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OPERATOR`S MANUAL

1. OL2 2 01 05 39 PANEL e MAIN CONTROL PANEL lt ENGINE 24y 100 ols nione PURPLE ANALOGUE boda EMULATOR 18 STARTER B SHUT OVN RELAY OW IDLE BANS SEE NOTES 2 amp 3 our edt TQ STARTER Bt PG RED 6 D mi 1a BLACK K p ONCE sO ane ne ro COG eN e iN 315 ub EE Q32 112 RID mje AA ay PENGTH To ENGINE PURPLE aK a D2
2. eom 1 0128 20 RED Ec 0020 12 FED gt O28 RED SWITCH CONNECTOR An TUE 66 BLK M tl 390 HN N S SPEED SELECT BUMP i 1 UNLESS COLOR CODED ALL A D E INSTALLED CONDUCTORS pun rr RR I ARE TO BE GREY AND MUST BE IDENTIFIED BY WIRE ee as eie en MARKER AT EACH CONNECTION POINT S SENT x lere aed UNLOCK MB ORG 1 SR N lt HIDDEN DASHED LINES REPRESENT CUSTOMER SUPPLIED AND Ae ae z x Is CONNECTED ITEMS MIL POWERVIEW DISPLAY creat Qt Em nix o P PEAK S STATE GND ag HA FED ANALOGUE THROTTLE 5K OHMS RECOMMENDED HOWEVER OVERALL RESISTANCE FROM ZK TO 15K SHOULD WORK WIPER TO LOW END RESISTANCE SHOULD BE ZERO OHM MIN 1250 OHM MAX CAN TERVINATOR Lie POWEEQIEW ENCLOSURE 2 bum c eme at Mm Re rr matar Sk aei OEA d 41 LT qua LT Su maT A20 6 D C Wiring AUD gi FUR Standard Ground 12 Volt L1066A ez PETS Drawing D 3748B ht neal gt lt rive D206 720 BLK
3. SP18 Check and clean reverse gear oil cooler First number for mechanically controlled fuel system engines second for electronically controlled fuel system engines OL2 2 06 10 12 Updated 6 24 10 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 ACEA Specification 1 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 These oils are acceptable after the first 100 hours a API Service CC CD single viscosity oils API Service CD CG 4 CF 4 multi viscosity oils ACEA Specification E3 E2 multi viscosity oils CCMC Specification D5 and Mercedes Benz 228 3 CCMC Specification D4 and Mercedes Benz MB228 1 Usethe proper weight oil for your average operation temperature Air Temperature Multi Viscosity Single Viscosity Above 32 F 0 SAE 30W SAE15 40W 10 F to 32 F 23 C 0 SAE 10W SAE10 30W Below 10 F 23 C SAE 5W SAE5 20W Some increase in oil consumption may be expected when SAE 5W and SAE 5 20W oils are used
4. L Lugger marine propulsion engine Lugger model number 106 mm bore 4 cylinder D Naturally aspirated T Turbocharged or A Aftercooled 106 mm bore 6 cylinder Lugger naturally aspirated marine propulsion L1064D engine with a John Deere Powertech Tier Il 4045 engine block with a mechanically controlled fuel System L1064A Lugger aftercooled marine propulsion engine with John Deere Powertech Tier 11 4045 engine block with a electronically controlled fuel system Serial Numbers L1066T Lugger turbocharged marine propulsion _ 1 _ engine with a John Deere Powertech Tier Il 6068 engine block electronically controlled fuel system L1066A Lugger aftercooled marine propulsion engine with a John Deere Powertech Tier Il 6068 engine block electronically controlled fuel system When referencing Northern Lights Inc equipment by serial number please refer only to the number stamped on the Northern Lights or Lugger serial number plate LUGGER by NORTHERN LIGHTS Serial No Model No Northern Lights 4420 14th Ave NW Seattle WA 98107 OL2 2 06 10 Warranty A warranty registration certificate is supplied NOTE If the warranty is to apply the servicing with your set It entitles the original purchaser of instructions outlined in this manual must be our equipment to a warranty covering material followed If further
5. 7 SA Roath AWG 2 D BATIERY CABLES MAX LENGTH TO ENGINE 8 FT EACH SIDE SEE NOTE 3 T to 7 GAUGE LAMP TT E mue Ein apa U ere 6 i DIMMER ayi mol ey II H fije 0 e E hi mr d f 8 B 24V0C STARTER MOTOR Gi 22 41648 in ENG BLOCK TSA HIG YELLOW wg 474 pb xtuow START SLAVE RELAY gy 23 pe nae ALIE RNATOR m D _ 24N 75A Al I I TS e nex Fb ORANCE l KS 40277 8 j z g nz o gs gu ous RED vmire i gt naag i Z T FETU E 79A 6 YELLOW 02 gt gt 03 onza a 340 OWN SELECT BUMP 1 DOWN ma me az o Reo ane excel Ib ly BUMP ENABLE i i T i 0390 no gos EN r E TH pem uc 2 mm WRA d OWERVIEW a i I DISPLAY I GE Iso ma ap PE R VIEW NOTES 1 UNLESS COLOR CODED ALL A D E INSTALLED CONDUCTORS ARE TO BE GREY AND MUST BE IDENTIFIED BY WIRE MARKER AT EACH CONNECTION POINT HIDDEN DASHED LINES REPRESENT CUSTOMER SUPPLIED AND CONNECTED ITEMS ANALOGUE THROTTLE SK OHMS RECOMMENDED HOWEVER OVERALL RESISTANCE FROM 2K TO 15K SHOULD WORK WIPER TO LOW E
6. ANALOG d PPM BREET y Ware IEEE N lt nee DK ERN B om Ga td 5 po 3h y E Z m must I E asl 166 mu Bur t K sss GN r gt mac gm nto 2 x a 3 d amp Spx w 3 Alc ees T 4 1 2 A 16 qun ur EN 7N n x Soe xar aE u I I 2 gt Mig Dv 3e 5 H pm ann XL OPTIONAL Fl YBRIDGE MONITOR PANEL gt is lt lt 1 J HEAR RE A 1 3 gt B 4 d um m y Rd E vv 5 pg L W cle sia 74 erm m cameos des RSS SSS 5 IY gt o j r k X S e I TRAF n AE RAYS los pressure I sino Git aN m B I 29129 GAUGE M s SR D QEGDIN BENI s E a eae RTM emm Hmc s i aisle z DRA nm Wty 4 pe T lt 411 p ERU mr A yee NE SPEED SELECT BUNP Lil ie reg eee l Eq TEL E EI pss w nn rt sp Li A N n HUP ftii TH Rot gre mra l gt uA I I TEMP t EE m DXX pun mor 1 coun IS F I gt I d ax tp jt PP l
7. pz Dez 10 g ECU X08 4 6 BROWNS 41 amp 22A p2 mE Ea 2228 112 FED 226 118 RETS OU FEDS Ax gt lt pin ORANGE ir SES ra T FEBS m qe SEE 05 US 417 20 PUPPLE oz Z 474 nB YELLOW magpa S BJ 0542471 ms lt 112 1B RED 947 n6 Am pi D HG RANDE H v He ROWS ps GN r CS cs KOET B2 Al ine ic 24NDQ SIARTER MOTOR 22241648 qm ENO gt n geom ux o po __440 EU REY SS DZ aS 096 S RA N FEEN lt 3054 1670 Dk GEN d D ic LL coma S e mace ma E x esau T h 95 16 IK LEN S c lt 9220 16 RED 1 OWNS z s ps m H AX pa WHITES c 429 Hue AR p2 RID 9128 RED ps em mur ps ma THROTTLE SWITCH 912 p6 amp RED ai wn SE ai DLE i E 316 YELLOW ioi D C VOLTNETER 120 TERMINATOR HE YELLOW H wan YtLLO ANAC ZD YtLLEM rah YELLOW 20 20 YELLOW 290 SPEED SELECT BUNP 00 BLACK ITE AA 412 BLK He HK
8. Replace secondary filter element Water or dirt in the fuel system Drain flush fill and bleed system Dirty or faulty injection nozzles Have your dealer check injection nozzles Air in fuel system Inspect clamps and hoses on suction side of fuel pump for air leak bleed fuel system Improper type of fuel Consult fuel supplier and use proper type of fuel for operating condition Lack of Engine Power Intake air restriction Service air cleaner Service aftercooler 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 Injection pump out of time See your dealer Electronic fuel system problem See your dealer Turbocharger not functioning if equipped See your dealer Leaking exhaust manifold gasket See your dealer Defective aneroid control line See your dealer Restricted fuel hose Clean or replace fuel hose Low fast idle speed See your dealer Improper valve clearance Reset valves Best done by dealer Dirty or faulty injection nozzles Replace injectors Best done by dealer See your local dealer v Engine Overheats Engine overloaded Reduce the load Low coolan
9. containing soluble oil Servicing COOLANT TESTING 1 Coolant test kits are available to allow on site evalu ation of the coolant condition The kits use small strips of paper which are dipped into the coolant The paper changes color and indi cates the SCA concentration It also indicates the amount of EGC antifreeze Test kits are available through your Northern Lights or Lugger Dealer 4 Pack Part Number 50 Pack Part Number 20 00005 20 00010 SP15 CHECKING COOLANT LEVEL 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 Check the coolant level each day before starting the engine 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 when the engine is cold When filling with cool ant 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 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
10. p TEE iN NOTES 1 UNLESS COLOR CODED ALL A D E INSTALLED CONDUCTORS ARE BE GREY AND MUST BE IDENTIFIED BY WIRE MARKER AT EACH CONNECTION POINT 2 HIDDEN DASHED LINES REPRESENT CUSTOMER SUPPLIED AND T GAU Lii es TR CONNECTED ITEMS l La AR VED li i i o e 3 ANALOGUE THROTTLE 5K OHMS RECOMMENDED HOWEVER OVERALL T Fg lam fou gn ruar RESISTANCE FROM 2K TO 15K SHOULD WORK WIPER TO LOW 1 I S END RESISTANCE SHOULD BE ZERO OHM MIN 1250 OHM MAX Sarl os gt D amp 4A HG D MSAN YELLD POWERVIEW DISPLAY YN WU 415 LX x D C Wiring Standard Ground 12 Volt L1066T Drawing D 3870A OL2 2 01 05 37 MAIN CONTROL PANEL 412 REO Ou PRESSLURE GAUGE ENGINE oor EE INTERCONNECT WRING LOCATION AND CONNECTION BY OTHERS SLOW DLE STOR v ANALOG THROTTLE EMULATOR ANALOGUE THROTILE ay RS Z 24 YELLOW IK T T 315 DK EN C Lar SEE NOTES 2 AND X DET Z Daz men SS SMS Z lt 47 ns YELLOW DIZ 112 RED 04 416 YELLOW ez ENGINE AWG 2 0 BATTERY CABLES AX LENGTH TO ENGINE B FT EACH SIDE onor
11. ENABLE Rr 8 I _ aiw me J sie 2 gi Tx 0208 DR BEAR D PN az pa Ren sanas I Mr d l 1 T l RUS l SE m Bre E I X POWERVIEW pu I TU DISPLAY 87 I are _ A M H SPARES HH 1 I I CAN TERMINATOR x00 OPTIONAL 1 ETN m aS moy os E 1 T _ I ens 325 ey STGP SWITCH 1 0 PANEL L rma mere NND AM des AA I qu P de Eps sragr swircH 1 I ole S one az a 1181 s me i I NOTES o 3 T DN mE ceno REGIE Lovo I 1 UNLESS COLOR CODED ALL ALD E INSTALLED CONDUCTORS PRIMARY Spe bm ARE BE GREY AND MUST IDENTIFIED BY WIRE POWERVIEW_ENCLOSURE g I Ste No a MARKER AT EACH CONNECTION POINT un ESTAS cil _ 00 Hd 2 HIDDEN DASHED LINES REPRESENT CUSTOMER SUPPLIED AND enone n CONNECTED ITEMS m 6 eee i y tpl 3 ANALOGUE THROTTLE SK OHMS RECOMMENDED HOWEVER OVERALL E SEGONDARY see 7 OPTOMA Enche RESISTANCE FROM 2K TO 15K SHOULD WORK WIPER TO LOW POWERVEW ENCLOSURE DH T sa et END RESISTANCE SHOULD BE ZERO OHM MIN 1250 OHM MAX OPTIONAL SECOND LOCATION B LENT gest on REMOVE JUMPERS AT CONNEC
