OM175C2 pages 1-28 04-05
Contents
1. OPERATOR S MANUAL omsc2 For Model M175C2 ENGINE TEM NORTHERN LIGHTS 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 2005 Alaska Diesel Electric Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Alaska Diesel Electric Inc Printed in U S A PART NO OM175C2 04 05 OPERATOR S MANUAL OM175C2 for Model M175C2 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 ccc cseeecteeecneeeeesees 2 Turbo Rometsch eege deed ed 17 Models Included sisirin 2 Cooling System General esseeseeeeseeeeseeeeeee 17 Model Number 2 Engine Coolant Specifications 18 19 tial Numbers sugue dE 2 Cooling System Flushing e eeeeee 19 Heat Exchanger Cleaning 0 0 0 0 eceseseeeeeeeeees 19 WARRANTY AAA 3 Fe Rape eh eee oa suedessine Sdaiez cane soe 20 SAFETY RULES nnn 3 Raw Water PUMP errersnsssersenesereseresersserne 20 Generator ENS tee Eed EE 20 COMPONENT LOCATIONS Electrical System General 20 MUSEL A Booster Batteries sniene 21 Batterie2. 6 Northern Lights Control Panels 1 SHUTDOWN BYPASS SWITCH This switch bypasses the safety shutdown feature during the starting process 2 ENGINE CONTROL SWITCH To start the engine hold this switch in the START Series 3 position until the engine is running Generator Set g 4 Control Panel NOTE Excessive cranking of marine sets equipped GER with water lift muffler systems can cause engine damage 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 Figure 3 Series 3 Generator Control Panel 3 OIL PRESSURE GAUGE The oil pressure gauge shows the oil pressure in the engine lubricating system If the pressure drops below 15 PSI at a speed higher than idling stop the engine and investigate TS SHUT GENERATOR GENERATOR Own BYPASS START HOURS j nobba o oome Iia stent 4 COOLANT TEMPERATURE GAUGE apen Water temperature gauge shows the temperature of 4 the cooling water If the gauge registers over 200 or drops below 140 stop the engine and investigate 5 HOUR METER Keeps track of the engine running time 6 DC VOLTMETER When the engine is running it indicates the voltage output of the alternator Figure 5 Series 3C Generator Control Panel OM175C2 04 0
3. Diesel engine exhaust and some of its constituents are known to the State of California to cause from power driven parts Check for any loose electrical connections or faulty wiring Always disconnect ECU Electronic Control Unit connectors and engine control system to vessel ground before welding High currents or electro static discharge in electronic components from welding may cause permanent damage 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 this book to alert you to possible danger areas Please take special notice of these sections D CAUTION This symbol is used throughout cancer birth defects and other reproductive harm OM175C2 04 05 Figure 1 amp 2 M175C2 1 Junction Box 7 Coolant Fill 2 Air Cleaner 8 Expansion Tank 3 Secondary Fuel Filter 9 Heat Exchanger 4 Primary Fuel Filter 10 Heat Exchanger Zincs 5 Lube Oil Filter 11 Belt Guard 6 Injection Pump 12 Fuel Manifold M175C2 Component Locations Lube Oil Drain 19 Alternator Lube Oil Fill 20 Thermostat Cover Turbocharger Electronic Control Unit Starter Aftercooler OM175C2 04 05
4. OIL CHANGES LUBRICATION Break in oil 1 Use one of the following during the first 100 hours of operation a John Deere Engine Break In Oil b API Service CE oil c ACEA Specification E1 2 Do not use John Deere PLUS 50 oil or engine oils meeting API CG4 API CF4 ACEA E3 or ACEA E2 performance levels during the first 100 hours of operation of a new or rebuilt engine These oils will not allow the engine to break in properly Lubrication General 1 Use only clean high quality lubricants stored in clean containers in a protected area 2 These oils are acceptable after the first 100 hours a API Service CC CD single viscosity oils b API Service CD CG 4 CF 4 multi viscosity oils c ACEA Specification E3 E2 multi viscosity oils d CCMC Specification D5 and Mercedes Benz MB228 3 e CCMC Specification D4 and Mercedes Benz MB228 1 3 Use the proper weight oil for your average operation temperature Air Single Multi Temperature Viscosity Viscosity i SCT SAE 30W SAE15 40W 0 C 10 F to 32 F 23 C to 0 C SAE 10W SAE10 30W Below 10 F 4 Some increase in oil consumption may be expected when SAE 5W and SAE 5 20W oils are used Check oil level frequently 5 Never put additives or flushing oil in crankcase SP1 CHECK ENGINE OIL LEVEL 1 Check the oil level in the crankcase with the oil dipstick daily 2 The oil level must be between the Waffled area and the oo Never a
5. contact your local Northern Lights dealer ELECTRICAL SYSTEM GENERAL Never switch battery switch off or break the circuit between the alternator and batteries while the engine is running Regulator damage can result DO NOT reverse the polarity of battery cables when installing the battery When welding on the unit disconnect the regulator and battery Isolate the leads Disconnect battery cables when servicing the DC alternator Never test with a screwdriver etc against any terminal to see if it emits sparks A DC circuit breaker protects your control panel and wiring harness OM175C2 04 05 22 BOOSTER BATTERIES 1 Check electrolyte level every 50 hours or once per month Add distilled water to manufacturer s recommended level 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 corrosion 3 Check the battery condition with a hydrometer every 750 hours A CAUTION Battery Gas Can Explode Keep all flames and sparks away from batteries Turn charger off before connecting or disconnecting 2 battery charger Make last connection and first connection at a point away from battery Always connect Negative cable last and disconnect this cable first 1 Before changing or using booster batteries check battery electrolyte level Add distil
6. prior to removing filter open valve Fig 16 A on the bottom of the water separator bowl 1 Whenever the fuel system has been opened for service lines disconnected filter changed etc it will be necessary to bleed air from the system 2 Fuel filters must be pre filled whenever they are being RG13296 removed or rep laced Reproduced by permission of Deere amp Company c2004 Deere amp Company 3 To properly drain water from the filter the drain valve SEN Fig 17 must be unthreaded completely and the valve should drop down approximately 12 mm 0 5 in 6 To bleed the fuel system loosen the fuel outlet 4 Open the drain valve Fig 16 A on the primary Fig Fig 18 A on the transfer pump Unlock and operate 16 D and secondary 16 E filters and drain the water hand primer Fig 18 B until a steady flow of fuel and contaminates from the water separator bowl without bubbles comes out of the connection This 5 Pre fill the fuel filters Fig 17 C using the pre fill cup could take 270 to 330 strokes until the fuel flow 17 B comes out clear of bubbles Then retighten the fuel line Torque Specification Fuel Outlet Lines Toroue 24 Nem 18 lb ft 7 Operate hand primer 18 B until a steady flow of fuel comes out of the hose Pump hand primer while disconnecting JTO3472 coupler from diagnostic port OM175C2 04 05 17 RG13270 Reproduced by permission of Deere amp Company c2004 Deere amp Company All ri
