Home

O6125 - Northern Lights

Contents

1. a at A s Bel proe ce O A 83 Emsa ue I i EUN SOLO3NNOO Roc E B a ae XX T3NVd ANYTIXON FN TUE E E i PR S190 390v K nmz Cr ooo 7 777 WORTEN CU II S L5 LLL Lc ccscs ouem AA T pd NE LC Nya VINON NOUO 1 a PARE N ARS 1 s E a SE mace EMEN o i lt TINVO xy T 9 i amp sampna n 1 TWNOILdO 1 AL 2 3 n ame Ec f OF 0 poss ems 8 10m E o i MEME D a nd i a o oo Hal A ee s pde d l gp i 9Nd JYIN d Por 1 4396770 1 OMA DNIH 9nd OYIN and o3 JWA MOVIE poea we tg HB c 3wWaii 30Nvuo AVN 39NvMO TWA via Do aem n E7777 ME WO dg j 1 S3NOISNO AB SNOILOJNNOO N3HIO TIV CUM GPT o vga LINGNOD Q31070ANO2 v 1 HLM NJAO SYNSOTONA TANYA TOMINOS LR DE Lodi D we WON4 SIHINI N331H9I3 AT31VAIXOMdV ON3IX3 Ol SOV31 LIMOYID dv 9 h P E ugs mM f O3TWISNI 33V K sanr i SYJI0ON3IS NOLVIS WAG Q3JX30Y0 SI TANVd 390IX8A13 IVNOlIdO J G p Be 0393030 SI 13NYd XOV TWNOILdGO N3HM AINO G3TIVISNI 38V 1 dE dd SSS tora prada dh HE 31ANOJONY3HL ANY SH3JON3S IYNSSIYA WO HVID ANY OTOAINVA NIV y Fae A a II o FS 4 1 ama K wewer 2 A OWN WONJ 9 38 Ol HL9NZ1 ONIBDL NIBHS 1V3H HLIM 0333A02 e dus VERD ATIVACIAION 38 Ol 33V 03SN NIZA LON SSOIOnONOO SS3NMVH Tlv F SETE IN i INIOd NOILO3NNOO HOV3 1v ESE SR E MON d M3xNVA 3MIM AG O3IJILN3Q 38 ISNAN ANY A3Y9 38 OL 38V Ime
2. 20 00005 SP14 CHECKING COOLANT LEVEL CAUTION The cooling water in the engine A 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 1 Check the coolant level each day before starting the engine Check the coolant level by remov ing the pressure cap from the expansion tank 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 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 2 The pressure valve in the filler cap releases when the pressure is approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it is faulty 4 The makeup coolant added to compensate for loss or leaks must meet engine coolant require ments outlined in previous section SPIS FLUSHING THE COOLING SYSTEM 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 IMPORTANT Be su
3. jane ao Sm t nil e 4 Dus E eA ua NS sana IYIN AE af g Naren gt Seat sap 80 NOION UILIS DONE ea vg 1 Owe 5 JS E ane ed 20078 NINA arar avs E Avus a MU xn Gd i 1 Naand HOLIAS ADLYRISEN NOAD T VRE rare g 5 jdiS H2y3 14 G 3NIOI qn Ol ET s Ul je Ln TOXLNOD 3NI9N3 OL HLONST XVN 328y5 00 vi Uu LE 1 1 Ann RR yoy 7 SS Y soie Morao SSINUYH NOISN3LG die AMO HOVI EE ahy wed MUTA T TANVd lOMINOO NIVA igi 3919 O6125 03 03 31 Vorrr O jeg UdH IUEN 10 pUNOID prepuejs OA ZI WeIseIG Suny eurgugq Od er e Tasar TAY Sar 8 777 a 1 I Avia I NAY NWS E A E li E i A a sore Sf e OF TAS RA OO aa i car ur E T if VF post NGL rj vs QTaHSQNnOS El IHSON T SN v ATE YOON SNUAVIS aozi art narum 217 Tana Ug n wer weer 4108 vgOZ 033s aa T ure 17 URINE ad 1 INIO4 LAIA L ESL Osaa y NOILDINNO HOV3 IV AGNEW YIENAN AB OJAULNIA 38 SAN ONY A32 oec occi oe ger SH RUD DEDE 38 O1 38V SYOLIMONOI O3TIVISNI XO V Tiv 03009 30100 SSIINN Z Em et EU LA na dx Q310N Sv ONY aivd OJOTIHS O3LSIML 1d32X3 2vA009 ONVYISILINN p Ond 005 ESE 1 DOS guo year T 99 60 MIN 3dAL vi OMY 38 OL SHOLINONDI NOLVTIVIENI TW l zu nan i mas T 2H Tum Lent Dus 1 EIUN dene Hu oT NM SL A L MeZ NS a VE 3 ime T Sowas HOUMS 03345 WNO SSvdA8 ES NMOQLNHS je ae J A N San d a nA di8 aera ADE AN E IAs 4 HE E 3 thane 13 i Tia PED
4. Keep it away from 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 SUPPLEMENTAL COOLANT ADDITIVE SCA 1 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 Your engine is equipped with a spin on coolant filter conditioner element which provides the SCA s to protect your cylinder liners The inner element releases chemicals into the coolant to maintain a proper acid alkaline balance inhibit corrosion and suppress erosion pitting Important All engines ALWAYS change the coolant conditioner filter element according to the service chart in this manual Important Radiator and 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 syste
5. The oil level must be in the waffled area between the L and H Never allow the level to go below the L 2 Always add the same viscosity of oil as is already in the crankcase See above recom mendations SP2 OIL CHANGES 1 Using the oil recommended in the above dia gram change the engine oil and filter after the first 50 hours of operation the first 100 hours of operation and every 250 hours thereafter 2 During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes first 3 Change oil at any seasonal change in tempera ture when a new viscosity of oil is required 4 Change oil when engine is warm 5 Dispose of waste oil in an approved manner 6 Propulsion Engines with Optional Drain Pump a Your engine is fitted with a hand pump that drains the engine crankcase and marine gear b Usea wrench to turn the selector valve to drain the engine or gear Use marks on the valve stem as a guide See below c Turn pump handle in clockwise direction and pump oil into a suitable container When the engine is empty switch the valve and drain the gear oil d Close valve Refill engine and gear with recommended oils NOTE Make sure the valve is in the closed position before starting engine If it is left open it is possible for crankcase oil to be pumped into the reverse gear and out of the gear dipstick and breather This can ruin the engine To Drain Cran
6. Use the Trouble Shooting Guide on page 26 to isolate the cause of the overheat CAUTION Do not remove the water fill A cap of an overheated engine Escaping high temperature steam can cause severe burns c Allow the engine to cool and then remove the cap slowly using protective clothing d Make repairs and restart after the temperature gauge registers below 180 F 82 C e Watch the temperature gauge regularly and turn off the unit if the temperature rises above 205 F 96 C Repeat the troubleshooting process If the warning or 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 c If the oil level is normal DO NOT restart the engine Call your Northern Lights or Lugger dealer for assistance BREAK IN PERIOD 1 2 The first 100 hours on a new or reconditioned engine 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 o
7. WHOM wawy e PL LR Save 2 Laien Y zw waa Sn MONA MEUS pec Le SHN WWI L SHT 39v SIHA 39nvo El inl g H H a v Poe V V Rf A its nnn aceite laa 1 1 1 ee 1 Bl dr ii We aa oa e r 1H9N Naviv e RO 6 assi is A La TINVO IVOINVHO3A WNO DO lor o I 15 P Lo pci o b y Bn a E O A r a TNV XIN IVNOILO qa ls ee eee ean U a rar mary l CINEOL on 1 1 D 9nd DHIN 9nd IYIN 9nd IMAN Ond NIN bui i TIVA 30NV8O TIVA 39NVIO TVW vovg IVA HOVE o CE wu elo olpete dedos 1 r LE PaL f 4057 0 1 1 i 5 e he 2909 1 NOILVNINYSL JHM VIS Ol 10H Loa M TUN OY T anal INNA i N3HM QN3 HONId ONIBNL ANIYHS 1V3H HIIM Q3ddv3 ONY Sd JYIN p cL c WONi 9 XONdV 112 38 Ol 3sv SHOLONONOD SSINEVH G3SANN Ty G8 tA 0 acm OMA Y pg AISA SI T3Nvd 390048414 TVNOUdO JI Q3TIVISNI S430N3S TVhO v ER E Ysg gs i YINQLSNI A8 SNOIIO3NNOO YIHLO TV IInONOO Q3 1ONOO a AA T Taa e LST T QUO sa 3anSSasa 10 v l HIM MJAO3 38NSOTONI i13NVd 1031N02 NONI S3HONI was unis pog Sx i N331H9I3 ATILVNIXONdY ONJIX3 OL SOVJI LINDYIO dAVI S ENTUM NUNMENE eget A INIOS NOILO3NNO3 H2V3 LV 1 ho lo i M3MNVA IMM AB O3ISILNIOL 38 ISNW ONY A389 38 Ol 38V pO CE SYOLONONOD OITIVISNI 3 O v Tiv 03009 YOTOD SSN ZO AER TI ae RIN l gw auro i709 Q31ON Sv 1d32X3 ONVMISILIQDW 2vAO009 rro dodo SENIL i y MUN JdAl v1 SMV 38 OL SYOLONGNGD NOLVIIVISNI TIY L a aHan 1 I AE yeg 1 T x TOU f SALON A a e 3 sun
8. hours The SCA s released by the filter will significantly reduce erosion and pitting The chemicals in the additives reduce the quantity of vapor bubbles It also forms a protective film on the metal engine parts which act as a barrier against collapsing vapor bubbles 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 recom mended 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 by the reverse osmosis method unless it has been PH neutralized 2 Here are acceptable water quality specifications Contaminates Parts Per Grains Per Million Gallon Maximum Chlorides 40 2 5 Maximum Sulfates 100 5 9 Max Dissolved Solids 340 20 Max Total Hardness 170 10 PH level 5 5 to 9 0 If chlorides sulfates or total dissolved solids are higher than the above given specification the water must be distilled demineralized or deion ized before it is used in a cooling system If total hardness is higher than 170 ppm and all other parameters are within the given specifica tions the water must be softened before it is used to make coolant solution O6125 03 03 20 SERVICING ETHYLENE GLYCOL CONCENTRATE EGC ANTIFREEZE 1 Ethylene glycol coolant concentrate is commonly mixed with w
