OPERATOR`S MANUAL
Contents
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3. n und ma rag 66 68 r 66 01083105 8 2015 wows 1384 E d 0 9 MIS 3195 HOLMS 18015 2v1B OL dau of TOXLNOD 3NI9N3 SE H Fo 43 ZE ZE 0348 34 0 1 o P E EEGENEN Q38 MD TTA 3 8 nur vet OF e 335 Oif Kat oF HH 438011 m ox 1201 i SL DES NICA 135 OL HI9N31 af 318y2 Z OMY 08 304v33N39 NI 0317207 8c s T0 wc 18 3NION3 m dyoga AVI3M gt lt NOT WISN gt lt TANVd lOSINOO OMP 06 02 32 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 V
4. 2400 HOURS SP11 Check fuel injection pump SP16 Check and clean heat exchanger SP17 Check and clean reverse gear oil cooler 06 02 12 LUBRICATION Break in oil 1 Use one of the following during the first 100 hours of operation a John Deere Engine Break In Oil b API Service CE oil c ACEA Specification 2 Do not use John Deere PLUS 50 oil or engine oils meeting API CG4 API 4 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 Useonly clean high quality lubricants stored in clean containers in a protected area 2 These oils are acceptable after the first 100 hours a API Service CC CD single viscosity oils b API Service CD CG 4 CF 4 multi viscosity oils c ACEA Specification E3 E2 multi viscosity oils d CCMC Specification D5 and Mercedes Benz MB228 3 e CCMC Specification D4 and Mercedes Benz MB228 1 3 Use the proper weight oil for your average operation temperature Air Single Multi Temperature Viscosity Viscosity Above 32 F 0 SAE 30W SAE15 40W 10 F to 32 F 23 C 100 C SAE TOW SAE10 30W Below 10 F 23 SAE 5W SAE5 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 N
5. Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer DC ELECTRICAL SYSTEM Low battery output v Battery Will Not Charge Check electrolyte level and condition Loose or corroded connections Clean and tighten battery connections Sulfated or worn out batteries Check specific gravity of each battery cell Check electrolyte level of each battery cell Loose or defective alternator belt e Adjust belt tension Replace belt Starter Inoperative Check DC circuit breaker Ifthe breaker is tripped reset it 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 e IC low fill cells with distilled water Crankcase oil too heavy Hill with oil of appropriate viscosity Loose or corroded connections Clean and tighten loose connections Entire Electrical System Does Not Function Check DC circuit breaker e If breaker is tripped reset it Faulty connection Clean and tighten battery and harness plug
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8. See your dealer Engine Emits White Smoke Improper fuel Use correct fuel for temperature Cold engine Warm up engine to normal operating temperature Defective thermostat Remove and check thermostat Engine out of time See your dealer OMP 06 02 26 Specifications 1800 and 1500 RPM GENERATOR SETS Model Number MP445D MP445T MP445H MP668T MP668H AC Output 1800 RPM 60 Hz 40 kW 55 kW 65 kW 80 kW 99kW 1500 RPM 50 Hz 33 kW 45 kW 55 kW 66 kW 80kW Phase Models Available in Single or Three Phase Output RPM Hz All Models Available in 1800 RPM 60 Hz and 1500 RPM 50 Hz Voltages 60 Hz All Models 60 Hz 120 208 120 240 127 220 139 240 219 380 240 416 254 440 and 277 480 Voltages 50 Hz All Models 50 Hz 110 190 110 220 115 230 120 208 127 220 220 380 and 240 416 Engine Aspiration Natural Turbo Turbo Turbo Turbo Oylinders Inline 4 Inline 4 Inline 4 Inline 6 Inline 6 Displacement 276 cu in 276 cu in 276 cu in 414 cu in 414 cu in 4 56 4 5 4 5 6 6 8 6 6 8 0 4 2 in 4 2 in 4 2 in 4 2 in 4 2 in 106 mm 106 mm 106 mm 106 mm 106 mm Stroke 5 0 in 5 0 in 5 0 in 5 0 in 5 0 in 127 mm 127 mm 127 mm 127 mm 127 mm at 1800 RPM 2 67 83 93 120 149 Specific Fuel Rate 0 367 Ib bhp hr 0 35 Ib bhp hr 0 36 Ib bhp hr 0 343 Ib bhp hr 0 345 Ib bhp hr Approx Fuel Rate 5 3 3 gph 4 4 gph 4 7 gph 6 53 gph 7 28
9. OPERATOR S MANUAL NORTHERN LIGHTS 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 2002 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 OMP 06 02 INORTHERN LIGHTS OPERATOR S MANUAL for Models MP445D MP668D MP445T MP668T MP6680T MP445H MP668H MP40C MP55C MP65C MP80C and MP99C INTRODUCTION n 2 Models Included eee 2 Model Numbers eee 2 Serial Numbers 2 WARRANTY ttr mte cnn 3 SAFETY RULES 3 COMPONENT LOCATIONS MPAA SD 4 MPAA SH 5 171 50 deet xs ageet Gegen 6 ENGINE amp GENERATOR CONTROL PANELS Series 1 3 R amp A reln ener 7 8 OPERATING PROCEDURES Before Startins 9 Generator E 9 10 Shutdown Procedures 25 9 Break M Period ee eet eee 10 SERVICING SCHEDULE CHART 11 SERVICE RECORD emm 12 SERVICING Lubrication Gene
10. Q 1200 RPM H High output MP445D Northern Lights naturally aspirated 1800 RPM marine diesel generator set with a John Deere 55 KW Northern Lights commercial marine MP668D Powertech 4045 or 6068 engine block 55 7 generator set with a John Deere Powertech 4045T engine block MP445T Northern Lights turbocharged marine genera tor set with a John Deere Powertech 4045Hor 2 MP668T 6068H engine block MP65C Northern Lights turbocharged 1200 RPM MP668QT 1 marine generator set with a John Deere Pow MP80C ertech 6068 engine block 65 kW Northern Lights high output marine generator set with a John Deere Powertech 4045T engine block 80 kW Northern Lights commercial marine generator set with a John Deere Powertech 6068T 1111 engine block MP445H _ Northern Lights high output marine genera TS MP668H tor set with a John Deere Powertech 4045H or _ 99 kW Northern Lights commercial marine 6068H engine block MP99C generator with a John Deere Powertech 6068T engine block 40 kW Northern Lights commercial marine gen 40 erator set with a John Deere 40450 engine block Serial Numbers When referencing Alaska Diesel Electric equipment by serial number please refer only to the number stamped on the Northern Lights serial number plate NORTHERN LIGHTS Serial No Model No AA ALASKA DIESEL ELEC
11. You will need the following special tools JDE38A Injection Nozzle Puller JDE39 Nozzle Bore Cleaning Tool JD258 Pilot Tool a 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 b Immediately fit protective caps over the nozzle tips and the line connections to avoid handling damage c Do not bend the fuel delivery lines When loosening the fuel pressure lines hold male union of nozzle line stationary with a backup wrench d 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 NOTE Do not use screwarivers pry bars or similar tools for this as they might damage the injection nozzle 3 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 d