7. Bleed fuel system Engine overloaded e Reduce load Leaks in fuel supply system e Locate leaks and repair Improper type of fuel e Use correct fuel for temperature Clogged or dirty air cleaner e Service air cleaner Improper valve clearance defective e See your dealer Injection nozzles dirty e See your dealer Defective turbocharger e See dealer Injection pump out of time e See qualified dealer Engine not at proper temperature e Check your thermostats e Check water temperature with thermometer and replace gauge if necessary Compression too low e Determine cause of low compression and repair Coolant in combustion chamber cylinder head gasket failure or cracked cylinder head e See dealer repair or replace Fuel in Oil Cracked cylinder head e Locate crack repair or replace as needed See dealer If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer OM175C2 04 05 25 v Coolant in Crankcase Cylinder head gasket damaged e Replace See dealer Cylinder head or block cracked e Locate crack repair or replace See dealer Cylinder liner seals leaking e Remove and inspect cylinder liners Coolant pump seal or bearing leaking e Replace seals See dealer Below Normal Engine Temperature Thermostats not working properly e Check thermostats Temperature gauge not working properly e Check water temperature with thermometer Low Oil Pressure Lo
8. Overheated engine e See Engine Overheats in next category Below normal engine temperature e Remove and check thermostat Improper valve clearance e Reset valves Best done by dealer Dirty or faulty injection nozzles e Replace injectors Best done by dealer e See your local dealer v Engine Overheats Low coolant level e Fill tank or radiator to proper level e Check hoses for loose connections and leaks Engine overloaded e Reduce load Low engine oil level e Check oil Keel cooling tubes have been painted marine e Remove paint from tubes Cooling system needs flushing e Flush cooling system Damaged cylinder head gasket e Replace Belt stretched or loose e Adjust belt tension Replace belt as needed Defective thermostat e Remove and check thermostat Defective temperature gauge e Check water temperature with thermometer and replace gauge if necessary Water pump impeller worn broken e Check impeller and replace if necessary v Engine Knocks Insufficient oil e Call your dealer Poor fuel quality e Drain and replace fuel Injection pump out of time e Call your dealer Below normal engine temperature e Check your thermostats e Check water temperature to see if temperature gauge is working properly Electronic Control Unit has problems e See qualified dealer Air intake system has air leak on suction side e Check hoses and pipe connections repair High Fuel Consumption Air in fuel system e
9. e Replace fuse Starter Cranks Slowly Low battery output e Battery is too small e Battery cables are too small Check specific gravity of each battery cell e Replace battery if necessary Check electrolyte level of each battery cell e If low fill cells with distilled water Crankcase oil too heavy e Fill with oil of appropriate viscosity Loose or corroded connections e Clean and tighten loose connections Entire Electrical System Does Not Function Check DC circuit breaker e If breaker is tripped reset it Faulty connection e Clean and tighten battery harness plug ground strap starter or alternator connections Sulfated or worn out batteries e Check specific gravity and electrolyte level of each battery cell Troubleshooting DC ELECTRICAL SYSTEM v Battery Will Not Charge Y Undercharged System Added accessories making too big a load e Remove accessories or install higher output alternator ENGINE v Engine Hard to Start or Will Not Start Improper starting procedure e See starting section of this manual Take special note of Bypass Switch operation No fuel e Check level of fuel in fuel tank Low battery output e Check electrolyte level and condition Excessive resistance in starting circuit e Clean and tighten all battery connections Crankcase oil too heavy e Use oil of proper viscosity Improper type of fuel e Consult fuel supplier and use proper type of fuel for operating condition
10. ege EE Ed 21 ENGINE amp GENERATOR CONTROL PANELS Winterizing Out of Bernie 21 Seres EE 5 6 OPERATING PROCEDURES TROPETESHOOUNG Blerctberegt ee ee Ee 22 Bios ANTONIE ememr 7 EH e 22 24 Shutdown Procedures c cceseseeeseeeeeerees 7 8 Break In Period neccen eeediecectaeene 8 WIRING DIAGRAMS SERVICING SCHEDULE CHART 9 AG E Te 25 IDC El ctical neger 26 27 SERVICE RECORD ceececeeeereteteeeeeees 10 ON BOARD SPARE PARTS 28 SERVICING Lubrication General 0 0 ecceceeceeseereeeeeees 11 Checking Oil ie aintiectininineiiieein 11 On CH Aan SES fs peeisess ege eege E 11 Changing Oil Etgen ence tanion 11 TU 11 Valve Clearances secrecion 12 Fuels General perenner 13 Fuel Filters sisccistacd doce eens 13 Crankshaft Damper cececseeesseneeeeeeeeneeeee 14 Bleeding the Fuel System eee 15 16 InjSCtOr Service vos oi hes apse 16 Turbocharger cccccceccccessssecseereeseeeeeeeseeseeeeees 17 Proprietary Information This publication is the property of Alaska Diesel Electric Inc It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric Inc Alaska Diesel Electric Inc All rights reserved Litho U S A Publication number OM175C2 04 05 OM175C2 04 05 3 Introduction Servicing of marine engines and generator sets presents Failures begin with minor problems that are overlooked unique problems In many cases boats ca
11. exchanger see Component Locations Keel Cooled engines a Drain expansion tank and remove zinc holder from tank see Component Locations 2 Scrape or steel brush the zinc electrode clean If more than 50 of the electrode has eroded away replace it with a new one The electrode screws out of the holder 3 Reinstall the zinc holders Be sure the threads are clean and have good metal to metal contact SP19 RAW WATER PUMP Heat exchanged cooled engines only 1 Change the sea water pump impeller as needed 2 Remove the pump end cover Remove impeller with water pump pliers Be sure you remove all pieces of a failed impeller 3 Clean the inside of the housing 4 Press in the new impeller and place the sealing washer in the outer end of the impeller center if this has not already been done 5 Replace the cover using a new gasket Note Make sure there is always an extra impeller and cover gasket in reserve and on board SP20 21 DRIVEN EQUIPMENT Gears and PTO s 1 Manufacturer s service recommendations vary See your Owner s Manual for service information If you do not have a manual see your local dealer for the equipment in question NOTE Some PTO and marine gears have rigid lubrication requirements Follow service recommendations closely Generator Ends 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