9. will lower engine output and may cause black exhaust smoke and soot Listen along air line while engine is running A whistling or hissing sound indicates leakage Leakage on the pressure side between turbo and engine can be found by applying soapy water to the air line Tighten the hose clamps replace hose or gas kets as required 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 750 hours Your engine can have a boost gauge perma nently installed so you can monitor the turbo s output from the control panel See page 6 06125 03 03 19 SERVICING COOLING REQUIREMENTS 1 To meet cooling system protection requirements the coolant solution must consist of a Quality water b Ethylene glycol concentrate EGC com monly known as antifreeze c Supplemental coolant additives SCA s 2 Acoolant solution of ethylene glycol concentrate EGC antifreeze quality water and supplemen tal coolant additives SCA s MUST be used YEAR ROUND to protect against freezing boil over liner erosion or pitting and to provide a stable noncorrosive environment for cooling system components 3 Ethylene glycol coolant concentrate anti freeze normally DOES NOT contain the SCA chemical inhibitors needed to control liner pitting
10. 10 15 208 Figure 12 Pointer and Crankshaft Damper are closed b Rotate crankshaft in counter clockwise d Confirm that the stamped line a on the direction 30 40 1 8 turn to remove gear injection pump is aligned with the stamped lash line b on the coupling c Align the injection timing stamp line to e Ifthe stamped lines are out of alignment data plate specification on No 1 cylinder loosen nuts and align the stamped lines by on the crankshaft damper with the pointer by shifting the coupling and re tightening the slowly rotating the crankshaft in the clock nuts to 43 46 foot Ibs torque 5 8 6 2 kgm wise direction see Fig 12 Figure 11 Injection Pump Servicing Points 1 Injection line clamps 4 Lubrication line inlet 7 Pump mounting bolts 10 Hand priming pump 2 Fuel injection line 5 Lubrication line outlet 8 No 1 delivery line 11 Air vent point 3 Fuel feed line 6 Fuel return line 9 Electric Governor opt O6125 03 03 18 SERVICING 2 Delivery Valve Method Use delivery valve method when a repaired or replaced injection pump is installed a Disconnect fuel injection line from the No 1 cylinder delivery valve on the injection pump see Fig 11 8 b Remove delivery valve holder Remove spring and delivery valve and put valve holder back in injection pump c Place the throttle Fig 11 9 in the full fuel forward position d Slowly rotate the crankshaft
11. Electric Inc It may not be reproduced in whole or part without the written permission of Alaska Diesel Electric Inc Alaska Diesel Electric Inc All rights reserved Litho USA Publication number 06125 03 03 06125 03 03 E INTRODUCTION 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 equip ment 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 usu ally begin with minor problems that become amplified when not corrected during routine maintenance As owner operator it is your obligation to learn about your equipment and its proper maintenance This manual is not a comprehen sive technical service manual Nor will it make the reader into an expert mechanic Its aim is to aid you in maintaining and servicing your equipment properly UNIT IDENTIFICATION MODEL NUMBER L M NL L Lugger marine propulsion engine M Northern Lights marine generator set NL Northern Lights industrial generator set Examples Lugger turbocharged aftercooled marine propulsion ee engine Komatsu 6125 block M6125T Northern Lights turbocharged 1800 or 1500 RPM m
12. changing the element Do not run the engine with the air cleaner removed SP5 V BELTS 1 Check the tension and wear on the V belts 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 belts can be depressed about 3 8 in 10 mm 3 Belts that operate in pairs should both be replaced in pairs even if only one of them needs to be replaced SP6 VALVE CLEARANCES 1 Check the valve clearances after the first 100 hours and every 750 hours thereafter 2 Shut off fuel supply Turn off battery switch 3 Remove fuel return line from top of injectors Loosen fuel injection lines from the injection pump and injectors and lay them out of the way Remove valve covers which are held by four bolts Use a 10 mm 12 point socket 4 Use a breaker bar with a 24 mm or 15 16 socket on one of the bolts holding the crankshaft pulley to rotate the crankshaft in a clockwise direction Align the 1 6 TOP mark on the vibration damper with the pointer In this position No 1 cylinder is at top dead center of the compression stroke and No 6 cylinder s intake valves will start to move see figure 8 5 Adjust the valve clearance for valves marked with an X in Fig 9 rip tdt 310P 10 15 20 Figure 8 Timing Mark Cylinder No 1 2 3 4 5 6 Intake Valve X X O X O O Exhaus
13. condition v Lack of engine power Engine overloaded Reduce 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 See your local dealer Dirty or faulty injection nozzles See your local dealer O6125 03 03 28 TROUBLESHOOTING CONT v Lack of engine power cont Injection pump out of time See your local dealer Improper propeller Consult your dealer and prop chart Grass etc on bottom of boat Clean hull Turbocharger malfunction Stop the engine Remove the air cleaner Make sure the compressor wheel is stationary and then rotate it with your hand to see whether it is stiff to rotate First rotate the wheel under light pressure then by lightly pulling axially If the wheel is stiff to rotate blades are damaged or blades hit housing the turbocharger should be replaced as soon as possible v Engine overheats Engine overloaded Reduce load generator sets Check propeller size propulsion Low coolant level Fill tank to proper level Check hoses for loose connections and le
14. driim Duty ciones 9 272 BTU min Continuous Duty eese 7 680 BTU min Cooling Heat Exchanger Raw water intake diameter 2 in 51 mm Raw water discharge diameter 3in 75 mm Raw water pump flow at rated speed High output sees 74 US gpm 310 Ipm Medium Duty serseri 74 US gpm 310 Ipm Continuous Duty 68 US gpm 257 Ipm Raw water pump maximum suction head 39 in 1 m Maximum raw water temperature at inlet 85 F 30 C Freshwater system capacity eng only 8 5 US gal 32 ltr Cooling Keel Cooled Water hose inside diameter 2 7 8 in 73 mm Keel cooler head diameter 2 5 in NPT Turbo tube length High Output 64 ft 19 5 m Medium Duty as eere riter tree oes 56 ft 17 m Continuous DULY eere eerte 48 ft 14 6 m Skin cooler aluminum High Output 69 ft 6 4 m Medium Duty teer 60 ft 5 7 n Continuous Duty ooocooccocccocconcconcnncnnncnnonos 50 ft 4 7 n Skin cooler steel High Output 230 f 21 4 m Medium D ty inicia 200 ft 19 m Continuous Duty sese 162 f 15 m Note DC Electrical VONAGE rc 12 volt standard 24 volt optional Minimum battery capacity 200 amp hrs 800 cca Battery cable size oooonocnncnncnnccnnonncnnnnss 00 up to 10 ft ru
15. have the same pump voltage rating 4 Check freshwater antifreeze mixture If refilling 3 First connect positive terminal of booster run the engine up to operating temperature to battery to positive terminal of main battery circulate the antifreeze Then connect negative terminal of booster 5 Fill fuel tank and add biocide as per manufactur battery to ground on the engine block See Fig er s instructions 14 6 Seal air cleaner inlet exhaust opening crankcase breather pipe and fuel tank vent with plastic bags and tape 7 Change the crankcase oil and filter Loosen drive belts 9 Disconnect and clean battery Remove to warm storage place if possible 10 Clean outside of unit Paint any scratched or chipped surfaces Put corrosion preventative on all exposed metal surfaces 99 Battery Booster Battery Figure 14 Booster Battery Connections 4 Remove booster battery after starting engine 5 Sealed batteries see manufacturer charging and booster instruction SP24 25 BATTERY CARE 1 Check electrolyte level every 50 hours or weekly Add distilled water to manufacturer s recommended level 2 Batteries cables and cable terminals should be checked and cleaned every 100 hours Clean O6125 03 03 24 THREE BLADED PROPELLER SIZING CHART Use this chart to find aproximate propeller sizes for boats with a single engine using a three blade propeller and gears with a 3 loss facto
16. in ON position while the engine is running STOP BUTTON Hold down until engine is completely stopped INSTRUMENT LIGHTING DIMMER ZEN 3 7 4 2 10 1I 12 13 14 Adjust instrument panel lights On some panels this is an on off switch and not a dimmer WARNING LIGHTS a Light comes on when oil pressure is too low b Light comes on when engine is too hot ALARM HORN Will sound in case of overheating or low oil pressure Stop engine and investigate Remember horn will sound when key is in ON position with engine stopped because there is no oil pres sure START BUTTON Will start engine only if key on main panel is in ON position EXHAUST TEMPER ATURE Maximum temperature 975 F 510 C TURBO BOOST GAUGE See page 17 for boost range GEAR PRESSURE Figure 5 GAUGE e Auxilliary Panel See Gear Manual for operating range Figure 4 Flybridge Panel O6125 03 03 8 CONTROL PANELS Northern Lights Generator Sets SERIES 3 GENERATOR CONTROL PANEL ENGINE HOURS Figure 6 SERIES 4 GENERATOR CONTROL PANEL Series 4 Generator Set Control Panel Figure 7 1 SHUTDOWN BYPASS PREHEAT SWITCH Two functions are built into this switch The preheating of the engine and bypassing of the engine safety shutdown circuit enabling a quicker start Hold switch in up position 10 20 seconds before starting en
