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OPERATOR`S MANUAL

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9. Prevent Battery Explosions Battery gas is highly flammable Battery explosions can cause severe injury or death To help prevent battery explosions keep sparks lighted matches and open flame away from the top of battery When checking battery electrolyte level use a flashlight Never check battery charge by contacting the posts with a metal object Use a volt meter or hydrometer Frozen batteries may explode if charged Never charge a battery that has not been allowed to warm to at least 16 C 60 F Always remove grounded battery clamp first and replace ground clamp last Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin eat holes into clothing and other materials and cause blindness if splashed into eyes To Avoid Hazards Fill batteries only in well ventilated areas Wear appropriate eye protection and rubber gloves Never use air pressure to clean batteries Wear appropriate ventilation equipment to avoid inhaling fumes when adding electrolyte Do not spill or drip electrolyte Use correct jump start procedure if required If acid is spilled on skin or in eyes 1 Flush skin with water 2 Apply baking soda or lime to help neutralize acid 3 Flush eyes with water for 15 30 minutes 4 Get medical attention immediately If acid is swallowed 1 DO NOT induce vomiting 2 Drink large amounts of water or milk without exceeding 2 liters 2
10. OPERATOR S MANUAL 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 2013 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 OM2 2 7 13 NORTHERN LIGHTS OPERATOR S MANUAL OM2 2 for Models M1064A M1064D M1064T1 M106412 M1066A1 M1066A2 M1066A3 M1066T M40C2 M55C2 M65C2 and M99C2 Read this operator s manual thoroughly before starting to operate your equipment This manual contains information you will need to run and service your new unit Table of Contents INTRODUCTION RII 2 Models Included 2 Model ERE RR 2 Serial Numbers 2 WARRANTY avus 3 SAFETY RULES 3 7 Lockout Tag Out Procedures 8 COMPONENT LOCATIONS T 10 IE OGG oc cae us 11 Uie NA 12 Emission Related Installation Instructions 15 OPERATING PROCEDURES Before Starting 15 Shutdown Procedures
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12. 4 Or whenever necessary 5 Check the cooling system at 500 hours flush at 2000 hours 6 Check hoses and o rings replace element at 500 hours OM2 2 9 15 17 Revised 9 16 15 Service Schedule Chart Electronically Controlled Fuel System The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your marine generator set More detailed coverage of each Service Point SP 15 listed on the page noted in the page column DAILY SP1 Check oil level in engine SP8 Check primary fuel filter SP15 Check cooling water level SP26 Check crankcase vent system filter svc indicator button AFTER FIRST 50 HOURS SP2 Change engine oil SP3 Change lube oil filter EVERY 50 HOURS SP21 Check electrolyte in batteries AFTER FIRST 100 HOURS EVERY TWO WEEKS SP2 Change engine oil after first 100 hrs then check every 2 wks SP3 Change oil filter after first 100 hrs then check every 2 wks SP7 Check crankshaft vibration damper SP15 Check coolant level EVERY 250 HOURS SP2 Change engine oil SP3 Change lube oil filter SP4 Check air cleaner SP19 Check zincs SERVICE 2000 POINT OPERATION DAILY Hours EVERY 500 HOURS YEARLY SP4 Replace air cleaner SP5 Check belt condition SP9 Change primary filter element Racor SP10 Change secondary fuel filter SP11 Check injectors SP14 Check turbocharger boost pressure SP16 Check cooling system SP20 Change impeller in raw wate
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14. 1 800 762 0165 www northern lights com Northern Lights and Lugger are registered trademarks of Northern Lights Inc NORTHERN LIGHTS 2013 All rights reserved Litho USA
15. 15 Break In Period 16 SERVICING SCHEDULE CHARTS 17 18 SERVICING Lubrication General 19 Checking Oil C 19 BORSE TE 19 Changing Oil Filter 19 A FET uu u u uuu a e 19 Valves CALCE aa 20 21 Crankshaft Vibration Damper 6 Cyl 22 22 23 Bleeding the Fuel System 23 n ecfor SOL VIC WA 23 25 IAI GOON 25 27 DOC AS 28 Turbo BO OSE kia 28 Cooling System 28 Engine Coolant Specifications 28 29 Cooling System Flushing 30 Heat Exchanger Cleaning 30 Z ie all o u uuu ee 30 31 Raw Water Pump 31 Generator Ends 31 Electrical System General 31 Dooster BASICS 32 aug AU MODO Ossa 32 Winterizing Out of Service 32 TROUBLESHOOTING S IS re nee PNE SE E 32 stoppen messed adn 33 34 WIRING DIAGRAMS PIERII CU MERO 35 37 DC E 38 48 Panel Wiring 49 51 ON BOARD SPARE PARTS 52 Proprietary Information This publication is the property of No
16. Drain flush fill and bleed system Clogged primary fuel filter element Clean or replace filter element Clogged secondary fuel filter element Replace filter element Dirty or faulty injection nozzles Have your dealer check injection nozzles Electronic Fuel System problem if equipped See your dealer Injection pump not getting fuel or air in fuel system Check fuel flow at supply pump or bleed fuel system OM2 2 9 15 Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer v Engine Runs Irregularly or Stalls Frequently Below normal engine temperature Remove and check thermostat Clogged primary fuel filter element Clean or replace filter element Clogged secondary fuel filter element 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 nspect clamps and hoses on suction side of fuel pump for air leak bleed fuel system Improper type of fuel Consult fuel supplier and use proper type of fuel for operating condition Lack of Engine Power Intake air restriction Service air cleaner Service aftercooler Clogged primary fuel filter element Clean or replace filter element Clogged secondary fuel filter element Replace filter element Improper type of fuel Consult fuel
17. Handle Fuel Safely Avoid Flames Follow All Safety Instructions Carefully read and understand all safety messages in this manual and on your machine s safety signs Keep signs in good and clean condition Replace missing or damaged signs Be sure new equipment components and repair parts include the current safety signs For replacement signs ALWAYS STOP ENGINE proper placement of safety signs or clarification on any BEFORE FUELING safety issue consult your Northern Lights dealer or the MACHINE Always fill Diesel is highly flammable and should be treated with care at all times Do do not refuel while smoking or when near sparks or open flame S A factory portable fuel tank outdoors There can be additional safety Information contained Never fuel a hot engine OM2 2 9 15 3 Revised 4 10 12 Safety Rules Continued Prevent accidental discharge of starting fluids by storing all cans in cool safe place away from sparks or open flame Store with cap securely on container Never incinerate or puncture a fuel container Prevent fires by keeping machine clean of accumulated trash grease and debris Always clean any spilled fuel as swiftly as possible Do not store oily rags which can ignite and burn spontaneously Be prepared if a fire starts Keep a first aid kit and fire extinguisher handy Keep emergency contact numbers for fire department doctors ambulance and hospital near the telephone Se
18. commercial marine generator with a John Deere Powertech Tier 6068 engine block and an electronically controlled fuel system MP99C2 Serial Numbers When referencing Northern Lights equipment by serial number please refer only to the number stamped on the Northern Lights serial number plate Serial No Model No N ALASKA DIESEL ELECTRIC Inc 4420 14TH AVE NW SEATTLE WA U S A NORTHERN LIGHTS O O NORTHERN LIGHTS Northern Lights 4420 14th Ave N W Seattle WA 98107 206 789 3880 Generator Set Data O Set Serial No Set Model No O OM2 2 9 15 Revised 4 10 12 Warranty A warranty registration certificate 1s supplied NOTE If the warranty 15 to apply the servicing with your set The extent of coverage is described instructions outlined in this manual must be in the Limited Warranty Statement We recommend followed If further information 15 needed please that you study the statement carefully contact an authorized dealer or the factory Safety Rules A NOTICE 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 IMPORTANT SAFETY INSTRUCTIONS on parts and components from outside suppliers Electromagnetic equipment including generator sets that is not reproduced in this manual Consult the and their accessories
19. Old 95119373 IVNOlLdO 990 901 JNI5NI m quiis aan SONILLAS HOLIMS 03345 43 0 B Naa 2 nas u ion H MOTI3A 024 06 MOTA dnd E AY oso wie KIJIJI TA wre SS way _ 39nv9 M3IAH3MOd TVNOLLdO p 310N 33S _ 5 18 0 057 0 IONS s _ mu i dW31 3 I N3 ama 98 Sa ee ov18 l 34155344 AS ONNOIS 3ILLOMHI 33 9 S16 mE 916 1 TST nyao 335 ATTE MV39 ONIY 3N9N3 HAMS qas 1 2 d Enc E un BUM Ja 2 56 8 0000 Ls 7E ALON 335 09 450 NEM m P 6 aay nan 6 21908 LL pe ae e oso ON so T l zo I I 2 9 B E AV133 N 23 Jidund 9 N3349 024 S06 9 IZ og 0 8 MOTI3A OZ 06 HOLIMS m i ee ISd 81 wal 8 _ MEM on 31dund Ltt 116 E 3339 616 WHS 80 MOTI3A 16 n e on d NN 2 c gw Ds Ni _ _ 39055389 MO Avi38 NMOGLNHS 39NvHO Le dnd 6 lt MOTA 956
20. can cause bodily harm and suppliers for additional safety information life threatening injuries when improperly installed operated or maintained To prevent accidents be aware Learn how to operate the machine and how to use of potential dangers and act safely the controls properly Only trained personnel should operate machines or work on or around them READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL Keep you machine in proper working condition PRIOR TO THE INSTALLATION UNAUTHORIZED MODIFICATIONS TO THE OF ANY GENERATOR SET OR MACHINERY MAY IMPAIR ITS FUNCTION ACCESSORY KEEP THESE AND SAFETY PARAMETERS INSTRUCTIONS FOR FUTURE REFERENCE Prevent Bypass and Accidental Starting Recognize Safety Symbols and Instructions In addition to the information found in this section this WARNING operator s manual uses three different signal words to outline potential dangers of a specific nature Do not start engine by shorting Z across start terminal Engine will A D AN E DANGER indicates a hazardous situation which if start if normal circuitry is bypassed not avoided will result in death or serious injury cre atin ga hazar d by runaway WARNING indicates a hazardous situation which if machinery not avoided could result in death or serious injury CAUTION indicates a hazardous situation which Start engine only from operator 75 station A C AUTION if not avoided could result in minor or moderate injury