12. if the temperature rises above 200 F 94 C Repeat the troubleshooting process If the 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 after a few seconds of operation If the oil level is normal DO NOT restart the engine Call your Northern Lights or Lugger dealer for assistance BREAK IN PERIOD are critical to its life and performance Constantly check the engine temperature and oil pressure gauges Oil consumption is greater during break in as piston rings and cylinder liners take time to seat Break In Oil Changes Change engine oil and filter at 50 hours Change oil and filter again at 100 hours See Gear Owner s Manual for break in oil change procedures Consult Lubricants Section for oil recommendation Operating Procedures OPERATING INSTRUCTIONS Maintain at least a 75 load on your 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 rings The first 100 hours on a new or reconditioned engine OM175C2 04 05 10 Servicing Schedule Chart The Servicing Schedule Chart below shows the service schedule required for proper ma
13. is faulty 1 Drain the cooling system 4 The makeup coolant added to compensate for loss 2 Remove the cooling water pipes between the heat or leaks must meet engine coolant requirements exchanger and the water pump inlet outlined in previous section 3 Disconnect hose to seawater pump Unscrew the attaching bolts holding the heat exchanger to the expansion tank SP15 FLUSHING THE COOLING SYSTEM A CAUTION The cooling water in the engine 5 Remove bolts holding heat exchanger cover reaches extremely high temperatures You must 6 Wash the core inside and out If necessary chemical use extreme caution when working on hot engines agents can be used Also clean the accessible parts of to avoid burns Allow the engine to cool before the heat exchanger housing working on the cooling system Open the filler cap 7 Reassemble using new gaskets and sealing rings carefully using protective clothing when the engine is warm OM175C2 04 05 21 SP18 ZINC ANODES 1 Zincs are installed in the cooling system to protect your engine from electrolysis Check them faithfully every 250 hours If you are in warm salt water or where electrolysis is a known problem check them more often If the rod flakes apart when tapped install a new zinc plug Heat exchanger cooled engine a Drain the raw water from heat exchanger see Component Locations b Remove zinc holders from back of the tank and from front and port side of the heat
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15. 4 Warranty A warranty registration certificate is supplied with your set The extent of coverage is described in the Limited Warranty Statement We recommend that you study the statement carefully NOTE If the warranty is to apply the servicing instructions outlined in this manual must be followed If further information is needed please contact an authorized dealer or the factory Safety Rules CAUTION Accident reports show that careless use of engines causes a high percentage of accidents You can avoid accidents by observing these safety rules Study these rules carefully and enforce them on the job Never leave engine without proper security e Keep your hands feet hair and clothing away Turn the coolant tank cap slowly to relieve pressure before removing Add coolant only when the engine is stopped and cool Mount a fire extinguisher near engine Always disconnect the battery ground strap before making adjustments Operate engines in properly ventilated areas Keep trash and other objects away from engine Escaping fluids under pressure can penetrate your skin Use a piece of cardboard or wood not your hands to search for leaks Avoid wearing loose clothing when working around engines Do not oil or grease engine while it is running Use caution in handling fuel Never refuel a hot or running engine Do not smoke while filling fuel tank or servicing fuel system CALIFORNIA Proposition 65 Warning
16. 5 7 Northern Lights Control Panel l NORTHERN LIGHTS pt ADA REL ELECT CRATE mp LRA Engine Hours Pepe 1 2 Series 4 Generator Set Control Panel Engine Terrperatoe AC Aerer amp Vorrei Selector Switch Figure 6 Series 4 Generator Control Panel 1 SHUTDOWN BYPASS SWITCH 7 This switch bypasses the safety shutdown feature during the starting process 2 ENGINE CONTROL SWITCH The control switch starts and stops the engine 3 OIL PRESSURE GAUGE The oil pressure gauge shows the oil pressure in the engine lubricating system If the pressure drops below 15 PSI at a speed higher than idling stop the engine and investigate 9 4 COOLANT TEMPERATURE GAUGE Water temperature gauge shows the temperature of the cooling water If the gauge registers over 200 or drops below 140 stop the engine and investi 10 gate 5 HOUR METER Keeps track of the engine running time 6 DC VOLTMETER When the engine is running it indicates the voltage output of the alternator AC VOLTMETER The voltmeter shows the generator output voltage phase to phase If the voltage fluctuates greatly from the normal reading shut down the unit and investi gate FREQUENCY METER Indicates engine speed The correct reading for 1800 RPM sets is 60 Hz If meter does not indicate correct hertz stop and investigate AMMETER SELECTOR SWITCH The ammeter switch is used for checking each phase for load condit
17. CTORS 1 Fuel injectors should be checked by a Northern Lights dealer or qualified fuel injection shop every 500 hours A IMPORTANT Do not attempt to service injection pump or fuel injectors yourself special training and tools are required In addition modification or alteration of the injection pump fuel injectors or the injection pump timing in ways that are not recommended by the manufacturer could terminate the warranty And tampering with the fuel system that leads to alteration of emission related equipment on the engine could result in fines or other penalties per EPA regulations or other local emission laws OM175C2 04 05 18 SP12 TURBOCHARGER 1 Check for air leaks every 200 hours Air leakage will lower engine output and may cause black exhaust smoke and soot 2 Listen along air line while engine is running A whistling or hissing sound indicates leakage 3 Leakage on the pressure side between turbo and engine can be found by applying soapy water to the air line 4 Tighten the hose clamps replace hose or gaskets as required 5 Check to see that the lubrication and cooling lines are tight and without leaks SP13 TURBO BOOST 1 This check measures the amount of air the turbo is pushing into the engine It should be done by an authorized dealer every 500 hours 2 On the inlet manifold there is a 1 8 NPT threaded port Remove the plug and install the boost gauge hose Refer to your engi