12. Fuels General Fuel Filters Crankshaft Vibration Damper Bleeding the Fuel System Injector Service Injection Pump WIRING DIAGRAMS Lugger DC Electrical ON BOARD SPARE PARTS Proprietary Information This publication is the property of Northern Lights Inc It may not be reproduced in whole or in part without the written permission of Northern Lights Inc Northern Lights Inc All rights reserved Litho U S A Publication number OL2 2 1 10 OL2 2 06 10 1 Revised page 3 2 10 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 equipment Failures often occur in remote areas far from competent assistance Marine engines are taxed far more severely than auto or truck engines therefore maintenance schedules must be adhered to more strictly Model Numbers Failures begin with minor problems that are overlooked and become amplified when not corrected during routine maintenance As operator it is your obligation to learn about your equipment and its proper maintenance This is not a comprehensive technical service manual Nor will it make the reader into an expert mechanic Its aim is to aid you in maintaining your unit properly Model numbers give the unit s application block model aspiration and RPM L 1064 or 1066 D T orA
13. OPERATOR S MANUAL 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 2010 Alaska Diesel Electric Inc All rights reserved Northern LightsTM and the Northern Lights logo are trademarks of Northern Lights Inc Printed in U S A PART NO OL2 2 1 10 NORTHERN LIGHTS OPERATOR S MANUAL 2 2 for Models L1064D L1064A L1066T and L1066A Read this operator s manual thoroughly before starting to operate your equipment This manual contains information you will need to run and service your new unit Table of Contents INTRODUCTION Models Included Model Numbers Serial Numbers Turbocharger Turbo Boost Cooling System General Engine Coolant Specifications Cooling System Flushing Heat Exchanger Cleaning Zinc Electrodes WARRANTY SAFETY RULES Raw Water Pump Electrical System General Booster Batteries Battery Care Winterizing Out of Service COMPONENT LOCATIONS LUGGER CONTROL PANELS OPERATING PROCEDURES Before Starting Shutdown Procedures Break In Period TROUBLESHOOTING Electrical SERVICING SCHEDULE CHART SERVICING Lubrication General Checking Oil Oil Changes Changing Oil Filter Air Filter Valve Clearances
14. SP12 INJECTION PUMP 1 Since operating conditions may vary considerably it is difficult to give a definite service interval But as arule the pump settings maximum speed idle speed and exhaust smoke should be checked by your dealer after every 2400 hours of operation Service of the fuel injection pump should only be done if checks indicate pump malfunction Black smoke can be an indication of pump malfunctions Before servicing pump check the other possible causes a Check cleanliness of air filter b Check valve clearances c Clean and check injectors 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 unau thorized persons OL2 2 06 10 18 INJECTION PUMPS REMOVAL Clean the fuel injection pump lines and area around the pump with cleaning solvent or a steam cleaner IMPORTANT Never steam clean or pour cold water on a fuel injection pump while the pump is running or while it is warm Doing so may cause seizure of internal rotating pump parts Rotate the engine to TDC Top Dead Center of number cylinder compression stroke and install the JDG1511 timing pin into the flywheel Install the injection pump timing pin JDG1559 into the pin bore of the injection pump Fig 19A before
15. The makeup coolant added to compensate for loss or leaks must meet engine coolant requirements outlined in previous section SP16 FLUSHING THE COOLING SYSTEM A 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 OL2 2 06 10 24 Flush the cooling system and check for leaks and blockage every 600 hours or yearly The engine must be stopped and cold Close the seacock Remove the pressure cap from the expansion tank with caution If applicable open the cooling system air vent on top of turbocharger Open the drains on the exhaust manifold and engine block Drain the fresh water system see Component Locations page 4 For vessels with keel cooling the vessel must be out of the water to allow draining of the keel cooler With drains open pour clean water into the expansion tank When the water from drain is clear and free from discoloration and sediment close that drain When all drains are closed flushing is complete Fill the fresh water system by pouring the recommended coolant mixture as described in previ ous sections Close cooling system air vent on turbocharger Open the seacock Start the engine Check hoses and connections and repair any leakage
16. uP BLACK Por L 16 ire pee Vina E NOTES 1 POWERMEW 11 DISPLAY 1 UNLESS COLOR CODED ALL A D E INSTALLED CONDUCTORS 3 ARE T BE GREY AND MUST BE IDENTIFIED BY WIRE MARKER AT EACH CONNECTION POINT HIDDEN DASHED LINES REPRESENT CUSTOMER SUPPLIED AND CONNECTED ITEMS ANALOGUE THROTTLE 5K OHMS RECOMMENDED HOWEVER OVERALL i i l RESISTANCE FROM 2K TO 15K SHOULD WORK WIPER TO LOW g END RESISTANCE SHOULD BE ZERO OHM MIN 1250 OHM MAX POWERVIEW ENCLOSURE eA A ALAA SAN TERMINATOR 420 CRN ih fv NAN u a ge mix 012 16 RED 9048 20 YELLOW D C Wiring Standard Ground 24 Volt L1066T Drawing D 3871A OL2 2 01 05 38 GAUGE LAMP DIMMER 9 g SHUT DOWN RELAY A4 pk BLACK ENGINE CONTROL SWITCH PURPLE 5DA 2 922 12 RED A12 YELLOW RED MAIN CONTROL _PANEL 12 15 RED SDR 16 REO NI 012 1 EOF THROTT AT BY OTHERS SLOW QE STOP ii E SS SEE NOTES 2 amp 3 AND CONNECTON 7 OTHERS fast ime soe ANALOG THROTTLE CONNECTOR 4148 16 YELL 015 g E DK S118 ENGINE ETATIS ATA ur pup veL ECU X06 i u pa 2 gunt n
17. Battery Booster Battery Figure 27 Booster Battery Connections Then connect negative terminal of booster battery to ground on the engine block see Figure 27 Remove booster battery after starting engine Sealed batteries see manufacturer charging and booster instructions SP21 22 BATTERY CARE LEAD ACID TYPE BATTERIES 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 corro sion 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 OL2 2 06 10 26 Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer DC ELECTRICAL SYSTEM v Battery Will Not Charge 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 Undercharged Electrical System Excessive electrical load from added accessories Take off accessories or install higher output alternator Engine idling excessively e Increase the engine RPM when there is a heavy electrical load Poor electrical connec
18. Check oil level frequently 5 Never put additives or flushing oil in crankcase SP1 CHECK ENGINE OIL LEVEL Check the oil level in the crankcase with the oil dipstick daily The oil level must be between the Waffled area and the Never allow the level to go below the Always add the same viscosity of oil as is already in the crankcase Servicing SP2 OIL CHANGES 1 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 Refill engine with recommended oil Engine Lube Oil Capacity L1064D T1 L1064A L1066T L1066A 14 7 liters 20 5 liters 19 0 liters 32 5 liters 15 5 qts 21 6 qts 20 ats 34 3 qts depending on oil pan size SP3 CHANGING OIL FILTER 1 2 Chanee 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 wrench tighten filter one half turn farther Overtightening can do damage to filter housin
19. removing the pump from the engine IMPORTANT Always use a backup wrench when loosening or tightening fuel lines at injection pump so that discharge fittings are not altered which will prevent internal pump damage Remove the injection pump drive gear cover Then remove the gear retaining nut and washer from the end of the pump shaft Do not let the washer fall inside the timing gear cover eproduced by permission of Deere ompany Deere ompany rights reserved Figure 18 reproduced ission of Deere amp C 2004 Deere amp Ci All righ d RG12002 Servicing INJECTION PUMPS REMOVAL CONTINUED Remove the temperature sensor connector Fig 21A and the fuel control solenoid connector B 5 Attach the drive gear puller JDG1560 to the injection pump drive gear Fig 20 B using two IMPORTANT Always use a backup wrench when screws C Tighten the screws even and tighten loosening or tightening fuel delivery lines at fuel injec the center forcing screw D against the end of the tion pump so that the pump discharge fittings are not pe shaft altered This prevents possible internal pump damage Tighten the center forcing screw Fig 20 D until the pump drive gear is free from the tapered shaft Disconnect the fuel supply line Fig 21 D and return Then remove the puller JDG1560 from the drive line C Remove the clamp E holding the fuel delivery pressure lines F Disconnect all the fuel delive
20. 71 s ATS 16 mE 2h REMOTE UN DFF X95 Z RED Dzm giz POWER FUSE FOI DZE 12 men FUCL PRESS DOT 0146 YEL gt is AWG 2 0 BATTERY CABLES MAX LENGTH ENGI B FT EACH SIDE MO BLACK A A57 16 PURPLE SSR ooze pin REG 12VDC Ho III 1 12VUC STARTING MOTOR RE70957 ENG BLOCK gt 27 GIL PRESSURE GMIGE 474 no YELLOW CASE GROUND 1022 az RED pm START SLAVE RELAY 422 12 RED SER E S22 12 REQ w 914 16 YELLOW 12 Y R 4 22 p2 RED 14 BLACK SE h AD 12 BLK SHEL 4 1 206 1211 012 418 REO 4 A N mim p RED 416 PNK 90 A DES 412 RED lt 412 4B RED we creey ne wont 514 416_YELLOW 76A 416 YELLOW s a 4 oom je HQURMEIER s q2 BA Pane s 954 YELL m ALT RRATOR 12V B5 s N AT173824 BC ure 4 dq p ENGINE TEMP sPARC ae 34 GREYS LOSS OF CLNT id 412 AiB RED AE GROUND 114 BROWN gt s lt 41 ZO PURPLE PUP EVENT ecg DAG BUNK cones xia Dk 47 M 16 Pusat YELLOW YELLOW ion YELLOW D mna Varro M E I a 12 445 pa 1