12. 12 00713 8 Snubbing washer 15 70007 17 Lock washer 15 00702 9 Neoprene washer 15 19504 Heat Exchanger Kit LP MP445 668 Drawing C 4143 OMP 06 02 28 Diagrams irin W pue YSEWNN 9313119391 SYOLONGNOD O YN JHL 39NVO3OOOV NI INIOd NOILOANNOD H2V3 XJMYYN 38 LSNW 38 OL 35 Tiv 03002 30102 SSIINN e 53909 WOOT ONY 38 OL Z OVA 009 ONVYLSILINW MLN 3dAL 2 40 38 OL SYOLONGNOD NOLLVTIVISNI 11 899 20 35340 C3 L 3313 110 Kee 4 gt Ce Wei gt 1 by 4082 0 067 0 Lei ee T Wi jg 71 D 3mB 08 8 NOIWNN3LV OL 154 08 0 e oun eu NE EI 98 101 08 0 ER Ww aunis 001 T Xx 1 ONY9 GIS AZ os ue La QNQUD 4 LN 2696935 O3wMVW 061c93N 3NI9N3 Ol HI9N31 OG 3N9N3 HOLOW 318V9 071 8 OL 1 2
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14. a high mineral content Tap water should NEVER be put in a cooling system unless first tested by a water quality laboratory Do not use water made by the reverse osmosis method unless it has been PH neutralized 2 Here are acceptable water quality specifications Parts Grains Contaminates per Million per Gallon Maximum Chlorides 40 2 5 Maximum Sulfates 100 5 9 Maximum Dissolved Solids 340 20 0 Maximum Total Hardness 170 10 0 PH Level 5 5 to 9 0 OMP 06 02 20 3 Ifchlorides sulfates or total dissolved solids higher than the above given specification the water must be distilled demineralized or deionized before it is used in a cooling system 4 hardness is higher than 170 ppm and all other parameters are within the given specifications the water must be softened before it is used to make coolant solution EGC ETHYLENE GLYCOL CONCENTRATE ANTIFREEZE A CAUTION Antifreeze is flammable Keep it away from any open flame Avoid contact with eyes Avoid contact with skin Do not take inter nally 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 1 Bthylene glycol coolant concentrate is commonly mixed with water to produce an engine coolant with a low freeze point and high boiling point 2
15. 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 20 00005 50 Pack Part Number 20 00010 SP14 CHECKING COOLANT LEVEL 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 work ing 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 The makeup coolant added to compensate for loss or leaks must meet engine coolant requirements outlined in previous section SP15 FLUSHING THE COOLING SYSTEM A CAUTION The cooling wat
16. equipped 15 Bleed air from fuel system as outlined on page 15 Start engine and run for several minutes Check the entire system for leaks OMP 06 02 19 Check for air leaks every 200 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 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 600 hours 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 1 To meet cooling system protection requirements the coolant solution must consist of a Quality water b Ethylene glycol concentrate EGC commonly known as antifreeze c Supplemental coolant additives SCA s Acoolant solution of ethylene glycol concentrate EGC antifreeze quality water and supplemental coolant additives SCA s MUST be used YEAR ROUND to protect against freezing boil over liner erosion or pitting and to provide a stabl
17. 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 2 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 warranties on the engine become null and void if the injection pump seals are broken by unau thorized persons DB4 AND DB2 INJECTION PUMPS REMOVAL N All Stanadyne DB2 and DB4 injection pumps will have a retained drive shaft shaft stays in pump when pump is removed from engine 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 Disconnect shutoff cable and speed control link age or cold start switch if equipped Disconnect electrical connection to shutoff solenoid or throttle positioning solenoid Tag electrical wires for correct reassembly IMPORTANT Always use a backup wrench when loosening or tightening fuel lines at injection pump so that d
18. rotate the flywheel one complete turn and reinstall the timing pin in the flywheel 5 Valve 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 4 CYLINDER ENGINES NOTE Firing order is 1 3 4 2 Ek D D Reproduced by permission of Deere amp Company c2000 Deere amp Company rights reserved Dh Ip ibm Front of Engine No 1 Piston at TDC Compression Stroke No 4 Piston at TDC Compression Stroke Exhaust Valve Intake Valve mo gt Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 and No 3 exhaust 6 CYLINDER ENGINES NOTE Firing order is 1 5 3 6 2 4 Reproduced by permission of Deere amp Company c2000 Deere amp Company All rights reserved Front of Engine No 1 Piston at TDC Compression Stroke No 6 Piston at TDC Compression Stroke Exhaust Valve Intake Valve mb op gt Lock No 1 piston 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 FUELS GENERAL 1 Useonly clean high quality fuels of the following specifications as defined by ASTM designation D975 for diesel fuels a
19. to 1 7 Ib ft 2 Nem 9 Align timing mark on the pump flange Figure 14 B with timing mark on the cylinder block front plate A eproduced by permission of Deere Deere rights reserved Figure 14 reproduced ission of Deere amp Ci 2000 Deere amp All righ d 10 Tighten the three hex nuts securing the pump to the front plate to 20 foot Ibs 27 Nem Connect injection pump pressure lines Figure 15 E Beginning with outlet connection to 1 cylinder Figure 16 B and continue around the pump head in counterclockwise direction attaching lines in same order as engine firing 1 5 3 6 2 4 on 6 cylinder engines and 1 3 4 2 on 4 cylinder engines 11 igure 16 Reproduced by permission of Deere amp Company c 2000 Deere amp Company All rights reserved 12 Tighten fuel delivery pressure lines to 20 foot Ibs 27 Nem using a suitable 17mm deep well crows foot socket IMPORTANT Always use a backup wrench when loosening or tightening fuel delivery lines at fuel injection pump so that the pump discharge fittings are not altered This prevents possible internal pump damage Connect fuel supply line Figure 15 C and fuel return line Figure 15 D Connect fuel shutoff cable and speed control linkage if equipped Install and securely tighten electrical connections to shutoff solenoid and throttle position ing solenoid if equipped Connect cold start switch if