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19. Pint Part Number 20 00002 1 2 gallon Part Number 20 00003 DO NOT use any coolant system additives containing soluble oil OM175C2 04 05 COOLANT TESTING 1 Coolant test kits are available to allow on site 1 Flush the cooling system and check for leaks and evaluation of the coolant condition blockage every 600 hours or yearly The engine 2 The kits use small strips of paper which are dipped must be stopped and cold into the coolant The paper changes color and 2 Close the seacock indicates the SCA concentration It also indicates the 3 Remove the pressure cap from the expansion tank amount of EGC antifreeze with caution If applicable open the cooling system 3 Test kits are available through your Northern Lights air vent on top of turbocharger or Lugger Dealer 4 Open the drains on the exhaust manifold and engine 4 Pack Part Number 20 00005 block Drain the fresh water system see Component 50 Pack Part Number 20 00010 Locations page 4 Thermostats should be removed to alow entire cooling system to be drained SP14 CHECKING COOLANT LEVEL 5 For vessels with keel cooling the vessel must be out of the water to allow draining of the keel cooler A CAUTION The cooling water in the engine 6 With drains open pour clean water into the expansion reaches extremely high temperatures You must tank When the water from drain is clear and free use extreme caution when working on hot engines from discoloration and
20. Water dirt or air in fuel system e Drain flush fill and bleed system Clogged primary fuel filter element e Clean or replace filter element Clogged secondary fuel filter element e Replace filter element Dirty or faulty injection nozzles e Have your dealer check injection nozzles Electronic Control Unit faulty e See authorized service dealer Engine Runs Irregularly or Stalls Frequently Below normal engine temperature e Remove and check thermostat Clogged primary fuel filter element e Clean or replace filter element Clogged secondary fuel filter element e Replace secondary filter element Water or dirt in the fuel system e Drain flush fill and bleed system Dirty or faulty injection nozzles e Have your dealer check injection nozzles Air in fuel system e Inspect clamps and hoses on suction side of fuel pump for air leak bleed fuel system Improper type of fuel or crankcase oil e Consult fuel supplier and use proper type of fuel or crankcase oil for operating condition If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer OM175C2 04 05 Troubleshooting v Lack of Engine Power Intake air restriction e Service air cleaner Clogged primary fuel filter element e Clean or replace filter element Clogged secondary fuel filter element e Replace filter element Improper type of fuel e Consult fuel supplier and use proper type of fuel for operating conditions
21. bly should be replaced every 4500 hours or 60 months whichever occurs first as the vibration damper assembly is not repairable Always replace the vibration damper when the crankshaft is replaced or a major engine overhaul takes place OM175C2 04 05 16 BLEEDING THE FUEL SYSTEM CAUTION Escaping diesel fuel under pressure can A penetrate the skin causing serious personal injury Before disconnecting lines be sure to relieve all pressure Before applying pressure to the system be sure all connections are tight and the lines pipes and hoses are not damaged Fuel escaping from a very small hole can be almost invisible Use a piece of cardboard or wood rather than the hands to search for suspected leaks If injured by escaping S fuel see a doctor at once Serious infection or S reaction can develop if proper medical treatment is x nor administered immediately Reproduced by permission of Deere amp Company c2004 Deere amp Company Do not disconnect or attempt repair of fuel lines GER Fig 16 sensors or any other components between the high pressure fuel pump and nozzles on engines with High Pressure Common Rail fuel systems as high pressure fluid remaining in the fuel lines could cause serious injury Only technicians familiar with this system should attempt repair Due to the High Pressure Common Rail system the fuel in the filter is likely to be under high pressure To relieve pressure and avoid injury
22. e generator and run for three to five minutes for cool down period 2 Turn the Engine Control Switch to the OFF position 3 Close the sea cock and fuel valves and put the battery switch in the OFF position if the unit will be off for an extended period NOTE Do not turn the battery switch to OFF while the engine is running 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 Do not rely on your 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 shutdown system is activated next page OM175C2 9 04 05 a Check the temperature gauge If the temperature is above 205 F 97 C shut off the engine immediately b Use the Trouble Shooting Guide on pages 22 24 to isolate the cause of the overheat A 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 180 F 83 C d Watch the temperature gauge regularly and turn off the unit
23. er arms show excessive valve clearance check them more thor oughly for damage 7 Rotate flywheel in clockwise direction viewed from All rights reserved Fig 7 Ab an complete turn and reinstall the timing pin in the flywheel Use a bent feeler gauge Fig 9 to check the valve clearances on numbers 1 3 and 5 exhaust valves and numbers 1 2 and 4 intake valves 9 Valve checking clearance Rocker arm to valve tip Intake Valve 0 016 0 020 in 0 41 0 51 mm Exhaust Valve 0 026 0 030 in 0 66 0 76 mm 10 If valves need to be adjusted adjust valve clearance on number 1 3 and 5 exhaust valves and number 1 2 and 4 intake valves to below specification Loosen the nut on the rocker arm adjusting screw and turn the adjusting screw until the feeler gauge slips with a sli ght drag Tighten the lock nut while Reproduced by permission of Deere amp Company c2005 Deere amp Company holding the adjusting screw with a screwdriver SE Ze Valve clearances Rocker arm to valve tip Intake Valve 0 018 in 0 46 mm Exhaust Valve 0 028 in 0 71 mm Valve Adjusting Screw Lock Nut TOGU Eeron a 27 Nem 20 1b ft 1 Koch e water pump with the Flywheel Turning Tool until S the Timing Pin Fig 8A amp B engages timing hole in z the flywheel Both rocker arms for No 1 cylinder Reproduced by permission of Deere amp Company 2005 Deere amp Company will be loose at Top Dead Center If they are not A
24. ghts reserved Fig 18 8 Loosen the high pressure fuel supply line 18 C and operate hand pump until a stream of fuel without bubbles comes out Tighten the high pressure fuel supply line to the specification as follows High Pressure Fuel Line Torque 24 Nem 18 lb ft 9 Loosen one of the high pressure fuel supply lines 18 D and use hand pump until steady stream of fuel comes out Tighten the high pressure fuel supply line to the above specification 10 Loosen fuel line fitting on fuel rail flow limiter 6 18 E Use a rag to put around the fitting to absorb excess fuel Pump the hand primer fuel flows steadily Tighten the line back to above specifica tion 11 Pump the hand primer about 30 more times and then lock it by pulling up then pushing down 12 Crank the engine no more than 15 seconds If the engine fails to start wait another 15 seconds and then crank for an additional 15 seconds If it starts then run it at 1200 to 1500 RPM for 3 to 5 minutes If the engine still fails to start loosen the fuel line fitting on the High Pressure Common Rail flow limiter Fig 18 E Use a rag around the fitting to absorb the fuel and pump the hand primer until a steady flow of fuel comes out of the flow limiter Tighten the fuel lines to the specification below and lock the hand primer by pulling up then pushing down on it to lock it High Pressure Fuel Line Torque 24 Nem 18 lb ft P11 INJE
