP3 13 Change lube oil filters1, 5 ••
SP4 13 Check air cleaner1, 4 •
SP5 13 Check V-belt tension1•
SP7 14 Check valve clearances5•
FUEL SYSTEM:
SP8 15 Check primary filter2•
SP9 15 Change primary filter element2, 3 •
SP10 15 Change secondary fuel filter1, 3 •
SP11 16 Bleed the fuel system3
SP12 17 Check injectors1, 6 •• •
SP13 18 Check fuel injection pump •
COOLING SYSTEM:
SP14 20 Check cooling water level •
SP15 20 Check and flush cooling system •
SP16 21 Check and clean heat exchanger •
SP17 21 Change impeller in raw water pump1, 3 •
SP18 21 Check zinc electrodes4•
ELECTRICAL SYSTEM:
SP19 23 Check electrolyte level in batteries1, 4 •
SP20 23 Check condition of batteries with hydrometer1•
OUT OF SERVICE:
SP23 23 Winterizing or out-of-service3
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 09/07
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Service
Point HOURS/ DATE
Service Record
OPERATION
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 09/07
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Servicing
LUBRICATION - GENERAL
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.
3. Use the proper weight oil for your average operation
temperature.
Figure 5: Lube Oils
4. Never put additives or flushing oil in crankcase.
Air Single Multi-
Temperature Viscosity Viscosity
Above 32° F SAE 30W SAE 15-40W
(0° C)
-10° to 32° F SAE 10W SAE 10-30W
(-23° to 0° C)
SP1. CHECKING OIL LEVEL
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.
SP2. OIL CHANGES
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 ...................................7.8 qts. (7.4 liters)

OM864W 09/07
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SP5. V-BELTS
1. Check the tension and wear on the V-belt after
every 50 hours.
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.
Servicing
SP3. CHANGING LUBE OIL FILTER
1. Change the lube oil filter every 200 hours.
2. Use a filter wrench to remove old filter. Dispose of
filter in approved manner.
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 .............................................#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 mani-
fold. 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 09/07
16
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 cylin-
der 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”.
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
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.

OM864W 09/07
17
FUELS - GENERAL
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. 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.
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.
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 ........................................#24-52020
Servicing

OM864W 09/07
18
SP11. BLEEDING THE FUEL SYSTEM
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.
Figure 10: Fuel System
Servicing
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.
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 pro-
cess, 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 con-
nection. Do each line one-at-a-time.
4. After the engine has started, use a piece of
cardboard to look for fuel leaks.

OM864W 09/07
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Servicing
SP12. INJECTOR SERVICE
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.
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.
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.
Figure 11: Injectors
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.
NOTE: Do not use pry bars to remove injectors
from the cylinder head.
3. Injector Repair and Cleaning
a. Take injectors to your Northern Lights dealer
or local injection repair station for testing and
service.
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.
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.

OM864W 09/07
20
SP13. INJECTION PUMP
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, maxi-
mum 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.
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.
3. Any repair which involves disassembly of the injec-
tion pump must be carried out by specially trained
mechanics with the proper tools and test equipment.
NOTE: All warranties on the engine become null
and void if the injection pump seals are
broken by unauthorized persons.
A. Injection Line Clamps
B. Fuel Injection Lines
C. Fuel Feed Line
D. Timing Mark Plug
E. Fuel Return Line
F. Injector (4)
G. Throttle Lever
H. Hand Priming Pump
I. Air Vent Point
Figure 12: Fuel System
J. (4) Mounting Bolts
K. Flare Nuts
Servicing