21. SP17 HEAT EXCHANGER CLEANING If applicable Drain the cooling system Remove the cooling water pipes between the heat exchanger and the water pump inlet Disconnect hose to seawater pump 4 Unscrew the attaching bolts holding the heat exchanger to the expansion tank Remove bolts holding heat exchanger cover Wash the core inside and out If necessary chemical agents can be used Also clean the accessible parts of the heat exchanger housing Reassemble using new gaskets and sealing rings SP19 ZINC ANODES 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 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 exchanger see Component Locations Keel Cooled engines a Drain expansion tank and remove zinc holder from tank see Component Locations 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 Reinstall the zinc holders Be sure the threads are clean and have good metal to metal contact SP20 RAW WATER PUMP Heat exchanged cooled engines only Change the sea water pump impelle
22. drops into the recess in the injection pump drive shaft F igure 23 Reproduced by permission of Deere amp Company c 2004 Deere amp Company All reserved RG12004 igure 22 Reproduced by permission of Deere amp Company c 2004 Deere amp Company All reserved RG12019 Note When rotating engine to Top Dead Center of compression stroke on number 1 cylinder turn engine only in direction of rotation to prevent gear backlash Poor engine performance could result if gear backlash occurs and thr OWS the injection pump timing ofi f by F igure 24 Reproduced by permission of Deere amp Company c 2004 Deere amp Company reserved several degrees RG12008 Make sure that the number 1 cylinder is locked at the Rotate the gear counterclockwise as viewed TDC of the compression stroke and install a timing from front ofthe engine to remove any backlash pin JDG1571 in the flywheel Also leave the injec and tighten the gear mounting nut to below tion pump timing pin JDG1559 in during pump specification installation Fig 19 A Install the pump onto the mounting studs and tighten Injection Pump Gear Mounting Nut Torque the three pump mounting stud nuts Fig 23 A to 195 Nem 145 ft lb below specification Position the drive gear while installing the pump Install the injection pump gear access plate and remove timing pin Fig 19 A from the pump Injection Pump Stud Nuts Torque 25 Nem 19 ft
23. information is needed please or assembly faults The extent of coverage is contact an authorized dealer or the factory described in the Limited Warranty Statement We recommend that you study the statement carefully 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 Use caution in handling fuel Never refuel a hot or running engine Do not smoke while filling Turn the coolant tank cap slowly to relieve m fuel tank or servicing fuel system pressure before removing Add coolant only when the engine is stopped and cool Keep your hands feet hair and clothing away eee from power driven parts Mount a fire extinguisher near engine Check for any loose electrical connections or Always disconnect the battery ground strap faulty witing before making adjustments ee Engines should be operated only by Operate engines in properly ventilated areas knostedecable qualified personnel Keep trash and other objects away from engine Escaping fluids under pressure can penetrate that everything is clear before starting your skin Use a piece of cardboard or wood Do not operate an engine that isn t in proper not your hands to search for leaks g prop working order I
24. 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 fuel see a doctor at once Serious infection or reaction can develop if proper medical treatment is not administered immediately OL2 2 06 10 16 1 Whenever the fuel system has been opened for service lines disconnected filter changed etc it will be nec essary to bleed air from the system a To bleed the fuel system loosen the bleed plug on the fuel filter Operate the primer pump lever on fuel transfer pump see component locations until most of the air bubbles are expelled and clear fuel escapes the bleed plug Tighten the bleed plug If the engine will not start it may be necessary to loosen the fuel supply pipe at the pump Operate primer lever of fuel supply pump until fuel flow is free from air bubbles Retighten fuel supply line to 22 ft Ib 30 Nem If engine still doesn t start loosen fuel line connection at injection nozzle Always use a back up wrench when loosening or tightening fuel lines at nozzles and injection pump to avoid damage With throttle on full crank the engine over with the starter until fuel without air flows from the loose fuel pipe connection Repeat proced
25. on pilot tool Use a new seal washer Figure 16 A to help slide the carbon seal into place until it seats in its groove on nozzle body Continue to slide upper sealing washer onto nozzle body until it seats against inlet fitting Install injection nozzles NOTE Before installing injection nozzles make sure nozzles are clean and free from oil or grease Do not grease or oil the nozzles Remove plug if installed previously from nozzle bore in cylinder head and blow out bore with compressed air Make sure that the sealing surface of the cylinder head on which the seal washer will be resting is smooth and free of damage or dirt This could prevent proper sealing Dirt and roughness could also cause distortion to nozzle when the attaching screw is tightened making the valve stick Install nozzle in cylinder head using a slight twisting motion as nozzle is seated in bore Install spacer and cap screw Do not tighten capscrew at this stage OL2 2 06 10 Reproduced by permission of Deere amp Company Deere amp Company All Rights reserved Figure 17 Shows relationship of parts required for installation e Connect fuel pressure line to nozzle Leave connection slightly loose until air is bled from system f Tighten nozzle hold down cap screws to 27 foot Ib 37 m g Install leak off assembly h Bleed air from loose injection line connection Tighten connection using two wrenches
26. 0 RPM 93 2200 RPM 85 2000 RPM 51 US gal 2400 rpm 192 Itr 2400 rpm 6147 BTU min 2 0 inch NPT 53 2400 rpm 200 pm 2400 rpm 39 in 1 m 86 F 30 C 5 5 US gal 21 Itr 640 CCA ace 20 ft 6 m 360 cfm 2400 rom 10 2 m3 min 2400 rpm 105 sq in 068 m 858 cfm 9 2400 rpm 24 3 m min 2400 rpm 887 F 2400 rpm 475 C 2400 rpm 30 in 750 mm H 0 3 in 75 mm 5 in 127 mm 3 8 in 9 mm 39 in 1 m 21 7 US qts 20 5 Itr Counter Clockwise SAE 4 SAE 5 0 Added page 2 4 09 updated 6 10 09 Model Number L1066T Crankshaft Hp High Output 170 2500 RPM Medium Duty Continuous Duty 165 2400 RPM 135 2200 RPM Crankshaft kW High Output 126 2500 RPM Medium Duty Continuous Duty 122 2400 RPM 100 2200 RPM 1 Based on SAE J816b 2 Based on EN ISO 8665 2006 Cooling General Freshwater circulating pump flow 63 US gal 2500 rpm 240 Itr 2500 rpm Heat rejection to jacket water 5570 BTU min Cooling Heat Exchanger Raw water intake amp discharge dia 1 25 inch NPT Raw water pump flow RPM 31 gpm 2500 rpm 117 pm 2500 rpm Raw water pump max suction head 39 in 1 Max raw water temp at inlet 85 F 30 Freshwater system capacity 6 5 US gal 24 6 Itr Specifications L1066 L1066A 250 9 2400 RPM 200 2200 RPM 185 9 2400 RPM 185 2400 RPM 148 2200 RPM 137 2400 RPM 61 US gal 2400 rpm 2
27. 2 120 ptg men gt a A ud amp FT EACH S 1 a 2 FUSE Y H2 i mar at 2 SEE NOTE B ECU 2G A2 R _ BY OTHERS rast oe se __ AC Up 294 i n GAUGE LAMP i SDR AR DIMMER An ED penam a 2m eun A m FUEL PRESS Hii Mies n Jo i IQ oN 12 RED ata Tah gi 24 penal A m Ke zn S jaza gin muna S547 3 SAMA Dt ese ae 24 0 STARTER MOTOR INTERCONNECT WIRING na Nase EEE NES sa a 22 41648 i MIRO PANEL E Ei EE w 46 4 SBT ns 467 1 HOURMETER 122 12 RED gt br amp lt rr P E lt 1 P nz nalen 48 DS ELS BERE ata YELLOW sue S27 g ry a cc UR Uc ct tnum m lt mel E TACHOMETER mf E gt ha 7 am een lt E wan x a era m r lt PETA SS PTT gt res B se 28 gt a amp d gt 52 I lt a R z 16 dae 3 416 j N f i zm N i p SEC NOTE 6 eee eS gt EMRE CRANE MULA a i vmm eem E D um LE B3 447 PURPLE gt L 79h 118 16_PURPLE DES amp x 1 I 1 2 S ss i lt at ne pe pun even F gt gaits P Aur lt a Ds xac Z TEN lt
28. 29 Itr 2400 rpm 5382 BTU min 2 inch NPT 53 2400 rpm 200 2400 rpm 39 in 1 m 85 F 30 6 5 US gal 24 6 Itr Cooling Keel Cooled Water hose inside diameter Head diameter 1 1 2 in 38 mm Turbo tube length 24 ft 7 3 m One inch plain round tube length 56 ft 17 m Skin cooler Aluminum 26 sq ft 2 4 m Steel 85 sq ft 8 9 m Based on 70 F seawater and minimum boat speed of 8 knots at full speed Return water on keel cooling 70 to 130 F 2 3 8 in 60 mm Electrical Minimum battery capacity 12V 800 CCA 800 CCA Battery cable size up to 10 ft run 000 000 Standard harness length 20 ft 6 m 20 ft 6 m Air Engine air consumption 417 cfm 9 2500 rpm 118 m3 min 2500 rpm 118 sq 073 m 1038 2500 rpm 29 4 m min 9 2500 rpm 876 F 2500 rpm 469 C 2500 rpm Maximum exhaust back pressure 30 in 750 mm 0 Suggested dry exhaust I D Dry 3 in 75 mm Wet 4 in 100 mm 629 cfm 2400 rpm 17 8 m3 min 2400 rpm 184 sq in 012 m 1465 2400 rpm 41 5 m min 2400 rpm 860 F 2400 rpm 460 C 2400 rpm 30 in 750 mm 0 Minimum engine room vent area Exhaust gas flow Exhaust gas temperature at rpm 4 in 100 mm 5 in 127 mm Fuel and Oil Min fuel suction and return line 3 8 in 9 5 mm 3 8 in 9 5 mm Maximum fuel pump head 39 in 1 m 39 in 1 m Crankcase oil capacity 19 US qts 18 Itr 19 US qts 18 Itr Gear P