25. h tighten filter one half turn farther Overtightening can do damage to filter housing Fill engine with recommended oil Start engine and check for leakage Stop engine and check oil level Add additional oil if necessary SP4 AIR CLEANER 1 Inspect air cleaner valve daily Replace filter when indicator show a vacuum of 625 mm 25 in H 0 Clean the rubber tube at the cleaner Loosen the hose clamp and the attaching strip for the cleaner Make sure the rubber tube is in good condition and that new filter is absolutely clean and installed properly Start the engine and check for leaks NOTE Make absolutely sure no impurities enter the engine while changing the element Do not run the engine with the air cleaner removed OM175C2 04 05 13 SP6 VALVE CLEARANCES Caution Always disconnect the negative battery A terminal when making valve adjustments to prevent accidental starting of the engine The following special tools will be needed JDE 820 or JDE 81 1 Flywheel Turning Tool and JDE 81 4 Timing Pin 1 Valve clearances must be checked and adjusted with the engine cold Disconnect the wiring harness Remove rocker arm cover with ventilator tube Remove the wires from electronic injectors Fig 7B Take off carrier Remove plastic plugs in cylinder block bores Check all contact surfaces of valve tips and rocker arms for excessive wear or cracks replace parts that show damage If any of the rock
26. h 50 70 load for 30 minutes at break in 2 Perform all maintenance once a year even if hour level has not been reached 6 Ges air cleaner element when restriction indicator shows 3 Consult manufacturer s maintenance schedule note on chart vacuum of 625 mm 25 in H 0 4 Whenever necessary 7 Replace damper every 4500 hours or after 60 months OM175C2 04 05 11 Service Record Service Point OPERATION HOURS DATE 50 HOURS SP21 Check electrolyte in batteries 100 HOURS SP9 Change primary fuel filter element SP13 Check turbocharger air oil amp cooling lines for leakage SP19 Check zinc electrodes 250 HOURS SP2 Change engine oil SP3 Change lubricating oil filters SP4 Replace air cleaner SP5 Check belt condition SP9 Change primary filter element SP25 Check engine mounts 500 HOURS SP7 Check crankshaft damper SP10 Change secondary fuel filter SP11 Check injectors SP14 Check turbocharger boost pressure SP16 Check cooling system SP17 Check and clean heat exchanger SP20 Change impeller in raw water pump SP22 Check state of charge of batteries EVERY 2000 HOURS SP6 Check valve clearances Test thermostats SP12 Check fuel injection pump SP18 Check and clean gear oil cooler SP16 Flush cooling system OM175C2 04 05 12 SP2
27. hile the engine is running the battery charging regulator could be ruined Starting Lk While holding the Shutdown Bypass switch in the ON position push the Engine Control switch to the START position As soon as the engine starts release both switches Do not crank the starter for more than 20 seconds If the engine fails to start the first time be sure the starter has stopped for at least 2 minutes before reengaging NOTE If there is a governor locked at a specific speed on the generator set there may not be a slow idle function so in that case operate the engine at high idle for 1 to 2 minutes before adding load If the stand by generator set is loaded as soon as it reaches rated speed this procedure would not apply Operating 1 Check Gauges Often Oil pressure must be above 29 PSI if not above 15 PSI within 5 seconds of starting the engine should be stopped and the problem should be explored Normal oil pressure is 50 PSI at rated load speed 1800 to 2500 RPM The DC voltmeter should read between 13 14 volts 26 28 volts 24 volt systems 2 Check AC voltage and frequency meters Series 4 Panel If gauges deviate from normal levels shut down the set and investigate Check belt for good alignment 4 Let the unit run unloaded for a three to five minute warm up period before applying load 5 Do not add full electrical load until engine is at pa maximum operating temperature Shutdown 1 Unload th
28. intenance of your marine engine or generator set More detailed coverage of each Service Point SP is listed on the page noted in the page column DAILY SP9 Change primary filter element Racor SP1 Check oil level in engine SP25 Check engine mounts SP8 Check primary fuel filter EVERY 500 HOURS YEARLY SP15 Check cooling water level SP7 Check crankshaft vibration damper SP10 Change secondary fuel filter AFTER FIRST 50 HOURS SP11 Check injectors SP2 Change engine oil SP14 Check turbocharger boost pressure SP3 Change lube oil filter SP16 Check cooling system EVERY 50 HOURS SP20 Change impeller in raw water pump SP21 Check electrolyte in batteries SP22 Check the state of the charge of the batteries SP26 Clean crankcase vent tube AFTER FIRST 100 HOURS EVERY TWO WEEKS SP27 Check air intake hoses SP2 Change engine oil after first 100 hrs then check every 2 wks SP29 Check electrical ground connection SP3 Change oil filter after first 100 hrs then check every 2 wks SP30 Check engine speeds SP4 Check air cleaner valve amp restriction indicator gauge EVERY 2000 HOURS SP7 Check crankshaft vibration damper 7 SP6 Check amp adjust valve clearance SP12 Check fuel injection pump SP15 Check coolant level SP16 Flush cooling system EVERY 250 HOURS f ERIA SP17 Check and clean heat exchanger SP2 Change engine oil amp filters fuel filter water bowl SP18 Check and clean gear oil cooler SP4 Replace air cleaner SP23 Test thermostat
29. ion Leave it in the ON position while the engine is running AC AMMETER The ammeter indicates the phase load Check for load unbalance If the unbalance is greater than 30 have an electrician balance the load properly This will ensure longer generator life and better economy OM175C2 04 05 8 Operating Procedures BEFORE STARTING 1 e Check the water level by removing the pressure cap from the expansion tank In order to give the cooling water room to expand the level should be about 1 3 4 in 4 5 cm below the filler cap sealing surface when the engine is cold When filling with coolant the venting cock on top of the turbocharger should be opened to ensure that no air pockets form in the cooling system see Service Point 12 CAUTION Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns Check the oil level in the crankcase with the dipstick The oil level should be between the waffled area and the oo Never allow the level to go below the oo Always add the same viscosity of oil as is already in the crankcase see Service Point 1 Check the fuel tank level and open any fuel valves Disengage clutch if equipped Close the seacock check and clean the strainer and reopen the seacock 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 w
