OPERATOR`S MANUAL
Contents
1. OL6125 For Model L6125H OPERATOR S MANUAL LUGGER NORTHERN LIGHTS Marine Generators Marine Diesel Engines Land Based Generators A 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 Northern Lights Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Northern Lights Inc Printed in U S A PART NO OL6125 06 10 NORTHERN LIGHTS OPERATOR S MANUAL OL6125 for Model L6125H 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 INTRODUCTION t ees 4 Turbo Boost une deme een 17 Models Included sss 4 Linear Erosion seseeeeseeeeeneene 18 Model Numbers eene 4 Cooling System General 19 Serial Numbers sse 4 Water Quality oriit rro e tene 19 Engine Coolant Specifications 19 WARRANTY eee eee eee eee eee eee eee eee ee eee eee ee eee eee eee eee ee ee ees 5 Supplemental Cooling Additive Se eR PR 20 SAFETY RULES 5 Rn TSUN Et vias cece thea 20 Checki2. 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 2 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 3 Oil consumption is greater during break in as piston rings take time to seat 4 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 5 Frequently check the engine temperature and oil pressure gauges OL6125 06 10 11 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 SP24 Check sea water strainer AFTER FIRST 50 HOURS SP2 Change engine oil SP3 Change lube oil filter EVERY 50 HOURS SP20 Check electrolyte in batteries FIRST 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 fi
3. 17 Workshop Manual 1 18 Drive Belts 2 Heat exchanger cooled engines only OL6125 04 10 29 MAIN CONTROL PANEL UA IGTAIL HARNESS AND INTERCONNECTS PANEL CONNECTOR 5 FT EACH SIDE die eue 2 0 102 12 RED g DT hi Hii 102 12 RED pur ma STANT SUAVE RELAY ix puvm mD p 35 pa vaLow reD E d eem Eo TT hor gna muc 35 12 ven pna veio nen qm p2 aux qna sux NEVE V E 1 i 012 12 RD 351 lora 12 nen EN m z lt x Pi POY a Ly NS VV Nie a perm run 16 ono esa pe ec ne ono pev RERE 16 onec ETNA ALTERNATOR 22 45018 a BLCK agri caer 6 BLCK To B es OPTIONAL ALTERNATOR VE VENE ve ve NE MEM NENNEN NIE NINE didi dd dd optional LE OPTIONAL LOCAL OR ENGINE ROOM CONTROL PANEL SEE NOTE 13 Si S HM 0124 RED START SMTTCH ee exp i us sue amen EPR APERS A 20 0 m o d png Dg ge ap BS ES BES Be PS E WHITE 47 X BLACK apg ea epg rf
4. 6 Cylinder 125mm bore turbo charged L6125H Lugger turbocharged propulsion engine with a John Deere engine block aftercooled Tier Il Serial Numbers 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 Oy O LUGGER by NORTHERN LIGHTS Serial No Model No Northern Lights 4420 14th Ave NW Seattle WA 98107 OL6125 06 10 4 A warranty registration certificate is supplied with your set The extent of coverage is described in the Limited Warranty Statement We recommend that you study the statement carefully Safety Rules NOTE If the warranty is to apply the servicing instructions outlined in this manual must be followed If further information is needed please contact an authorized dealer or the factory CAUTION Accident reports show that careless use of engines causes a high percentage of accidents You can avoid accidents by observing these safety rules Study these rules carefully and enforce them on the job 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 e Mount a fire extinguisher near engine Always disconnect the battery ground strap before making adjustments Operate engines in properly vent
5. 611 03 Injector Wiring Shorted to Power Source 611 04 Injector Wiring Shorted to Ground 627 01 Injector Supply Voltage Problem 629 13 ECU Error 636 02 Cam Position Input Noise 636 08 Cam Position Input Missing 636 10 Cam Position Input Pattern Error 637 02 Crank Position Input Noise OL6125 04 10 26 Diagnostic Trouble Codes SPN FMI Description 637 08 Crank Position Input Missing 637 10 Crank Position Input Pattern Error 651 05 Cylinder 1 EUI Circuit Open 651 06 Cylinder 1 EUI Circuit Shorted 652 05 Cylinder 2 EUI Circuit Open 652 06 Cylinder 2 EUI Circuit Shorted 653 05 Cylinder 3 EUI Circuit Open 653 06 Cylinder 3 EUI Circuit Shorted 654 06 Cylinder 4 EUI Circuit Open 654 06 Cylinder 4 EUI Circuit Shorted 655 05 Cylinder 5 EUI Circuit Open 655 06 Cylinder 5 EUI Circuit Shorted 656 05 Cylinder 6 EUI Circuit Open 656 06 Cylinder 6 EUI Circuit Shorted 1569 31 Fuel Derate NOTE The Diagnostic Gauge on the electronic instrument panel could have communication problems that could result in error codes being shown on its LCD display The following error codes all indicate that there is a diagnostic gauge communication error with the ECU Contact your dealer for help in correcting these codes EE Error XXXXX BO No Data BUS EP XXXXX EP ACP Err No Addr ACP Err XXXXX BR No Data OL6125 04 10 2
6. A DC circuit breaker protects your control panel and wiring harness PRECAUTIONS FOR WELDING ON VESSELS WITH AN ELECTRONIC ENGINE CONTROL UNIT ECU Caution Always disconnect the Electronic Con trol Unit connectors and engine control system to vessel ground before welding High currents or electro static discharge in electronic components from welding may cause permanent damage A Remove the ground connection for the engine control system to vessel frame Disconnect the connectors from the ECU Connect the welder ground close to the welding point and be sure that the ECU or other electronic compo nents are not in the ground path BOOSTER BATTERIES CAUTION Battery Gas Can Explode Keep all flames and sparks away from batteries Before changing or using booster batteries check bat tery electrolyte level Add distilled water Booster and main batteries must have the same voltage rating First connect positive terminal of booster battery to positive terminal of main battery O 9 O 9 Battery Booster Battery Figure 4 Booster Battery Connections 4 NM Then connect negative terminal of booster battery to ground on the engine block see Figure 4 Remove booster battery after starting engine Sealed batteries see manufacturer charging and booster instructions SP20 21 BATTERY CARE LEAD ACID TYPE BATTERIES Check