17. in a clockwise direction while operating the priming pump Fig 11 10 This is best done by two people e Stop rotating and pumping when fuel stops flowing out of the delivery valve holder Fig 11 8 f Ifthe injection timing stamp line on the crankshaft damper is aligned with the pin corresponding to the data tag specification it should be correct see Fig 12 1 Ifthe injection timing line has passed the pointer the timing is retarded 2 If the injection timing line has not reached the pointer the timing is advanced g To adjust timing rotate the crankshaft 30 40 1 8 turn in counter clockwise direc tion from No 1 cylinder top dead center to remove gear lash h Align the injection timing line on the damper with the pointer by slowly rotating the crank shaft in the clockwise direction i Loosen two nuts on the coupling Rotate the coupling on the pump side little by little while operating the priming pump see Fig 11 10 until no fuel flows out of the delivery valve holder Fig 11 8 j Tighten two nuts Now re check the injec tion timing to see it is properly adjusted by repeating steps d through g k Ifline b on coupling does not align with the line a on the pump re stamp coupling with new line l Reassemble the delivery valve and reinstall fuel lines see Fig 11 2 and clamps Fig 11 1 Bleed fuel system SP12 TURBOCHARGER 1 Check for air leaks every 250 hours Air leakage
18. intersect for an approxmate propeller size See the column bottom for shaft RPM and shaft diameter Example 460 HP rating 20 knot boat with 2 1 gear needs a 30 x 29 three blade propeller 2 1 30x18 30x20 30x23 30x26 30x29 30x32 30x34 30x36 30x38 30x40 1150 2 25 2 5 1 34x21 34x24 34x27 34x30 34x33 34x37 920 2 5 4 1 46x25 46x30 46x34 46x40 525 4 06125 03 03 25 2 5 1 35x22 35x24 35x28 35x32 35x36 35x39 3 1 38x24 38x30 38x33 38x36 38x40 766 3 0 4 5 1 50x28 50x32 50x38 50x44 466 4 5 3 1 38x28 38x32 38x36 38x40 38x44 3 5 1 42x30 42x34 42x38 42x42 657 3 5 5 1 53x30 53x35 53x40 420 4 5 3 511 44x32 44x36 44x42 6 1 58x34 58x40 58x48 LUGGER DATA Displacement cscssccsscscsscssssscseeees 674 in 11 liters Bore x Stroke 4 92 in 125 mm x 5 91 in 150 mm High Output 460HP 2300RPM Medium Duty 425HP 2300RPM Continuous Duty esee 325HP 2100RPM Approximate dry weight Keel cooled less gear 2400 lbs 1090 kg Heat exchanger cooling less gear 2450 lbs 1115 kg Cooling General Freshwater circulating flow at rated speed High Output 101 US gpm 382 Ipm Medium Duty esses 98 US gpm 371 Ipm Continuous Duty 94 US gpm 355 Ipm Heat rejection to jacket water High Output o ii 10 540 BTU min Me
19. 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 Hill the fuel tank at the end of each day s operation This will reduce conden sation SP7 9 FUEL FILTERS 1 Your engine or generator set should have a primary fuel filter installed We recommend the Racor brand of fuel filter water separators a Check the primary fuel filter daily as recom mended by the filter manufacturer Empty the collection bowl as necessary Change the element every 250 hours or when necessary If the bowl fills with water change the pri mary and secondary element immediately 2 Change secondary fuel filter every 750 hours a Remove the filter cartridge by turning it counterclockwise with a filter wrench Fill the new cartridge with fuel and install it after applying engine oil to gasket surface Screw on until the gasket surface comes into contact with sealing surface of filter base Then tighten it two thirds of a turn by hand A BLEEDING THE FUEL SYSTEM CAUTION Escaping diesel fuel under pressure can penetrate the skin causing serious personal injury Bef
20. optional SAE 4 8 or 10 SAE 3 11 5 Max operating angle Any direction 35 for less than 2 minutes Max installed operating angle 10 rear down 0 front down Based on 70 F 21 C seawater temperature and minimum boat speed of 8 knots at full rpm Return water 120 165 F 50 75 C 06125 03 03 26 NORTHERN LIGHTS MARINE SPECIFICATIONS Model Number M6125A M6125T AC Output 1800 RPM 60 Hz 240 kW 185 kW Phase Optional Phase 3 3 1 RPM Hz Available in 1800 RPM 60 Hz and 1500 RPM 50 Hz Voltages 60 Hz 120 208 120 240 127 220 139 240 220 380 240 416 254 440 and 277 480 Voltages 50 Hz 110 190 110 220 115 230 120 208 127 220 220 380 240 416 Engine Aspiration Turbo AC Turbo AC Oylinders Inline 6 Inline 6 Displacement cu in I 674 11 674 11 Bore in mm 4 92 125 4 92 125 Stroke in mm 5 91 150 5 91 150 Specific Fuel Rate lb bhp hr 0 422 0 390 Fuel Rate Full Load gal hr 19 9 15 0 Model Number M6125QA M6125QT AC Output 1200 RPM 60 Hz 125 kW 105 kW Phase Optional Phase 3 1 3 1 Voltages 60 Hz 120 208 120 240 127 220 139 240 220 380 240 416 254 440 and 277 480 Engine Aspiration Turbo AC Turbo AC Cylinders Inline 6 Inline 6 Displacement cu in I 674 11 674 11 Bore in mm 4 92 125 4 92 125 Stroke in mm 5 91 150 5 91 150 Specific Fuel Rate Ib bhp hr 0 365 0 362 Fuel Rate Full Load gal hr 9 5 7 8 1 Prime kW rating 1 kW equals 1000
21. zno io 1 a 8E i oF oy po vA E any E m i SLN3N313 Wd qn I A OMINOO 39019481 14 IVNOILdO 1V3H38d mE NONN Za RE S oe EN J maawa 0 i t Gy ae ee Me z55 a0 A Q umsw wot M n ei cIM Dici bovis NOAR ST EN jane SS A nnn eo 000000 op RSE SER SRS lt 77 39NY 0 Y IVY LY By by SA y OYE Role Raro A Ea ssl O ac po AE zi Old IINA SIH z 2 12 E B POS NNOudO 8 lz 8 5 3 XN PS demi mmi ENT NTE NROBB 3UHK poet aa E E 1 re N3385 MN bid gag uem y 0 anz M i uu TANYA aw JONVEO bo ANTAS Ooo gv dS UN NMOUE 11H Ea o cT i CA SI A NANGUG 3LIHM PA 5 1 50 S T son rev 4 WIV gt 3018 3114 3enssas 10 i ER RS ros aema EN 367 SUR AVID Hams mota GRANADE 100 98 108 1 A389 31184 JigBnd 3H B3INM MVHTVNOLLJO rama O ES E 2 j f E E E OS Ay NOM E Hen YILIN NOH A AY Y suauo xg ian 1 20018 INANI o poe MYS Jays 48 0 0000 ALIS WLAN VNO SO T Medio TIT mea X78 OF E d RR r 310N 138 H2UIMS v z 1 OION3 0S JOS BOLONANDO Z vi e Tay isa F m co ana NYL ION3TOS JOLS o PAS Ny Sue TONS 3NiON3 1 TEA 09 0 1 NN dais vy 29 l EA x 14301 IYN Lor Seva ama Juon 29nva EN jaar we eae Enn v r AE ZI WI is a wa qim i 038 MOT134 NES PARE f unas BR UND TT a NL E Se LLZDv 22 ien ANUS a 2 aL 3NIN3 HOIVNH3ITIV TWNG LAG Yovig AvuS a Ya A oA 388 3mg i and beg 4 UY ES LO zT Sd 091 0 y Ayz Q33 MQTT34 wdiviiiriv aaa oif gt Lo
22. 2 15 Zinc 6 12 16 Drive Belt Raw Water Pump 0 2 17 Fuel Washer Kit 1 1 18 Raw Water Pump 0 1 19 Workshop Manual 0 1 20 Gasket Kit Top 0 1 21 Gasket Kit Bottom 0 1 Note Heat exchanger cooled engines only Note Double this quantity if engine is keel cooled O6125 03 03 34 NORTHERN LIGHTS 4420 14th Ave NW Seattle WA 98107 NORTHERN ORTA Tel 206 789 3880 1 800 762 0165 Fax 206 782 5455 FZ Northern Lights and Lugger are registered trademarks of Northern Lights Inc www northern lights com 2003 All rights reserved Litho USA
23. Far x T NOUS po ri er T mars Q310N Sv ONY aivd Q3QT3IHS OJISIML 1d32X3 IVADO9 1 o nah Del WIVIV 3d ONVULSILIAN 9 501 MIN 3dAL OMY 38 OL SHOI900NOO NOLVIWISNI TW poro 108 pum 033058340 TWNOILJO z E V aat aw loe OOD Na COR oT et BS S310N L OION31OS wava Lo de de Se 3onvouauws I T met Jsa BL a un E 960E SSE 19 Gii ssw BAN awviDO2 dm a EO m FOLWS S5y AE T J ud E 59 AE MOTTA E ze i SEZ Loc ID3JNNOISKO ned ce yy 7 Wt por fae 3 HO OZ E i e e o j a a a o e a e r ome L aDIVNH3LY WNOILJO Y B ZH nan E ZH nam BL ae ou 2a sz Tee ee ima 881 AM im e Ss i a EF TT uvis ol Lusi z TL HLSL 3NEON E O ERU dais Tam d CO pp SAY iivardNi Nm i o 1 Lea BONIS HAWS 03345 vWOlet x 3 Lun 1 1 ae RES 1 e m i SNTE OTI IS t WNOud vw y MUN NM M RU l M Cu WO OOO OOO Pen AA ee ee E Seg Ti oni oni 23 mt peser y UL E Sa CUORE A i x l vZv Ave m IA i AAi l i Te HUNT MATA 0000000000 7 PEF anon a e E gi Old WNOLSD i fe wig as em 1041N09 INON J I 118 M00 ou Ej nomas 03305 1 A i LI THATI 1 p INOM3D 319NIS E ed n TR M 4 fav PS rA JA E 8 3945 4h l f ION 35 4 r yam ni NES NL DAN A f ABUSA US D I ees P tot SSS ee eee wpe an 213035 aK NGL INSNI T 4M L I VASP gol S O gt Y LLL LA MP 2 qaas 19 ONNOS 12 8 E m E E a0 5 E M
24. N o ad 30055384 UO iam m I 5 i Aviay Is Na Nv m I EE Par wove 914 HOLIMS 34NSS3IYA TIO AQSZ VG L eU cro LER Pub wai Ie aM 9 e E ZA TE TIT i M34v3HB LINDE 5 x a E DI HASNT Y 3U0N 335 Dis ae ral 1 PR EN Y id SOAZ xn Tava 0 2 Baw X08 P NOIVH3N3D NI O3IVIOT sumo 48 P S TWwnoudo YO S lt uia INNI e4 QNVOB AVI3M p soannowan lt lt 4NVd IOYLNOD TWNOILdO 06125 03 03 33 ONBOARD SPARE PARTS Safety at sea depends on careful preparation product knowledge and having the right tools and parts Below is a list of parts Alaska Diesel Electric Inc recommends you carry onboard at all times Onboard Parts Kits are available from your dealer Standard Kits are suitable for inland and offshore cruising World Class Kits are for world cruising and trans ocean cruising We consider these minimum quantities Your vessel s operating condi tions may require more of a given part Consult your dealer Standard World Item Description Quantity Class 1 Lube Oil Filter 4 2 Air Filter Element 1 1 3 Fuel Filter 2 2 4 Water Filter 2 4 2 4 5 Injector 0 6 6 O Ring 0 6 7 O Ring 0 12 8 Gasket 0 6 9 Impeller and Gasket 2 2 10 Thermostat 2 2 11 Thermostat Ring 2 2 12 Relay 0 2 13 Valve Cover Gasket 6 6 14 Alternator Drive Belt 1