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22. 38 OL 33V SYOLONGNOD SS3NYVH 3MIM 3NI9N3 TW 78 Sd SZ n aqasn 4 434 03103135 STVNINH3L TONLNOD 03395 Z JONVOHOLIMS 88 319NV 333930 06 V TONLNOD SSOMO GINOHS 50 31 IN333nO T3A31 1 1005 on 5 2 UHMM HOIH Q3NIVINIVN 38 NVO 21 JO 3ONVISIQ v 5531 SS3NMVH dii NNOILdO al Fa 3NION3 3HL T3TlVMVd NI SYOLONGNOD LNSYYND H9IH ONILNOY QIOAV 79 38055384 10 68 KINO SHOLWNYSLIV G31lOX3 AT31VMVd3S NO MOLVNM3LIV OL G3LOSNNOO S 0311 15 1 38 a NOLO Z ASN 430 35 NOLVIS VNC 0351 3NV ST3Nvd 10MINOO Q39nv9 OML dl P LL GALVOIGNI LNIOd 1v ANNONS ANO Nev 349 5 QN3 3NO 1Y M0018 38 OL 33V 5013 5 MIVd Q3ISIML WNOILdO ON INIOd NOILOJNNOO HOV3 LV iva 3MIM A8 O3lJILN3O 38 LSNW ONY 94 L gt AvM9 38 OL 3YV SYOLONGNOD G3TIVISNI Tv 93909 0109 5531 72 26 1 SV fe SuIVd Q31SIML SS3NNVH 3 JHL 1d39X3 GNVYLSILINW 2 501 lt 2 2 009 MLN 3dAL L 38 OL 33V SYOLONGNOD NOLLVTIVISNI Tv gt 29 g aay xovi8 NMON8 is ION ON Q HOLIMS Si PS pas whale cov Des 52018 3NION3 I 8 W3lNvis OL yana oof w f de ovigV xy _ 3umw 3oNvuo 6
23. AG 1031311301 38 LSNW AVYD 38 Ol 38V SYOLONGNOD Q3TIVISNI NN Tiv d3d09 30109 SS3INn Q310N SV SulVd Q31SIML SS3NMVH 3MIM ANIONS 3HL 1d30X3 ONVYLSILINW 9 501 OVA009 MLN 38 OL 34V SYOLONGNOD NOLVTIVISNI TV 1 SALON N 00 5 WS elev cigv 02 dalva 0081 vvoc 110 6691 Galva 0051 ZH 2 Wd 5 3365 225661 2254 NING SONILLAS HOLIMS Q33dSH3AO 438 Q Py 5 I 8 85 L oam _ 9 IAYSMOd IWNOILLdO wep et Dos w OL T yawa tot 8 JUHM AIBA dS 6 x 98 8 T sn 17 qup lis NOY eL___ __Jg A gt D 3 gt 0 0 8 R oto yds mE 4 E d u e E AV133 NAOGQ1InHS 18 pe LYVLS 48 0 Kal Lg ef 7 935 944 via dAL LINDID 8 98 qus AA EE MEM C 7 S310N 33S SOIVH3N3O 5122 1 Qq3riadns YAWOLSNOD OM2 2 9 15 45 Added 4 10 12 Notes OM2 2 9 15 46 Added 4 10 12 iagram D iring Panel W v9 9c v 9UI MSIA O BuurM Jeueg oe s ae s V 4 EA dt V Ofild SS3NVH H 3015 9 lt S
24. Change lube oil filter SP4 Check air cleaner SP9 Change primary fuel filter element SERVICE POINT PAGE OPERATION DAILY ENGINE SP1 15 Check oil level SP2 15 Change engine oil 2 SP3 15 Change lube oil filters 2 SP4 15 Check replace air cleaner 2 4 5 5 Check belt condition 2 SP6 16 Check valve clearances 2 SP7 17 Check crankshaft vibration damper FUEL SYSTEM SP8 17 Check primary filter Racor 3 SP9 17 Change primary filter element Racor 3 4 SP10 17 Change secondary fuel filter 2 4 SP 11 18 19 Check injectors 2 SP12 20 22 Check fuel injection pump TURBOCHARGER Check air oil amp cooling water lines for leakage Check boost pressure Check crankcase vent system COOLING SYSTEM Check cooling water level Check and flush cooling system Check and clean heat exchanger Check zinc electrodes Change impeller in raw water pump ELECTRICAL SYSTEM Check electrolyte level in batteries Check condition of batteries with hydrometer Test thermostats 1 Change the oil and filter at 50 hours using break in oil again until changing it at 100 hours then at every 250 hours 2 Perform all maintenance once a year even if hour level has not been reached 3 Consult manufacturer s maintenance schedule EVERY 2000 HOURS SP6 Check valve clearances adjust if necessary SP12 Check fuel injection pump SP17 Check and clean heat exchanger 2000 Hours 1 1 1 1 e e e e e e
25. Check all gauges and check for leaks 6 Sealed batteries see manufacturer charging and SP26 CRANKCASE VENT SYSTEM 1 For sea water aftercooled units the crankcase vent SP21 22 BATTERY CARE LEAD ACID system Is a good option and now standard equip BATTERIES ment for M1064A M1066A1 M1066A2 and M1066A3 units as of July 2008 Check the red filter service indicator button daily booster instructions 1 Check electrolyte level every 50 hours or once per month Add distilled water to manufacturer s recom if it pops up the filter element needs to be changed mended level After changing the element unscrew the clear 2 Batteries cables and cable terminals should be plastic cover on the button and push the indicator checked and cleaned every 100 hours Clean corro down to reset 1 then replace the cover sion with a water and baking soda solution Flush Note This service should be performed with with clean water Tighten terminals and grease them Me M Mid HO RET canister because of engine operation may make difficult to take apart Normally the filter element should be changed to inhibit corrosion 3 Check the battery condition with a hydrometer every 500 hours every 750 hours SP24 WINTERIZING OUT OF SERVICE SP30 AFTERCOOLER If the generator set will not be used for more than 6 1 The aftercooler should be removed and inspected months the following preparations should be
26. Keep all 2 Drain flush and refill the cooling system flames and sparks away from batteries 3 Crank the engine a few times with a starter 1 Before changing or using booster batteries check nour s EMI NA 4 Remove and clean batteries battery electrolyte level Add distilled water 5 All engine openings should be sealed with plastic bags and tape 6 Store in a dry protected place 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 To Remove Generator Set from Long Term Storage 1 Take off all protective coverings and unseal all the openings that were covered up 2 Install batteries that are fully charged and connect the terminals 3 Install the fan and alternator belts if they had been removed 4 Fill the fuel tank Perform all pre start checks A 6 Crank the engine for 20 seconds with the starter without letting the engine start Wait 2 minutes Battery Booster Battery and crank the engine an additional 20 seconds to make sure all bearing surfaces are well coated Figure 26 Booster Battery Connections 7 Start the engine and run at no load In a low idle for 4 Then connect negative terminal of booster battery to ground on the engine block see Figure 26 up and check gauges before going under load 5 Remove booster battery after starting engine 8
27. SZ S a3sn 3 NOILWONddY X3d 03193135 SH38WnN STVNIWN3L 1041409 Q33dS 7 FONVOHOLIMS 319Nv 334930 06 V TONLNOD SSOND GINOHS 50 31 IN333nO TAI INV 1009 5 2 HOIH Q3NIVINIVN 38 NVO 21 30 3ONVISIQ v 55310 SSINYYH 2581 WHOS lt Las 3NION3 JHL T3TIVeWd SYOLONGNOD LNSYYND H9IH ONILNOY QIOAV 9 34055344 10 Sa 68 KINO Q31l0X3 AT31VNVd3S NO OL 13103NNOO S NYviV 34d j 0311 15 38 ON a a SY3ON3S 15 0351 513 4 TOMINOD 39 OML dI v NAL ANIONS x La Q31VOIQNI LNIOd LV AINO QN3 G3GNNOYD 52018 38 01 SQT3IHS Q3lSIML ud RE _ NOLLO3NNOO HOV 1V M3 JVA 3BIM AB 38 LSA L gt 38 OL 33V SYOLONGNOD G3TIVISNI TY 03000 40109 5531 Z a ae E 76 G3LON SV 8 O3lSIML 553 T3NVd JHL 1939 3 GNVYISLLINW 2 501 lt 31 on C 2 009 MLN 3dAL 38 OL SYOLONANOO NOHVTIVISNI 11 71 gt AA m yo HONS Mors MOVIB NMOM8 NOLLO3NNOO ON IVNOLLdO amp 39NVNO HOLIMS Way S Xv31 INIT land gt vss WNOLLdO L 581 E A A A ae 6 ovia y HAIN 76 J QAZ HOLMI
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29. can be generated when paint is heated by welding soldering or using a torch To avoid potentially toxic fumes and dust remove paint before heating Remove paint a minimum of 100 mm 4 in from the area that will be affected by heat If paint cannot be removed wear an approved respirator If you sand or grind paint use an approved respirator If you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers from the area Allow at least 15 minutes for fumes to disperse before welding or heating Do not use a chlorinated solvent in an area where welding will occur Work only in areas that are well ventilated Dispose of paint and solvent properly Service Cooling System Safely _ WARNING gt 51225 Q Opening a pressurized cooling system can release explosive A fluids and causing serious burns Before opening any pressurized cooling system make sure the engine has been shut off Do not remove a filler cap unless it is cool enough to comfortably grip with bare hands Slowly loosen cap to relieve pressure before opening fully Avoid High Pressure Fluids Relieve pressure prior to disconnecting pressurized lines Escaping fluid under pressure can penetrate the skin causing serious injury Always relieve pressure before disconnecting hydraulic or other pressurized lines Tighten
30. coolant concentrate antifreeze normally DOES NOT contain the SCA chemical inhibitors needed to control liner pitting or erosion rust scale and acidity LINER EROSION PITTING 1 Cylinder liner walls Figure 25 A which are in contact with engine coolant Figure 25 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 25 C are formed when the piston s impact causes the liner walls to vibrate sending pressure waves into the coolant 3 These tiny vapor bubbles collect on the surface of metal parts As the bubbles collapse pop a microscopic piece of metal is eroded from the metal part Over a period of time this pitting may progress completely through the cylinder liner of a wet sleeve heavy duty diesel engine This allows coolant to enter the combustion chamber Engine failure or other serious damage will result A Cylinder Liner Walls Engine Coolant C Vapor Bubbles Figure 25 4 Unprotected engines with low quality water as coolant can have liner failure in as few as 500 hours WATER QUALITY 1 Distilled deionized soft water is preferred for use in cooling systems Bottled distilled water from a food store or water supplier is recommended Tap water often has a high mineral content Tap water should NEVER be put in a cooling system unless first tested by a water quality labora