30. l tank at the end of each day s operation This will reduce condensation SP8 10 FUEL FILTERS 1 Your engine or generator set should have a primary fuel filter installed We recommend the Racor brand RG11620 of fuel filter water separators a Check the primary fuel filter daily as recommended by the filter manufacturer Empty the collection bowl as necessary Change the element every 250 hours or whenever Reproduced by permission of Deere amp Company c2005 Deere amp Company All rights reserved Fig Il D Front of Engine b necessary c If the bowl fills with water change the primary and secondary elements immediately 2 Change secondary fuel filter every 600 hours NOTE The fuel filter on the engine is considered the secondary fuel filter The engine will be fitted with a quick change disposable secondary fuel filter a Turn off the fuel b Open the filter drain plug and drain the filter c Remove the secondary fuel filter by turning the filter clamp counter clockwise until the filter cartridge slides out OM175C2 04 05 15 NOTE Before installing a new filter cartridge make sure the surfaces where the cartridge comes in contact with the mounting plate are absolutely clean Dirt can be washed into the fuel injection system This may result in severe damage to the fuel injection pump or nozzles 4 d Install new filter cartridge e Fuel filter cartridge numbers are RE503676 Pri
31. led water 2 Booster and main batteries must have the same SP24 WINTERIZING OUT OF SERVICE voltage rating 3 First connect positive terminal of booster E If the generator set will not be used for more than 6 battery to positive terminal of main battery months the following preparations should be taken for long term storage 1 Change the engine oil and replace the filter Service the air cleaner 2 Drain flush and refill the cooling system 3 Crank the engine a few times with a starter 4 Remove and clean batteries 5 All engine openings should be sealed with plastic bags and tape 6 Store in a dry protected place To Remove Generator Set from Long Term Storage Battery Booster Battery 1 Take off all protective coverings and unseal all the openings that were covered up Install batteries that are fully changed and connect the terminals 3 Install the fan and alternator belts if they had been removed Fill the fuel tank Perform all pre start checks Crank the engine for 20 seconds with the starter without letting the engine start Wait 2 minutes and crank the engine an additional 20 seconds to make sure all bearing surfaces are well coated 7 Start the engine and run at no load in a low idle for several minutes Make sure the engine is warmed up and check gauges before going under load 8 Check all gauges and check for leaks Figure 20 Booster Battery Connections 2 4 Then connec
32. ll rights reserved Fig 8 remove the timing pin and rotate the flywheel one A Flywheel Turning Tool B Timing Pin RG12605 Reproduced by permission of Deere amp Company c2005 Deere amp Company RG11559 OM175C2 04 05 14 FUELS GENERAL Compression stroke at Top dead center shown below 1 Use only clean high quality fuels of the following specifications as defined by ASTM designation D975 or EN590 for diesel fuels a Use grade no 2 diesel at ambient temperatures above freezing 30 F 0 C b Use grade No 1 at ambient temperatures below freezing and for all temperatures at an altitude of above 5 500 ft 1500 meters 2 Sulphur content should not exceed 0 5 preferably less than 0 05 3 The cetane number should be a minimum of 45 Greater than 50 is preferred 4 DO NOT use these unsuitable grades of fuel RG11569 a Domestic heating oils all types Reproduced by permission of Deere amp Company c2005 Deere amp Company b Class B engine EE E c Class D domestic fuels ig e S A Front of Engine d Class E F G or H industrial or marine fuels B No 1 Cylinder TDC e ASTM D975 60T No 4 D and higher number C No 6 Cylinder TDC fuels f JP4 5 Storing fuel a Keep dirt scale water and other foreign matter After adjusting valves tighten rocker arm cover ut of fuel in the ord h below KEE b Avoid storing fuel for long periods of time c Fill the fue
33. llow the level to go below the oo 3 Always add the same viscosity of oil as is already in the crankcase L Using the oil recommended above change the engine oil and filter after the first 50 hours of operation the first 100 hours and every 250 hours thereafter During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes first Change oil at any seasonal change in temperature when a new viscosity of oil is required a Run engine 5 minutes to warm up oil shut off engine b Remove plug from outlet in base frame Screw in owner supplied drain hose c Open valve at oil pan outlet After oil has been drained into suitable container close valve remove drain hose and replace plug in base frame outlet d Refill engine with recommended oil e Crank engine for 30 seconds without letting engine start This will ensure lubrication of engine components before engine starts f Start engine and check for leaks Stop engine and check oil level after 10 minutes Engine Lube Oil Capacity M175C2 30 1 qts 28 5 liters SP3 CHANGING OIL FILTER Change the lube oil filter every 250 hours Use a filter wrench to remove old filter Dispose of filter in approved manner Make sure the gasket from the old filter is removed and discarded Lubricate the rubber gasket on the new filter and screw it on nipple until gasket meet the sealing surface Using hands only no wrenc
34. lows coolant to enter the combustion chamber Engine failure or other serious damage will result A Cylinder Liner Walls B Engine Coolant C Vapor Bubbles Figure 19 4 Unprotected engines with low quality water as coolant can have liner failure in as few as 500 hours WATER QUALITY 1 Distilled deionized soft water is preferred for use in cooling systems Bottled distilled water from a food store or water supplier is recommended Tap water often has a high mineral content Tap water should NEVER be put in a cooling system unless first tested by a water quality laboratory Do not use water made by the reverse osmosis method unless it has been PH neutralized 2 Here are acceptable water quality specifications Parts Grains Contaminates per Million per Gallon Maximum Chlorides 40 2 5 Maximum Sulfates 100 5 9 Maximum Dissolved Solids 340 20 0 Maximum Total Hardness 170 10 0 PH Level 5 5 to 9 0 OM175C2 04 05 19 3 If chlorides sulfates or total dissolved solids are higher than the above given specification the water must be distilled demineralized or deionized before it is used in a cooling system If total hardness is higher than 170 ppm and all other parameters are within the given specifications the water must be softened before it is used to make coolant solution EGC ETHYLENE GLYCOL CONCENTRATE ANTIFREEZE A CAUTION EGC Antifreeze is flammable Keep it away fro