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21. Alow silicate form of ethylene glycol coolant is recommended for all diesel engines 3 Use an ethylene glycol coolant concentrate meeting ASTM D 4985P SAEJ1941 General Motors Performance Specification GM1899M or formulated to GM6038M 4 This product is concentrated and should be mixed to the following specification 5 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 Antifreeze Freeze Point Boiling Water Point A IMPORTANT 1 DO NOT use methyl alcohol or methoxy propanol base EGC These concentrates are not compatible with chemicals used in supplemental coolant additives Damage can occur to rubber seals on cylinder liners which are in contact with coolant 2 DO NOT use an EGC containing sealer or stop leak additives 3 DO NOT use 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 ADDITIVE SCA 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 f
22. DC VOLTMETER When the engine is running it indicates the voltage output of the alternator 3 Generator Control Figure 4 C Series 3C Generator Control Panel OMP 06 02 7 Northern Lights Control Panel SHUTOOWN E LLL EN ANO PREMEAT ONE CONNOR STOP START Figure 5 Series 4 Generator Control Panel 1 SHUTDOWN BYPASS SWITCH 7 AC VOLTMETER This switch bypasses the safety shutdown feature during the starting process ENGINE CONTROL SWITCH The control switch starts and stops the engine OIL PRESSURE GAUGE The oil pressure gauge shows the oil pressure in the engine lubricating system If the pressure drops below 15 PSI at a speed higher than idling stop the engine and investigate COOLANT TEMPERATURE GAUGE Water temperature gauge shows the temperature of the cooling water If the gauge registers over 200 or drops below 140 stop the engine and investi gate HOUR METER Keeps track of the engine running time DC VOLTMETER When the engine is running it indicates the voltage output of the alternator The voltmeter shows the generator output volt age phase to phase If the voltage fluctuates greatly from the normal reading shut down the unit and investigate FREQUENCY METER Indicates engine speed The correct reading for 1800 and 1200 RPM sets is 60 Hz For 1500 RPM sets it is 50 Hz If meter does not indi cate correct hertz stop and investigate AMMETER SE
23. Do not oil or grease engine while it is running 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 Use caution in handling fuel Never refuel a hot or running engine Do not smoke while filling fuel tank or servicing fuel system Keep your hands feet hair and clothing away from power driven parts Check for any loose electrical connections or faulty wiring Engines should be operated only by knowledge able qualified personnel Look completely around engine to make sure that everything is clear before starting Do not operate an engine that isn t in proper work ing order If an unsafe operating condition is noted tag the set and control panel so others will also know about the problem Provide first aid kits CAUTION This symbol is used throughout this book to alert you to possible danger areas Please take special notice of these sections OMP 06 02 3 01 P Figure 1 MP445D Expansion Tank Raw Water Pump Drive Belt Lube Oil Fill Lube Oil Filter Fuel Lift Pump Lube Oil Dipstick Lube Oil Drain Electric Starter Fuel Manifold DC Circuit Breaker Air Cleaner D C Alternator Wet Exhaust Elbow MP Component Locations Exhaust Manifold Drain Engine Block Drain Fuel Injection Pump Heat E
24. ING OUT OF SERVICE CAUTION Battery Gas Can Explode Keep all 1 Drain seawater cooling systems completely flames and sparks away from batteries Remember to shut off sea cocks before opening drain cocks 1 Before changing or using booster batteries check battery electrolyte level Add distilled water 2 Booster and main batteries must have the same voltage rating 3 First connect positive terminal of booster battery to positive terminal of main battery Drain seawater supply lines and wet exhaust line Loosen the seawater pump cover and drain pump Check freshwater antifreeze mixture If refilling use the proper mix of coolant AY Battery Booster Battery Figure 18 Booster Battery Connections 4 Then connect negative terminal of booster battery to ground on the engine block see Figure 18 5 Remove booster battery after starting engine 6 Sealed batteries see manufacturer charging and booster instructions SP16 17 BATTERY CARE LEAD ACID TYPE BATTERIES 1 Check electrolyte level every 50 hours or once per month Add distilled water to manufacturer s recommended level 2 Batteries cables and cable terminals should be checked and cleaned every 100 hours Clean corrosion with a water and baking soda solution Flush with clean water Tighten terminals and grease them to inhibit corrosion 3 Check the battery condition with a hydrometer every 750 hours OMP 06 02 24
25. Injectors 6 27 A V R Fuse 6 Fuel Lift Pump 14 Electric Starter 22 Thermostat Cover 28 Fuel Filter 7 Lube Oil Dipstick 15 Engine Block Drain 23 Optional Hydrolastic 8 Lube Oil Drain 16 Fuel Injection Pump Mounts OMP 06 02 6 Northern Lights Control Panels 1 SHUTDOWN BYPASS SWITCH This switch bypasses the safety shutdown feature during the starting process 2 ENGINE CONTROL SWITCH To start the engine hold this switch in the START position until the engine is running NOTE Excessive cranking of marine sets equipped ENGINE HOURS with water lift muffler systems can cause engine damage MAN PRENEAT S pubem After the engine starts release the switch and it will return to RUN position To stop the engine hold the switch in the STOP position NOTE The rocker switch is used on Series 1 panels only and has a light that glows when the set is running Figure 4 A Series 3 Generator Control Panel 3 OIL PRESSURE GAUGE The oil pressure gauge shows the oil pressure in the engine lubricating system If the pressure drops BYPASS START y 3 below 15 PSI at a speed higher than idling stop the 5 engine and investigate 4 COOLANT TEMPERATURE GAUGE Water temperature gauge shows the temperature of the cooling water If the gauge registers over 200 or drops below 140 stop the engine and investi gate 5 HOUR METER Keeps track of the engine running time 6