31. 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 CLEANER 1 Inspect air cleaner every 100 hours Replace filter every SP1 CHECK ENGINE OIL LEVEL 500 hours or yearly whichever comes first for 1 Check the oil level in the crankcase with the oil mechanically controlled fuel system engines For elec dipstick daily tronically controlled units replace air cleaner element 2 The oil level must be between the Waffled area and every 500 hours the oo Never allow the level to go below the oo 2 Clean the rubber tube at the cleaner Loosen the hose 3 Always add the same viscosity of oil as 1s already in clamp and the attaching strip for the cleaner the crankcase 3 Make sure the rubber tube is in good condition and that SP2 OIL CHANGES new filter is absolutely clean and installed properly 1 Using the oil recommended above change the 4 Start the engine and check for leaks engine oil and filter after the first 50 hours of opera NOTE Make absolutely sure no impurit
32. process 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 with water lift muffler systems can cause engine damage After the engine starts release the switch and it will return to RUN position To stop the engine hold the switch in the STOP position 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 F 93 3 C or drops below 140 F 60 C stop the engine and investigate HOUR METER Keeps track of the engine running time DC VOLTMETER When the engine 15 running it indicates the voltage output of the alternator OM2 2 9 15 13 Northern Lights Control Panel 10 Generator r Amperes 7 8 Generator Hertz Series 4 Generator Set Control Panel 6 Ammeter amp Voltmeter Selector Switch Figure 8 Series 4 B Generator Control Panel SHUTDOWN BYPASS SWITCH 7 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 lubric
33. taken for for deposits and the air side cleaned every 2000 I hours ong term storage OM2 2 9 15 31 Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer DC ELECTRICAL SYSTEM v Battery Will Not Charge Loose or corroded connections 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 Adjust belt tension Replace belt Undercharged Electrical System Excessive electrical load from added accessories Take off accessories or install higher output alternator Engine idling excessively ncrease the engine RPM when there is a heavy electrical load Poor electrical connections on battery ground strap starter or alternator nspect connections and clean if necessary Defective battery Test battery Battery charging rate too high Test charging system Starter Inoperative PTO engaged Disengage PTO Check DC circuit breaker Ifthe breaker is tripped reset it Faulty start circuit relay See dealer Blown main system fuse Replace fuse Loose or corroded connections Clean and tighten loose battery and harness plug connection Low battery output Check specific gravity of each battery cell Check electrolyte level of each battery cell Defective electrical system ground wire Repai
34. type 5 If additional coolant solution needs to be added deposit 15 created in the cooling system which Optimum Minimum Maximum to the engine due to leaks or loss the glycol concentration should be checked with a hydrometer to assure that the desired freeze point is maintained Distilled Water EGC Antifreeze Freeze Point Boiling Point TC 34 F 109 C 50 226 F 50 24 C 12 F 106 C 60 222 F 40 52 62 111 40 232 60 OM2 2 9 15 28 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 15 available from your Northern 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 Servicing 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
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38. 2004 Deere amp Company All rights reserved OM2 2 9 15 24 RG5659 Disconnect all fuel delivery pressure lines Figure 18 B from injection pump using a suitable 17 mm deep well crowsfoot socket Remove injection pump drive gear cover Remove drive gear retaining nut and washer from end of pump shaft Be careful not to let washer fall inside timing gear cover Servicing NOTE The injection pump drive gear fits snugly onto IMPORTANT Injection pump mounting flange timing a tapered drive shaft and indexed by a hollow pin or mark Figure 20 A and front plate timing mark Woodruff key installed in drive shaft Figure 20 B presence and alignment MUST be 6 Attach JDG670A Drive Gear Puller Figure 19 A to verified before removing pumps from engine DO injection pump drive gear as shown NOT reference internal timing marks on pump cam NOTE Replace 6mm Grade 12 9 cap screws C as ring and governor weight retainer If timing mark is needed not clearly visible on front plate make a visible 7 Evenly tighten the two 6mm Grade 12 9 screws reference mark as accurately as possible in line with threaded in drive gear and snugly tighten center mark on pump flange forcing screw Figure 19 B against end of pump shaft 10 Remove three injection pump mounting stud nuts Remove injection pump from mounting studs 11 Plug or cap all openings on injection pump and take pump to dealer for service DB4 amp DB2 INJECTION PUMP INST
39. 4 Deere amp Company All rights reserved RG6278 10 Tighten the three hex nuts securing the pump to the 11 front plate to 20 foot lbs 27 Nem Connect injection pump pressure lines Figure 23 E Beginning with outlet connection to 1 cylinder Figure 24 B and continue around the pump head in counter clockwise 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 OM2 2 9 15 26 Figure 23 Reproduced by permission of Deere amp Company c 2004 Deere amp Company All rights reserved RG5664 Figure 24 Reproduced by permission of Deere amp Company c 2004 Deere amp Company All rights reserved 12 13 14 RG9089 Tighten fuel delivery pressure lines to 20 foot lbs 27 Nem using a suitable 17 mm 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 23 C and fuel return line Figure 23 0 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 equipped 15 Bleed air from fuel system as outlined on page 18 Start engine and run for
40. ALLATION 1 Lubricate a new square sealing ring with clean 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 Figure 19 reproduced by permission of Deere amp Company c 2004 Deere amp Company All rights reserved alignment with pump drive gear key slot RG7757 IMPORTANT Shaft roll pin may be easily damaged 8 Tighten center forcing screw until pump drive gear if improperly assembled Pump drive gear should is free from tapered shaft Remove JDG670A puller not move when initially installing pump index pin into Figure 19 A and screws from drive gear drive gear key slot 9 Check to make sure that timing marks on back side of front plate Figure 20 A and injection pump flange 3 Install injection pump partially onto mounting studs Figure 20 B are present and properly aligned This without engaging pump pilot hub into engine front assures that repaired or replacement pump can be plate properly timed to engine when installed IMPORTANT DO NOT tighten hex nuts more than three full turns on mounting studs Pump drive shaft index pin may be damaged if pin is not properly aligned with drive gear key slot and if the nuts are tightened more than three turns 4 Install three flat washers lock washers and hex nuts onto pump mounting studs Tighten nuts three turns only so that pump
41. Biodiesel blends must be used within 90 days of their manufacture Oil level leaking microbial growth plugging and component degradation all must be checked more frequently using biodiesel blends Request a certificate of analysis from an approved biodiesel fuel distributor to make sure the blend meets specifications NOTE Using raw pressed or partially refined vegetable oils or recycled greases as fuel which have not been through transesterification could cause engine failure SP8 10 FUEL FILTERS m 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 500 for electroni cally controlled fuel system units or whenever necessary c If the bowl fills with water change the primary and secondary elements immediately 2 Change secondary fuel filter every 500 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 SP7 CRANKSHAFT VIBRATION DAMPER 6 Cylinder Engines Only 1 Remove belts 2 Try to turn the vibration damper in both directions while grasping it with both hands If rotation can be felt the damper is defective and should be replaced Reprodu
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45. Y O Component Locations Figure 3 amp 4 M1066T Mechanically Controlled Fuel System Coolant Fill 9 Expansion Tank 10 DC Alternator 11 Lube Oil Fill 12 Lube Oil Filter 13 Fuel Lift Pump 14 Lube Oil Dipstick 15 Lube Oil Drain 16 Air Cleaner DC Circuit Breaker Turbocharger Wet Exhaust Elbow Exhaust Manifold Drain Electric Starter Engine Block Drain Fuel Injection Pump 17 Heat Exchanger Zinc 2 18 Heat Exchanger Drain 19 Heat Exchanger 20 Raw Water Pump 21 Fuel Injectors 6 22 Thermostat cover 23 Optional Hydrolastic Mounts OM2 2 9 15 11 24 25 26 A V R Fuse 28 Optional Governor Actuator Drive Belt Cover Fuel Manifold Fuel Filter Component Locations 90 _ rd Figure 5 amp 6 M40C2 Mechanically Controlled Fuel System 1 Junction Box 6 Coolant Fill 11 Lube Oil Drain 16 Exhaust Manifold 2 Fuel Filter 7 Expansion Tank 12 Lube Oil Filter 17 Injection Lines 3 Fuel Lift Pump 8 Belt Guard 13 Dipstick 18 Fuel Injection Pump 4 Air Cleaner 9 Coolant Pump 14 Electric Starter 5 Alternator 10 Centerbonded Mounts 15 Closed Crankcase Vent OM2 2 9 15 12 Northern Lights Control Panels Series 3 Generator Set Control Pane Shutdown Bypass A Preheal Swich Figure 7 Series 3B Generator Control Panel SHUTDOWN BYPASS SWITCH This switch bypasses the safety shutdown feature during the starting
46. after each fuel injection nozzle has been removed Cap fuel line openings as soon as they are disconnected Immediately fit protective caps over the nozzle tips and the line connections to avoid handling damage Servicing 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 screwdrivers pry bars or similar tools for this as they might damage the injection nozzle Clean Injector Bore Always turn the tool clockwise through the bore even when removing from bore otherwise tool may become dull a Clean nozzle bore with JDE39 Nozzle Bore Cleaning Tool Blow debris from bore with compressed air and plug the bore to prevent entry of foreign material Clean injection nozzles a Remove carbon stop seal Figure 15 A and upper sealing washer Figure 15 B using a needle nose pliers Discard seals b Clean exterior of nozzle by soaking in clean solvent or diesel fuel Clean tip with b