7. ON position because there is no oil pressure A 2 Do the following when your shutdown system is acti vated 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 18 19 to isolate the cause of the overheat NOTE Do not rely on your warning or shutdown Watching your gauges can prevent damage to the unit and dangerous power losses 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 3 Ifthe shutdown is activated and the temperature gauge shows temperature within normal temperature range a Check the engine crankcase oil level b Ifthe oil level is low fill with recommended lubricating oil and restart Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading after a few seconds of operation c Ifthe oil level is normal DO NOT restart the engine Call your Northern Lights or Lugger dealer for assistance system to the exclusion of careful gauge monitoring Operating Procedures BREAK IN PERIOD
8. Remove and inspect oil cooler See your dealer High oil temperature Remove and inspect oil cooler See your dealer Defective oil pump Remove and inspect oil pump See your dealer Oil pressure regulating valve failure Remove and inspect oil pressure regulating valve See your dealer Broken piston spray jet Replace piston spray jet See your dealer Clogged oil pump screen or cracked pick up tube Remove oil pan and clean screen replace pick up tube Excessive main or connecting rod bearing clearance Determine bearing clearance See your dealer High Oil Pressure Regulating valve not operating correctly Remove and inspect oil pressure regulating valve See your dealer Plugged piston spray jet Replace piston spray jet See your dealer Filter bypass valve stuck or damaged Remove and inspect filter bypass valve See your dealer High Oil Consumption Crankcase oil too low viscosity Drain crankcase and refill with correct oil Crankcase oil level too high Drain oil until level is correct External oil leak Check for leaks in lines around gaskets and drain plug Oil control rings worn or broken Replace piston rings See your dealer Scored cylinder liners or pistons Remove and inspect cylinders and liners replace as required See your dealer Worn valve guides or stems nspect and measure valve stems and valve guides repair as required See your dealer Piston grooves worn Rem
9. Mg ANALOG THROTTLE l NOTES 1 ALL INSTALLATION CONDUCTORS ARE TO BE AWG 10 TYPE MTW l GOOVAC 105 C MULTISTRAND EXCEPT THE ENGINE WIRE HARNESS I l ARP ADAGE mw m TWISTED PAIRS AND AS NOTED 2 UNLESS COLOR CODED ALL NU INSTALLED CONDUCTORS B S BN Bli N EJ 3 THE MAIN CONTROL PANEL ENGINE CONTROL SWITCH MUST BE IN THE ON POSITION TO ENABLE OPTIONAL FLYBRIDGE PANEL S START AND LL LOCATION BY OTHERS STOP CONTROLS 4 ISOLATE CONDUCTORS USING HEAT SHRINK TUBING IF UNUSED 5 CUSTOMER SUPPLIED AND CONNECTED NEUTRAL SAFETY SWITCH 6 ANALOG THROTTLE 5000 OHMS RECOMMENDED HOWEVER OVERALL RESISTANCE FROM 2K TO 15K SHOULD WORK WIPER TO LOW END RESISTANCE SHOULD BE 1250 OHM MAX 7 HIDDEN DASHED LINES REPRESENT CUSTOMER SUPPLIED AND CONNECTED ITEMS 8 IF NO ENGINE ROOM PANEL IS CONNECTED INSTALL ENGINE CONNECTOR CAP WITH TERMINALS A AND B JUMPERED AS SHOWN SUPPLIED BY Nu POWERVIEW 9 IF NO FLYBRIDGE PANEL IS USED INSTALL 120 OHM TERMINATOR DISPLAY ON MAIN CONTROL PANEL ALARM HORN CONNECTOR B BE l GAUGE l I REAR VIEW mke 0 T Js 19 ALTERNATOR EXCITER CONNECTOR UNUSED ON SELF EXCITED ALTERNATORS v I 4 mato TOR Z m OPTIONAL TIEMS SECONDARY POWERVIEW CONNECTIONS POWERVIEW ENCLOSURE 14 ADD GROUND STRAP FOR STANDARD GROUND UNIT
10. be between the Waffled area and the Add Never allow the level to go below the Add Always add the same viscosity of oil as is already in the crankcase SP2 OIL CHANGES l Using the oil recommended above change the engine oil and filter after the first 100 hours of operation 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 Engine Lube Oil Capacity 32 liters 6125 34 0 qts SP3 CHANGING OIL FILTER l 2 Change the lube oil filter every 250 hours Use a filter wrench to remove old filter Dispose of filter in approved manner Make sure the gasket from the old filter is removed and discarded Lubricate the rubber gasket on the new filter and screw it on nipple until gasket meet the sealing surface Using hands only no wrench tighten filter one half turn farther Overtightening can do damage to filter housing Fill engine with recommended oil Start engine and check for leakage Stop engine and check oil level Add additional oil 1f necessary SP4 AIR FILTER CRANKCASE BREATHER l Inspect air cleaner every 100 hours clean and re oil every 600 hours or yearly or when red service light is visible in air filter restriction indicator whichever comes first Replace filter element after 5 to 7 clean ing