29. 5455 Northern Lights and Lugger are registered trademarks of Northern Lights Inc www northern lights com 2010 All rights reserved Litho USA
30. 9 WITH MALE TERMINALS P N 12124582 AND CABLE SEAL see Noe 6 E __ RE ee rawing D 3889B P N 12010293 LOCATE ASSEMBLY NEAR 21 PIN CONNECTOR Ge 9 OL2 2 01 05 40 On Board 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 conditions may require more of a given part Consult your dealer World Item Description Standard Class 1 Lube Oil Filter 4 4 2 Air Filter Element 1 1 3 Fuel Filter 2 2 4 Injector 0 6 5 Thermostat 2 2 6 Thermostat Ring 2 2 7 Relay 0 2 8 Valve Cover Gasket 1 2 9 Gasket Kit Top 0 1 10 Gasket Kit Bottom 0 1 11 Zinc 6 12 12 Raw Water Pump Impeller 2 2 13 Raw Water Pump Cover Gasket 2 2 14 Raw Water Pump 0 1 15 Workshop Manual 0 1 16 Set of Alternator Belts 1 1 17 Fuel Washer Kit Std 1 wic 1 Heat exchanger cooled engines only OL2 2 01 05 39 NORTHERN LIGHTS 4420 14th Ave NW Seattle WA 98107 NORTHERN Tel 206 789 3880 1 800 762 0165 Fax 206 782
31. ESSURE 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 immediately OL2 2 06 10 6 Added page 01 15 10 Figure 2 Lugger Instrument Control Panel TACHOMETER The tachometer shows the engine speed in revolutions per minute RPM Numbers are mul tiples of 100 HOUR METER Keeps track of the engine running time DC VOLTMETER When the engine is stopped the voltmeter shows the condition of the battery When the engine is running it indicates the voltage output of the alternator KEY SWITCH Turning the key clockwise to the first position will switch on the current continue turning the key clockwise to start the engine When the engine starts immediately turn the key back to the first position while the engine is running The key must be kept in the on or first position while the engine is running Note Optional flybridge panels have engine start switches instead of key switches SM Lugger Control Panel Z e E 20 7 a wt mo Q5 STOP BUTTON Stops engine immediately INSTRUMENT PANEL LIGHTING The switch turns on the instrument panel lights OIL PRESSURE FAULT LIGHT Indicates low oil pressure ENGINE TEMPERATURE FAULT LIGHT Indicates engine is over heating Activates in conjunction with alarm horn ALARM HORN Shut down engine if possible and investigate im
32. MS IOHINOO 3NI9N3 A389 39v 18 1385 TANVd I OSHLNOO MOTA SIH 390v OL2 2 06 10 32 09 09 079017 HOA tz punog piepuelS BuutM DC Wiring Diagram G333038O SI 13NVd XNV TVNOI1dO N3HM AINO Q3TIVISNI 38V JIDNODOWYIHL S33G0N3S JYNSS3Yd WO AVIS ANY CIOJINVN Iv OM1d OH3N WONJ 9 38 Ol HION31 ANIYHS IV3H Q333A02 ATIWNQIAIGNI 38 OL Q3Sn SNI38 LON SYOLONONOD SS3NSVH 11 LNIOd NOLLOJNNOO HOV3 IV M3 xuvW 38IM 0313113301 38 ISAW ANY A3HO 38 01 SHOLONGNOD Q3TIVISNI 3 0 v TIv 03009 30109 SSIINN AJLON SV 1d32X3 ONVMISIEIQGN 2vAOO9 2 601 MLN 3dAL vL SMV 38 OL SYOLSNGNOD NOILVIIVISNI TIV 7 310N 9nd IYIN JIVW314 39NVHNO 30N3S 38 553 4 Q O3INVW IV HJLMS NONI NMONB 31IHA HOLIMS 38155384 3NDN3 58 lt gt SB quy 4 3 1 S27 avus NBDH Wwuv1v xq WNOLdO 3M18 311HM NMOULAHS A389 31IHA 310N 335 32v18 390v9H21IMS QN9 13431 LNVIOOD 3 30N3S 3NDN3 TWNOILGO i 5 553 10 p 3NI N3 3 qW34 wNOILJO ava ONY OF BHM zi 1 L TE 1 A385 OF 3Hruv34 3ONVAQV 12 15 D OO M d
33. ND RESISTANCE SHOULD ZERO OHM MIN 1250 OHM MAX 2048 20 RN o X OKO Oxec rz Q D C Wiring Standard Ground 24 Volt L1064A Drawing D 3869 OL2 2 01 05 36 AIN CONTROL PANEE meo oo ENGINE SLOW OLE ANALOGUE THROTILE 7 gh m Y OTHERS yy BiAA 16 YELL ox CH S PLA 2 7 4 315 Dx aye 2 0 BATTERY CABLE Ax LENGTH TQ ENGINE SEE NOTES 2 amp 3 Z ho REO Sti 012 16 FAST OLE STOP ne GAUGE LAMP peste Bs pmi DIMMER DXX mac 12 ne FED ksaq n REY lll go 12VDC i Ils E Sr A8 14 A gt a Ca e eee BELLO 1 922 412 BED _ 3 ha p B TA om A 3 e ruw x 2 2 lt LO 4 12 Y R jp SMP M gt gt 497 gig PURPLE 14 BLACK 25 VELL ANALOG THROTTLE EMULATOR 12 YELLGW RED CASE c GROUND SELD s 2 012 415 RED E T L L z WR ES oy TES uc DU RUE EOD E ie E a cde EN cc as P S Une g mot START SLAVE RELAY lo A12 6 REO gt t t i 2 5 z z le A A12 wa pa onc gt B3 lt DR ANGE p A22 m2 RED ALTERNATOR i SEEN 1 lt 48 47 AB APRE
34. NOTE Do not use screwdrivers pry bars or similar tools for this as they might damage the injection nozzle Clean Injector Bore Always turn the tool clockwise through the bore even when removing from bore otherwise tool may become dull a Clean nozzle bore with JDE39 Nozzle Bore Cleaning Tool Blow debris from bore with compressed air and plug the bore to prevent entry of foreign material Clean injection nozzles a Remove carbon stop seal Figure 15 A and upper sealing washer Figure 15 B using a needle nose pliers Discard seals Clean exterior of nozzle by soaking in clean solvent or diesel fuel Clean tip with brass wire Reprinted by permission of Deere amp Company 2004 All rights reserved RG6300 Figure 15 NOTE Do not scrape or disturb the teflon coat ing on the nozzle body above the carbon stop seal groove Servicing This coating will become discolored during normal operation but this is not harmful Do not use a motor driven brush to clean up nozzle body Figure 16 5 Install seals on injection nozzle NOTE Each time an injection nozzle is removed from the cylinder head replace carbon stop seal B with a new one Position JD258 ROS16477 Pilot Tool Figure 16 C over nozzle tip If Pilot Tool included in cleaning kit is not available use a No 16189 Nozzle Protector Cap found on every new or re placement nozzle Position a new carbon stop seal Figure 16 B
35. 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 ruined Starting Put the gear control in the neutral position Move the throttle control to the full speed position and return back to idle Turn the key switch to the first position Check the voltage meter to see the condition of the batteries For starting the voltmeter should not read below 12 volts 24 volts for 24 volt systems Turn the key to the starting position and as soon as the engine starts release the key Move the throttle up until the engine is running at approximately 1000 RPM Do not crank the starter for more than 15 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 to 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 Check the voltmeter It should read 13 to 14 volts 26 to 28 volts for 24 volt systems at 60 F 16 C Water temperature should not rise over 200 F 94 C If it does shut down the engine and investi gate the cause of overheating Do not exceed 800 RPM when shifting marine gear Repeated shifts at higher engine s
36. SS p1 2829 GRAND 12 65 pe pa xy Pee sn WA rm C TN M MEME E meer ae a ibat 7 lt JAT T3524 grs ge aroba 1 cz CRAG D lt GN _ BLACK a Ap 1 K 8 pa m TEE 412 RED o Euo 415 ORANE 78 m YELLOW S mman YELLOW 00 0 uror i pestes t ete e 120 GRANDE gt J lt po GREY ny 1 RRS oo eR jet t L a MIGL 2 L d MEE Su al L flaw ONT RS ri K lt nan go rin mesum ep IE r GREEN s Sb gi X DEN S nS Oe E SIE H6 BROW ENGINE er LP pase GROUND 12D nv ERMNATOR BACK aD feel IP B4 ABS ia 2 onzA ne DG Perce zin gu utl H 2 __ P au 5 ED Arah YELLE 416 YELL D204 bro F 0208 DR A706 420 BLK SPEED SELECT BUMP E H Dim mex eR a 4 bl ES WHITE aot I lt VIT H as RED S e mi te EE Erg nux 7 BUNF ENABLE ENDE BLACK ee eee 120 DX G int gt rm mn 1 o P ue 993 Qni 020 DK GRN o
37. STANCE SHOULD BE ZERO OHM MIN 1250 OHM MAX OL2 2 01 05 35 INTERCONNECT WIRING LOCATION AND CONNECTION BY QTHERS SLOW STON aN ANALOCUE THROTILE 5 BEY DERS NM OE d SEC NOTES 2 amp lt DC d FAST STOD I we ll 7 1 Yen lI SPEED SELECT BUMP k L aam me nz pe 6 DK REEN jd a ae ei m fq POWERVIEW DISPLAY EK 9 i PI ANALOG THR TTLC ENI ECU X08 941 15 BROWNS 4 ENGINE AWG 2 0 BATTERY CABLE MAX LENGTH TO ENGINE 8 FT EACH SIDE 062 RED 12VOC im TERS a Z Wa TY 447 20 PURPLE B2 62 415 318 6 GREY Gy C7475 ORANCE l 947 M amp PURDLI wi pt mee o l 020 CRT SS D2 aK BLACK g H n 1 FE a d IE RONS E 4359 P6 B gt E N 24 Mie TEL ssa 12v0C 2 7KW ENG BLOCK ARTI MOTOR Cid S A A o O CASE GROUND START SLAVE_RELA o p SJ ALTERNATOR 12V G5A AT1 73624 ssa 412 HIE BED SEE NOTE CASE GROUND Standard Ground 12 Volt L1064A D C Wiring Drawing D 3867 MAIN CONTROL INTERCONNECT ENGINE SHUT DOWN RELAY wa ug Q 5 SLOW IDLE Bae S ANALOGUE THROTTLE A gv
38. TIVE SCA CAUTION Supplemental coolant additive contains alkali Avoid contact with eyes Avoid contact with skin Do not take internally In case of contact imme diately wash skin with soap and water For eyes flush with large amounts of water for at least 15 min utes Call a physician KEEP OUT OF REACH OF CHILDREN Follow all warnings on the container Important heat exchanger cooled engines 24 C 12 F 106 C 60 4222 F Minimum 40 52 C 62 F 111 ane 232 60 OL2 2 06 10 23 Additional SCA s should NOT be added to the mix ture of EGC H 0 on initial fill up of engines with a coolant conditioner filter A high SCA concen tration 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 con centration meets recommended levels SCA is available from your Northern Lights dealer in the following sizes Pint Part Number 20 00002 20 00003 DO NOT use any coolant system additives