35. m any open flame Avoid contact with eyes Avoid contact with skin Do not take internally In case of contact immediately wash skin with soap and water For eyes flush with large amounts of water for at least 15 minutes Call a physician KEEP OUT OF REACH OF CHILDREN Follow all warnings on the container Ethylene glycol coolant concentrate is commonly mixed with water to produce an engine coolant with a low freeze point and high boiling point A low silicate form of ethylene glycol coolant is recommended for all diesel engines Use an ethylene glycol coolant concentrate meeting ASTM D 4985P SAEJ1941 General Motors Performance Specification GM1899M or formulated to GM6038M This product is concentrated and should be mixed to the following specification If additional coolant solution needs to be added to the engine due to leaks or loss the glycol concentration should be checked with a hydrometer to assure that the desired freeze point is maintained Distilled EGC Freeze Boiling Water Antifreeze Point Point en se o E 57 TE Maximum 40 60 EE E IMPORTANT 1 DO NOT use methyl alcohol or methoxy propanol base EGC These concentrates are not compatible with chemicals used in supplemental coolant additives Damage can occur to rubber seals on cylinder liners which are in contact with coolant DO NOT use an EGC containing sealer or stop leak additives DO NOT use EGC containing more than 0 1 anh
36. mary amp RE506428 Secondary 5 f Turn on the fuel 3 To check the vibration damper radial runout place the dial indicator touching the outer diameter of the damper Fig 14 For dual dampers check the runout on the inner damper only Fig 15 Make sure the engine is at operating temperature then rotate the crankshaft using the JD820 Fly wheel turning tool If the runout reading exceeds the below specifica tion replace the vibration damper SP 7 CHECKING CRANKSHAFT DAMPER Vibration Damper Maximum Radial Punout eee 1 02 mm 0 040 in Note Always replace two dampers as a set on units RG7065 equipped with dual dampers b 1 Remove belts 2 Try to turn the vibration damper in both directions while grasping it with both hands If rotation can be felt the damper is defective and should be replaced Reproduced by permission of Deere amp Company c2004 Deere amp Company All rights reserved Fig 14 Position of dial for single damper ES N E v D Reproduced by permission of Deere amp Company c2005 Deere amp Company All rights reserved Single Damper Fig 12 Reproduced by permission of Deere amp Company c2004 Deere amp Company All rights reserved Fig 15 Position of dial for dual damper Ra t gt O Ei Reproduced by permission of Deere amp Company c2005 Deere amp Company All rights reserved Dual Damper Fig 13 Note The vibration damer assem
37. ne specifications for correct pressure COOLING REQUIREMENTS 1 To meet cooling system protection requirements the coolant solution must consist of a Quality water b Ethylene glycol concentrate EGC commonly known as antifreeze c Supplemental coolant additives SCA s 2 A coolant solution of ethylene glycol concentrate EGC antifreeze quality water and supplemental coolant additives SCA s MUST be used YEAR ROUND to protect against freezing boil over liner erosion or pitting and to provide a stable noncorro sive environment for cooling system components 3 Ethylene glycol coolant concentrate antifreeze normally DOES NOT contain the SCA chemical inhibitors needed to control liner pitting or erosion rust scale and acidity LINER EROSION PITTING 1 Cylinder liner walls Fig 19 A which are in contact with engine coolant 19 B can be eroded or pitted unless the proper concentration and type of SCA s are present in the coolant Water pump impellers are also susceptible to pitting 2 Vapor bubbles Fig 19 C are formed when the piston s impact causes the liner walls to vibrate sending pressure waves into the coolant 3 These tiny vapor bubbles collect on the surface of metal parts As the bubbles collapse pop a microscopic piece of metal is eroded from the metal part Over a period of time this pitting may progress completely through the cylinder liner of a wet sleeve heavy duty diesel engine This al
38. nnot be moved and become amplified when not corrected during to a repair facility Marine engines cannot be compared routine maintenance to the servicing of automobiles trucks or even farm equipment Failures often occur in remote areas far As operator it is your obligation to learn about your from competent assistance Marine engines are taxed equipment and its proper maintenance This is not a far more severely than auto or truck engines therefore comprehensive technical service manual Nor will it maintenance schedules must be adhered to more make the reader into an expert mechanic Its aim is to strictly aid you in maintaining your unit properly Model Numbers Model numbers give the unit s application block model aspiration and RPM M 175 Model b M Northern Lights marine generator set 4 6 imate ge Northern Lights turbocharged 1800 RPM marine diesel M175C2 generator set with a John Deere 6081 Tier II engine block two valve with high pressure common rail Serial Number Plates When referencing Alaska Diesel Electric equipment by serial number please refer only to the number stamped on the Northern Lights serial number plate Serial No Model No aN ALASKA DIESEL ELECTRIC Inc we 4420 14TH AVE NW SEATTLE WAU S A NORTHERN LIGHTS Alaska Diesel Electric 4420 14th Ave N W a o Generator Set Data o Set Serial No o Set Model No o OM175C2 04 05
39. r Coolant in combustion chamber cylinder head gasket failure or cracked cylinder head e See dealer repair or replace Abnormal Engine Noise Main or connecting rod bearings worn e Check bearing clearance See your dealer Crankshaft end play excessive e Check end play See your dealer Main bearing caps loose e Check bearing clearances replace bearings and screws as needed See your dealer Connecting rod bushings and piston pins worn e Inspect the rod bushings and piston pins See your dealer Scored pistons e Check pistons See dealer Excessive backlash or worn timing gears e Check timing gear backlash See dealer Valve clearance excessive e Check and adjust valve clearance See dealer Camshaft lobes worn e Inspect camshaft See dealer Rocker arm shafts possibly worn e Check rocker arm shafts See dealer Turbocharger noise e Check turbocharger Repair or replace Engine not lubricated properly e Check oil and filter If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer OM175C2 04 05 DEOLS A SULI o E Be x aI ZL PUE P HAY O97XS LON AYIM Y YO 3dVL 131419773 ONISN XIS avd ALVIOSI O9kyG