26. LECTOR SWITCH The ammeter switch is used for checking each phase for load condition Leave it in the ON position while the engine is running AMMETER The ammeter indicates the phase load Check for load unbalance If the unbalance is greater than 30 have an electrician balance the load properly This will ensure longer generator life and better economy OMP 06 02 8 Operating 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 14 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 Close the seacock check and clean the strainer and reopen the seacock Place the battery switch in the ON position NOTE The battery switch must always be kept ON while the
27. T 100 HOURS SP2 Change engine oil SP3 Change lube oil filter EVERY 250 HOURS SP2 Change engine oil SP3 Change lube 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 AFTER FIRST 600 HOURS SP6 Adjust valves EVERY 600 HOURS YEARLY SP4 Replace air cleaner SP5 Check V belt condition SP9 Change secondary fuel filter SP10 Check injectors SP13 Check turbocharger boost pressure SP15 Check and flush cooling system SP19 Change impeller in raw water pump SP23 Check the state of the charge of the batteries EVERY 1200 HOURS SP6 Adjust valves EVERY 2400 HOURS SP11 Check fuel injection pump SP16 Check and clean heat exchanger SP17 Check and clean gear oil cooler SERVICE 50 250 600 1200 2400 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours ENGINE SP1 14 Check oil level SP2 14 Change engine oil 1 SP3 14 Change lube oil filters 1 SP4 14 Check replace air cleaner 1 3 5 5 Check belt condition 1 e SP6 15 Check valve clearances 1 FUEL SYSTEM SP7 16 Check primary filter Racor 2 SP8 16 Change primary filter element Racor 2 3 SP9 16 Change secondary fuel filter 1 3 SP10 17 18 Check injectors 1 11 18 20 Check fuel injection pump 9 TURBOCHARGER SP12 21 Check air oil amp cooling water lines f
28. TRIC Inc 4420 14TH AVE NW SEATTLE WA U S A Seattle 8107 eeler o Generator Set Data Set Serial No o Set Model o Alaska Diesel Electric 4420 14th Ave N W OMP 06 02 2 warranty registration certificate is supplied with your set The extent of coverage is described in the Limited Warranty Statement We recommend that you study the statement carefully NOTE If the warranty is to apply the servicing instructions outlined in this manual must be Safety Rules Warranty followed If further information is needed please contact an authorized dealer or the factory CAUTION Accident reports show that careless use of engines causes a high percentage of accidents You can avoid accidents by observing these safety rules Study these rules carefully and enforce them on the job Never leave engine without proper security Turn the coolant tank cap slowly to relieve pres sure before removing Add coolant only when the engine is stopped and cool Mount a fire extinguisher near engine Always disconnect the battery ground strap before making adjustments e Operate engines in properly ventilated areas Keep trash and other objects away from engine e Escaping fluids under pressure can penetrate your skin Use a piece of cardboard or wood not your hands to search for leaks Avoid wearing loose clothing when working around engines e
29. Use grade no 2 diesel at ambient temperatures above freezing 30 F 0 C b Use grade No 1 at ambient temperatures below freezing and for all temperatures at an altitude of above 5 500 ft 1500 meters 2 Sulphur content should not exceed 0 596 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 d valves and No 1 and No 2 intake valves b Class B engine c Class D domestic fuels Rotate flywheel 360 Lock No 4 piston at TDC com d Class E F G or H industrial or marine fuels pression stroke C e ASTM D975 60T No 4 D and higher number Adjust valve clearance on No 2 and No 4 exhaust fuels valves and No 3 and No 4 intake valves f OMP 06 02 14 FUELS GENERAL continued 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 condensation 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 recommended by the filter manufacturer Empty the collection bowl as necessary b Change the element every 250 hours or whenever necessary c If the bowl fills with water change the primary and se
30. aching 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 see page 28 for assembly drawing SP18 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 OMP 06 02 22 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 2 Scrape or steel brush the zinc electrode clean If more than 5046 of the electrode has eroded away replace it with a new one The electrode screws out of the holder 3 Reinstall the zinc holders Be sure the threads are clean and have good metal to metal contact SP19 RAW WATER PUMP Heat exchanged cooled engines only 1 Change the sea water pump impeller as needed 2 Remove the pump end cover Remove impeller with water pump pliers Be sure you remove all pieces of a failed impeller 3 Clean the inside of
31. alve Cover Gasket 1 2 9 Gasket Kit Top 0 1 10 Gasket 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 w c 1 Heat exchanger cooled engines only OMP 06 02 33 NORTHERN LIGHTS 4420 14th Ave NW Seattle WA 98107 E Tel 206 789 3880 1 800 762 0165 Fax 206 782 5455 Northern Lights and Lugger are registered trademarks of Northern Lights Inc www northern lights com 2002 rights reserved Litho USA
32. condary elements immediately 2 Change secondary fuel filter every 600 hours NOTE The fuel filter on the engine is considered the secondary fuel filter The engine will be fitted with a quick change disposable secondary fuel filter a Turn off the fuel b Open the filter drain plug Figure 6 A and drain the filter A Drain Plug B Filter Clamp Cartridge D Bleed Screw Figure 6 Secondary Fuel filter c Remove the secondary fuel filter by turning the filter clamp Figure 6 B counter clockwise until the filter cartridge Figure 6 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 d Install new filter cartridge e Fuel filter cartridge number is 24 51005 f Turn on the fuel BLEEDING THE FUEL SYSTEM CAUTION Escaping diesel fuel under pressure can A penetrate the skin causing serious personal injury Before disconnecting lines be sure to relieve all pres sure 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