47. all connections firmly before re applying pressure If searching for leaks use a piece of cardboard Always protect your hands and other body parts from high pressure fluids If an accident occurs see a doctor immediately Any high pressure spray injected into the skin must be removed within a few hours to prevent the risk of gangrene or other infection Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns and bodily injury Pressurized lines can rupture when heat goes beyond the immediate flame area Do not weld solder or use a torch or open flame near pressurized lines or other flammable fluids p Do Not Open High Pressure Fuel System Many Northern Lights engines use high pressure fuel injection High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt any repair of fuel lines sensors or other OM2 2 9 15 6 Revised 4 10 12 Safety Rules Continued components between the high pressure fuel pump material containing asbestos Keep all bystanders and nozzles on engines with high pressure fuel away from any area where asbestos dust may be systems generated ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH Use Proper Lifting Equipment and Techniques PRESSURE FUEL INJECTION SYSTEMS 1 WARNING Avoid Hot Exhaust Lifting heavy components incorrectly can cause severe
48. ap 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 93 3 C Repeat the troubleshooting process If the shutdown is activated and the temperature gauge shows temperature within normal temperature range a Check the engine crankcase oil level b Ifthe oil level is low fill with recommended lubricating oil and restart Watch the oil pressure gauge carefully and shut off the engine if 1t does not show a normal reading after a few seconds of Operation c Ifthe oil level was normal DO NOT restart the engine Call your Northern Lights or Lugger dealer for assistance OM2 2 9 15 16 BREAK IN PERIOD Your engine 1s ready to be put into service However the first 100 hours on a new or reconditioned engine are critical to its life and performance This is especially true of an engine that runs at a constant speed such as a generator engine Operate the engine under various conditions particularly heavy loads with minimal idling to help seat engine components properly Oil consumption is greater during break in as piston rings take time to seat Your engine comes equipped with break in oil Change engine oil and filter at 50 hours using API Service Category CC CD or CE break in oil Change the oil and filter again at 100 hours Consult the lub
49. at may be generated when handling components containing asbestos fibers including some Disposing of waste improperly can threaten the Dispose of Waste Properly The asbestos used in these components is usually environment and lead to unsafe working conditions found in a resin or otherwise sealed Normal Potentially harmful waste used in Northern Lights handling of these components is not dangerous equipment can include oil fuel coolant filters and as long as airborne dust containing asbestos is not batteries generated Avoid creating dust Never use compressed air for Use leakproof containers to drain fluid Do not cleaning Avoid brushing or grinding materials use food or beverage containers that may mislead containing asbestos When servicing wear an someone into drinking from them approved respirator A special vacuum cleaner is recommended to clean asbestos If this vacuum is Do not pour waste onto the ground down a drain or not available apply a mist of oil or water on the into any water source OM2 2 9 15 7 Added 4 10 12 Lock Out Tag Out Procedures During maintenance repairs or retooling of a Northern Lights generator set simply turning the machine off or unplugging it while it is being worked on does not give enough protection to others who are not performing the maintenance or repair Many serious accidents happen when someone thought the machine was turned off or all of its energy was safely blocked or re
50. ating 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 93 3 C or drops below 140 60 C stop the engine and investigate HOUR METER Keeps track of the engine running time DC VOLTMETER When the engine is running it indicates the voltage output of the alternator OM2 2 9 15 14 10 AC VOLTMETER The voltmeter shows the generator output voltage phase to phase If the voltage fluctuates greatly from the normal reading shut down the unit and 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 indicate correct hertz stop and investigate AMMETER SELECTOR SWITCH The ammeter switch is used for checking each phase for load condition Leave it in the ON position while the engine is running AC AMMETER The ammeter indicates the phase load Check for load unbalance If the unbalance is greater than 30 have an electrician balance the load properly This will ensure longer generator life and better economy revised 3 19 13 Emission Related Installation amp Instructions Failing to follow these instructions when installing a certified engine in a vessel violates federal law 40 CFR 1068 105 b subject to fines o
51. ced by permission of Deere amp Company c2004 Deere amp Company All rights reserved RG8018 Figure 12 NOTE The vibration damper assembly should be replaced every 4500 hours or 60 months whichever occurs first as the vibration damper assembly is not repairable 3 Place a dial indicator Figure 13 so that the probe contacts the damper s outer diameter in order to check the damper radial runout 4 Make sure the engine is at operating temperature then rotate the crankshaft using the JD281A JDE8 1 4 or the JDE83 Flywheel Turning Tool 5 Ifthe runout reading exceeds the below specification replace the vibration damper Vibration Damper Maximum Radial Runout 1 50 mm 0 060 in Reproduced by permission of Deere amp Company c2004 Deere amp Company All rights reserved RG7508 Figure 13 OM2 2 9 15 21 Servicing SP8 10 FUEL FILTERS Continued a Turn off the fuel b Open the filter drain plug Figure 14 A and drain the filter A Drain Plug B Filter Clamp C Cartridge D Bleed Screw Figure 14 Secondary Fuel filter c Remove the secondary fuel filter by turning the filter clamp Figure 14 B counter clockwise until the filter cartridge Figure 14 C slides out NOTE Before installing a new filter cartridge make sure the surfaces where the cartridge comes in contact with the mounting plate are absolutely clean Dirt can be washed into the fuel injection syste
52. com mendations closely Generator Ends The maintenance and operation recommendations for the generator end are in a separate Owner s Manual If you do not have one of these manuals contact your local Northern Lights dealer ELECTRICAL SYSTEM GENERAL Heat exchanged cooled engines only 1 Never switch battery switch off or break the circuit between the alternator and batteries while the engine 1 Change the sea water pump impeller as needed is running Regulator damage can result 2 Remove the pump end cover Remove impeller with 2 DO NOT reverse the polarity of battery cables when water pump pliers Be sure you remove all pieces of installing the battery a failed impeller 3 When welding on the unit disconnect the regulator 3 Clean the inside of the housing and battery Isolate the leads 4 Press in the new impeller and place the sealing 4 Disconnect battery cables when servicing the DC washer in the outer end of the impeller center if this alternator has not already been done 5 Never test with a screwdriver etc against any 5 Replace the cover using a new gasket terminal to see if it emits sparks 6 A DC circuit breaker protects your control panel and Note Make sure there is always an extra impeller wiring harness and cover gasket in reserve and on board OM2 2 9 15 30 Servicing BOOSTER BATTERIES 1 Change the engine oil and replace the filter Service the air cleaner A CAUTION Battery Gas Can Explode
53. concentration It also indicates the amount of EGC antifreeze 3 Test kits are available through your Northern Lights or Lugger Dealer 4 Pack Part Number 20 00005 50 Pack Part Number 20 00010 SP15 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 working on the cooling system Open the filler cap carefully using protective clothing when the engine is warm 1 Check the coolant level each day before starting the engine 2 Remove the pressure cap from the expansion tank and check water level In order to give the coolant an opportunity to expand the level should be about 1 3 4 in 4 5 cm below the filler cap sealing surface 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 cooling system 2 The pressure valve in the filler cap releases when the pressure is approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it 1s faulty 4 The makeup coolant added to compensate for loss or leaks must meet engine coolant requirements outlined in previous section SP16 FLUSHING THE COOLING SYSTEM CAUTION The cooling water in the engine reaches extremely hi
54. decreases after break in Crankcase oil too light Use proper viscosity oil Oil leaks Check for leaks in lines around gaskets and drain plug Engine Emits Black or Gray Exhaust Smoke Clogged or dirty air cleaner Service air cleaner Clogged aftercooler Service aftercooler Defective muffler back pressure too high Have dealer check back pressure Improper fuel Use correct fuel for temperature Engine overloaded Reduce load Electronic fuel system problem See your dealer Turbocharger not functioning See your dealer Injection nozzles dirty See your dealer Engine out of time See your dealer Engine Emits White Smoke Improper fuel Use correct fuel for temperature Cold engine Warm up engine to normal operating temperature Defective thermostat Remove and check thermostat Engine out of time See your dealer Defective injection nozzles See your dealer 2 2 9 15 34 Revised 4 10 12 46899 9 SIWd uoN seDeyoA jy BuutlM O m e O 310 335 301711935 lt 39VL10A OV Q3Sn Si 599 3AON39 ZH09 YO OS 304 YAWN JVILNGGIJNDO ANY A3Vvl3liddUsd 7 310N 33S gounos q3123103d 2 61 2 0 2 002 OL L93NNOO dl31S OV 7 10 33S 124005 319310 OL 193NNOO