11. bleed the fuel system open the drain valve Figure 2 A on the fuel filter and use hand primer to drain water and contaminants b Attach an open line to the diagnostic port above the hand primer and put the end of the line in a container for diesel fuel using tool 53 50005 c Pump the hand primer until a steady flow of fuel without bubbles comes out Disconnect the line from the diagnostic port Close the return line Pump primer until firm Crank the engine until it starts 15 seconds maximum 60 seconds rest h Open return line moe OL6125 06 10 17 SP12 TURBOCHARGER 1 Check for air leaks every 250 hours Air leakage will lower engine output and may cause black exhaust smoke and soot 2 Listen along air line while engine is running A whistling or hissing sound indicates leakage 3 Leakage on the pressure side between turbo and engine can be found by applying soapy water to the air line 4 Tighten the hose clamps replace hose or gaskets as required 5 Check to see that the lubrication and cooling lines are tight and without leaks SP13 TURBO BOOST 1 This check measures the amount of air the turbo is pushing into the engine It should be done by an authorized dealer every 600 hours 2 On the inlet manifold there is a 1 8 NPT threaded port Remove the plug and install the boost gauge hose Refer to your engine specifications for correct pressure LINER EROSION PITTING 1
12. cause of overheating Do not exceed 800 RPM when shifting marine gear Repeated shifts at higher engine speeds can damage the reverse gear Low idle is 650 RPM Maximum working engine speed is 2100 RPM for High Output 1900 RPM for Medium Duty and 1800 RPM for Continuous Duty If the proper propeller is used the engine should reach its appropriate maximum RPMs at full throttle If the maximum rated RPMs for your engine applica tion is exceeded at full throttle then your propeller is too small If you cannot 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 consumption SHUTDOWN I A 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 battery switch in OFF position NOTE Do not turn the battery switch to OFF while the engine is running OL6125 06 10 10 ALARMS 1 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 the key is in the
13. cycles depending on condition Note Use part 24 20019 Cleaning and Re Oiling Kit do not use motor oil or other oils to re oil filter Replace oil separator filter every 600 hours or yearly or if oil leakage 1s seen at crankcase pressure regulator vent whichever comes first Note Air filter element must be removed to access retaining clamp and cover that retains oil separator filter inside Check hoses and clamps on crankcase pressure regula tor plumbing for tightness chafing or deterioration Start the engine and check for leaks NOTE Make absolutely sure no impurities enter the engine while changing the element Do not run OL6125 06 10 14 Servicing AIR FILTER SERVICE PROCEDURE 1 Remove v band clamp or retianing springs and air filter 3 Carefully raise service handle on oil separator element Pull out of housing with equal force 4 Once oil separator element is removed reach inside housing and pull first element stage down Discard both elements and replace with new Reassemble by placing o rings silencer lid v band or retaining springs and air filter back into place IMPORTANT Drainage window must be positioned at bottom of primary element or system will malfunc tion Both first stage and coalescing elements must be replaced at the same time OL6125 06 10 15 SP6 VALVE CLEARANCES amp ELECTRONIC UNIT INJECTOR PRELOAD Have your deaer adjust intake a
14. electrolyte level every 50 hours or once per month Add distilled water to manufacturer s recommended level Batteries cables and cable terminals should be checked and cleaned every 100 hours Clean corrosion with a water and baking soda solution Flush with clean water Tighten terminals and grease them to inhibit corrosion Check the battery condition with a hydrometer every 750 hours OL6125 06 10 22 SP22 WINTERIZING OUT OF SERVICE The following long term storage preparation guides are good for storage up to one year after that the engine should be started warmed up and prepared again for long term storage 1 Change oil and replace filter Used oil will not give adequate protection Service the air cleaner 3 For storage less than a year it is not necessary to drain and flush the cooling system For a year or more of storage the cooling system should be drained flushed and refilled with appropriate coolant Remove the fan and alternator belts optional 5 Remove and clean the batteries Store them in a cool dry place and be sure they are fully charged 6 Disengage the clutch to engine drivelines 7 Clean the exterior of the engine with salt free water and touch up painted surfaces with good paint 8 Coat all exposed machined metal surfaces with grease or corrosion inhibitors if they cannot be painted 9 Seal all openings with plastic bags and tape 10 Store the engine in a dry protected p
15. 7 Updated 5 27 09 amp 6 21 10 Specifications 16125H Specifications and Installation Data Output rating Continuous Medium High Output FWHP kW 350 261 440 328 470 350 Maximum RPM 1800 2200 2300 Cylinders Configuration Cycle All 6 Inline 4 Displacement CID ltr All 674 11 Aspiration All Turbocharged Aftercooled Bore x Stroke in mm All 4 92 x 5 91 125 x 150 Seawater pump flow US gpm lpm 58 219 71 269 74 280 Heat rejection to sea water BTU min 8040 11350 13390 Freshwater system capacity US gal Itr All 9 34 Raw water intake dia in mm All 2 51 Raw water discharge dia in mm All 2 51 Max raw water temp at inlet F C All 86 30 Electrical Voltage All 24V standard ground Min battery capacity All 200 amp hours 800 CCA Battery cable size up to 10 ft run All 00 Standard panel harness length ft m All 20 ft 6m Engine air consumption cfm m min 590 16 7 936 26 5 1024 29 Exhaust gas flow at cfm m min 1715 49 2323 66 2508 71 Exhaust gas temperature F C 961 516 777 414 759 404 Max exhaust back pressure in mm H 0 All 30 762 Suggested dry exhaust I D in mm All 6 Suggested wet exhaust I D in mm All 8 Minimum fuel suction line in mm All 0 5 12 Minimum fuel return line in mm All 0 38 10 Maximum fuel pum