33. connections Sulfated or worn out batteries Check specific gravity and electrolyte level of each battery cell ENGINE v Engine Hard to Start or Will Not Start Improper starting procedure See starting section of this manual Take special note of Bypass Switch operation No fuel Check level of fuel in fuel tank 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 Cleanor replace filter element Clogged secondary fuel filter element Replace filter element Dirty or faulty injection nozzles Have your dealer check injection nozzles Engine Runs Irregularly or Stalls Frequently Below normal engine temperature Remove and check thermostat Clogged primary fuel filter element Cleanor replace filter element Clogged secondary fuel filter element Replace secondary filter element Water or dirt in the fuel system Drain flush fill and bleed system Dirty or faulty injection nozzles Have your dealer check injection nozzles Air in fuel system Inspect clamps and hoses on suction side of fuel pump for air leak bleed fuel system Improper type of fuel Consult fuel supplier and use proper ty
34. d This assures that repaired or replacement pump can be 4 Install three flat washers lock washers and hex nuts properly timed to engine when installed onto pump mounting studs Tighten nuts three turns only so that pump will not fall off mounting studs NOTE The pump drive gear should begin to move forward away from engine front plate with the pump when flange is approximately 1 8 in 3 2mm away from engine front plate B F igure 1 2 Reproduced by permission of Deere amp Company 2000 Deere amp Company All rights reserved OMP 06 02 18 5 Install pump mounting flange flush to engine front plate with drive gear held flush against front side of engine front plate IMPORTANT Do not use tightening force of pump mounting stud nuts to pull pump shaft into drive gear 1 0 6 With the pump shaft index pin properly engaged in the drive gear key slot finger tighten mounting stud nuts 7 Push pump drive gear firmly onto shaft taper Install washer and retaining nut Figure 13 C onto end of shaft Tighten retaining nut to 90 Ib ft 122 Nem for DB2 150 Ib ft 203 Nem for DB4 igure 1 3 Reproduced by permission of Deere amp Company 2000 Deere amp Company rights reserved IMPORTANT Do not overtighten cap screws on pump cover plate to avoid damage to O ring 8 Install access cover plate using a new gasket Apply LOCITE 242 TY9370 to cap screw threads and tighten
35. e noncorro 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 17 A which are in contact with engine coolant Figure 17 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 SP12 TURBOCHARGER 1 Vapor bubbles Figure 17 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 A Oylinder Liner Walls B Engine Coolant C Vapor Bubbles Figure 17 4 Unprotected engines with low quality water as cool ant can have liner failure in as few as 500 hours WATER QUALITY 1 Distilled deionized soft water is preferred for use in cooling systems Bottled distilled water from a food store or water supplier is recommended Tap water often has
36. e sealing surface 5 Using hands only no wrench tighten filter one half turn farther Overtightening can do damage to filter housing 6 Fill engine with recommended oil Start engine and check for leakage Stop engine and check oil level Add additional oil if necessary SP4 AIR CLEANER 1 Inspect air cleaner every 100 hours Replace filter every 600 hours or yearly whichever comes first 2 Clean the rubber tube at the cleaner Loosen the hose clamp and the attaching strip for the cleaner 3 Make sure the rubber tube is in good condition and that new filter is absolutely clean and installed prop erly 4 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 OMP 06 02 13 SP6 VALVE CLEARANCES The following special tools will be needed JDE 820 or JDE 83 Flywheel Turning Tool JDE 81 4 Timing Pin 1 Check the valve clearances after the first 600 hours the first 1200 hours and every 1200 hours thereafter 2 Remove rocker arm cover with ventilator tube 3 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 1 cylinder will be loose at Top Dead Center If they are not remove the timing pin and
37. ebris from bore with compressed air and plug the bore to prevent entry of foreign material 4 Clean injection nozzles a Remove carbon stop seal Figure 7 A and upper sealing washer Figure 7 B using a needle nose pliers Discard seals b Clean exterior of nozzle by soaking in clean solvent or diesel fuel Clean tip with brass wire brush A Reproduced by permission of Deere amp Company 94620 amp Company All rights reserved Igure 7 Reprinted by permission of Deere amp Company RG6300 Deere amp Company All rights reserved NOTE Do not scrape or disturb the teflon coating on the nozzle body above the carbon stop seal groove 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 8 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 a Position JD258 ROS16477 Pilot Tool Figure 8 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 b Position a new carbon stop seal Figure 8 B on pilot tool Use a new seal washer Figure 8 A to help slide the carbon seal into place until it seats in its groove on nozzle body c Continue to slide upper sealing washer onto nozzle body until it seats again
38. engine is running If the switch is turned OFF while the engine is running the battery charging regulator could be ruined GENERATOR Starting 1 While holding the Shutdown Bypass switch in the ON position push the Engine Control switch to the START position As soon as the engine starts release both switches Do not crank the starter for more than 20 seconds If the engine fails to start the first time be sure the starter has stopped before reengaging Operating 1 Check Gauges Often Oil pressure must be above 29 PSI The D C 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 200 F 94 Check AC voltage and frequency meters Series 4 Panel If gauges deviate from normal levels shut down the set and investigate 3 Let the unit run unloaded for a three to five minute warm up period before applying load 4 Do not add full electrical load until engine is at maximum operating temperature Shutdown 1 Unload the generator and run for three to five minutes for cool down period 2 Turn the Engine Control Switch to the OFF position Close the sea cock and fuel valves and put the battery switch in the OFF position if the unit will be off for an extended period NOTE Do not turn the battery switch to OFF while the engine is running SHUTDOWNS AND ALARMS Your unit is fitted with a system to p