39. TO Engine Angle Engine rotation facing flywheel Counter Clockwise Counter Clockwise Flywheel housing size SAE 2 SAE 2 Front PTO size optional SAE 5 SAE 5 Max intermittent operating angle Front down 0 0 Rear down OL2 2 06 10 31 2029 0 Buiweiq 1790171 HOA ZL punog puepuels O d OfYld IYIN d3H3Q0HO SI TANVd Xnv WNOlldO N3HM AINO Q3TIVISNI 33V 31HnO2OWH3Hl ONY SH3ON3S 3HhSS3Nd 110 3v39 ONY GIOJINVW OU3N WOHJ 9 38 OL HION3T1 onld ONIBNL NIBHS 1V3H HLM 038H3 02 ATIWNOWION 38 OL 33V 0351 ONIZBG LON SSOIOnQNOO SS3NBVH T1V 4NIOd NOILOSNNOD HOV lV 8333 3HIM 9313113301 LSNW ONY A3395 38 OL SYOLONONOD Q3TIVISNI 3 0 v TY 03009 301029 SSIINN Q31ON Sv 1d329X3 ONVYLSILINW OvAOO9 2 S0L MIW 3dAL 1 SMV 38 OL SMOIO9nONOO NOLVTIVISNI TI L Na 392 we a e 1Sd 00 0 17 1 m M30N3S 5359 ID 439 SALON gt amg r URE Q wongo 3lanoqOWu3H1 JION 335 1 M3UN3S JSS I Q YOJNYN uiv HOLMS JING 8t NNQ3B 3LIHM HOLMS 33155249 10 NINI 49797 it n amp 132018 3 ES JONVOHOLIMS T3A31 LNV1009 TWNOILdO a ang 310038 m HOLS dN MOT 3NIONI 1 301 3NN02 3n8 3unM sa lt 98 reap 6 JONV YO IWNOILdO A 2 rn NI Te
40. TOR WHEN THROTTLE IS CONNECTED POWERVEW eT qn CT t 4 ISOLATE ANY UNUSED LEADS USING ELECTRICAL TAPE m licae ail d umawa mamam cea T 5 IF ND FLYBRIDGE PANEL 18 USED INSTALL 120 OHM TERMINATOR ON C adi Iv PNP EER a EEEE PTO X 1 cm MAIN CONTROL PANEL ALARM HORN CONNECTOR gt Wr ai Pal ped jy E 6 OPTIONAL AUXILIARY PANEL CONNECTIONS REMOVE STANDARD I Pan l REID T a 2 8 y Leos 927 1 HARNESS CONNECTIONS AT TERM S N AND P INSTALL AUX e ER abe mts oe 1m PANEL CONDUCTORS TO TERM S N AND P AS SHOWN ER 5 gt SCR zone N gt lt gt lt P aa 3 7 REMOTE LOUD ALARM HORN LEADS ARE EXTEND APROXIMATELY 5 Af Larei OPTIONAL ITEMS i EM a oe EM dm SIX FEET FROM 21 PIN CONNECTOR LOCATION COVER WITH 1 4 z PANEL CONVOLUTED CONDUIT BUNDLE LOOP SIX FOOT RUN SECURE 1 WITH WIRE TIES AND HANG BUNDLE NEAR 21 PIN CONNECTOR GREEN fps d TERMINATE LEADS USING 8 RING TERMINALS ees i D C Wiring 8 REMOVE CONDUCTORS FROM 21 PIN CONNECTOR TERMINALS L TO ENGINE AND M CONNECT TO ANALOG THROTTLE EMULATOR CONNECTOR AS 21 PN AK qr Isolated Ground 24 Volt L1066A SHOWN USE PACKARD WEATHER PACK 3 CAVITY CONNECTOR P N So m SEE NOTE ry RM D 2082
41. Y 1 Distilled de ionized 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 Grains per Gallon Parts Contaminates per Million 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 OL2 2 06 10 22 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 CAUTION EGC Antifreeze is flammable Keep it away from any open flame Avoid con tact 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 min utes Call a physician KEEP OUT OF REACH OF CHILDREN Follow all warnings o
42. ce SP4 Check air cleaner valve amp restriction indicator gauge SP7 Check crankshaft vibration damper SP7 Check crankshaft vibration damper SP12 Check fuel injection pump SP15 Check coolant level SP16 Check and flush cooling system EVERY 250 HOURS 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 thermostats SP5 Check V belt condition SP30 Adjust variable speed droop SERVICE 50 100 POINT PAGE OPERATION DAILY Hours Hours ENGINE SP1 15 Check oil level SP2 15 Change engine oil SP3 15 Change lube oil filters SP4 15 Check air cleaner valve SP5 Check belt condition SP6 16 Check valve clearances SP7 17 Check crankshaft vibration damper SP25 Check engine mounts SP27 Check air intake hoses SP30 Check engine speeds FUEL SYSTEM SP8 Check primary filter Racor SP9 Change primary filter element Racor SP10 Change secondary fuel filter SP11 Check injectors SP12 Check fuel injection pump TURBOCHARGER SP13 Check air oil amp cooling water lines for leakage SP14 Check boost pressure COOLING SYSTEM SP15 Check cooling water level SP16 Check and flush cooling system SP17 Check and clean heat exchanger SP18 Check and clean gear oil cooler SP19 Check zinc electrodes SP20 Change impeller in raw water pump ELECTRICAL SYSTEM SP21 Check electrolyte level in batteries SP22 Check condi
43. col 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 non corro sive environment for cooling system components Ethylene glycol coolant concentrate antifreeze normally DOES NOT contain the SCA chemical inhibitors needed to control liner pitting or ero sion rust scale and acidity LINER EROSION PITTING 1 Cylinder liner walls Figure 26 A which in contact with engine coolant Figure 26 B can be eroded or pitted unless the proper concentration and type of SCA s are present in the coolant Water pump impel lers are also susceptible to pitting A Cylinder Liner Walls Vapor bubbles Figure 26 C are formed when the piston s impact causes the liner walls to vibrate sending pressure waves into the coolant 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 allows coolant to enter the combustion chamber Engine failure or other serious damage will result B Engine Coolant C Vapor Bubbles Figure 26 4 Unprotected engines with low quality water as cool ant can have liner failure in as few as 500 hours WATER QUALIT
44. d TINA 3NADVNVIS J mat aay oig 9nd 283N JIWAN 39NV 4Ov a V S 14 IYIN MOVIE NOIO3NNOO TAN d AMVTIIXNY JINVYO maviv AW INONT 1 SIN IYIN Fib v t VOLON QNUEVIS 20 vZ 11020 72 WSL NZ MOLWNYITY 306 HIWI 13 8 3NION3 OL HISN31 18v2 Z DMY g MOvB 1 IS3NHVH NOISN31X3 TYLA 3IIHM NMOB 3LIHM OL2 2 06 10 JHN 34055339 10 3018 31HM A385 3LIHW HOLS GIONJWS 2015 VAN 9 B313N8nOH HOLINS 1H9n 39nv9 X9v1B 9 ILANA ga oif 31duNd HOLIMS TOYLNOD 3NI9N3 8 10 A389 3v 18 4389 TANVd IOYLNOS NIVW 5 lt 39nv9 33 MAIN CONTROL PANEL SHUT DOWN RELAY Qu ENGINE CONTROL SWITCH GAUGE LAMP DIMMER 1K OHM 2 WATT NOTES 1 UNLESS COLOR CODED ALL A D E INSTALLED CONDUCTORS ARE TO BE GREY AND MUST BE IDENTIFIED BY WIRE MARKER AT EACH CONNECTION POINT 2 HIDDEN DASHED LINES REPRESENT CUSTOMER SUPPLIED AND CONNECTED ITEMS 3 ANALOGUE THROTTLE 5K OHMS RECOMMENDED HOWEVER OVERALL RESISTANCE FROM 2K TO 15K SHOULD WORK WIPER LOW END RESI
45. d for more than 6 months the following preparations should be taken for long term storage 1 Change the engine oil and replace the filter Ser vice the air cleaner Drain flush and refill the cooling system Crank the engine a few times with a starter with out starting the engine Remove and clean batteries All engine openings should be sealed with plastic bags and tape Store in a dry protected place A CAUTION Battery Gas Can Explode Keep all flames and sparks away from batteries Before changing or using booster batteries check battery electrolyte level Add distilled water Booster and main batteries must have the same volt age rating First connect positive terminal of booster battery to positive terminal of main battery To Remove Generator Set from Long Term Storage 1 Take off all protective coverings and unseal all the openings that were covered up Install batteries that are fully charged and connect the terminals 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 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 Check all gauges and check for leaks
46. e clearances must be checked with the engine cold Intake Valve 0 012 0 015 in 0 31 0 38 mm Exhaust Valve 0 016 0 019 in 0 41 0 48 mm If the valves need adjusting loosen the jam nut A on Figure 9 on the rocker arm adjusting screw Turn the adjusting screw until you feel a slight drag when the feeler gauge slips With a screwdriver hold the adjusting screw from turning while tightening the jam nut to specifications Check the clearance again after tightening the jam nut Re adjust as needed Reproduced by permission of Deere amp Company c2004 Deere amp Company All rights reserved RG7409 Figure 9 4 CYLINDER ENGINES Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 and No 3 exhaust valves and No 1 and No 2 intake valves Rotate flywheel 360 Lock No 4 piston at TDC compression stroke C NOTE Firing order is 1 3 4 2 Reproduced by permission of Deere amp Company c2004 Deere amp Company All rights reserved RG4776 Figure 10 Front of Engine No 1 Piston at TDC Compression Stroke No 4 Piston at TDC Compression Stroke Exhaust Valve Intake Valve Adjust valve clearance on No 2 and No 4 exhaust valves and No 3 and No 4 intake valves 6 CYLINDER ENGINES NOTE Firing order is 1 5 3 6 2 4 Reproduced by permission of Deere amp Company c2004 Deere amp Company All rights RG4777 Figure 11 reserved Front of Engine No 1 Pisto
47. electrolyte level of each battery cell ENGINE v Engine Hard to Start or Will Not Start Engine starting under load Disengage PTO if applicable Improper starting procedure See starting section of this manual Take special note of Bypass Switch operation No fuel Check level of fuel in fuel tank Low battery output Check electrolyte level and condition Excessive resistance in starting circuit Clean and tighten all battery connections Crankcase oil too heavy Use oil of proper viscosity Improper type of fuel Consult fuel supplier and use proper type of fuel for operating condition Water dirt or air in fuel system Drain flush fill and bleed system Clogged primary fuel filter element Clean or replace filter element Clogged secondary fuel filter element Replace filter element Dirty or faulty injection nozzles Have your dealer check injection nozzles Electronic Fuel System problem if equipped See your dealer Injection pump not getting fuel or air in fuel system Check fuel flow at supply pump or bleed fuel system OL2 2 06 10 27 Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer 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