16. Cylinder liner walls Figure 3 A which are in contact with engine coolant Figure 3 B can be eroded or pitted unless the proper concentration and type of SCA s are present in the coolant Water pump impellers are also susceptible to pitting 2 Vapor bubbles Figure 3 C are formed when the piston s impact causes the liner walls to vibrate send ing pressure waves into the coolant 3 These tiny vapor bubbles collect on the surface of metal parts As the bubbles collapse pop a micro scopic 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 fail ure or other serious damage will result A Cylinder Liner Walls B Engine Coolant C Vapor Bubbles Figure 3 4 Unprotected engines with low quality water as coolant can have liner failure in as few as 500 hours OL6125 06 10 18 3 Ifchlorides 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 4 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 cool ant solution COOLING REQUIREMENTS 1 To meet cooling system protection requirements the coolant sol
17. IL PRESSURE Shows oil pressue of transmission Figure 1d Auxiliary panel OL6125 06 10 9 Operating Procedures BEFORE STARTING 1 A Check the water level by removing the pressure cap from the expansion tank In order to give the cool ing water room to expand the level should be about 1 3 4 in 4 5 cm below the filler cap sealing surface when the engine is cold When filling with coolant the venting cock on top of the turbocharger should be opened to ensure that no air pockets form in the cool ing 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 Add Never allow the level to go below the Add Do not fill above the crosshatch pattern Oil levels within the crosshatch are considered in the acceptable operating range Always add the same vis cosity of oil as is already in the crankcase see Service Point 1 Check the fuel tank level and open any fuel valves Check for leakage from fuel line Check that there is no leakage of fuel or damage to the hoses and tubes If any problem is found carry out repairs Check the oil level in the reverse gear Methods may vary from gear to gear See your Gear Owner s Manual Check transmission and gear oil coller for oil leakage from hydraulic hoses and j
18. OT use EGC containing more than 0 1 anhy drous metasilicate This type of concentrate which is intended for use in aluminum engines may cause a gel like deposit to form that reduces heat transfer and coolant flow Check container label or consult with supplier SUPPLEMENTAL COOLANT ADDITIVE SCA A CAUTION Supplemental coolant additive con tains alkali Avoid contact with eyes Avoid contact with skin Do not take internally In case of contact immediately wash skin with soap and water For eyes flush with large amounts of water for at least 15 minutes Call a physician KEEP OUT OF REACH OF CHILDREN Follow all warnings on the container Important heat exchanger cooled engines Additional SCA s should NOT be added to the mixture of EGC H 0 on initial fill up of engines with a coolant conditioner filter A high SCA concentration will result and can cause silicate dropout When this happens a gel type deposit is created in the cooling system which retards heat transfer and coolant flow If additional SCA s are needed prepare a mixture of 50 quality water and 50 EGC antifreeze Add liquid SCA at a rate of 3 by volume Example 30 mL of SCA per liter of H O EGC mixture 1 0 fl oz of SCA per qt of H O EGC Add the resulting mixture to the cooling system in quart increments Run the engine for 2 hours and retest the coolant Continue process until SCA concentration meets recommended levels SCA is available from your Nor
19. S ONLY SEE NOTE 12 MES amm i NORTHERN LIGHTS Mile dud Seattle WA 98107 208 700 2000 NORTHERN LIGHTS 4420 14th Ave NW Seattle WA 98107 EZ7 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 2010 All rights reserved Litho USA
20. auge readout and the second line will have SrvcCode on it The following is a table of the SPNs FMIs and description of the diagnostic fault codes that can occur in various engine systems Not all of the codes will be present in all engine applications When these trouble codes appear on the gauge see your dealer as soon as possible for repairs SPN FMI Description 29 03 Throttle 2 Input High 29 04 Throttle 2 Input Low 91 03 Throttle 1 Input High 91 04 Throttle 1 Input Low 94 01 Fuel Supply Pressure Extremely Low 94 03 Fuel Supply Pressure Input Voltage High 94 04 Fuel Supply Pressure Input Voltage Low 94 16 Fuel Supply Pressure Moderately High 94 18 Fuel Supply Pressure Moderately Low 97 00 Water in Fuel Continuously Detected 97 03 Water in Fuel Signal Voltage High 97 04 Water in Fuel Signal Voltage Low 97 16 Water in Fuel Detected 100 01 Engine Oil Pressure Extremely Low 100 03 Engine Oil Pressure Input Voltage High 100 04 Engine Oil Pressure Input Voltage Low 100 18 Engine Oil Pressure Moderately Low 110 00 Engine Coolant Temperature Extremely High 110 03 Engine Coolant Temperature Input Voltage High 110 04 Engine Coolant Temperature Input Voltage Low 110 16 Engine Coolant Temperature Moderately High 158 17 ECU Power Down Error 174 03 Fuel Temperature Input Voltage High 174 04 Fuel Temperature Input Voltage Low