39. er 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 10 COOLANT TESTING 1 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 pages 4 6 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 SP16 HEAT EXCHANGER CLEANING Drain the cooling system Remove the cooling water pipes between the heat exchanger and the water pump inlet Disconnect hose to seawater pump Unscrew the att
40. ever put additives or flushing oil in crankcase SP1 CHECK ENGINE OIL LEVEL 1 Check the oil level in the crankcase with the oil dipstick daily 2 The oil level must be between the Waffled area and the Never allow the level to go below the 3 Always add the same viscosity of oil as is already in the crankcase 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 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 temperature when a new viscosity of oil is required 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 4 Engine Lube Oil Capacity 445 Series 14 ats 13 2 liters 668 Series 18 qts 17 0 liters SP3 CHANGING OIL FILTER 1 Change the lube oil filter every 250 hours 2 Use a filter wrench to remove old filter Dispose of filter in approved manner 3 Make sure the gasket from the old filter is removed and discarded 4 Lubricate the rubber gasket on the new filter and screw it on nipple until gasket meet th
41. gph 12 5 ph 16 7 ph 17 8 ph 24 7 27 6 ph Dimensional Data Length 64 in 68 in 71 in 81 in 86 in 1630 mm 1730 mm 1800 mm 2060 mm 2180 mm Width 30 in 30 in 30 in 30 in 30 in 762 mm 762 mm 762 mm 762 mm 762 mm Height 40 2 in 40 2 in 40 2 in 40 2 in 40 2 in 1021 mm 1021 mm 1021 mm 1021 mm 1021 mm Approximate Weight 1865 lbs 1920 Ibs 2150 Ibs 2720 lbs 2930 Ibs 846 kg 871 kg 975 kg 1230 kg 1330 kg 1200 RPM GENERATOR SETS Model Number MP668QT AC Output 1200 RPM 60 Hz 50 kW Phase All Models Available in single or three phase Voltages 60 Hz All Models 60 Hz 120 208 120 240 127 220 139 240 220 380 240 416 254 440 and 277 480 Engine Aspiration Turbo Cylinders Inline 6 Displacement 414 cu in 6 8 6 Bore 4 2 in 106 mm Stroke 5 0 in 127 mm at 1200 RPM 2 75 Specific Fuel Rate 0 353 Ib bhp hr Approx Fuel Rate 3 63 gph 13 8 Dimensional Data Length 81 44 in 2070 mm Width 30 in 762 mm Height 40 2 in 1021 mm Approximate Weight 3 0 2635 105 1200 kg Prime kW rating 1 kW equals 1000 watts 0 8 power factor Net flywheel hp rating for fully equipped engine at 1800 1200 RPM under SAE J816b Based on prime HP rating at 1800 1200 RPM Based on prime kW rating at 1800 1200 RPM Fuel rate may vary depending on operating cond
42. ischarge fittings are not altered which will prevent internal pump damage Disconnect fuel return line Figure 10 A and fuel supply line Figure 10 C Igure 1 0 Reproduced by permission of Deere amp Company c 2000 Deere amp All rights reserved OMP 06 02 17 4 Disconnect all fuel delivery pressure lines Figure IMPORTANT Injection pump mounting flange timing 10 B from injection pump using a suitable 17mm mark Figure 12 A and front plate timing mark deep well crowsfoot socket Figure 12 B presence and alignment MUST be veri 5 Remove injection pump drive gear cover Remove fied before removing pumps from engine DO NOT drive gear retaining nut and washer from end of reference internal timing marks on pump cam ring pump shaft Be careful not to let washer fall inside and governor weight retainer If timing mark is not timing gear cover clearly visible on front plate scribe a visible reference NOTE The injection pump drive gear fits snugly onto mark as accurately as possible in line with mark on a tapered drive shaft and indexed by a hollow pin or pump flange Woodruff key installed in drive shaft 2 10 Remove three injection pump mounting stud nuts 6 Attach JDG670A Drive Gear Puller Figure 11 A to Remove injection pump from mounting studs injection pump drive gear as shown 11 Plug or cap all openings on injection pump and take NOTE Replace 6mm Grade 12 9 cap screws C as
43. itions Installation data for units with standard mounts heat exchanger cooling 1800 RPM and 3 phase generator ends Dimensions and weight are effected by optional equipment AC output and cooling configuration Contact factory for more information AER 06 02 27 Heat Exchanger SHOWN FOR REFERENCE PARTS COME ASSEMBLED ON HEAT EXCHANGER ASSEMBLY NOTES 1 INSTALL ITEMS 7 INTO EXPANSION TANK WITH LOCKTITE 242 BLUE APPLY LOCKTITE 7649 PRIMER TO TAPPED HOLES PRIOR TO STUD INSTALLATION SHOWN FOR REFERENCE PARTS COME ASSEMBLED ON 2 PRELOAD ITEMS 9 BY TURNING ITEMS 10 1 3 EAT EXCHANGER TO 1 2 TURN PAST THE POINT THAT ITEMS 8 va CONTACT ITEMS 9 11 SHOWN FOR REFERENCE 09 PARTS COME ASSEMBLED L ON HEAT EXCHANGER 3 APPLY LIBERAL AMOUNT OF GREASE LUBRIPLATE 5 r7 7 654 1630 2 OR EQ TO ITEMS 3 AND 15 PRIOR TO ASSEMBLY f ggg 4 o Vy c 27 fi af des AW DONN Description and Part Numbers 1 Heat Exchanger 20 19501 10 Hex nut 14 00322 2 Gasket 11 11043 11 Hose 18 62520 3 O ring 16 19502 12 Hose clamp 19 01028 4 Capscrew 12 00312 13 Tube 27 11035 5 Capscrew 12 00354 14 Plug 21 00530 6 Lock washer 15 00302 15 O ring 16 14804 7 Stud 13 00335 16 Capscrew
44. lush 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 1 Important heat exchanger cooled engines Additional SCA s should NOT be added to the mixture of EGC H 0 on initial fill up of engines with a coolant conditioner filter A high SCA concentration will result and can cause silicate dropout When this happens a gel type deposit is created in the cooling system which retards heat transfer and coolant flow 2 If additional SCA s are needed prepare a mixture of 50 quality water and 50 antifreeze Add liquid SCA at a rate of 396 by volume Example 30 mL of SCA per liter of H O EGC mixture 1 0 fl oz of SCA per qt of H O EGC Optimum 50 50 GE 1 09 C Add the resulting mixture to the cooling system in EH quart increments Run engine for 2 hours and i 24 106 retest the coolant Continue process until SCA ER SE 0 12 F 222 concentration meets recommended levels 3 SCA is available from your Northern Lights dealer Maximum 4096 60 DAG in the following sizes 624 4232 F Pint Part Number 20 00002 1 2 gallon Part Number 20 00003 4 DO NOT use any coolant system additives containing soluble oil OMP 06 02 21 Coolant test kits are available to allow on site evalu ation of the coolant condition 2 The kits use small strips of paper which are dipped into the coolant The paper