25. OPERATOR S MANUAL 06125 For Models L6125 and M6125 ENGINE TEM 40 j E ra hi Dr HE TDOWN BYp ND PREHEAT S AM m METER SWITCH OFF NORTHERN LIGHTS Ed CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constitu ents are known to the State of California to cause cancer birth defects and other reproductive harm Northern Lights 4420 14th Avenue N W Seattle WA 98107 Tel 206 789 3880 Fax 206 782 5455 Copyright 2003 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 O6125 03 03 INORTHERN LIGHTS M nn 06125 OPERATOR S MANUAL FOR MODELS L6125 and M6125 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 Introdag Ion nan 4 Servicing cont Unit Identification Injection Pump TIMES osuere bns 18 Model DesigriatiOfi indonesio 4 T rb chatget sitas 19 se al NUDE cornisa 4 ps AAA 19 Warranty oie 5 Cooling System Requirements 20 22 Safety Rules vainas 5 Checking Coolant Level teint 22 Component Locations Flashing the Cooling System erri 22 Lugaer Propulsi n auus ro REPRE MEEIE 6 Heat Exchanger Cleaning eret 23 Northern Lights Marine Generator Set 7 Cleaning Ge
26. RO p EST i pl I A y or ave EE d sy a il E IT Lose ae lla por __ NER T amp r we rn gt lt a i JOMWOHOINS Z2 See eee 15 Aia Lo DART 1 INNOU GO E QN wa 38 NMOBB je GNANI HOLAS i MEM IB Jam a o ONOS NONI L J e 1 9112313 TWNOILGO I I I I asc 39nvo i an Me t i X anl INGONI I TWNOILGO F IA l eta a M rzzzzzzzzza3 e i I l HOS mG b 39nvo i rsa A 3ISSIAS YO a a I ou D W u3raun H A ce 9p Q3u MU aig O Avi3H luvis MOIVNH3LIv TvwNOLdO g 38 Op pia 90018 ON3 JS HWI L4 S 3 v3uB una Stra STA 3NIONZ Ol HINN ji pene VIE OF diu off IHE xvm 318v2 0 1 SMV 2 ra m 3nzi r S TWNOUdO HO S xoB r sOLvu3N3O NI 021v201 l Ee AEE JINI DNI amp 08089 ayay gt dmo lt 4 13NYd TOYINOD YOLVN LLTV IWNOILGO 06125 03 03 32 19 Lea l Um MLA 3dAL 9 OMY 38 OL SYOLONONOD 13Nvd TOYINOD v SIHIS v A DS ks ea cime 99 s 00L ZZ N d YOLIN g8ISrr O l i e T 1139 139 JIBVISAPOV HLM 32v1d38 NV YOLVNY3L TV WONJ YOIVINIIY ADOLS ag USO IUEI 10 PUNOIL prepuris 110 3A0N3N OJAI SI YOLVINIIS ITOVISNPOV HLM NOLVNHJ3ITV UNV SE JI re L agge L r NIOd NOILDINNO H2V3 IV BAVA 3YIM AB Q3IHIN3O 38 ISNW 2 as a ray INI IL HOv3 y MA 3MIM IJIN3QI 38 1 ure18e rq Sun eurdug DG 39v UMS amp oc VAT ONY A389 38 OL FV SHOIDAQNOO Q3TNISNI 3 0 Y TIV 03000 NO100 SS3TNn Z T3097 WO Mous EARE
27. Ue EN T3NVd ONINO3 35A d WNNOILO en SYOLONGNOD QO3TIVISNI 30 TIY 03002 YOTOD SSIINN nooo 1 0310N SV Ld3DX3 ONVYLSILINW DWADOY 9 GOL aicehiec cd sz eben Se i L Tg E EA AAA EN LA 3dAL vL IMW 38 Ol SYOLONGNOD NOILVTIVLSNI TIV NER NER Rams 77 SONVMO I gown Y 9y LY BY TY SA IY OG Ee le qi Mj IEEE mo E RENE DNI Ja ig e Pl 2 27 n a zx da S310N E a ECC iis PERE FER E i E een gu 7 Poo ggg ANS i Hi i MM j awe z B NT INVIQOS exti ed ua WINS NYOH nui m an NO av39 Nod 4 Yovra wore E ada sank saree fe GUNT 100 ime Mibu um 2 aX qt MUN i a man i roule Ss GNnow9 35Y9 SE NMOUG 31H NMONB 3IHN Gy d eii NON E gaan g 1 od m Tonis v v Breves HOURS casta pod 3078 2114 1 Y 3TI 3LIHN prt un j gt i LESS rod 1 i Prag le Eiee a Uem ERN m wo lt p arar d WEA d Shit 39n8 Praxi vm BTS td m Y E 4 merge tn 08 i veal fern uU C 3idena 31HA 1 Swan SLM 5 ob Fae Mal bus 1 p I SONVOHOUMS i z ve CEA as ioo ETE lub ne sume pos FINO NVI NOIBNVdX3 3IOW3H HIM 0350 ONIBUM ate Nono 1 AM ova OF i f r 4 CM Cia ROSES 4092 0 NVI rr 3 A ION AOS aos o iat NA ORTA MUTO GC LL d lE Nee 1 xovg LI FS oaa yy Meu ume Sz 1 858 86 a ang 11 HT po Old SILOS E 9 J ava NYL 1 TS wis esae E qe Tunes am OSETIA Ead davis NAN NNUS E lt WI 4952 0 D 5 1 iah AVaS i 8 2 ae dN3L 3NON3 E g E M mon POV 8 4 80 3708 Y ETA pan E i DILINOVA E at
28. a AVS avis NEN E ES uae Ausg Lo Be Ya z BEEN wd L NY Sd 091 0 ri amos SATAS Y aunseaud 10 Y Tar A Lo 1 i alias a Y 1 an SUMY3H IAYLNI lt pos AVID OL ox OFF t t I somd oua pas od y PES dana 8 OF d v18 BA OL lt g gt nm Tang HOLMS em a oF ES 78 0 A i x JOYINOO 3NION3 ia O a aaus ETUR E A AW EPI Wiga oop o Hoya Las 007 AS EZ ante ELVIS OL Ono NG OL HLANII wna 707 saya Nosicibal ENAN 6008 22 N d i i TRI e 3NION3 ema eene gt gt Ow wis oH TANVd OHINOO NVN wem Sion J n M3ISWOHOVE IVNQlIGO O6125 03 03 30 A f 1 VI s M D 1 q886r O A bou Nue ci Nob DOGr D E 1933N 10 punodr prepuejs WOA tC c aeu cc c e ae aa 2 2 3 pe 1 r aes aa A urge Sula ourdug OC CE g as ES 210 0 me eos x Los 4 M NOLO3NNOO Ep NC TONYA AMVIIXTI Amisa ia ooo OMA A ESO AA 1 LR d tt e 1 Rar
29. aks Keel cooling tubes have been painted Cooling system needs flushing Defective thermostat Remove and check thermostat Defective temperature gauge sender Check water temperature with thermometer and replace gauge or sender if necessary Water pump impeller worn broken HE Engine v Engine knocks Insufficient oil Check dipstick 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 Engine overheating See Engine Overheating section v High fuel consumption Improper type of fuel Clogged or dirty air cleaner Service air cleaner Engine overloaded Reduce load Check proper propeller size Grass etc on bottom of boat If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer 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 temp with thermometer to see if tempera ture gauge is working properly v Below normal engine temperature Thermostats not working properly Check thermostats Temperature gauge not working properly Check water temperature with thermometer Y Low oil pressure Low oil level Improper type of oil Drain and fill crankc
30. ange on the pump drive Remove the four mounting bolts Fig 11 7 which hold the injection pump on the bracket 5 Injection Pump Installation a Position pump on bracket Positioning sleeves on two of the bolt holes help align the pump Tighten four mounting bolts see Fig 11 7 to 49 54 foot Ibs 6 75 7 50 kgm on L6125A M6125QT M6125T M6125A and M6125QA For M6125D and M6125Q torque is 23 26 foot Ibs 3 2 3 5 kgm Reinstall coupling bolts but do not tighten them until pump is timed as per next section Reinstall feed lines Fig 11 3 and lubrication oil lines Fig 11 4 amp 11 5 using new gasket washers on both sides of banjo bolts Torque nuts for line Fig 11 5 18 21 6 foot Ibs 2 5 3 kgm Torque nuts for line Fig 11 4 11 14 foot Ibs 1 5 2 kgm Reinstall fuel injection lines Fig 11 2 and line clamps Fig 11 1 Fuel delivery line sleeve nuts Fig 11 8 torque to 16 18 foot Ibs 2 4 2 5 kgm O6125 03 03 17 SERVICING TIMING INJECTION PUMP 1 The Match Mark Alignment Method This is used when the injection pump is installed on the original engine and the pump has NOT been repaired a Turn the crankshaft by hand in clockwise direction to bring the number one cylinder to top dead center of the compression stroke The compression stroke can be determined by removing the number one cylinder valve cover and turning the engine until all valves presa uut 510P
31. ar Oil Coolers acier 23 Panels ZING Elecirod ES crisis 23 Lugger Propulsion Engine ueniens 8 Raw Water PUipisscseinscseesusish on air ekb nne 23 Series 3 amp 4 Generator Sets c ise 9 Mos ru du M 23 Operating Procedures Gears PTOs and Generators 23 Before SEAT asco dioi emite ecc b e nds 10 Electrical System General isse 24 E ard M iriaren EEn Enen 10 Booster Batteries cornada 24 Propulsion Engine ninia 10 11 Battery Care primicias 24 Shutdown Procedures coman 11 Winterizing Out of Service 24 Shutdowns amp Ala aeree serae ihe 11 Propeller Sizing Chart scsi 25 Break in Period serrano 11 Data Sheets Servicing Schedule Chart 12 AE E 26 Service Record uus orbe e 13 Northern Lights Marine senos 27 Servicing Troubleshooting Lubrication Generali 14 riis A 28 Ol Changes inside 14 EOI dina 29 Changing Oil Filter iue 14 15 DC Wiring Diagrams AJT uli 15 12 Volt Lugger Engine cssosrinsicimsios 30 il 15 24 Volt Lugger Engine iet 31 Vale Italici incio 15 12 Volt Marine Generator Set 32 FUCHS General anidan 16 24 Volt Marine Generator Set 33 Fuel Filters S 16 Onboard Spare Parts eee eere 34 Bleeding the Fuel System cesis 16 TN ua PPP oo 16 17 Injection PUMP sssini ricus 17 Proprietary Information This publication is the property of Alaska Diesel