55. e heat exchanger to the expansion tank Remove bolts holding heat exchanger cover Wash the core inside and out If necessary chemical agents can be used Also clean the accessible parts of the heat exchanger housing Reassemble using new gaskets and sealing rings SP19 ZINC ANODES Zincs are installed in the cooling system to protect your engine from electrolysis Check them faithfully every 250 hours If you are in warm salt water or where electrolysis is a known problem check them more often Servicing 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 sure the threads are clean and have good metal to metal contact SP20 RAW WATER PUMP 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 re
56. en Check impeller and replace if necessary v Engine Knocks Low oil level Add oil to engine crankcase Injection pump out of time Call your dealer Below normal engine temperature Check your thermostats Check water temperature to see if temperature gauge 15 working properly Engine overheating See Engine Overheating section OM2 2 9 15 33 Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer High Fuel Consumption Engine overloaded Reduce load 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 Electronic fuel system problem See your dealer Engine not at proper temperature Check your thermostats Check water temperature with thermometer and replace gauge if necessary Below Normal Engine Temperature Thermostats not working properly Check thermostats Temperature gauge not working properly Check water temperature with thermometer Low Oil Pressure Low oil level Fill crankcase to proper level Improper type of oil Drain and fill crankcase with correct oil Partially plugged oil filter Replace filter High Oil Consumption Break in period Oil consumption
57. er applying Lock Out or Tag Out devices ensure that all potentially hazardous stored or residual energy is relieved disconnected restrained and otherwise rendered safe x 44 CAUTION x Verify the machinery or equipment is actually isolated and de energized prior to beginning work on a machine or on equipment that has been locked out x 44 CAUTION x Follow the procedures below prior to restoring energy Ensure that all machinery or equipment is properly reassembled Inspect the machinery or equipment to verify non essential items have been removed Ensure that all personnel are safely outside danger zones Notify personnel that lock out tag out devices have been removed and energy will be reapplied Only authorized personnel may remove lock out tag out devices or notices OM2 2 9 15 8 Notes OM2 2 9 15 9 Component Locations Figures 1 amp 2 1064 Mechanically Controlled Fuel System Junction Box Exhaust Elbow Turbocharger Air Cleaner Fuel Filter Fuel Lift Pump Lube Oil Fill NOOR WD 10 11 12 14 22 23 10 Coolant Fill 15 Lube Oil Drain 22 Injection Pump Drive Alternator 16 Fuel Manifold Coupling Access Cover Raw Water Pump 17 Expansion Tank Plate Lube Oil Dipstick 18 Thermostat Cover 23 Engine Block Drain Lube Oil Filter 19 Heat Exchanger Zincs Optional Hydrolastic Mount 20 Heat Exchanger Starter 21 Belt Guard OM2 2 9 15 X
58. evel in batteries Check condition of batteries with hydrometer Test thermostats Check electrical ground connection SP22 SP23 SP29 27 1 Change the oil and filter at 50 hours using break in oil again until changing it at 100 hours then at every 250 hours 2 Perform all maintenance once a year even if hour level has not been reached 3 Consult manufacturer s maintenance schedule 4 Or whenever necessary 6 5 Replace damper every 4500 hours or after 60 months 6 Check cooling system at 500 hours flush at 2000 hours 7 Check hoses and o rings on crankcase vent system change element at 500 hours OM2 2 9 15 18 updated 9 16 15 Servicing SP2 OIL CHANGES continued 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 Category CC CD or CE oil c ACEA Specification 2 Do not use John Deere PLUS 50 oil or engine oils meeting API CG4 API CFA ACEA E3 or ACEA E2 performance levels during the first 100 hours of operation of a new or rebuilt engine These oils will not allow the engine to break in properly Lubrication General 1 Use only clean high quality lubricants stored in clean containers in a protected area 2 These oils are acceptable after the first 100 hours a Oil Sequence 5 and 4 b API Service Category CI 4 or CH 4 c ACEA Oil Sequence E3 multi viscosity oil 3 Use t
59. g 91 5 WN O 4 SSVAAS NMOQINHS gt 011093454 zla And AALAWANOH ANC daa Mo vada VS 10 7 LINO 2 ANIONA OM2 2 9 15 51 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 Northern Lights 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 The example below lists typical items for either heat exchanged or keel cooled engines Item Description Quantity I Lube Oil Filter 4 2 Air Filter Element I 3 Fuel Filter 2 Fuel Filter Element l 5 Fuel Lift Pump I 6 InJector I 7 Thermostat 2 8 Thermostat Seal Ring 2 9 Thermostat Cover Gasket I 10 Rocker Cover Gasket 2 11 Engine Overhaul Gasket Kit I 12 Zinc Anode 6 13 Raw Water Pump Impeller 2 14 Raw Water Pump Cover Gasket 2 15 Raw Water Pump I 16 Raw Water Pump Bearing 2 17 Coolant Pump Repair Kit I 18 Coolant Pump Gasket I 19 Drive Belt I 20 Workshop Manual I Heat exchanger cooled engines only OM2 2 9 15 52 4420 14th Ave NW Seattle WA 98107 Tel 206 789 3880
60. g when valves and No 3 and No 4 intake valves the feeler gauge slips With a screwdriver hold the adjusting screw from turning while tightening the 6 CYLINDER ENGINES jam nut to specifications Check the clearance again NOTE Firing order is 1 5 3 6 2 4 after tightening the jam nut Re adjust as needed Reproduced by permission of Deere amp Company c2004 Deere amp Company All rights reserved RG4777 Figure 11 Reproduced by permission of Deere amp Company c2004 Deere amp Com pany rights reserved RG7409 Ficure 9 Front of Engine B No 1 Piston at TDC Compression Stroke No 6 Piston at TDC Compression Stroke 4 CYLINDER ENGINES E Exhaust Valve I Intake Valve Lock No 1 piston at TDC compression stroke f f Lock No piston at TDC compression stroke Adjust valve clearance on No 1 and No 3 Adjust valve clearance on No 1 No 3 and No 5 exhaust exhaust valves and No 1 and No 2 intake valves and No 1 No 2 and No 4 intake valves valves Rotate flywheel 360 Lock No 6 piston at TDC Rotate flywheel 360 Lock No 4 piston at compression stroke C Adjust valve clearance on No 2 TDC compression stroke C No 4 and No 6 exhaust valves and No 3 No 5 and No 6 intake valves OM2 2 9 15 20 Servicing FUELS GENERAL 1 poe Use only clean high quality fuels of the following specifications as defined by ASTM designation D975 for diesel fuel
61. gh temperatures You must use extreme I 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 OM2 2 9 15 29 p 10 Flush the cooling system and check for leaks and blockage every 2000 hours 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 15 complete Fill the fresh water system by pouring the recommended coolant mixture as described in previous sections Close cooling system air vent on turbocharger Open the seacock Start the engine Check hoses and connections and repair any leakage SP17 HEAT EXCHANGER CLEANING B p 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 th
62. he proper weight oil for your average operation temperature Air Temperature Multi Viscosity Single Viscosity Above 32 F 0 C SAE15 40W SAE 30W 10 F to 32 F SAE10 30W 23 C to 0 C Below 10 F 230 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 Never put additives or flushing oil in crankcase 2 4 M1064T2 60 Hz M1064T2 50 Hz During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes first Change oil at any seasonal change in temperature when a new viscosity of oil is required a Remove plug from outlet in base frame Screw in owner supplied drain hose b Open valve at oil pan outlet After oil has been drained into suitable container close valve remove drain hose and replace plug in base frame outlet c Refill engine with recommended oil Engine Lube Oil Capacity M1064D amp T1 15 5 qts 15 5 qts 21 6 qts 21 6 qts 15 5 qts 15 5 qts 15 5 qts 20 0 qts 34 3 qts 20 0 ats 14 7 liters 14 7 liters 20 5 liters 20 5 liters 14 7 liters 14 7 liters 14 7 liters 19 0 liters 32 5 liters 19 0 liters M1064A amp H M40C2 M55C2 M65C2 M1066T M1066A1 A2 A3 M99C2 depending on oil pan size SP3 CHANGING OIL FILTER Change the lube oil filter every 250 hours after the initial 50 and 100 hour change Use a
63. he strainer and reopen the seacock 6 Place the battery switch in the ON position NOTE The battery switch must always be kept ON while the engine is running If the switch is turned OFF while the engine is running the battery charging regulator could be ruined Starting 1 While holding the Shutdown Bypass switch in the ON position push the Engine Control switch to the START position 2 As soon as the engine starts release both switches Do not crank the starter for more than 20 seconds 3 Ifthe engine fails to start the first time be sure the starter has stopped before re engaging NOTE If there is a governor locked at a specific speed on the generator set there may not be a slow idle function so in that case operate the engine at high idle for 1 to 2 minutes before adding load If the stand by generator set is loaded as soon as it reaches rated speed this procedure would not apply Operating 1 Check Gauges Often Oil pressure must be above 29 PSI if not above 15 PSI within 5 seconds of starting the engine should be stopped and the problem should be explored Normal oil pressure is 50 PSI at rated load speed 1800 to 2500 RPM Oil temperature should be 115 C 240 F for normal operating temperature The D C voltmeter should read between 13 and 14 volts 26 28 volts 24 volt systems 2 Check AC voltage and frequency meters Series 4 Panel If gauges deviate from normal levels shut down the set and in