21. e 0 2 to 0 45 Nm 0 02 to 0 046 kgm 0 1 to 0 3 Ibft D Figure 2 Secondary Fuel filter Servicing BLEEDING THE FUEL SYSTEM CAUTION Escaping diesel fuel under pressure can penetrate the skin causing serious personal injury Relieve pressure before disconnecting fuel or other lines Tighten all connections before applying pres sure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard or paper to search for leaks DO NOT USE YOUR HAND If ANY fluid is injected into the skin it must be sugically removed within a few hours by a doctor familiar with this type of injury or gangrene may result Doctors unfamiliar with this type of machingery may call the Deere and Company Medical Department in Moline Illinois or other knowledgeable medical source CAUTION Due to High Pressue Common Rail system design fuel in filter is likely to be under high pressure To avoid possible personal harm open valve C on bottom of water seperator bowl to relieve the pressure prior to removing each filter 1 Normally it is not necessary to bleed the fuel system using the hand primer is usually sufficient But if the engine has run out of fuel or the fuel system was full of air use special tool 53 50005 to quickly prime and bleed the fuel system Note If tool is not available loosen diagnostic con nector on filter housing until air and fuel can escape a To
22. e the threads are clean and have good metal to metal contact SP19 RAW WATER PUMP Heat exchanged cooled engines only 1 Change the sea water pump impeller as needed 2 Remove the pump end cover Remove impeller with water pump pliers Be sure you remove all pieces of a failed impeller 3 Clean the inside of the housing 4 Press in the new impeller and place the sealing washer in the outer end of the impeller center if this has not already been done 5 Replace the cover using a new gasket Note Make sure there is always an extra impeller and cover gasket in reserve and on board OL6125 06 10 21 DRIVEN EQUIPMENT I A ELECTRICAL SYSTEM GENERAL 1 Gears and PTO s 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 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 termi nal to see if it emits sparks
23. eck crankshaft damper OL6125 06 10 13 LUBRICATION Break in oil 1 2 Use one of the following during the first 100 hours of operation a John Deere Engine Break In Oil b API Service CC CD oil c ACEA Specification El Do not use John Deere PLUS 50 oil or engine oils meeting API CF 4 API CG 4 API CH 4 API CI 4 ACEA E2 ACEA E3 ACEA F4 or ACEA ES perfor mance 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 CH 4 CJ 4 multi viscosity oils b API Service CD CG 4 CF 4 multi viscosity oils c ACEA Specification E3 d ACEA Specification E4 E5 Use the proper weight oil for your average operation temperature Air Single Multi Temperature Viscosity Viscosity Above 32 F sae 30w SAE15 40W 0 C 10 F to 32 F 23 C to 0 C SAE 1 OW SAE1 0 30W Below 10 F 23 C SAE 5W SAE5 20W 5 Some increase in oil consumption may be expected when SAE 5W and SAE 5 20W oils are used Check oil level frequently Never put additives or flushing oil in crankcase SP1 CHECK ENGINE OIL LEVEL 1 Check the oil level in the crankcase with the oil dip stick daily The oil level must
24. fill 2 Turbocharger 11 Expansion tank 3 Primary fuel filter 12 Heat exchanger 4 Spin on oil filter 13 Heat exchanger zinc anodes 5 Electronic Control Unit 14 Raw water pump 6 Lube oil drain 15 DC alternator 7 Final fuel filter 16 Starter OL6125 06 10 6 Lugger Control Panel 2 e QUARTZ 0010 W fj Hours LUGGER by NORTHERN LIGHTS Figure 1b L6125H 1 TACHOMETER 5 POTENTIOMETER Shows engine speed in revolutions per minute Dims panel lights RPM Numbers are multiples of 100 6 ALARM HORN 2 HOUR METER If alarm sounds shut down engine if possible and Tracks engine running time investigate immediately 3 DC VOLTMETER 7 COOLANT TEMPERATURE GAUGE When engine is stopped shows condition of battery Shows temperature of cooling water Ifthe gauge When engine is running shows voltage output of registers above 200 F or below 140 F stop the alternator engine and investigate 4 KEY SWITCH 8 OIL PRESSURE GAUGE Turn key clockwise to first position to switch current Shows oil pressure in the engine lubricating system on Continue turning clockwise to start the engine If the pressure drops below 15 PSI at a speed higher When the engine starts immediately turn the key than idling stop the engine immediately back to the first position while the engine is running The key must be kept in the first or on position while the engine is running Turn the key counterclockwise until it stops to stop the en
25. gine Note Optional flybridge panels have engine start switches instead of keys switches see page 8 OL6125 06 10 7 PowerView Control Panel POWERVIEW CONTROL PANEL 1 Amber Warning LED 2 Red Shutdown Derate LED 3 Enter key 4 Right arrow key scroll down 5 Left arrow key scroll up 6 Menu key 7 Menu For a full description and operator s instruction of the PowerView control panel please consult Murphy publication OPV 02121N OL6125 06 10 8 Optional Lugger Control Panels NOTE The control panels shown on this page are optional Your L6125H may or may not be equipped with these options FLYBRIDGE PANEL 1 TACHOMETER Shows engine speed in revolutions per minute RPM Numbers are multiples of 100 2 START BUTTON Hold down to start engine 3 STOP BUTTON Hold down to stop engine 4 ALARM HORN If alarm sounds shut down engine if possible and investigate immediately 5 COOLANT TEMPERATURE GAUGE Shows temperature of cooling water If the gauge LUGGER registers above 200 F or below 140 F stop the ty NOT engine and investigate Fi Le Flybri l 6 OIL PRESSURE GAUGE igure Ic Flybridge pane Shows oil pressure in the engine lubricating system If the pressure drops below 15 PSI at a speed higher than idling stop the engine immediately AUXILIARY PANEL 7 PYROMETER Shows engine exhaust temperature 8 BOOST GAUGE Shows status of turbobooster 9 GEAR O