32. arine diesel generator set Komatsu 6125 block Northern Lights turbocharged 1200 RPM marine M6125QT diesel generator set Komatsu 6125 block SERIAL NUMBERS NORTHERN LIGHTS Serial No Model No a ALASKA DIESEL ELECTRIC Inc we 4420 14TH AVE NW SEATTLE WA U S A Komatsu engine block 6 cylinder 125 mm bore Model numbers give unit s application block model aspiration and RPM A GA QT A Aftercooled turbo H High Output T Turbocharged QA 1200 RPM Aftercooled QT 1200 RPM Turbo charged 6125 Model number of Northern Lights aftercooled 1200 RPM marine diesel generator set Komatsu 6125 block M6125QA When referencing Alaska Diesel Electric equipment by serial number refer only to the number stamped on the Lugger or Northern Lights serial number plate NORTHERN LIGHTS Serial No Model No LaS ALASKA DIESEL ELECTRIC Inc v 4420 14TH AVE NW SEATTLE WA U S A Alaska Diesel Electric 4420 14th Ave N W o Seattle WA 98107 206 789 3880 o o Generator Set Data o Set Serial No Model No o Set Model No o 06125 03 03 4 WARRANTY A warranty registration certificate is supplied with your set It entitles the original purchaser of this equipment to a warranty covering mate rial or assembly faults The extent of coverage is described in the Limited Warranty Statement We recommend that you study the statement carefully If the warra
33. ase with correct oil Partially plugged oil filter Replace filter v High oil consumption Break in period Crankcase oil too light Use proper viscosity oil Oil leaks Check for leaks in lines around gaskets and drain plug Engine overheats See Engine Overheats v Engine emits black or gray exhaust smoke Clogged or dirty air cleaner Service air cleaner Defective muffler back pressure too high Improper fuel Engine overloaded Reduce load Check propeller size Injection nozzles dirty See your dealer Engine out of time See your dealer v Engine emits white smoke Improper fuel Cold engine Warm up engine to normal operating temperature Defective thermostat Remove and check thermostat Engine out of time See your dealer O6125 03 03 29 E FN V V f6cor O jw Y 19330 10 punoJc prepuejs 3 OA TI i on BN Ew A XW8 7 BIBAT 1 IN WISI Suny ourguq DA
34. ater to produce an engine coolant with a low freeze point and high boiling point 2 A low silicate form of ethylene glycol coolant is recommended for all diesel engines 3 Use an ethylene glycol coolant concentrate meet ing ASTM D 4985P SAEJ1941 General Motors Performance Specification GM1899M or formu lated to GM6038M 4 This product is concentrated and should be mixed to the following specification Distilled EGC Freeze Boiling Water Antifreeze Point Point Optimum 50 50 37 C 109 C 34 F 226 F Minimum 60 40 24 C 106 C 12 F 4222F 52 C 1119C 62 F 232 F Maximum 40 60 5 If additional coolant solution needs to be added to the engine due to leaks or loss the glycol concen tration should be checked with a hydrometer to assure that the desired freeze point is maintained 6 IMPORTANT DO NOT use methyl alcohol or methoxy pro panol 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 anhydrous 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 CAUTION EGC Antifreeze is flammable
35. case Vent 21 Manual Fuel Prime Pump 30 Data Plate 4 Raw Water Zincs 2 13 Injection Pump 22 Raw Water Drain 31 Manifold Drain 5 Heat Exchanger End Cover 14 Air Cleaner 23 DC Alternator 32 Dry Exhaust Elbow 6 Expansion Tank 15 Lube Oil Drain 24 Jacket Water Pump 33 Turbocharger 7 Jacket Water Filler Cap 16 Electronic Governor opt 25 Base Frame 34 Jacket Water Vents 2 8 Jacket Water Zinc 2 17 Primary Fuel Filter opt 26 OilPan 35 Rocker Arm cover 9 Lube Oil Fills 2 18 Lube Oil Filter 27 Block Drain 36 Fuel Injector O6125 03 03 7 INSTRUMENT PANEL Lugger Marine Propulsion Engine OIL PRESSURE GAUGE The oil pressure gauge shows the oil pressure in the engine lubricating system If the oil pres sure drops BELOW 15 PSI at a speed higher than idling stop engine immediately and inves tigate WATER TEMPERATURE GAUGE This gauge shows the temperature of the cool ing water If a temperature of over 205 is indi cated stop engine and investigate immediately TACHOMETER The tachometer shows the engine speed in revolutions per minute RPM Numbers are multiples of 100 VOLTMETER When the engine is stopped the voltmeter will indicate the condition of the battery When the engine is running it shows the alternator voltage output HOUR METER The hour meter keeps track of the accumulated length of the engine s operating time KEY SWITCH The key must be kept
36. e cap from the expansion tank In order to give the cooling water an opportunity 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 all the venting cocks should be opened to ensure that no air pockets form in the cooling system See Service Point 14 page 20 CAUTION Use protective clothing and open A 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 in the waffled area between the L and H Never allow the level to go below the L Always add the same viscosity of oil as is already in the crankcase See Service Point 1 page 12 3 Check the fuel tank level and open any fuel valves 4 Propulsion Only Check the oil level in the reverse gear Methods may vary from gear to gear See your Gear Owner s Manual 5 Close the sea cock check and clean the strainer and reopen the sea cock 6 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 regulator could be damaged GENERATOR Starting 1 While holding the Shutdown Bypass Preheat switch in ON position push the Engine Control switch to START position As soon as the engine starts release both switches Do not crank the starter for more t
37. eck electrolyte in batteries SP4 Replace air filter SP6 Check valve clearances FIRST 100 HOURS SP9 Change secondary fuel filter SP2 Change oil SP10 Check injectors SP3 Change lube oil filter SP13 Check turbocharger boost pressure SP6 Check valve clearances SP15 Check and flush cooling system FIRST 250 HOURS SP19 Change impeller in sea water pump SP20 Change coolant filter SP25 Check condition of batteries with hydrometer EVERY 250 HOURS or every 6 months SP2 Change engine oil SP3 Change lube oil filter SP4 Check air filter EVERY 2400 HOURS SP11 Check fuel injection pump SP16 Check and clean heat exchanger SP17 Check and clean gear oil cooler SERVICE 50 250 500 750 2400 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours ENGINE SP1 12 Check oil level SP2 12 Change engine oil 1 4 SP3 12813 Change lube oil filter 1 4 SP4 13 Replace air filter 1 3 d SP5 13 Check V Belt tension 1 e SP6 13 Check valve clearances 1 5 FUEL SYSTEM SP7 14 Check primary filter Racor 2 SP8 14 Change primary filter element 2 3 e SP9 14 Change secondary filter 1 3 SP10 14815 Check injectors 1 SP11 15816 Check fuel injection pump TURBOCHARGER SP12 17 Check air lines oil and cooling water lines for leakage 1 SP13 17 Check boost pressure COOLING SYSTEM SP14 18820 Check cool
38. erything is clear before starting the engine Do not operate an engine that isn t in proper working order If an unsafe operating condition is noted tag the engine so others will also know about it e Provide first aid kits O6125 03 03 5 COMPONENT LOCATIONS Lugger Propulsion L6125A Figure I L6125A 1 Coolant Filter 10 Lube Oil Dipstick 18 Injection Pump 26 Engine Oil Cooler 2 Raw Water Pump 11 Aftercooler 19 Manual Fuel Prime Pump 27 Starter 3 Jacket Water Drain 12 DC Circuit Breaker amp 20 Raw Water Drain 28 Gear Oil Dipstick 4 Raw Water Zincs 2 Relays 21 DC Alternator 29 Manifold Drain 5 Heat Exchanger End Cover 13 Air Cleaner 22 Starboard Oil Dipstick opt 30 Turbocharger 6 Expansion Tank 14 Lube Oil Drain Pump opt 23 Gear Oil Cooler Drain 31 Jacket Water Vents 2 7 Jacket Water Filler Cap 15 DC Harness Plug Ins 24 Gear Oil Cooler 32 Rocker Arm Cover 8 Jacket Water Zinc 2 16 Lube Oil Filter 25 Block Drain behind Gear Oil 33 Fuel Injector 9 Lube Oil Fills 2 17 Secondary Fuel Filter Cooler 06125 03 03 6 COMPONENT LOCATIONS M6125A Northern Lights Marine Generator Set 9 ie C 32 82 86 65 30 31 36 Figure 2 M6125A Generator Set 1 Coolant Filter 10 Lube Oil Dipstick 19 Secondary Fuel Filter 28 Engine Oil Cooler 2 Raw Water Pump 11 Aftercooler 20 Fuel Manifold 29 Starter 3 Jacket Water Drain 12 Crank
39. gine and continue holding in up position while starting engine Holding the switches on too long can burn out the heater elements ENGINE CONTROL SWITCH To start the engine hold switch in start position until the engine is running After the engine starts release switch and it will return to the center position To stop engine move switch to stop position and release OIL PRESSURE GAUGE The oil pressure gauge shows the oil pressure in the engine lubricating system WATER TEMPERATURE GAUGE Registers temperature of cooling water HOUR METER Keeps track of engine running time D C VOLTMETER When the engine is stopped the voltmeter indicates 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 9 Shows the generator output voltage FREQUENCY METER HERTZ The frequency meter indicates the frequency of alternating current 1200 or 1800 RPM 60 Hz 1500 RPM 50 Hz AMMETER SELECTOR SWITCH Used to check each phase for load condition You must always leave this switch in the ON posi tion while the unit is running 10 A C AMMETER Shows the generator load on each phase The phase is selected on the Ammeter Selector Switch switch 9 above O6125 03 03 OPERATING PROCEDURES BEFORE STARTING 1 Check the water level by removing the pressur