48. f an unsafe operating condition is Avoid wearing loose clothing without a belt noted tag the set and control panel so others will when working around engines also know about the problem Do not oil or grease engine while it is running Provide first aid kits Always disconnect the ECU Electronic Control Unit connectors and remove the ground connection for the engine control system to machine frame before welding on engine Make sure no other electronic components are in the ground path also CALIFORNIA Proposition 65 Warning 1 CAUTION This symbol is used throughout Diesel engine exhaust and some of its constituents this book to alert you to possible danger areas are known to the State of California to cause cancer Please take special notice of these sections birth defects and other reproductive harm OL2 2 06 10 3 Lugger Component Locations Figure 1 amp 2 L1064D Expansion Tank Coolant Fill Exhaust Manifold Air Cleaner Dry Exhaust Elbow Marine Gear Alternator Injection Pump Raw Water Pump Mounting Foot Dipstick Heat Exchanger Zincs Starter Heat Exchanger Fuel Filter Rocker Arm Cover Oil Filter OL2 2 06 10 4 Lugger Component Locations Figure 3 amp 4 L1066T Gear Output Flange Second Alternator Optional Oil Pan Coolant Fill Gear Dipstick Gear Oil Cooler V Dipstick Expansion Tank Dry Exhaust Elbow Marine Gear Exhaust Manifo
49. g 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 k Inspect air cleaner every 100 hours Replace filter every 600 hours or yearly whichever comes first for mechanically controlled fuel system engines For elec tronically controlled units replace air cleaner element every 500 hours 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 OL2 2 06 10 13 Servicing SP6 VALVE CLEARANCES The following special tools will be needed 1 2 3 4 JDE 820 JDE 83 Flywheel Turning Tool JDE 81 4 Timing Pin Remove rocker arm cover with ventilator tube Remove plastic plugs in engine timing holes on front side of flywheel Rotate flywheel in clockwise direction viewed from water pump with the Flywheel Turning Tool until the Timing Pin engages timing hole in the flywheel Both rocker arms for No cylinder will be loose at Top Dead Center If they are not remove the timing pin and rotate the flywheel one complete turn and reinstall the timing pin in the flywheel Valv
50. g break in oil again until changing 4 Whenever necessary at 100 hours then at every 250 hours 5 Check cooling system at 600 hours flush at 2000 hours or when 2 Perform all maintenance once a year even if hour level has not been reached needed 3 Consult manufacturer s maintenance schedule note on chart OL2 2 06 10 10 Updated 1 13 10 Service Schedule Chart Electronically Controlled Fuel System The Servicing Schedule Chart below shows the service schedule required for proper maintenance 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 ec Check Sil ieveltneneing SP9 Change primary filter element Racor SP25 Check engine mounts ELO c Check primary hiter SP26 Clean crankcase vent tube SP15 Check cooling water level SP27 Check air intake hoses AFTER FIRST 50 HOURS SP29 Check electrical ground connection SP2 Change engine oil SP30 Check engine speeds SP3 Change lube oil filter EVERY 500 HOURS YEARLY SP10 Change secondary fuel filter EVERY 50 HOURS SP11 Check injectors SP21 Check electrolyte in batteries SP14 Check turbocharger boost pressure AFTER FIRST 100 HOURS EVERY TWO WEEKS rs sus SP2 Change engine oil after first 100 hrs then check every 2 wks ent mee op app aaa ae SA EVERY 2000 HOURS SP3 Change oil filter after first 100 hrs then check every 2 wks SP6 Check amp adjust valve clearan
51. g ure 2 5 Reproduced by permission of Deere amp Company 2004 Deere amp Company All reserved RG12035 H Engine Block Side I Outlet Connection fo No 1 Cylinder OL2 2 06 10 21 Servicing SP13 TURBOCHARGER 1 Check for air leaks every 200 100 for electronically controlled fuel system engines hours Air leakage 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 gaskets as required Check to see that the lubrication and cooling lines are tight and without leaks SP14 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 600 hours 500 hours for electronically controlled fuel system engines On the inlet manifold there is a 1 8 NPT threaded port Remove the plug and install the boost gauge hose Refer to your engine specifications for correct pressure COOLING REQUIREMENTS il 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 A coolant solution of ethylene gly
52. gine Operate with an average of 75 load on your engine for the first 100 hours Maintain no less than a 50 load to ensure proper seating of the piston rings Oil consumption is greater during break in as piston rings take time to seat Your engine comes equipped with break in oil Change engine oil and filter at 50 hours using API Service Category CC CD or CE break in oil Change the oil and filter again at 100 hours Consult the lubricants section for oil recommendation Frequently check the engine temperature and oil pressure gauges OL2 2 06 10 9 Service Schedule Chart Mechanically Controlled Fuel System The Servicing Schedule Chart below shows the service schedule required for proper maintenance 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 SP23 Testthermostats SP1 Check oil level in engine AFTER FIRST 600 HOURS 5 8 Check primary fuel filter SP6 Check valve clearance SP15 Check cooling water level EVERY 600 HOURS YEARLY AFTER FIRST 50 HOURS SP4 Replace air cleaner SP2 Change engine oil SP5 Check belt condition SP3 Change lube oil filter SP7 Check crankshaft vibration damper EVERY 50 HOURS SP10 Change secondary fuel filter SP21 Check electrolyte in batteries SP11 Check injectors s SP14 Check turbocharger boost pressure FIRST IO HOURS SP16 Check and flush cooling system SP20 Change impeller
53. have a primary fuel filter installed We recommend the Racor brand of fuel filter water separators a Check the primary fuel filter daily as recommended by the filter manufacturer Empty the collection bowl as necessary Change the element every 250 hours 500 for electronically controlled fuel system units or whenever necessary If the bowl fills with water change the primary and secondary elements immediately Change secondary fuel filter every 600 500 for electronically controlled units 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 Do not prefill the new fuel filter as the fuel used may be contaminated and damage the fuel system components OL2 2 06 10 15 Servicing SP7 CRANKSHAFT VIBRATION DAMPER Remove belts Try to turn the vibration damper in both direc tions 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 RG8018 Figure 12 NOTE The vibration damper assembly should be replaced every 4500 hours or 60 months whichever occurs first as the vibration damper assembly is not repairable Place a dial indicator Figure 13 so that the probe contacts the damper s outer diameter in order to check the damper radial
54. in raw water pump SP22 Check the state of the charge of the batteries EVERY 250 HOURS SP2 Change engine oil EVERY 2000 HOURS 2 SP3 Change lube oil filter SP6 Check valve clearance adjust if necessary SP4 Check air cleaner SP12 Check fuel injection pump SP17 Check and clean heat exchanger SP18 Check and clean gear oil cooler SP2 Change engine oil SP3 Change lube oil filter SP9 Change primary fuel filter element SP13 Check turbocharger air oil amp cooling lines for leakage SP19 Check zinc electrodes 250 600 PAGE OPERATION Hours Hours ENGINE 15 Check oil level 15 Change engine oil 15 Change lube oil filters 15 Check replace air cleaner Check belt condition 16 Check valve clearances Check crankshaft vibration damper FUEL SYSTEM Check primary filter Racor Change primary filter element Racor Change secondary fuel filter Check injectors Check fuel injection pump TURBOCHARGER Check air oil amp cooling water lines for leakage Check boost pressure COOLING SYSTEM Check cooling water level Check and flush cooling system Check and clean heat exchanger Check and clean gear oil cooler Check zinc electrodes Change impeller in raw water pump ELECTRICAL SYSTEM Check electrolyte level in batteries Check condition of batteries with hydrometer Test thermostats OUT OF SERVICE Winterizing or out of service 1 Change the oil and filter at 50 hours usin
55. ine to normal operating temperature Defective thermostat Remove and check thermostat Engine out of time See your dealer Defective injection nozzles See your dealer OL2 2 06 10 29 Specifications 1064 Model Number Crankshaft Hp High Output Medium Duty Continuous Duty Crankshaft kW High Output Medium Duty Continuous Duty 1 Based on SAE J816b Cooling General Freshwater circulating pump flow Heat rejection to jacket water Cooling Heat Exchanger Raw water intake amp discharge dia Raw water pump flow RPM Raw water pump max suction head Max raw water temp at inlet Freshwater system capacity Cooling Keel Cooled Water hose inside diameter Head diameter Turbo tube length One inch plain round tube length Skin cooler Aluminum Steel Based on 70 F seawater and minimum boat speed of 8 knots at full speed Return water on keel cooling 70 to 130 F Electrical Minimum battery capacity 12V Battery cable size up to 10 ft run Standard harness length Air Engine air consumption Minimum engine room vent area Exhaust gas flow Exhaust gas temperature at rom Maximum exhaust back pressure Suggested dry exhaust I D Dry Wet Fuel and Oil Min fuel suction and return line Maximum fuel pump head Crankcase oil capacity Gear PTO Engine Angle Engine rotation facing flywheel Flywheel housing size Front PTO size optional Max intermittent operating a