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65. ication of pump malfunctions Before servicing pump check the other possible causes a Check cleanliness of air filter b Check valve clearances c Clean and check injectors Any repair which involves disassembly of the injection pump must be carried out by specially trained mechanics with the proper tools and test devices NOTE All warranties on the engine become null and void if the injection pump seals are broken by unauthorized persons DB4 AND DB2 INJECTION PUMPS REMOVAL 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 linkage 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 discharge fittings are not altered which will prevent internal pump damage Disconnect fuel return line Figure 18 A and fuel supply line Figure 18 C Figure 1 8 Reproduced by permission of Deere amp Company c
66. ies enter the tion the first 100 hours and every 250 hours thereaf engine while changing the element Do not run the engine ier with the air cleaner removed OM2 2 9 15 19 Servicing SP6 VALVE CLEARANCES NOTE Firing order is I 3 4 2 The following special tools will be needed JDE 820 or JDE 83 Flywheel Turning Tool JDE 81 4 Timing Pin 1 Remove rocker arm cover with ventilator tube 2 Remove plastic plugs in engine timing holes on front t t 7 side of flywheel 3 4 3 Rotate flywheel in clockwise direction viewed from E 1 E 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 rotate the flywheel one complete turn and Reproduced by permission of Deere amp Company 2004 Deere amp Company reinstall the timing pin in the flywheel rights reserved RG4776 Figure 10 4 Valve clearances must be checked with the engine Front of Engine cold 1 Piston at TDC Compression Stroke Intake Valve 0 012 0 015 in 0 31 0 38 mm C 4 Piston at TDC Compression Stroke Exhaust Valve 0 016 0 019 in 0 41 0 48 mm 5 Ifthe valves need adjusting loosen the jam nut on Figure 9 on the rocker arm adjusting screw Turn Adjust valve clearance on No 2 and No 4 exhaust the adjusting screw until you feel a slight dra
67. injury or damage to machinery Avoid unbalanced ING loads Do not use lifting eyes Lift the MB Avoid exposure to and physical generator set using lifting bars inserted contact with hot exhaust through the lifting holes on the skid gases Exhaust parts and streams can reach high Follow all recommended removal and installation temperatures during operation leading to burns or procedures in this and associated Northern Lights other serious injury manuals Cleaning exhaust filters can also lead to exposure to hot exhaust gas and the injury risk associated with Use Proper Tools it Avoid exposure to and physical contact with hot exhaust gases when cleaning exhaust filters A C AUTION During auto or manual stationary exhaust filter Makeshift tools and procedures cleaning operations the engine will run at can create safety hazards elevated temperatures for an extended period of Always use appropriate tools for time Exhaust parts and streams can reach high the job temperatures during operation leading to burns or other serious injury Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware always use the correct sized tools Avoid Harmful Asbestos Dust Do not use US measurement tools on metric fasteners or vice versa Use only service parts that meet Northern Lights specifications Inhaling asbestos fibers may cause lung cancer Avoid breathing any dust th
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69. le 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 15 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 15 tightened making the valve stick c Install nozzle in cylinder head using a slight twisting motion as nozzle is seated bore d Install spacer and cap screw Do not tighten capscrew at this stage Servicing Install injection nozzles continued _ Reproduced by permission of Deere amp Company RG6302 Deere amp Company All Rights reserved Figure 17 Shows relationship of parts required for installation e Connect fuel pressure line to nozzle Leave connection slightly loose until air is bled from system f Tighten nozzle hold down cap screws to 27 foot Ib 37 N m g Install leak off assembly h Bleed air from loose injection line connection Tighten connection using two wrenches SP12 INJECTION PUMP 1 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 exhaust smoke should be checked by your dealer after every 2000 hours of operation Service of the fuel injection pump should only be done if checks indicate pump malfunction Black smoke can be an ind
70. leased x A CAUTION x To avoid dangerous or hazardous situations refrain from any of the following Removing or bypassing a guard or other safety device Placing any part of your body in a position where you could be caught by moving machinery Cleaning or oiling machinery when in operation Adjusting circuits chillers pumps air handlers valves circuit breakers or fans while in operation Working on piping or high pressure systems Lock Out Tag Out Instructions Electrical Equipment Be sure the equipments ON OFF switch is the OFF position and is unplugged from any electrical source before attempting to perform any type of work on the equipment Obtain an electrical plug cap cover with lockset Secure the plug terminal end using the electrical plug lockout cap Lock the cap and retain the key If the equipment is directly wired into an electrical box with a shut off switch obtain a lock pad and or the appropriate colored tags and place the lock and tag through the shut off lever Retain the key until the repair is completed and the machine is safe to start Be certain the shut off lever is in the OFF position before restarting NEVER give a lock out key to unauthorized personnel If the equipment is directly wired into an electrical box without a shut off switch and lock out capability then a circuit breaker lock out will be required Obtain a circuit lock and tag set Install the lock onto the circuit b
71. m This may result in severe damage to the fuel injection pump or nozzles Your generator set may have two secondary filters depend ing on the fuel supply system Do not prefill the new fuel filter as the fuel used may be contaminated and damage the fuel system components d Install new filter cartridge e Turn on the fuel A BLEEDING THE FUEL SYSTEM CAUTION Escaping diesel fuel under pressure can penetrate the skin causing serious personal injury Before disconnecting lines be sure to relieve all pressure Before applying pressure to the system be sure all connections are tight and the lines pipes and hoses are not damaged Fuel escaping from a very small hole can be almost invisible Use a piece of cardboard or wood rather than the hands to search for suspected leaks If injured by escaping fuel 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 service 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 14 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 If the engine will not start it may be necessary to loosen the fuel supply pipe at
72. mm _ za IB m mM 20 2 xovi8 01 3015 HOW 13 8 3NI9N3 OL HI9N31 XVN 318 2 0 3uHM u 19 l T e _ 99 7 H i 89 3onvououws OS Wougo 11 v FESSA d ovia _ _ use ol 2 nz MN ead 1 13 31 1 1009 on 73uHW3ma L2 INNOILdO 5 34055344 10 a 68 Waviv 3ud Q TVNOLLd 2 ANAL 3NI9N3 gt _ _ 344 n zz WWNOLLEO _ i 9L 7 dm 26 lt on ee 86 T T ms Mor al L xovig NMONS _ ON TVNOLLdO pe WANN a vss WNOILdO LS A A A yovia v1g V y X ox L 76 J OQAFZ_HOLN19 Old 9312313 WNOLLdO xovg 020 gt Gus _ YA ai L 359 02 S06 3349 02 06 Ti a 7 4 Taund oso 1 YOQLOINNOO L 9VIQ yva 39nv _ 4 0SZ 0 Y30N3S 9 31 3NION3 154 08 0 T que U P 310N 33S pb J Www 33M AS 116 1 5 JTLLOYHL N33N9 616 NYNLIY MOTA 16 ONIY I33HMA 13 a I x lt aas 39018 3NI9N3 goo ON E ozo
73. nded for that purpose Keep all parts in good conditions and properly installed Fix damage immediately Replace any worn or broken parts Remove any build up of grease oil or debris Disconnect battery ground cable before making any adjustments or service work Stay Clear of Rotating Drivelines Entanglement in rotating drivelines can cause serious injury or death Keep shields in place at all times Make sure that rotating shields turn freely in pace with the drivelines Do not wear loose fitting equipment around rotating drivelines Stop the engine and make sure that all moving parts have stopped before making any adjustments connections or performing any other type of service to the engine or other driven equipment 9 lt OM2 2 9 15 Revised 7 9 12 Safety Rules Continued Install all Safety Guards _ WARNING ole Direct contact with rotating fans belts pulley and drives can cause serious injury Keep all guards in place at all times during engine operation Wear close fitting clothes Stop the engine and be sure all fans belts pulleys and drives are stopped before making adjustments connections or cleaning near fans and their components Do not allow anything on your person to dangle into or come in contact with a moving fan belt pulley or drive Fans can act as vacuums and pull materials up from below so avoid that area as well while in service Safe Battery Handling
74. 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 transfer and coolant flow Check container label or A consult with supplier SUPPLEMENTAL COOLANT ADDITIVE SCA CAUTION Supplemental coolant additive contains A 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 1 Ethylene glycol coolant concentrate is commonly mixed with water to produce an engine coolant with a low freeze point and high boiling point 2 A low silicate form of ethylene glycol coolant is recommended for all diesel engines 3 Usean ethylene glycol coolant concentrate 1 Important for heat exchanger cooled engines meeting ASTM D 4985P SAEJ1941 General Motors Performance Specification GM1899M or formulated to GM6038M Additional SCA s should NOT be added to the mixture of EGC H O on initial fill up of engines with a coolant conditioner filter A high SCA concentration will result and can cause 4 This product is concentrated and should be mixed to the following specification silicate dropout When this happens a gel