26. hamber maybe a Excessive crankshaft end play failed cylinder head gasket or cracked cylinder head Check crankshaft end play See your dealer Repair see your dealer v Engine Loose main bearing caps Emits White Smoke Check bearing clearance replace bearings and Water to air aftercooler fails bearing cap screws as needed See your Remove and inspect water to air aftercooler dealer See your dealer Worn connecting rod bushings and piston pins v Engine Idles Poorly nspect piston pins and bushings See your Improper type of fuel dealer Replace with correct fuel grade Scored pistons Air leak on suction side of air intake Inspect pistons See your dealer Check hose and pipe connections for tightness Worn timing gears or excessive back lash repair as required Check timing gear back lash See your dealer Electronic control system problem Excessive valve clearance See your dealer Check and adjust valve clearance See your dealer Worn camshaft lobes nspect camshaft See your dealer Worn rocker arm shafts nspect rocker arm shafts See your dealer OL6125 06 10 25 Diagnostic Trouble Codes Diagnostic Trouble Codes DTCs are found on the diagnostic gauge as 2 part code according to the J1939 standard The first part is a 2 to 4 digit Suspect Parameter Number SPN The second part is a 1 or 2 digit Failure Mode Identifier FMI code The diagnostic code will be on the first line of the g
27. hylene glycol coolant concentrate meeting ASTM D 6210 D4985P and D5345 PH Level 5 5 to 9 0 4 This product is concentrated and should be mixed to the following specification 5 Ifadditional 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 WATER QUALITY 1 Distilled deionized soft water is preferred for use in cooling systems Bottled distilled water from a food store or water supplier is recommended Tap water often has a high mineral content Tap water should NEVER be put in a cooling system unless first tested by a water quality laboratory Do not use water made by the reverse osmosis method unless it has been PH neutralized 2 Here are acceptable water quality specifications Distilled EGC Freeze Boiling Water Antifreeze Point Point 37 C 109 C i 0 0 Optimum 50 50 34 F 4226F 24 C 106 C TT o 0 Minimum 60 40 12 F 222 F 52 C 111 C n 0 O Maximum 40 60 62 F 232 F OL6125 06 10 19 IMPORTANT 1 1 4 DO NOT use methyl alcohol or methoxy propanol base EGC These concentrates are not compatible with chemicals used in supplemental coolant additives Damage can occur to rubber seals on cylinder liners which are in contact with coolant DO NOT use an EGC containing sealer or stop leak additives DO N
28. ilated areas Keep trash and other objects away from engine Escaping fluids under pressure can penetrate your skin Use a piece of cardboard or wood not your hands to search for leaks Avoid wearing loose clothing when working around engines Do not oil or grease engine while it is running 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 Donotoperate 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 OL6125 06 10 5 L6125H Component Locations Figure la L6125H 8 Turbo outlet 9 Lube oil fil 1 Air filter crankcase breather 10 Water
29. l Filterga ionic pere ta ee 16 NOTES Blank 31 32 Bleeding the Fuel System 17 T rbochatget iere certet 18 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 O Northern Lights Inc All rights reserved Litho U S A Publication number OL6125 06 10 OL6125 06 10 3 Introduction Servicing of marine engines presents unique problems Failures begin with minor problems that are overlooked In many cases boats cannot be moved to a repair and become amplified when not corrected during facility Marine engines cannot be compared to the routine maintenance servicing of automobiles trucks or even farm equipment Failures often occur in remote areas far As operator it is your obligation to learn about your from competent assistance Marine engines are taxed equipment and its proper maintenance This is not a far more severely than auto or truck engines 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 and aspiration L 6125 H L Lugger propulsion engine 4 Model number H After cooled
30. lace If the engine must be outside cover with waterproof canvas or other protective material and use strong waterproof tape OL6125 06 10 23 Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer v Engine Will Not Crank Weak battery Replace battery Corroded or loose battery connections Clean battery terminals and connections Defective main switch or start safety switch Repair switch as required Starter solenoid defective Replace starter or solenoid v Hard to Start or Will Not Start Poor fuel quality Drain fuel and replace with proper grade fuel Slow cranking speed Check for problems in the charging or starting system Electronic Control System Problem See your local dealer Engine Misfiring or Runs Irregularly Electronic Control System problem or basic engine problem See your dealer Lack of Engine Power Poor fuel quality Drain fuel and replace correct grade fuel Intake air restriction Service air cleaner Clogged primary fuel filter Clean or replace filter element Clogged secondary fuel filter element Replace secondary filter element Crankcase oil too heavy Fill with oil of appropriate viscosity Electronic Control System problem or basic engine problem See your dealer Low Oil Pressure Low crankcase oil level Fill crank case to proper level Clogged oil cooler or filter