56. ion nozzles dirty See your dealer Injection pump out of time See your dealer Electronic fuel system problem See your dealer Engine not at proper temperature Check your thermostats Check water temperature with thermometer and replace gauge if necessary Below Normal Engine Temperature Thermostats not working properly Check thermostats Temperature gauge not working properly Check water temperature with thermometer Low Oil Pressure Low oil level Fill crankcase to proper level Improper type of oil Drain and fill crankcase with correct oil Partially plugged oil filter Replace filter High Oil Consumption Break in period Oil consumption decreases after break in Crankcase oil too light Use proper viscosity oil Oil leaks Check for leaks in lines around gaskets and drain plug Engine Emits Black or Gray Exhaust Smoke Clogged or dirty air cleaner Service air cleaner Clogged aftercooler Service aftercooler Defective muffler back pressure too high Have dealer check back pressure Improper fuel Use correct fuel for temperature Engine overloaded Reduce load Electronic fuel system problem See your dealer Turbocharger not functioning See your dealer Injection nozzles dirty See your dealer Engine out of time See your dealer Engine Emits White Smoke Improper fuel Use correct fuel for temperature Cold engine Warm up eng
57. lb Install a plug in the injection pump timing pin hole and tighten to below specification 4 Install injection pump gear Fig 24 D on the drive shaft Install the injection pump gear mounting nut Pump Timing Pin Plug Torque 9 5 Nem 7 5 ft lb C but do not tighten it yet 7 Remove the timing pin from the flywheel Note Prevent the injection pump gear from rotating by holding it while applying torque OL2 2 06 10 20 Servicing INJECTION PUMPS INSTALLATION Continued Connect the injection pump fuel delivery pressure lines Fig 21 F Begin with the outlet connection to No 1 cylinder Fig 25 D and continue around the pump head in a counterclockwise direction Attach lines in the same order as the engine firing 1 5 3 6 2 4 on 6 cylinder engines Important Always use a back up wrench when loosen ing or tightening fuel delivery lines at fuel injection pump so that the pump discharge fittings are not altered This prevents possible internal pump damage 9 Tighten fuel delivery lines at the pump to below specification Fuel Delivery Lines Torque 27 Nem 20 ft lb 10 Put the clamp back Fig 21 E 11 Connect the fuel supply line Fig 21 D and fuel return line C Install the temperature sensor connector Fig 21A and fuel control solenoid connector B Bleed the air from the fuel system Start the engine and run it for several minutes and then check the entire fuel system for leaks i
58. ld Oil Filter Turbocharger Mounting Foot Alternator Fuel Filter Air Cleaner Starter Belt Guard 2nd Alternator Intake Manifold Gear Filter ECU Electronic Control Unit optional OL2 2 06 10 5 Lugger Control Panel Figure 5 Lugger Powerview Control Panel TACHOMETER The tachometer shows the engine speed in revolu tions per minute RPM Numbers are multiples of 100 HOUR METER Keeps track of the engine running time DC VOLTMETER When the engine is stopped the voltmeter shows the condition of the battery When the engine is running it indicates the voltage output of the alternator KEY SWITCH Turning the key clockwise to the first position will switch on the current continue turning the key clockwise to start the engine When the engine starts immediately turn the key back to the first position while the engine is running m TITT H Hours The key must be kept in the on or first position while the engine is running Turn the key counterclockwise as far as possible to stop the engine Note Optional flybridge panels have engine start switches instead of key switches POTENTIOMETER Dims the panel lights ALARM HORN Shut down engine if possible and investigate immediately 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 investigate OIL PR
59. llowing when your shutdown system is activated 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 26 28 to isolate the cause of the overheat CAUTION Do not remove the water fill cap of an overheated engine Escaping high temperature steam can cause severe burns Allow the engine to cool and then remove the cap slowly using protective clothing A 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 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 was normal DO NOT restart the engine Call your Northern Lights or Lugger dealer for assistance berating Procedures BREAK IN PERIOD 1 Your engine is ready to be put into service However the first 100 hours on a new or reconditioned engine are critical to its life and performance This is especially true of an engine that runs at a constant speed such as a propulsion en
60. mediately 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 investigate OlL 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 immediately OL2 2 06 10 7 perating Procedures BEFORE STARTING 1 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 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 13 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
61. n at TDC Compression Stroke No 6 Piston at TDC Compression Stroke Exhaust Valve Intake Valve Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 No 3 and No 5 exhaust valves and No 1 No 2 and No 4 intake valves Rotate flywheel 360 Lock No 6 piston at TDC compression stroke C Adjust valve clearance on No 2 No 4 and No 6 exhaust valves and No 3 No 5 and No 6 intake valves OL2 2 06 10 FUELS GENERAL L Use only clean high quality fuels of the following specifications as defined by ASTM designation D975 for diesel fuels a Use Grade No 2 diesel at ambient temperatures above freezing 30 F 0 b Use Grade No 1 at ambient temperatures below freezing and for all temperatures at an altitude of above 5 500 ft 1500 meters Sulphur content should not exceed 0 5 preferably less than 0 5 The cetane number should be a minimum of 45 DO NOT use these unsuitable grades of fuel a Domestic heating oils all types Class B engine Class D domestic fuels Class E E Gor H industrial or marine fuels ASTM D975 60T No 4 D and higher number fuels f JP4 Storing fuel a Keep dirt scale water and other foreign matter out of fuel b Avoid storing fuel for long periods of time Hill the fuel tank at the end of each day s operation This will reduce condensation SP8 10 FUEL FILTERS 1 Your engine or generator set should
62. n the container A 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 Water EGC Antifreeze Freeze Point Boiling Point 37 C 34 F 109 C ids 226 50 Servicing IMPORTANT 1 DO NOT use methyl alcohol or methoxy propanol base EGC These concentrates are not compatible with chemicals used in supplemental coolant addi tives 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 SUPPLEMENTAL COOLANT ADDI
63. na 9 2383N JIVWW JONVYO V V NIA O83N SIWW34 OV 18 NISSA 00 wi 1 S Aor S a I Y 07609 0 V V NMA on fo od 9NId IYIN 3VW Movld CE 0153NNO5 T3Nvd AuvTIXhVv SONVEO antes HON dW31_3NISN3 A382 3LIHM 310N 335 08 0 01 MXINJS 3if1v3 INIL 830 35 31155359 10 3NDN3 ONIY TIHTI ang s NIE 033 NOTI3A ANTA TWIS m A382 qma XOV1B X389 SINON IND phe naa I 2389 Dif 33133 FONVADY LUVLS O700 M dnd 3NI o 5285 yay oy 2119 uns NAN vor qu oif Qu veacuuvit 301VMIDLTV 033 orf NGI AZL 33018 3NON3 DC Wiring Diagram 59119 JHI JW SS3NHVH NOISN3IX 1 98 JUHM NMONB 3LIHM IHIN NAVIY 3unss3ud 10 JdYNd ALHM JION 335 3n18 3UHM A389 3LIHM HOUMS QION3IOS 2015 HOLIMS 4HON 390v9 BLIN 110 7270 3018 B Q33 NOTI3A 033 017 31du nd HOLI
64. ngle Front down Rear down Added page 2 4 09 updated 6 10 09 L1064D 67 2500 RPM 50 2500 RPM 2 Based on EN ISO 8665 2006 54 US gal 2500 rpm 204 Itr 2500 rpm 3415 BTU min 1 25 inch 31 gpm 2500 rpm 117 pm 2500 rpm 39 in 1 m 86 F 30 C 5 5 US gal 21 Itr 2 3 8 in 60 mm 1 1 2 in 38 mm 12 ft 4 m 28 ft 8 5 m 12 sq ft 1 3 m 42 5 sq ft 4 0 m 640 CCA 07 20 ft 6 m 166 cfm 2500 rpm 4 7 m min 2500 rpm 48 sq in 031 m 487 2500 rpm 13 8 m3 min 2500 rpm 920 F 2500 rpm 493 C 2500 rpm 48 in 1219 mm H 0 3 in 75 mm 4 in 100 mm 3 8 in 9 mm 39 in 1 m 14 US qts 13 2 Itr Counter Clockwise SAE 4 SAE 5 0 L1064T1 100 9 2500 RPM 75 2500 RPM 53 US gal 2500 200 Itr 2500 rpm 3465 BTU min 1 25 inch 31 gpm 2500 rpm 117 pm 2500 rpm 39 in 1 m 86 F 30 C 5 5 US gal 21 Itr 2 3 8 in 60 mm 1 1 2 in 38 mm 18 ft 6 m 42 ft 12 75 m 18 sq ft 1 65 m 60 sq ft 5 55 m 640 CCA m 20 ft 6 m 254 2500 rpm 7 2 m3 min 2500 rpm 73 sq in 047 m 544 cfm 9 2500 rpm 15 3 m min 2500 rpm 1184 F 2500 rpm 640 C 2500 rpm 30 in 762 mm H 0 3 in 75 mm 5 in 127 mm 3 8 in 9 mm 39 in 1 m 21 7 US qts 20 5 Itr Counter Clockwise SAE 4 SAE 5 0 OL2 2 06 10 30 L1064A 140 2400 RPM 125 2200 RPM 115 2000 RPM 104 9 240