75. quarts 3 Get medical attention immediately Battery posts terminals and related accessories can contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injur Among the potentially hazardous chemicals that may be used with Northern Lights products are lubricants coolants paints and adhesives d All potentially hazardous chemicals come with a Material safety Data Sheet MSDS The MSDS provides specific details on chemical products including physical hazards safety procedures and emergency response techniques OM2 2 9 15 Revised 4 10 12 Safety Rules Continued Read and understand the MSDS for each chemical before you start any job that includes it Follow the procedures and use appropriate equipment exactly as recommended Contact your Northern Lights dealer or Northern Lights factory for MSDS s used on Northern Lights products Work in Well Ventilated Areas Exhaust fumes from engines contain carbon monoxide and can cause sickness or death Work in well ventilated areas to avoid prolonged exposure to engine fumes If it Is necessary to run an engine in an enclosed area route the exhaust fumes out of the area with an approved leak proof exhaust pipe extension Remove Paint Before Welding or Heating Hazardous fumes
76. r or replace Starter Cranks Slowly Low battery output Battery is too small Battery cables are too small Check specific gravity of each battery cell Replace battery if necessary Check electrolyte level of each battery cell If low fill cells with distilled water Crankcase oil too heavy Fill with oil of appropriate viscosity Loose or corroded connections Clean and tighten loose connections Starter and Hour Meter Function but rest of Electrical System Does Not Function Blown fuse on magnetic switch Replace fuse Entire Electrical System Does Not Function Check DC circuit breaker If breaker is tripped reset it Faulty connection Clean and tighten battery and harness plug connections Sulfated or worn out batteries Check specific gravity and electrolyte level of each battery cell ENGINE v Engine Hard to Start or Will Not Start Engine starting under load Disengage PTO if applicable Improper starting procedure See starting section of this manual Take special note of Bypass Switch operation No fuel Check level of fuel in fuel tank Low battery output Check electrolyte level and condition Excessive resistance in starting circuit Clean and tighten all battery connections Crankcase oil too heavy Use oil of proper viscosity Improper type of fuel Consult fuel supplier and use proper type of fuel for operating condition Water dirt or air in fuel system
77. r other penalties as described in the Clean Air Act The installed exhaust system should not create exhaust back pressure greater than 30 760 mm of water for a turbocharged engine and 48 1200 mm for a non turbocharged unit measured at the engine exhaust elbow If you install the engine a way that makes the engine s emission control information label hard to read during normal engine maintenance you must place a duplicate label on the vessel as described in 40 CFR 1068 105 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 15 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 2 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 3 Check the fuel tank level and open any fuel valves 4 Disengage clutch if equipped 5 Close the seacock check and clean t
78. r pump SP22 Check the state of the charge of the batteries SP25 Check engine mounts SP26 Check crankcase vent system change element at 500 hrs SP27 Check air intake hoses SP29 Check electrical ground connection EVERY 2000 HOURS SP6 Check amp adjust valve clearance SP7 Check crankshaft vibration damper SP12 Check fuel injection pump SP16 Flush cooling system SP17 Check and clean heat exchanger SP23 Test thermostats SP30 Check aftercooler clean air side ENGINE SP1 Check oil level SP2 ig Change engine oil 2 1 1 SP3 15 Change lube oil filters 2 1 1 SP4 15 Check air cleaner k SP5 Check belt condition 2 SP6 16 Check valve clearances 2 SP7 17 Check crankshaft vibration damper 5 SP25 Check engine mounts SP27 Check air intake hoses FUEL SYSTEM SP8 17 Check primary filter Racor 3 SP9 x 17 x Change primary filter element Racor 3 4 x x x x x SP10 17 Change secondary fuel filter 2 4 SP11 18 19 Check injectors 2 SP12 20 22 Check fuel injection pump TURBOCHARGER Check air oil amp cooling water lines for leakage Check boost pressure Check aftercooler clean air side Check crankcase vent system COOLING SYSTEM SP15 25 Check cooling water level SP16 25 Check and flush cooling system SP17 25 Check and clean heat exchanger SP19 25 26 Check zinc electrodes SP20 26 Change impeller in raw water pump ELECTRICAL SYSTEM Check electrolyte l
79. rass wire brush Reproduced by permission of Deere amp Company RG6300 gpre amp Company All rights reserved Reprinted by permission of Deere amp Company 2004 All rights reserved RG63 00 Figure 15 NOTE Do not scrape or disturb the teflon coating on the nozzle body above the carbon stop seal groove OM2 2 9 15 23 P 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 a wantin i ud pomme m nnm mnt rmt uisa ef me 4 pe i 36 Figure 16 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 16 C over nozzle tip If Pilot Tool included in cleaning kit is not available use a No 16189 Nozzle Protector Cap found on every new or re placement nozzle b Position a new carbon stop seal Figure 16 B on pilot tool Use a new seal washer Figure 16 A to help slide the carbon seal into place until it seats in its groove on nozzle body c Continue to slide upper sealing washer onto nozzle body until it seats against inlet fitting Install injection nozzles NOTE Before installing injection nozzles make sure nozzles are clean and free from oil or grease Do not grease or oil the nozzles a Remove plug if installed previously from nozz
80. reaker box Ensure the unit ON OFF switch is in the OFF position before restarting Lock Out Tag Out Instructions Pheumatic and Hydraulic Equipment For servicing pneumatic and hydraulic equipment the following additional procedures must be implemented following completion of lock out tag out procedures for the unit to be serviced Shut off air water or supply valves at the equipment to be serviced Check the local bleed off point for completed release of pressurized air water or oil If shutting off of air water or other material cannot be achieved at the local supply valve shut off valves further back in the system and re check the bleed off point until complete shut off is achieved Affix a DO NOT OPERATE tag to each valve handle that requires shut off Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment Lock Out Tag Out Instructions Air Hose Connected Pneumatic Equipment Equipment connected to the compressed air system through an air hose with a detachable fitting must be shutdown and unplugged Excess air must be bled prior to removing the air hose prior to any maintenance or repair activities Affix a DO NOT OPERATE tag to the air hose near the detachable fitting Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment Check that the equipment cannot be operated by activating the ON switch Immediately aft
81. ricants section for oil recommendation Frequently check the engine temperature and oil pressure gauges Revised 9 16 15 Service Schedule Chart Mechanically Controlled Fuel System The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your marine generator set More detailed coverage of each Service Point SP is listed on the page noted in the column DAILY SP1 Check oil level in engine SP8 Check primary fuel filter SP15 Check cooling water level SP26 Check crankcase vent system filter svc indicator button AFTER FIRST 50 HOURS SP2 Change engine oil SP13 Check turbocharger air oil amp cooling lines for leakage SP19 Check zinc electrodes SP23 Test thermostats AFTER FIRST 500 HOURS SP6 Check valve clearances EVERY 500 HOURS YEARLY SP3 Change lube oil filter SP4 Replace air cleaner EVERY 50 HOURS SP5 Check belt condition SP21 Check electrolyte in batteries SP7 Check crankshaft vibration damper SP10 Change secondary fuel filter FIRST 100 HOURS SP11 Check injectors SP2 Change engine oil SP14 Check turbocharger boost pressure SP3 Change lube oil filter SP16 Check cooling system EVERY 100 HOURS SP20 Change impeller in raw water pump SP13 Check turbocharger air oil amp cooling lines for leakage SP22 Check the state of the charge of the batteries SP26 Check crankcase vent system change element at 500 hrs EVERY 250 HOURS SP2 Change engine oil SP3
82. rthern Lights naturally aspirated 1800 RPM marine diesel generator set with a John Deere Powertech Tier 114045 engine block with a mechanically controlled fuel system M1064D _ Northern Lights turbocharged marine M1064T1 generator set with a John Deere Powertech Tier 4045 engine block with a mechanically controlled fuel system Northern Lights turbocharged marine M1064T2 generator set with a John Deere Powertech Tier 4045 engine block with an electronically controlled fuel system Northern Lights aftercooled marine generator M1066A1 set with a John Deere Powertech Tier II 6068 series 1 engine block with an electronically controlled fuel system 1064 or 1066 A D amp T Model number A Aftercooled ud T Turbocharged Northern Lights turbocharged marine M1066T generator set with a John Deere Powertech Tier 11 6068 engine block with an electronically controlled fuel system 40 kW Northern Lights commercial marine MP40C2 generator set with a John Deere Powertech Tier 4045 engine block with a mechanically controlled fuel system MP55C2 _ 55 kW Northern Lights commercial marine generator set with a John Deere Powertech Tier 114045 engine block and a mechanically controlled fuel system 65 kW Northern Lights commercial marine 65 2 generator set with a John Deere Powertech Tier 11 6068 engine block and an electronically controlled fuel system 99 kW Northern Lights