40. han 20 seconds If the engine fails to start the first time be sure the starter has stopped before reengaging 2 Cold Weather Hold Shutdown Bypass Preheat switch in the ON position for 30 seconds before starting This will warm the air heater elements and will ease starting This is not necessary if engine is warm A longer preheat time may be required in extremely cold weather Operating 1 Check Gauges Often Oil pressure must be above 29 PSI The DC voltmeter should read between 13 and 14 volts 26 28 volts 24 volt systems at 60 F 16 C ambient temperature Water temperature gauge must be below 205 F 96 C Check AC voltage and frequency meters If gauges deviate from normal levels shut down the set and investigate 2 Letthe unit run unloaded for a three to five minute warm up period 3 Do not add full electrical load until the engine has reached normal operating temperature PROPULSION ENGINE Starting 1 Put the gear control in the neutral position 2 Move the throttle control to the full speed position and return back to idle 3 Turn the key switch to the first position Check the voltage meter to see the condition of the bat teries For starting the voltmeter should not read below 12 volts 24 volts for 24 volt systems 4 In cold weather turn the key to the preheat posi tion and hold there for 20 30 seconds 5 Turn the key to the starting position and as soon as the engine starts release the key Mo
41. il change procedures Consult Lubricants Section for oil recommendation Operating Instructions 1 Propulsion engines Never run full speed for more than 5 minutes during the first 50 hours Run engine at 50 to 75 of maximum working speed for the first 20 hours with as little idling time as possible Extended idling can inhibit ring seating causing cylinder walls to glaze Generator Sets Maintain at least a 75 load on your set for the first 100 hours If this is not pos sible maintain no less than a 50 load to ensure proper seating of the piston rings Vary the load to help seat rings 06125 03 03 11 SERVICING SCHEDULE CHART The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your unit 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 SP7 Check primary fuel filter SP14 Check cooling water level SP21 Check oil level in reverse gear FIRST 50 HOURS SP2 Change engine oil SP3 Change lube oil filter EVERY 50 HOURS or weekly SP5 Check V belt tension EVERY 250 HOURS Continued SP8 Change primary fuel filter element SP12 Check turbocharger air oil and cooling lines for leakage SP18 Check zinc electrodes HE engines only FIRST 500 HOURS SP20 Change coolant filter EVERY 500 HOURS or yearly SP20 Change coolant filter EVERY 750 HOURS or yearly SP24 Ch
42. ing water level SP15 20 Check and flush cooling system 1 SP16 20821 Check and clean heat exchanger 1 SP17 21 Check and clean gear oil cooler 1 SP18 21 Check zinc electrodes HE engines only 1 3 SP19 21 Change impeller in seawater pump 1 3 SP20 21 Change coolant filter 1 DRIVEN EQUIPMENT SP21 21 Check oil level in reverse gear SP22 21 Change oil in reverse gear 2 SP23 21 Clutch and PTO service 2 ELECTRICAL SYSTEM SP24 22 Check electrolyte level in batteries 1 3 SP25 22 Check condition of batteries with hydrometer 1 OUT OF SERVICE SP26 22 Winterizing or out of service 3 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 When necessary 4 Change at first 50 and first 100 hours 5 Adjust at first 100 hours O6125 03 03 12 SERVICE RECORD Sofie OPERATION HOURS DATE 50 HOURS or weekly SP5 Check V belt tension SP25 Check electrolyte in batteries 250 HOURS or every 6 months SP2 Change engine oil SP3 Change lubricating oil filter SP4 Check air cleaner SP8 Change primary fuel filter element SP12 Check turbocharger air oil amp cooling lines for leakage SP18 Check zinc electrodes HE engines only 500 HOURS or annually SP20 Change cooling s
43. k for leaks SPI7 CLEANING GEAR OIL COOLERS For propulsion engines only 1 Drain fresh water cooling circuit 2 Remove end covers of gear oil cooler 3 Wash the core in diesel fuel and blow it dry with compressed air Clean the end covers of the core with a steel brush and use a metal rod to clean inside of tubes 4 Re assemble using new gaskets Fill the cooling system start the engine and check for leaks SPIS ZINC ELECTRODES 1 Zincs are installed in the heat exchanger 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 Keel cooled engines do not have zincs 2 Heat exchanger cooled engines Drain the raw water from heat exchanger then drain the expan sion tank Remove zinc holders from the back end of heat exchanger and raw water pipe elbow 3 Scrape or steel brush the zinc electrode clean If more than 50 of the electrode is corroded away replace it with a new one The electrode screws out of the holder 4 Re install the zinc holders Be sure the threads are clean for good metal to metal contact 5 Refill cooling system start engine check for leaks SP19 RAW WATER PUMP 1 Heat exchanger cooled engines only Change the the sea water pump impeller every year or as needed 2 Remove the pump end cover Pry out the impeller with the help of two screwdrivers Be su
44. kcase To Drain Reverse Gear Hand pump selector valve s 8 Marine Generator Sets a Remove plug from outlet in base frame Screw in owner supplied drain hose b 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 c Refill engine with recommended oil Engine capacity with new oil filter is 8 5 gal lons 32 liters SP3 CHANGING OIL FILTER 1 Change the lube oil filter after the first 50 hours of operation after the first 100 hours of opera tion and every 250 hours thereafter Use a filter wrench to remove old filter Dis pose of filter in an 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 meets the sealing surface Using hands only no wrench tighten filter one half turn farther Overtightening can do damage O6125 03 03 14 SERVICING to filter housing 6 Fill engine with recommended oil Start engine and check for leakage Stop engine and check oil level Add additional oil if necessary SP4 AIR FILTER 1 Inspect air cleaner every 250 hours replace the filter every 750 hours or yearly whichever comes first 2 After replacing element and cover start engine and check for air leaks NOTE Make absolutely sure no impurities enter the engine while
45. ls contact your local Northern Lights dealer ELECTRICAL SYSTEM GENERAL 1 Never switch battery switch off or break the cir cuit between the alternator and batteries while the engine is running Regulator damage can result 2 Do NOT reverse the polarity of battery cables when installing the battery 3 When welding on the unit disconnect the regula tor and battery Isolate the leads 4 Disconnect battery cables when servicing the DC alternator AP pe LATIN 06125 03 03 23 SERVICING 5 Never test with a screwdriver or etc against any terminal to see if it emits sparks 6 Do not polarize the alternator or regulator 7 ADC circuit breaker protects your control panel and wiring harness See Fig 1 for loca corrosion with a water and baking soda solution Flush with clean water Tighten terminals and grease them to inhibit corrosion Check the battery condition with a hydrometer every 750 hours or yearly tion l SP26 WINTERIZING OUT OF SERVICE BOOSTER BATTERIES MARINE CAUTION Battery Gas Can Explode 1 Drain seawater cooling systems completely Keep all flames and sparks away from bat Remember to shut off sea cocks before opening teries drain cocks 1 Before changing or using booster batteries 2 Drain seawater supply lines and wet exhaust check battery electrolyte level Add distilled line water if necessary 3 Loosen the seawater pump cover and drain 2 Booster and main batteries must
46. m which retards heat transfer and coolant flow Important Engines with Keel Cooling The SCA in the spin on filter may not be able to treat the large volume of coolant in a vessel s keel cooling system The operator must use a test kit strip to determine the amount of addi tional SCA s that need to be added to the cooling system SCA S CONTINUED If additional SCA s are needed prepare a mix ture of 50 quality water and 50 EGC anti freeze Add liquid SCA at a rate of 3 by volume O6125 03 03 SERVICING Example 30 mL of SCA per liter of H O 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 5 SCA is available from your Northern Lights Lugger dealer in the following sizes Pint Part Number 20 00002 1 2 gallon Part Number 20 00003 6 DO NOT use any coolant system additives con taining soluble oil COOLANT TESTING 1 Coolant test kits are available to allow on site evaluation of the coolant condition 2 The kits use small strips of paper which are dipped into the coolant The paper changes color and indicates the SCA concentration It also indicates the amount of EGC antifreeze 3 Test kits are available through your Northern Lights or Lugger Dealer 4 Pack Part Number