31. lter element SP12 Check turbocharger air oil amp cooling lines for leakage SP18 Check zinc electrodes 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 SP21 Check the state of the charge of the batteries EVERY 2500 HOURS SP6 Check valve clearances SP16 Check and clean heat exchanger SP17 Check and clean gear oil cooler SP23 Check crankshaft damper SERVICE 50 250 600 2500 POINT PAGE OPERATION DAILY Hours Hours Hours Hours ENGINE SP1 10 Check oil level SP2 10 Change engine oil 1 SP3 10 Change lube oil filters 1 SP4 10 Check replace air cleaner 1 3 SP5 Check belt condition 1 SP6 11 Check valve clearances 1 SP23 11 Check crankshaft damper 4 FUEL SYSTEM SP7 12 Check primary filter 2 SP8 12 Change primary filter element 2 3 SP9 12 Change secondary fuel filter 1 3 SP10 Check injectors 5 6 TURBOCHARGER SP12 13 Check air oil amp cooling water lines for leakage 1 SP13 13 Check boost pressure COOLING SYSTEM SP14 15 Check cooling water level SP15 15 Check and flush cooling system 1 SP16 15 Check and clean heat exchanger 1 SP17 Check and clean gear oil cooler 1 SP18 15 16 Check zinc electrodes 1 3 SP19 16 Change impeller in raw water
32. nd exhaust valve clear ance and electronic unit injector EUI preload This one time adjustment for all new and overhauled engines is required after the first 2500 hours of opera tion FUELS GENERAL 1 Use only clean high quality fuels of the following specifications as defined by ASTM designation D975 for diesel fuels a Use grade no 2 diesel at ambient temperatures above freezing 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 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 F G or 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 c Fill the fuel tank at the end of each day s operation This will reduce condensation o oco c SP23 CHECK CRANKSHAFT DAMPER 1 Remove belt 2 Carefully inspect the vibration damper for torn or split rubber protruding from the front or back of assembly 3 Grasp vibration damper with both hands and attempt to turn it in both directions If rotation can be felt the damper is defective and should be replaced Note The vib
33. ng Coolant Level 20 COMPONENT LOCATIONS Cooling System Flushing ssse 21 OIL os sciet 6 Heat Exchanger Cleaning 21 Control Panels ccccccccccccccecccccccccccececseceesse 7 9 FANG Electrodes ute enses 21 Raw Water Pump ccsescceseseeceeeseeeseeeseees 21 OPERATING PROCEDURES Driven Equipments 2 eed rtr freto 22 Before Starting RR eeerietbes 10 Electrical System General 22 Shutdown Procedures sess 10 Welding and ECU Precautions 22 JATaFITIS onec ren 11 Booster Batteries 22 Break lia Petiod eiue mme 11 Battery CuIGuu bises eceteribussbet i 22 SERVICING SCHEDULE CHART 42 Winterizing Out of Service sss 23 SERVICE RECORD 13 TROUBLESHOOTING ENGINE arininn ea E ERES 24 25 SERVICING Lubrication General sessssss 14 DIAGNOSTIC TROUBLE CODEG 26 27 Checking Oll iiie recte ueris 14 Oil Changes ois cider irro rrt RTI 14 DATA SHEETS Changing Oil Filter iu ece ccrto termes 14 Unit Specifications nee 28 Air Filter Crankcase Breather 14 Air Filter Service 2 uioeoo venei 15 ON BOARD SPARE PARTS 29 Valve Clearances eee rase 16 Fuels General seseseeee 16 WIRING DIAGRAMS 30 Crankshaft Damper eee 16 Fue
34. ng 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 OL6125 06 10 20 SP15 FLUSHING THE COOLING SYSTEM CAUTION The cooling water in the engine reaches extremely high temperatures You must use extreme caution when working on hot engines to avoid burns Allow the engine to cool before working on the cooling system Open the filler cap carefully using protective clothing when the engine is warm 1 Flush the cooling system and check for leaks and 10 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 mix
35. oints If any problem is found repair the area where oil is leaking Close the seacock check and clean the strainer and reopen the seacock Place the battery switch in the ON position NOTE The battery switch must always be kept ON while the engine is running If the switch is turned OFF while the engine is running the battery charging regu lator could be ruined Starting 1 Put the gear control in the neutral position 2 Move the throttle control to the idle position 3 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 24 volts 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 gt Do not crank the starter for more than 15 seconds consecutively If the engne 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 26 28 volts at 60 F 16 C Water temperature should not rise over 200 F 94 C If it does shut down the engine and investigate the
36. ove and inspect pistons See your dealer Piston rings sticking in ring grooves Remove and inspect pistons See your dealer Insufficient piston ring tension Remove and inspect pistons See your dealer Piston ring gaps not staggered Remove and inspect pistons See your dealer Front and or rear crankshaft oil seal faulty Replace oil seals See your dealer OL6125 06 10 Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer v Excessive Fuel Consumption v Engine Emits Black or Gray Exhaust Smoke Intake air restriction Clogged or dirty air cleaner Service air cleaner Service air cleaner Improper type of fuel Defective muffler back pressure too high Consult fuel supplier and use proper type of Have dealer check back pressure fuel for operating conditions Improper fuel Engine overloaded Usecorrect fuel for temperature Reduce load on engine Electronic Control System problem Compression too low See your dealer Determine cause of low compression and v Engine Emits White Smoke repair Engine compression too low Leak in fuel supply Determine cause see dealer Locate source of leak and repair as required Defective thermostat does not close v Abnormal Engine Noise Remove and check thermostats replace if Worn main or connecting rod bearings needed Determine bearing clearance See your dealer Coolant entering combustion c