45. or leakage 1 SP13 21 Check boost pressure COOLING SYSTEM SP14 12 amp 23 Check cooling water level SP15 23 Check and flush cooling system 1 5 16 23 Check and clean heat exchanger 1 e SP17 Check and clean gear oil cooler 1 SP18 23 24 Check zinc electrodes 1 3 SP19 24 Change impeller in raw water pump 1 3 ELECTRICAL SYSTEM SP22 25 Check electrolyte level in batteries 1 3 5 23 25 Check condition of batteries with hydrometer 1 OUT OF SERVICE SP24 27 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 Whenever necessary OMP 06 02 2 OPERATION HOURS DATE 50 HOURS SP23 Check electrolyte in batteries 250 HOURS SP2 Change engine oil SP3 Change lubricating oil filters SP4 Check air cleaner SP7 Change primary fuel filter element SP12 Check turbocharger air oil amp cooling lines for leakage SP18 Check zinc electrodes 600 HOURS SP4 Replace air cleaner SP5 Check belt condition SP9 Change secondary fuel filter SP10 Check injectors SP13 Check turbocharger boost pressure SP15 Check and flush cooling system SP19 Change impeller in raw water pump SP23 Check state of charge of batteries EVERY 1200 HOURS SP6 Check valve clearances
46. ow 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 The first 100 hours on a new or reconditioned engine are critical to its life and performance 2 Constantly check the engine temperature and oil pressure gauges 3 Oil consumption is greater during break in as piston rings and cylinder liners take time to seat 4 Break In Oil Changes Change engine oil and filter at 50 hours Change oil and filter again at 100 hours See Gear Owner s Manual for break in oil change procedures Consult Lubricants Section for oil recommendation OPERATING INSTRUCTIONS Generator sets Maintain at least a 75 load on your set for the first 100 hours If this is not possible maintain no less than a 50 load to ensure proper seating of the piston rings Vary the load to help seat rings OMP 06 02 10 Servicing Schedule Chart 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 SP1 Check oil level in engine SP7 Check primary fuel filter SP14 Check cooling water level AFTER FIRST 50 HOURS SP2 Change engine oil SP3 Change lube oil filter EVERY 50 HOURS SP22 Check electrolyte in batteries FIRS
47. pe of fuel for operating condition Lack of Engine Power Intake air restriction Service air cleaner Clogged primary fuel filter element Clean or replace filter element Clogged secondary fuel filter element Replace filter element Lack of Engine Power continued 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 OMP 06 02 25 Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer Improper valve clearance e Reset valves Best done by dealer Dirty or faulty injection nozzles Replace injectors Best done by dealer e See your local dealer Engine Overheats Low coolant 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 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 Insufficient oil e Call your dealer Injection pump out of time e Call your dealer Below normal engine temperature Check you
48. prietary Information This publication is the property of Alaska Diesel Electric Inc It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric Inc Alaska Diesel Electric Inc All rights reserved Litho U S A Publication number OMP 06 02 OMP 06 02 1 Introduction Servicing of marine engines and generator sets pres Failures begin with minor problems that are overlooked ents unique problems In many cases boats cannot be and become amplified when not corrected during rou moved to a repair facility Marine engines cannot be tine maintenance compared to the servicing of automobiles trucks or even farm equipment Failures often occur in remote As operator it is your obligation to learn about your areas far from competent assistance Marine engines equipment and its proper maintenance This is not a are taxed far more severely than auto or truck engines comprehensive technical service manual Nor will it therefore maintenance schedules must be adhered to make the reader into an expert mechanic Its aim is to more strictly aid you in maintaining your unit properly Model Numbers Model numbers give the unit s application block model aspiration and RPM MP 445 4045 or 668 6068 D T Q amp H Model number D Naturally aspirated Northern Lights marine generator set 4 Cylinder 4 5 Liters Turbocharged Model number 6 Oylinder 6 8 Liters
49. pump to dealer for service needed 7 Evenly tighten the two 6mm Grade 12 9 screws DB4 amp DB2 INJECTION PUMP INSTALLATION threaded in drive gear and snugly tighten center 1 Lubricate a new square sealing ring with clean forcing screw Figure 11 B against end of pump shaft engine oil Install ring into groove on front face of pump mounting flange Slide injection pump onto mounting studs while inserting pump shaft into drive gear 2 Check pump shaft and index pin for proper alignment with pump drive gear key slot IMPORTANT Shaft roll pin may be easily damaged if improperly assembled Pump drive gear should not move when initially installing pump index pin into drive gear key slot 3 Install injection pump partially onto mounting studs without engaging pump pilot hub into engine front F igure 11 Reproduced by permission of Deere amp Company c 2000 Deere amp Company rights reserved plate 8 Tighten center forcing screw until pump drive gear IMPORTANT DO NOT tighten hex nuts more than is free from tapered shaft Remove JDG670A puller three full turns on mounting studs Pump drive shaft Figure 11 A and screws from drive gear index pin may be damaged if pin is not properly 9 Check to make sure that timing marks on back side aligned with drive gear key slot and if the nuts are of front plate Figure 12 A and injection pump flange tightened more than three turns Figure 12 B are present and properly aligne
50. r thermostats Check water temperature to see if temperature gauge is working properly Engine overheating See Engine Overheating section High Fuel Consumption Air in fuel system 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 Injection nozzles dirty See your dealer Injection pump out of time See your dealer Engine not at proper temperature Check your thermostats Check water temperature with thermometer and replace gauge if necessary v 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 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 Defective muffler back pressure too high Have dealer check back pressure Improper fuel Use correct fuel for temperature Injection nozzles dirty See your dealer Engine out of time