40. s SP5 Check V belt condition SP31 Adjust variable speed droop SERVICE 2000 POINT_ PAGE OPERATION DAILY Hours ENGINE SP1 15 Check oil level e e SP2 15 Change engine oil 1 2 J J L SP3 15 Change lube oil filters 1 2 e e SP4 15 Check air cleaner valve 2 4 6 SP5 Check belt condition 2 e SP6 16 Check valve clearances 2 Oo SP7 17 Check crankshaft vibration damper 7 SP25 Check engine mounts DI SP27 Check air intake hoses a SP30 Check engine speeds FUEL SYSTEM SP8 17 Check primary filter Racor 3 L SP9 17 Change primary filter element Racor 3 4 SP10 17 Change secondary fuel filter 2 4 e SP11 Check injectors e SP12 Check fuel injection pump a TURBOCHARGER SP13 Check air oil amp cooling water lines for leakage SP14 Check boost pressure COOLING SYSTEM SP15 25 Check cooling water level e SP16 25 Check cooling system flush 2000 hrs 2 e e SP17 25 Check and clean heat exchanger 2 J SP18 Check and clean gear oil cooler 2 e SP19 25 26 Check zinc electrodes 2 4 e SP20 26 Change impeller in raw water pump 2 4 O ELECTRICAL SYSTEM SP21 27 Check electrolyte level in batteries 2 4 e SP22 27 Check condition of batteries with hydrometer 2 J SP23 Test thermostats l SP29 Check electrical ground connection O 1 Change the oil and filter before the first 100 hours of operation during engine 5 Operate engine at rated speed wit
41. sediment close that drain to avoid burns Allow the engine to cool before When all drains are closed flushing is complete working on the cooling system Open the filler Install thermostats with new gaskets cap carefully using protective clothing when the 7 Fill the fresh water system by pouring the engine is warm recommended coolant mixture as described in previous sections 1 Check the coolant level each day before starting the 8 Close cooling system air vent on turbocharger engine Loosen temperature sending unit fitting in cylinder head or plug in thermostat housing to allow air to escape Retighten fitting and plug when all air is expelled Open the seacock Start the engine Check hoses and connections and repair any leakage Run engine until it reaches operating temperature to mix solutions through the entire system 2 Remove the pressure cap from the expansion tank and check water level In order to give the coolant an opportunity to expand the level should be about 1 3 4 in 4 5 cm below the filler cap sealing surface 9 when the engine is cold When filling with coolant 10 the venting cock on top of the turbocharger for engines fitted with turbocharger should be opened to ensure that no air pockets form in the cooling system 2 The pressure valve in the filler cap releases when the SP16 HEAT EXCHANGER CLEANING pressure is approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it
42. t negative terminal of booster battery to ground on the engine block away from battery see Fig 20 Note Always use 12 volt booster battery for 12 volt electrial systems and 24 Ao volt booster batteries for 24 volt electrical systems 5 Remove booster battery after starting engine disconnecting the negative cable first 6 Sealed batteries see manufacturer charging and booster instructions SP16 17 BATTERY CARE LEAD ACID TYPE BATTERIES A CAUTION Sulfuric Acid in battery is poisonous can burn skin and holes in clothing Fill batteries in well ventilated areas wearing eye protection and rubber gloves OM175C2 04 05 23 Loose or corroded connections e Clean and tighten battery connections Sulfated or worn out batteries e Check specific gravity of each battery cell e Check electrolyte level of each battery cell Loose or defective alternator belt e Adjust belt tension e Replace belt Starter Inoperative Engine drivelines engaged e Disengage Faulty start circuit relay or blown fuse e See dealer replace fuse Loose or corroded connections e Clean and tighten loose battery and harness plug connection Low battery output e Check specific gravity of each battery cell e Check electrolyte level of each battery cell Defective electrical system ground wire e Repair or replace Starter amp Hour Meter work but rest of Electri cal System does not Blown fuse on magnetic switch
43. uising World Class Kits are for world cruising and trans ocean cruising We consider these minimum quantities Your vessel s operating conditions may require more of a given part Consult your dealer World Item Description Standard Class Lube Oil Filter Air Filter Element Fuel Filter Injector Thermostat Thermostat Ring 8 Valve Cover Gasket 1 2 Raw Water Pump Cover Gasket Raw Water Pump Set of Alternator Belts Fuel Washer Kit Std 1 wie 1 Heat exchanger cooled engines only OM175C2 03 05 28
44. w oil level e Fill crankcase to proper level Improper type of oil e Drain and fill crankcase with correct oil Partially plugged oil filter e Replace filter Excessive main or connecting rod bearing clearance e Determine bearing clearance See dealer High Oil Consumption Break in period e Oil consumption decreases after break in Crankcase oil too light e Use proper viscosity oil Oil leaks e Check for leaks in lines around gaskets and drain plug Crankshaft oil seals possibly faulty e Replace seals See dealer Cylinder liners or pistons worn or scored e Inspect and replace if needed See dealer Worn valve guides or stems e Inspect and measure replace if needed See dealer Engine Emits Black or Gray Exhaust Smoke Clogged or dirty air cleaner e Service air cleaner Defective muffler back pressure too high e Have dealer check back pressure Engine overloaded e Reduce load Improper fuel e Use correct fuel for temperature Troubleshooting Injection nozzles dirty e See your dealer Turbocharger not functioning e See dealer Engine out of time e See your dealer Electronic Control Unit problem e See qualified dealer Engine Emits White Smoke Improper fuel e Use correct fuel for temperature Cold engine e Warm up engine to normal operating temperature Defective thermostat e Remove and check thermostat Engine out of time e See your dealer Engine compression too low e See deale
45. ydrous metasilicate This type of concentrate which is intended for use in aluminum engines may cause a gel like deposit to form that reduces heat transfer and coolant flow Check container label or consult with supplier SUPPLEMENTAL COOLANT ADDITIVE SCA A CAUTION Supplemental coolant additive contains alkali Avoid contact with eyes Avoid contact with skin Do not take internally In case of contact immediately wash skin with soap and water For eyes flush with large amounts of water for at least 15 minutes Call a physician KEEP OUT OF REACH OF CHILDREN Follow all warnings on the container Important heat exchanger cooled engines Additional SCA s should NOT be added to the mixture of EGC H 0 on initial fill up of engines with a coolant conditioner filter A high SCA concentration will result and can cause silicate dropout When this happens a gel type deposit is created in the cooling system which retards heat transfer and coolant flow If additional SCA s are needed prepare a mixture of 50 quality water and 50 EGC antifreeze Add liquid SCA at a rate of 3 by volume Example 30 mL of SCA per liter of HO EGC mixture 1 0 fl oz of SCA per qt of H O EGC Add the resulting mixture to the cooling system in quart increments Run the engine for 2 hours and retest the coolant Continue process until SCA concentration meets recommended levels SCA is available from your Northern Lights dealer in the following sizes
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