37. p head in m All 39 1 Crankcase oil capacity US qts ltr All 34 32 Engine rotation facing flywheel All Counter Clockwise Flywheel housing size All 1 SAE Optional front PTO size SAE inch All 4 8 4 10 or 3 11 5 Maximum operating angle any direction All 35 for less than 2 minutes Maximum installed operating angle All 10 rear down 0 front down Heat Exchanger Weight without gear 2867 Ibs 1300 kg 1 Flywheel Horsepower ratings based on SAE J816b 2 Kilowatt ratings based on EN ISO 8665 2006 OL6125 04 10 28 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 We consider these minimum quantities Your vessel s operating conditions may require more of a given part Consult your dealer Item Description Qty 1 Oil Filter 4 2 Air Filter Element 1 3 Fuel Filter Element 4 4 Fuel Transfer Pump 1 5 Oil Separator Element 2 6 Injector 1 7 Thermostat 2 8 Thermostat Cover Gasket 1 9 Speed Sensor 1 10 Rocker Arm Cover Gasket 1 11 Gasket Kit Engine Overhaul 1 12 Bearing 2 13 Zinc Anode 6 14 Raw Water Pump Impeller w Gasket 2 15 Raw Water Pump 1 16 Coolant Pump Repair Kit 1
38. pump 1 3 SP24 Check sea water strainer ELECTRICAL SYSTEM SP20 17 Check electrolyte level in batteries 1 3 SP21 17 Check condition of batteries with hydrometer 1 OUT OF SERVICE SP22 17 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 4 Replace crankshaft damper 4500 hrs or 60 mos which ever occurs first 5 At 2500 hrs an electronic injector preload adjusment must be made 6 Check at 5000 hours 12 OL6125 06 10 aa Saint OPERATION HOURS DATE 50 HOURS SP20 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 SP13 Check turbocharger boost pressure SP15 Check and flush cooling system SP19 Change impeller in raw water pump SP21 Check state of charge of batteries 2500 HOURS SP6 Check valve clearances SP16 Check and clean heat exchanger SP17 Check and clean reverse gear oil cooler SP23 Ch
39. ration damper assembly is not repairable and should be replaced every 4500 hours or 60 months whichever occurs first Always replace the vibration damper when ever the crankshaft is replaced or a major engine overhaul takes place SP7 9 FUEL FILTERS 1 Your engine will have a primary and final fuel filter installed We also recommend the addition of 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 primary element every 250 hours or whenever necessary c Ifthe bowl fills with water change the primary and secondary elements immediately 2 Change secondary fuel filter every 500 hours or annu ally NOTE The fuel filter on the engine is considered the secondary fuel filter a Turn off the fuel b Be sure area around fuel filter assembly is clean OL6125 06 10 16 3 Check for water and sediment in primary fuel filter water seperator Figure 2 a The water seperator forms one unit with the primary fuel filter 1 b It is possible to judge the water level and amount of sediment by looking through the transparent cap 2 Ifthere is any water or sediment collected at the bottom set a container to catch the drain water under drain valve 3 c Loosen drain valve and drain the water d When fuel starts to drain tighten drain valve 4 immediately Tightening torqu
40. thern Lights dealer in the following sizes Pint Part Number 20 00002 1 2 gallon Part Number 20 00003 DO NOT use any coolant system additives containing soluble oil COOLANT TESTING 1 Coolant test kits are available to allow on site evaluation of the coolant condition 2 The kits use small strips of paper which are dipped into the coolant The paper changes color and indicates the SCA concentration It also indicates the amount of EGC antifreeze 3 Test kits are available through your Northern Lights Dealer 4 Pack Part Number 20 00005 50 Pack Part Number 20 00010 SP14 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 coolant 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 cooli
41. ture 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 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 SP18 ZINC ANODES 1 Zincs are installed in the cooling system to protect your engine from electrolysis Check them faithfully every 250 hours If you are in warm salt water or where electrolysis is a known problem check them more often 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 50 of the electrode has eroded away replace it with a new one The electrode screws out of the holder 3 Reinstall the zinc holders Be sur
42. ution must consist of a Quality water b Ethylene glycol concentrate EGC commonly known as antifreeze c Supplemental coolant additives SCA s 2 Acoolant solution of ethylene glycol concentrate EGC antifreeze quality water and supplemental EGC ETHYLENE GLYCOL CONCENTRATE coolant additives SCA s MUST be used YEAR ANTIFREEZE ROUND to protect against freezing boil over liner erosion or pitting and to provide a stable noncorrosive CAUTION EGC Antifreeze is flammable environment for cooling system components A Keep it away from any open flame Avoid contact 3 Ethylene glycol coolant concentrate antifreeze with eyes Avoid contact with skin Do not take inter normally DOES NOT contain the SCA chemical nally In case of contact immediately wash skin with inhibitors needed to control liner pitting or erosion soap and water For eyes flush with large amounts rust scale and acidity of water for at least 15 minutes Call a physician KEEP OUT OF REACH OF CHILDREN Follow all warnings on the container Parts Grains Contaminates per Million per Gallon 1 Ethylene glycol coolant concentrate is commonly MaximumiChlorid s 40 25 mixed with water to produce an engine coolant with a low freeze point and high boiling point Maximum Sulfates 100 5 9 2 A low silicate form of ethylene glycol coolant is rec Maximum Dissolved Solids 340 20 0 ommended for all diesel engines Maximum Total tiardness 170 10 0 3 Use an et
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