51. ral 13 Checlanpg Oll onte meis 13 Oil Changes ooo tae erp eek ei 13 Qil Filter et er 13 Air Filter oce re ee teer tus 13 Valve Clearanges cec eege Peine 14 Fuels General 14 15 SEI 15 Bleeding the Fuel System 15 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 5 Injector 16 17 Injection Pump 17 19 rboch rger ghe epi 20 Turbo Boost ER 20 Cooling System General 20 Engine Coolant Specifications 20 21 Cooling System Flushing 22 Heat Exchanger Cleaning 22 Cleaning Gear Oil Coolers 22 Zinc Ge EE 22 23 Raw Water Pumpen 23 Generator Ende deest 23 Electrical System General 23 Booster Batteries sees 24 Battery 24 Winterizing Out of Service 24 TROUBLESHOOTING Electrical iis dE 25 ENEE 25 26 DATA SHEETS Unit Specifications eene 27 HEAT EXCHANGER DRAWING eege 28 WIRING DIAGRAMS DC Electrical EEN 29 30 DC Electrical 24V sess 31 32 ON BOARD SPARE 33 Pro
52. rotect it from high water temperature or low oil pressure a Generator sets have shutdown systems to stop the engine They have no warning horns b Other alarms and shutdowns are available as optional equipment NOTE Do not rely on your warning or shutdown system to the exclusion of careful gauge monitoring Watching your gauges can prevent damage to the unit and dangerous power losses 2 Do the following when your shutdown system is activated 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 25 26 to isolate the cause of the overheat CAUTION Do not remove the water fill cap of an overheated engine Escaping high temperature steam can cause severe burns Allow the engine to cool and then remove the cap slowly using protective clothing c Make repairs and restart after the temperature gauge registers below 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 OMP 06 02 9 Operating Procedures 3 Ifthe 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 sh
53. see a doctor at once Serious infection or reaction can develop if proper medical treatment is not administered immediately 1 Whenever the fuel system has been opened for ser vice lines disconnected filter changed etc it will be necessary to bleed air from the system a To bleed the fuel system loosen the bleed plug Figure 6 D 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 b 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 c 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 procedure for remaining nozzles if necessary until engine starts or until air has been removed from system Tighten the connections to 20 foot Ib 27 OMP 06 02 15 SP10 INJECTORS 1 Fuelinjectors should be checked by a Lugger North ern Lights dealer or qualified fuel injection shop every 600 hours 2 Injector Removal
54. st inlet fitting OMP 06 02 16 6 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 a Remove plug if installed previously from nozzle bore in cylinder head and blow out bore with compressed air b 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 c Install nozzle in cylinder head using a slight twisting motion as nozzle is seated in bore A Reproduced by permission of Deere amp Company WOEN Deere amp Company All Rights reserved Figure 9 Shows relationship of parts required for installation d Install spacer and cap screw Do not tighten capscrew at this stage 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 N m g Install leak off assembly h Bleed air from loose injection line connection Tighten connection using two wrenches SP13 INJECTION PUMP l Since operating conditions may vary considerably it is difficult to give a definite service interval But as a rule the pump settings maximum speed idle speed and
55. the housing 4 Press in the new impeller and place the sealing washer in the outer end of the impeller center if this has not already been done 5 Replace the cover using a new gasket Note Make sure there is always an extra impeller and cover gasket in reserve and on board SP20 21 DRIVEN EQUIPMENT Gears and PTO s 1 Manufacturer s service recommendations vary See your Owner s Manual for service information If you do not have a manual see your local dealer for the equipment in question NOTE Some PTO and marine gears have rigid lubrication requirements Follow service recommendations closely Generator Ends 2 The maintenance and operation recommendations for the generator end are in a separate Owner s Manual If you do not have one of these manuals contact your local Northern Lights dealer ELECTRICAL SYSTEM GENERAL 1 Never switch battery switch off or break the circuit 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 regulator and battery Isolate the leads 4 Disconnect battery cables when servicing the DC alternator 5 Never test with a screwdriver etc against any terminal to see if it emits sparks 6 A DC circuit breaker protects your control panel and wiring harness OMP 06 02 23 BOOSTER BATTERIES SP27 WINTERIZ
56. xchanger Zinc 2 Heat Exchanger Drain Heat Exchanger Coolant Fill 22 Thermostat Cover 23 Fuel Injectors 4 24 A V R Fuse 25 Fuel filter OMP 06 02 4 MP Component Locations Figure 2 MP445H note MP445T models have similar component locations Expansion Tank 7 Optional Flow Switch 15 Optional Governor 22 Heat Exchanger Zinc 2 2 Injection Pump Drive 8 Fuel Lift Pump Actuator 23 Heat Exchanger Drain Coupling Access Cover 9 Lube Oil Dipstick 16 DC Alternator 24 Heat Exchanger Plate 10 Fuel Manifold 17 Wet Exhaust Elbow 25 Coolant Fill 3 Drive Belt Cover 11 Lube Oil Drain 18 Exhaust Manifold Drain 26 Thermostat Cover 4 Lube Oil Fill 12 Electric Starter 19 Engine Block Drain 27 Fuel Injectors 4 5 Lube Oil Filter 13 DC Circuit Breaker 20 Fuel Injection Pump 28 Turbocharger 6 Optional Power Takeoff 14 Air Cleaner 21 Optional Hydrolastic Mount 29 A V R Fuse 30 Fuel Filter OMP 06 02 5 MP Component Locations Figure 3 8 note components of MP668QT are in a similar location 1 Coolant Fill 9 Air Cleaner 17 Heat Exchanger Zinc 2 24 Optional Governor 2 Expansion Tank 10 DC Circuit Breaker 18 Heat Exchanger Drain Actuator 3 DC Alternator 11 Turbocharger 19 Heat Exchanger 25 Drive Belt Cover 4 Lube Oil Fill 12 Wet Exhaust Elbow 20 Raw Water Pump 26 Fuel Manifold 5 Lube Oil Filter 13 Exhaust Manifold Drain 21 Fuel
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