47. n Standard instrument harness length 20 ft 6 m Air Intake and Exhaust Engine air consumption at rated speed High Output inne 885 min 25 m min Medium Duty 800 min 23 m min Continuous Duty 652 fP min 18 m min Minimum engine room intake vent area High Output eene 235 in 0 15 m Medium Duty teretes 212 in 0 14 m Continuous Duty sess 173 in 0 11 m Exhaust gas flow at rated speed High Outp t i ee 2639 f min 75 m min Medium Duty 2295 f min 65 m min Continuous Duty 1865 f min 53 m min Maximum exhaust gas temperature at rated speed High Outputs ccc oes 975 F 528 C Medium Duty minoria ii 975 F 528 C Continuous Duty sees 840 F 448 C Maximum exhaust back pressure 30 in 760 mm H O Suggested dry exhaust I D High Output 6 inch Med amp Continuous Duty 5 inch Suggested wet exhaust I D High Output 8 inch Med amp Continuous Duty 6 inch Fuel and Oil Minimum fuel line Suction return eec eee 1 2 12 mm Maximum fuel pump head 39 in 1 m Crankcase oil capacity 34 US qts 32 Itr Gear PTO Engine Angle Engine rotation facing flywheel Counter clockwise Flywheel housing size SAE 2 11 5 SAE 1 14 optional Front PTO size
48. nd harness plug connections Sulfated or worn out batteries Check specific gravity and electrolyte level of each bat tery ENGINE Y Engine hard to start or will not start Improper starting procedure No fuel Low battery output Check electrolyte level and specific gravity of battery Excessive resistance in starting circuit Clean and tighten all connections on batteries 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 Fuel pump primer lever left on upward end of stroke v Engine runs irregularly or stalls frequently 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 Dirty or faulty injection nozzles Have your dealer check injection nozzles Air in fuel system nspect 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
49. njection pump fuel line connecting nuts and rocker arm housing cover b Remove rocker arm housing cover c Remove fuel line nuts on fuel inlet connector and injection pump Remove fuel line clamps Pull fuel lines loose d Remove fuel inlet connector Note loosen lock nut first and then screw out connector 06125 03 03 16 SERVICING Connector should be replaced e Remove injector hold down bolts f Remove injectors from the head Hold down bolts can be inserted into bolt holes in the injector holder Squeeze the bolts together and pull to remove injector If injector is dif ficult to remove reinsert mounting bolts and fuel return line bolt Using hold down bolt as a fulcrum pry up on return line bolt 3 Clean Injector Bore Injector seat in cylinder head can be cleaned by wrapping a clean lint free rag around the tapered end of a wooden rod and wiping the bore and seat Hardened carbon can be removed from the seat by using a tapered wire brush to break carbon free Then clean the bore with rag and rod Have injectors tested and rebuilt if necessary Or take them to a Lugger Northern Lights dealer and use them as core exchange for rebuilt injec tors 5 Injector Installation a Install new o ring in groove on injector b Insert injector into bore Install bolts and torque to 14 16 foot Ibs 1 9 2 2 kgm c Install injector fuel return line with new gasket washers Torque banjo b
50. nty is to apply the servicing instruc tions outlined in this manual must be followed If further information is needed please contact an authorized dealer or the factory SAFETY RULES Accident reports show that careless use A of engines cause 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 Turn the coolant tank cap slowly to relieve pressure before removing Add coolant only when the engine is idling or stopped Mount fire extinguisher near engine e 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 e Avoid wearing loose clothing without a belt when working around engines Do notoil or grease engine while it is running Use caution in handling fuel Never refuel a hot or running engine Do not smoke while fill ing fuel tank or servicing fuel system e 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 knowl edgeable qualified personnel e Walk completely around engine to make sure that ev
51. olts to 8 11 foot lbs 1 0 1 5 kgm d Install injector lines Torque fuel line nuts to 17 18 foot lbs 2 3 2 5 kgm e Bleed the fuel system start the engine and check the system for leaks using a piece of cardboard SP11 INJECTION PUMP 1 The 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 Low power and no smoke can indicate a fuel injection pump malfunction Check for full throttle proper solenoid adjustment and air filter cleanliness before replacing pump Black smoke occasionally may indicate an injection pump problem Any repair which involves disassembly of the injection pump must be carried out by specially trained mechanics with the proper tools and test devices NOTE All warranties on the engine become null and void if the injection pump seals are broken by unauthorized persons 4 Injection Pump Removal a Clean injection pump hoses and area around the pump with cleaning solvent or a steam cleaner NOTE Never steam clean or pour cold water on an injection pump while the engine is running or the pump is warm Remove line clamps see Fig 11 1 and fuel injection lines Fig 11 2 Remove feed lines Fig 11 3 and lubrication tubes Fig 11 4 amp 11 5 and return line Fig 11 6 Remove coupling bolts between the coupler and the fl
52. or erosion rust scale and acidity 4 Your engine is equipped with a spin on coolant filter conditioner element which provides the SCA s to protect your cylinder liners 5 The coolant filter conditioner element performs two functions at once The outer paper element filters out rust scale or dirt particles in the coolant The inner element releases chemicals into the coolant to maintain a proper acid alkaline balance inhibit corrosion and suppress erosion pitting which is discussed below A Cylinder Liner Walls B Engine Coolant C Vapor Bubbles LINER EROSION PITTING 1 Cylinder liner walls A which are in contact with engine coolant 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 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 B 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 allows coolant to enter the combustion chamber Engine failure or other serious damage will result Unprotected engines with low quality water as coolant can have liner failure in as few as 500
53. ore disconnect ing lines be sure to relieve all pressure Before applying pressure to the system be sure all con nections 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 fuel see a doctor at once Serious infection or reaction can develop if proper medical treatment is not administered immedi ately 1 Whenever the fuel system has been opened for service lines disconnected filter changed etc it should be bled To bleed the fuel system loosen the vent plug in the top of the fuel filter housing Unscrew the hand primer knurled knob on the injection pump and loosen until it can be pulled up by hand see Fig 11 10 Operate the hand primer up and down until most of the air bubbles are expelled and clear fuel escapes the vent plug Push hand primer down and tighten Tighten the vent plug If the engine will not start it may be necessary to loosen the fuel pipes at the injectors With the throttle on full crank the engine over with the starter until fuel without air flows from the loose fuel pipe connections Tighten the connections SP10 INJECTORS 1 Fuel injectors should be checked by a Lugger Northern Lights dealer or qualified fuel injection shop after every 750 hours 2 Injector Removal a Thoroughly clean the area around i
54. r NOTE Prop size is influenced by many factors hull design load boat use It is impossible to make an absolute recom mendation For more accurate recommendations contact your dealer High Output Rating 460 flywheel HP at 2300 RPM Gear Ratios and Propellers Speed Knots 11 13 13 15 15 17 17 19 19 21 21 23 23 25 25 27 27 29 29 31 31 33 Sft rpm Sft dia in 1 1 20x13 20x14 20x15 20x16 20x17 20x18 20x19 20x22 2300 1 5 1 511 26x14 26x15 26x17 26x19 26x21 26x23 26x25 26x27 26x29 26x31 26x34 1533 1 75 1 77 1 28x16 28x18 28x20 28x22 28x24 28x26 28x28 28x30 28x32 28x34 1299 2 Medium Duty Rating 425 flywheel HP at 2300 RPM Gear Ratios and Propellers Speed Knots 9 11 11 13 13 15 15 17 17 19 19 21 21 23 Sft rpm Sft dia in Continuous Duty Rating 325 flywheel HP at 2100 RPM Speed Knots 5 7 7 9 9 11 11 13 13 15 Sft rpm Sft dia in 1 5 1 25x18 25x20 25x23 1533 1 75 1 77 28x19 28x21 28x23 28x26 28x28 1299 2 0 2 1 30x18 30x20 30x22 30x24 30x27 30x30 30x33 1150 2 25 Gear Ratio and Propellers 2 51 34x21 34x25 34x29 840 2 5 3 1 38x21 38x25 38x30 38x34 700 3 3 5 1 42x20 42x24 42x30 42x35 42x40 600 3 5 Find the boat speed your boat builder expects from an engine of this horsepower in the left column Locate the gear ratio desired on the top line Find where two columns