83. rthern Lights Inc It may not be reproduced in whole or in part without the written permission of Northern Lights Inc Northern Lights Inc All rights reserved Litho U S A Publication number OM2 2 7 13 OM2 2 9 15 1 Introduction Servicing of marine engines and generator sets presents unique problems In many cases boats cannot be moved to a repair facility Marine engines cannot be compared to the servicing of automobiles trucks or even farm equipment Failures often occur in remote areas far from competent assistance Marine engines are taxed far more severely than auto or truck engines therefore maintenance schedules must be adhered to more strictly Failures begin with minor problems that are overlooked and become amplified when not corrected during routine maintenance As operator it is your obligation to learn about your equipment and its proper maintenance This is not a comprehensive technical service manual Nor will it make the reader into an expert mechanic Its aim 1s to aid you in maintaining your unit properly Model Numbers Model numbers give the unit s application block model aspiration and RPM M Northern Lights marine generator set 106 mm bore 4 Cylinder D Naturally aspirated 106 mm bore 6 Cylinder Northern Lights aftercooled 1800 RPM M1064A marine diesel generator set with a John Deere Powertech Tier 11 4045 engine block with an electronically controlled fuel system No
84. rvice Machines Safely Do not wear a necktie scarf necklace rings or other jewelry or any loose clothing when working near moving parts Tie long hair behind your head If any of these items get caught in moving machinery severe injury or death could result ec G Check for any loose electrical connections or faulty wiring Look completely around engine to make sure that everything 1s clear before starting Wear Protective Clothing To prevent catching anything in moving machinery always wear close fitting clothes and safety equipment appropriate to the job Prolonged exposure to loud noise can cause hearing loss or impairment Wear suitable authorized hearing protection such Go as earmuffs or plugs to protect against loud noises n 58 a A Operating equipment requires the full attention of the operator Do not use radio or music headphones while operating machinery Practice Safe Maintenance Understand all service procedures before starting work Keep area clean and dry Never lubricate service or adjust machine while it 1s in operation Keep hands feet and clothing away from power driven equipment When shutting down an engine disengage all power and operator controls Allow the engine to cool completely before beginning any service work Securely support any machinery elements that must be raised for service work with support or lifting machinery specifically inte
85. s 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 b Class B engine c Class D domestic fuels d Class E F G or H industrial or marine fuels e ASTM D975 60T No 4 D and higher number fuels 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 Biodiesel Biodiesel involves the transesterification of vegetable oils or animal fats Mainly in the U S soybean methyl ester is used SME but in Europe mainly rapeseed canola methyl ester is made RME and in Asia palm methyl ester is made PME 100 biodiesel B100 is made in compliance with ASTM D6751 or EN14214 EU specifications Biodiesel may be used in a 5 blend 5 biodiesel 95 diesel from a BQ 9000 accredited pro ducer 20 biodiesel blends can only be used if they meet ASTM D6751 or EN14214 EU specifications A 2 reduction in power and a 3 reduction in fuel economy can be expected using a 20 blend and a fuel conditioner is recommended
86. several minutes Check the entire system for leaks Servicing SP13 TURBOCHARGER 1 Check for air leaks every 100 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 SP14 TURBO BOOST 1 This check measures the amount of air the turbo is pushing into the engine It should be done by an authorized dealer every 500 hours 2 On the inlet manifold there is a 1 8 NPT threaded port Remove the plug and install the boost gauge hose Refer to your 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 2 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 stable noncorro sive environment for cooling system components 3 Ethylene glycol
87. supplier and use proper type of fuel for operating conditions Overheated engine See Engine Overheats in next category Below normal engine temperature Remove and check thermostat Injection pump out of time See your dealer Electronic fuel system problem See your dealer Turbocharger not functioning if equipped See your dealer Leaking exhaust manifold gasket See your dealer Defective aneroid control line See your dealer Restricted fuel hose Clean or replace fuel hose Low fast idle speed See your dealer Improper valve clearance Reset valves Best done by dealer Dirty or faulty injection nozzles Replace injectors Best done by dealer See your local dealer v Engine Overheats Engine overloaded Reduce the load Low 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 Stretched belt or defective belt tensioner Check automatic belt tensioner and check belts for stretching Replace as required Low engine oil level Check oil level add oil as needed Incorrect grade of fuel Use correct grade of fuel Cooling system needs flushing Flush cooling system Defective thermostat Remove and check thermostat Defective temperature gauge Check water temperature with thermometer and replace gauge if necessary Water pump impeller worn brok
88. the pump Operate primer lever of fuel supply pump until fuel flow is free from air bubbles Retighten fuel supply line to 22 ft Ib 30 Nem If engine still doesn t start loosen fuel line connection at injection nozzle Always use a back up wrench when loosening or tightening fuel lines at nozzles and injection pump to avoid damage With throttle on full crank the engine over with the starter until fuel without air flows from the loose fuel pipe connection Repeat 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 Nem For models 1066 2 and M1066A3 bleed the fuel system using the electronic transfer pump The ignition should be on and allow 40 seconds for the pump to complete the priming If additional system bleeding is needed do it by loosening the fuel line connections at the injection nozzles SP11 INJECTORS Fuel injectors should be checked by a Lugger Northern Lights dealer or qualified fuel injection shop every 500 hours 1 Injector Removal You will need the following special tools JDE38A Injection Nozzle Puller JDE39 Nozzle Bore Cleaning Tool JD258 Pilot Tool a OM2 2 9 15 22 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
89. tory Do not use water made by the reverse osmosis method unless it has been PH neutralized 2 Here are acceptable water quality specifications Grains per Gallon Parts Contaminates per Million Maximum Chlorides 40 2 5 Maximum Sulfates 100 5 9 Maximum Dissolved Solids 340 20 0 Maximum Total Hardness 170 10 0 PH Level 5 5 to 9 0 OM2 2 9 15 27 Servicing IMPORTANT DO NOT use methyl alcohol or methoxy propanol 3 If chlorides sulfates or total dissolved solids are higher than the above given specification the water L must be distilled demineralized or deionized before base EGC These concentrates are not compatible it is used in a cooling system with chemicals used in supplemental coolant 4 If total hardness is higher than 170 ppm and all other parameters are within the given specifications 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 3 DO NOT use EGC containing more than 0 1 anhydrous metasilicate This type of concentrate the water must be softened before it is used to make 2 coolant solution EGC ETHYLENE GLYCOL CONCENTRATE ANTIFREEZE which is intended for use in aluminum engines may l l cause a gel like deposit to form that reduces heat CAUTION EGC Antifreeze is flammable Keep it away from any open flame Avoid contact with eyes Avoid contact with skin Do
90. vestigate 3 Check belt for good alignment 4 Letthe unit run unloaded for a three to five minute warm up period before applying load 5 Do not add full electrical load until engine is at maximum operating temperature Shutdown 1 Turn the Engine Control Switch to the OFF position 2 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 OM2 2 9 15 15 revised 3 19 13 Operating Procedures SHUTDOWNS AND ALARMS 1 Your unit is fitted with a system to protect it from high water temperature or low oil pressure a Generator sets have shutdown systems to stop the engine They have no warning horns b Other alarms and shutdowns are available as optional equipment NOTE Do not rely on your warning or shutdown system to the exclusion of careful gauge monitoring Watching your gauges can prevent damage to the unit and dangerous power losses 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 26 28 to isolate the cause of the overheat CAUTION Do not remove the water fill cap of an overheated engine Escaping high temperature steam can cause severe burns Allow the engine to cool and then remove the c
91. 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 2 mm away from engine front plate Figure 20 Reproduced by permission of Deere amp Company c 2004 Deere amp Company All rights reserved RG6293 OM2 2 9 15 25 5 Servicing 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 mount ing stud nuts to pull pump shaft into drive gear I D With the pump shaft index pin properly engaged in the drive gear key slot finger tighten mounting stud nuts Push pump drive gear firmly onto shaft taper Install washer and retaining nut Figure 21 C onto end of shaft Tighten retaining nut to 90 Ib ft 122 Nem for DB2 150 Ib ft 203 Nem for DB4 Figure 2 1 Reproduced by permission of Deere amp Company c 2004 Deere amp Company All rights reserved RG 7630 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 to 1 7 lb ft 2 Nem Align timing mark on the pump flange Figure 22 B with timing mark on the cylinder block front plate A Figure 22 Reproduced by permission of Deere amp Company c 200

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