65. peeds can damage the reverse gear If the proper propeller is used the engine should reach its approximate RPM s at full throttle If the maximum rated RPMs for your engine application is exceeded at full throttle then your propeller is too small If you cannon reach your maximum rated RPMs at full throttle either your propeller is too large or bottom growth is slowing the boat To establish maximum cruising RPM establish the RPM at full throttle and subtract 200 300 RPM This will promote engine life and reduce fuel con sumption Shutdown 1 Run engine three to five minutes in neutral at 1000 RPM for cool down period Return engine to low idle Turn the key switch counterclockwise as far as pos sible to stop the engine Close the sea cock and fuel valves and put the bat tery switch in OFF position NOTE Do not turn the battery switch to OFF while the engine is running SHUTDOWNS AND ALARMS 1 OL2 2 06 10 Your unit is fitted with a warning system to indicate high water temperature or low oil pressure Propulsion engines have warning horns to sound and warn you of a problem Remember when the engine is not running the horn will sound when key is in the ON position because there is no oil pres sure 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 fo
66. r as needed Remove the pump end cover Remove impeller with water pump pliers Be sure you remove all pieces of a failed impeller Clean the inside of the housing 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 Replace the cover using a new gasket Note Make sure there is always an extra impeller and cover gasket in reserve and on board Servicing 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 recom mendations closely 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 ter minal to see if it emits sparks A DC circuit breaker protects your control panel and wiring harness OL2 2 06 10 25 Servicing BOOSTER BATTERIES SP24 WINTERIZING OUT OF SERVICE If the generator set will not be use
67. runout Make sure the engine is at operating temperature then rotate the crankshaft using the JD281A JDE8 1 4 or the JDE83 Flywheel Turning Tool Ifthe runout reading exceeds the below specifica tion replace the vibration damper Vibration Damper Maximum Radial Runout 1 50 mm 0 060 in Reproduced by permission of Deere amp Company c2004 Deere amp Company All RG7508 Figure 13 rights reserved Updated 1 13 10 Servicing SP8 10 FUEL FILTERS Continued a Turn off the fuel b Open the filter drain plug Figure 14 A and drain the filter q A Drain Plug 4 B Filter Clamp 2 C Cartridge D Bleed Screw Figure 14 Secondary Fuel filter c Remove the secondary fuel filter by turning the filter clamp Figure 14 B counter clockwise until the filter cartridge Figure 14 C slides out 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 Your generator set may have two secondary filters depending on the fuel supply system d Install new filter cartridge e Turn on the fuel BLEEDING THE FUEL SYSTEM CAUTION Escaping diesel fuel under pressure A can penetrate the skin causing serious personal injury Before disconnecting
68. ry lines Fig 21 F from the injection pump and install protective caps Remove the three injection pump mounting stud nuts Fig 21 G Remove the pump and place it on a clean level surface and with good lighting inspect the shaft outside diameter for metal transfer caused by gear slippage Inspect the inside diameter of the injection pump drive gear for the same If there is evidence of metal transfer on the pump shaft OD or the drive Figure 19 Reproduced by permission of Deere amp Company 2004 Deere amp Company All reserved gear ID the injection pump and drive gear must be RG12036 replaced Note The tapered surfaces of the pump drive shaft OD and drive gear ID must be clean of oil or protec tive coatings when replacing the injection pump drive gear or installing a new pump Use a cleaner that does not leave a residue Mating surfaces must be assembled dry and lubricants must not be used y F igure 2 0 Reproduced by permission of Deere amp Company c 2004 Deere amp Company All reserved RG12000 igure 21 Reproduced by permission of Deere amp Company c 2004 Deere amp Company All reserved RG12001 OL2 2 06 10 19 Servicing INJECTION PUMPS INSTALLATION 1 Place an injection pump timing pin JDG1559 Fig 22 A into the pump timing pin bore before installing the injection pump Insert a small punch or screw driver into the hole on the pump drive shaft B until the timing pin
69. t level Fill tank or radiator to proper level Check hoses for loose connections and leaks Keel cooling tubes have been painted marine Remove paint from tubes Faulty radiator cap Have technician check Stretched belt or defective belt tensioner Check automatic belt tensioner and check belts for stretching Replace as required Low engine oil level Check oil level add oil as needed Incorrect grade of fuel Use correct grade of fuel Cooling system needs flushing Flush cooling system Defective thermostat Remove and check thermostat Defective temperature gauge Check water temperature with thermometer and replace gauge if necessary Water pump impeller worn broken Check impeller and replace if necessary Engine Knocks Low oil level e Add oil to engine crankcase 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 OL2 2 06 10 Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer v High Fuel Consumption Engine overloaded e Reduce load Air in fuel system e Bleed fuel system Improper type of fuel Use correct fuel for temperature Clogged or dirty air cleaner Service air cleaner Improper valve clearance See your dealer Inject
70. tion of batteries with hydrometer SP23 Test thermostats SP29 Check electrical ground connection 5 Operate engine at rated speed with 50 70 load for 30 minutes at 1 Change the oil and filter before the first 100 hours of operation during engine least break in 6 Replace air cleaner element when restriction indicator shows 2 Perform all maintenance once a year even if hour level has not been reached vacuum of 625 mm 25 in H 0 3 Consult manufacturer s maintenance schedule note on chart 7 Replace damper every 4500 hours or after 60 months 4 Whenever necessary OL2 2 06 10 11 Service Record OPERATION HOURS DATE 50 HOURS Check electrolyte in batteries 250 HOURS Change engine oil Change lubricating oil filters Check air cleaner Change primary fuel filter element Check turbocharger air oil amp cooling lines for leakage Check zinc electrodes 600 HOURS 500 HOURS Replace air cleaner Check belt condition Change secondary fuel filter Check turbocharger boost pressure Check and flush cooling system Change impeller in raw water pump Check state of charge of batteries EVERY 1200 HOURS 2000 HOURS Check valve clearances 2400 HOURS 2000 HOURS SP12 Check fuel injection pump SP17 Check and clean heat exchanger
71. tions on battery ground strap starter or alternator Inspect connections and clean if necessary Defective battery Test battery Battery charging rate too high Test charging system Starter Inoperative PTO engaged Disengage PTO Check DC circuit breaker Ifthe breaker is tripped reset it Faulty start circuit relay See dealer Blown main system fuse Replace fuse Loose or corroded connections Clean and tighten loose battery and harness plug connection Low battery output Check specific gravity of each battery cell Check electrolyte level of each battery cell Defective electrical system ground wire Repair or replace Starter Cranks Slowly Low battery output Battery is too small Battery cables are too small Check specific gravity of each battery cell Replace battery if necessary Check electrolyte level of each battery cell If low fill cells with distilled water Crankcase oil too heavy Fill with oil of appropriate viscosity Loose or corroded connections Clean and tighten loose connections Starter and Hour Meter Function but rest of Electrical System Does Not Function Blown fuse on magnetic switch Replace fuse Entire Electrical System Does Not Function Check DC circuit breaker If breaker is tripped reset it Faulty connection Clean and tighten battery and harness plug connections Sulfated or worn out batteries Check specific gravity and
72. ure for remaining nozzles if necessary until engine starts or until air has been removed from system Tighten the connections to 20 ft Ib 27 Nem SP11 INJECTORS 1 Fuel injectors should be checked by a Lugger Northern Lights dealer or qualified fuel injection shop every 600 hours Injector Removal You will need the following special tools JDE38A Injection Nozzle Puller JDE39 Nozzle Bore Cleaning Tool JD258 Pilot Tool Before removal carefully remove all dirt from the cylinder head around fuel injection nozzles Clean with compressed air to prevent dirt from entering the cylinders or valve seats Plug the bore in the cylinder head after each fuel injection nozzle has been removed Cap fuel line openings as soon as they are disconnected Immediately fit protective caps over the nozzle tips and the line connections to avoid handling damage Do not bend the fuel delivery lines When loosening the fuel pressure lines hold male union of nozzle line stationary with a backup wrench Loosen nuts to remove leak off lines and T fittings and disconnect fuel injection line from nozzle NOTE When all fuel injection nozzles have to be removed disconnect leak off line assembly at fuel tank at injection pump and at each nozzle T fitting Lift off complete leak off line as an assembly e Remove cap screw clamp and spacer f Pull injection nozzle out of cylinder head with JDE38A Injection Nozzle Puller

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