55. re to close the sea cock before working on the engine cooling system 1 Flush the cooling system and check for leaks and blockage every 750 hours or yearly 2 The engine must be stopped and cold Remove the filler cap with caution Open cooling system air vents on top of the turbocharger at the front and rear of the aftercooler and for heat exchanged units on top of heat exchanger HE see Fig 1 3 Drain the jacket fresh water circuit of the cooling system 4 To drain the raw water circuit of HE engines open the drain at the bottom of the heat exchanger see Fig 1 22 5 With drains open pour clean water into the expansion tank When the water from each drain is clear and free from discoloration and sediment close that drain When all drains are closed flushing is complete 6 Re drain the engine and refill the jacket fresh water circuit with coolant mixture as described in previous section 7 Close cooling system air vent Open sea cock 9 Start engine Monitor temperature gauge carefully and check cooling system for leaks SPI6 HEAT EXCHANGER CLEANING 1 Clean the heat exchanger core once a year or after 2400 hours of operation 2 Drain expansion tank and heat exchanger 3 Remove heat exchanger covers oo O6125 03 03 22 SERVICING 4 Clean the inside of exchanger core tubes using a metal rod 5 Re assemble using new gaskets Fill the cooling system start the engine and chec
56. re you remove all pieces of a failed impeller NOTE Place some kind of protection under the screwdrivers in order not to damage the housing 3 Clean the inside of the housing 4 Press in the new impeller and place the sealing washers 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 that there is always an extra impeller and cover gasket in reserve on board SP20 COOLANT FILTER 1 Change coolant filter after the first 250 hours the first 500 hours and every 500 hours thereafter Shut off both valves on filter body Use filter wrench to remove filter Make sure old gasket is removed Lubricate new filter gasket and screw on new filter until gasket meets housing Hand tighten two thirds of a turn more Open valves on filter body Start the engine and check for leaks Stop engine and check water level in expansion tank SP21 22 23 GEARS PTOS AND GENERA TORS 1 Manufacturer s service recommendations vary See your Owner s Manual for service informa tion 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 rec ommendations closely 2 If you have a Northern Lights generator set the maintenance and operation recommendations for the generator end are in a separate Owner s Manual If you do not have one of these manua
57. t Valve X O X O X JO Figure 9 Valve Clearance Chart 6 To adjust the valve clearance first adjust the crosshead Loosen the crosshead lock nut Fig 10 5 then the adjustment screw Fig 10 6 Hold top of crosshead lightly and tighten adjust ment screw until it contacts valve stem then tighten 20 more Then loosen nut see Fig 10 1 on valve adjustment screw Fig 10 2 insert feeler gauge between crosshead Fig 10 3 and rocker arm Fig 10 4 and adjust the clearance with the adjustment screw until the thickness gauge slides with a slight drag After the clearance is properly adjusted tighten the lock nut to secure the adjustment screw using 47 to 54 foot lbs of torque 7 to 7 5 kgm Valves should be set cold with the following clearances a Intake Valves 013 in 33mm b Exhaust Valves 028 in 71mm Rotate the engine one full revolution Adjust valves marked O to above clearances Intake Exhaust Figure 10 06125 03 03 15 SERVICING FUELS GENERAL 1 Use only clean high quality fuels of the follow ing specifications as defined by ASTM designa tion D975 for diesel fuels a Use grade No 2 diesel at ambient tempera tures above freezing 32 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 Use fuel having less than 1 sulphur preferably
58. um Cruising RPM Establish the RPM at full throttle and subtract 200 300 RPM This will promote engine life and reduce fuel consumption SHUTDOWN PROCEDURES 1 Run for three to five minute cool down period a Propulsion engines in neutral at 1000 RPM then return throttle to low idle b Generators unloaded 2 Push STOP button until the engine has completely stopped Turn key switch to OFF position 3 Close the sea cock fuel valves and put the battery switch in OFF position NOTE Do not turn battery switch to OFF while 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 Propulsion engines have warning horns to sound and warn you of a problem Remem ber when engine is not running the horn will sound when key is in the ON position because there is no oil pressure Propulsion engines do not have shutdown systems c 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 monitor ing Watching your gauges can prevent damage to the unit and dangerous power losses 2 Dothe following when your warning or shutdown system is activated a Check the temperature gauge If the tempera ture is above 205 F 96 C shut off the engine immediately b
59. ve the throttle up until the engine is running at approxi mately 1000 RPM 6 Do not crank the starter for more than 20 seconds consecutively If the engine fails to start with the first attempt be sure that the starter has stopped completely before re engaging NOTE Never race a cold engine Operate at 1000 RPM for a 3 5 minute warm up period Operating 1 Check oil pressure as soon as the engine has started Oil pressure should be above 15 PSI The engine must never be run if the oil pressure is below 15 PSI 2 Check the voltmeter It should read 13 to 14 volts 26 28 volts 24 volt systems at 60 F 16 C 3 Water temperature should not rise over 205 F 969C If it does shut down the engine and inves tigate the cause of overheating 4 Do not exceed 800 RPM when shifting marine gear Repeated shifts at higher engine speeds can damage the reverse gear 5 Low Idle is 650 RPM Maximum working engine speed is 2300 RPM for pleasure craft 2300 RPM for light commercial craft and 2100 RPM for continuous duty applications O6125 03 03 10 OPERATING PROCEDURES 6 If the proper propeller is used the engine should reach its appropriate maximum speed at full throttle If at full throttle the maximum speed is exceeded then the propeller is too small If maxi mum speed cannot be attained then the propeller is too large or bottom growth may be slowing the boat See Prop Chart page 23 7 To Establish Maxim
60. watts 0 8 power factor 2 Net flywheel hp rating for fully equipped engine at RPM under SAE J816b 3 Based on prime HP rating at rated 1800 or 1200 RPM 4 Based on prime kW rating at rated 1800 or 1200 RPM Fuel rate may vary depending on operating conditions 06125 03 03 27 TROUBLESHOOTING If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer ELECTRICAL v 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 Defective alternator v Starter inoperative Check DC circuit breaker Loose or corroded connections Clean and tighten loose battery and harness plug connec tion Low battery output Check specific gravity of each battery Check electrolyte level of each battery Defective electrical system ground wire Repair or replace v Starter cranks slowly Low battery output Batteries too small Battery cables too small Check specific gravity of each battery Check electrolyte level of each battery Crankcase oil too heavy Loose or corroded connections Clean and tighten loose connections v Entire electrical system does not function Check DC circuit breaker Faulty connection Clean and tighten battery a
61. ystem filter 750 HOURS or annually SP4 Replace air cleaner SP6 Check valve clearances SP9 Change secondary fuel filter SP10 Check injectors SP13 Check turbocharger boost pressure SP15 Check and flush cooling system SP19 Change impeller in sea water pump SP25 Check state of charge of batteries 2400 HOURS SP11 Check fuel injection pump SP16 Check and clean heat exchanger SP17 Check and clean gear oil cooler 06125 03 03 13 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 single viscosity oils b API Service CC CD SF multi viscosity oils 3 Use the proper weight oil for your average operation temperature Air Single Multi Temperature Viscosity Viscosity Above 32 SAE 30W SAE 15 40W rc 10 to 32 F SAE 10W SAE 10 30W 23 10 09C Below 10 F SAE 5W SAE 5 20W 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 crank case 6 Propulsion Engines See Gear Owner s Manual for gear lubrication recommendations SPI CHECK OIL LEVEL 1 Check oil in the crankcase daily with the dip stick

Download Pdf Manuals

Related Search

Related Contents

RCA 25260 Quick Start Guide  HDS1021M Handheld Digital Storage Oscilloscope  Asus 1201N-PU17-BK Laptop User Manual  PORTABLE LED LIGHT SYSTEM USER MANUAL    1 Le défaut (Rapport belge) par Pauline COLSON  SYRIS TAG user manual v0250.pd f  Portrait de Sophie Calle en héroïne perecquienne  MASTER CONTROL MV-58 Owner`s Manual  BORDER 304 SPEED  

Copyright © All rights reserved. Failed to retrieve file