O6140 - Northern Lights
Contents
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3. The coolant filter conditioner element performs two functions at once The outer paper element filters out rust scale or dirt particles in the coolant The inner element releases chemicals into the coolant to maintain a proper acid alkaline balance inhibit corrosion and suppress erosion pitting which is discussed below A Cylinder Liner Walls B Engine Coolant C Vapor Bubbles LINER EROSION PITTING 1 Cylinder liner walls A which are in contact with engine coolant B can be eroded or pitted unless the proper concentration and type of SCA s are present in the coolant Water pump impellers are also susceptible to pitting Vapor bubbles C are formed when the piston s impact causes the liner walls to vibrate sending pressure waves into the coolant These tiny vapor bubbles collect on the surface of metal parts As the bubbles collapse pop a microscopic piece of metal is eroded from the metal part Over a period of time this pitting may progress completely through the cylinder liner of a wet sleeve heavy duty diesel engine This allows coolant to enter the combustion chamber Engine failure or other serious damage will result Unprotected engines with low quality water as coolant can have liner failure in as few as 500 hours The SCA s released by the filter will significantly reduce erosion and pitting The chemicals in the additives reduce the quantity of vapor bubbles It also forms a prot
4. 5 Cleaning Gear Qil Coolers acier 21 Panels ZINE BISCO NCS tlli treni puer 21 Lugger Propulsion Engine 6 Raw Water 21 Series 3 amp 4 Generator Sets 7 Mos ru du u u nunan 21 Operating Procedures Gears PTOs and Generators 21 Before ase recti rtt id coton denke beca 8 Electrical System 22 Generalt r 8 Booster 22 Propulsion EMG INS Dey Battery Care M I 22 Shutdown PIroOCeduTes uus 9 Winterizing Out of Service 22 Shutdewns Ge Alarms anan e 9 Propeller Sizing Chart 1 seem 23 Break in Period uisi etate 9 Data Sheets Servicing Schedule Chart 10 Cl 24 Record asesino eel bb ciens 11 Northern 25 Servicing Troubleshooting Lubrication General 12 P M 26 12 27 Changing Oil Filter 12 13 DC Wiring Diagrams M 13 12 Volt Lugger Engine 28 prog e 13 24 Volt Lupgger Enpine acsi ees 29 Valve 13 24 Volt Standard Marine Gen Set 30 lys General 14 AC Wiring Diagram Fuel Dites
5. Fuel Rate 1 2 Load gal hr Iph 7 7 29 14 1 Prime kW rating 1 kW equals 1000 watts 0 8 power factor 2 Net flywheel hp rating for fully equipped engine at RPM under SAE J816b 3 Based on prime HP rating at rated 1800 or 1200 RPM 4 Based on prime kW rating at rated 1800 or 1200 RPM Fuel rate may vary depending on operating conditions 06140 03 03 27 TROUBLESHOOTING If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer ELECTRICAL Battery will not charge Loose or corroded connections Clean and tighten battery connections Sulfated or worn out batteries Check specific gravity of each battery Check electrolyte level of each battery Loose or defective alternator belt Adjust belt tension Replace belt Defective alternator Starter inoperative Check DC circuit breaker Loose or corroded connections Clean and tighten loose battery and harness plug connec tion Low battery output Check specific gravity of each battery Check electrolyte level of each battery Defective electrical system ground wire Repair or replace v Starter cranks slowly Low battery output Batteries too small Battery cables too small Check specific gravity of each battery Check electrolyte level of each battery Crankcase oil too heavy Loose or corroded connections Clean and tighten loose connections v Entire electrical system does not f
6. 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 2003 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 O6140 03 03 INORTHERN LIGHTS 06140 OPERATOR S MANUAL FOR MODELS 16140 L6140AL2 M6140AL amp M6140AL2 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 bic e obe tied 2 Servicing cont Unit Identification Injection Pump 16 Model D sitgriattofi 2 17 Seral NUMDETS 2 Turbo 17 Warranty 3 Cooling System Requirements 18 20 Safety Rules 3 Checking Coolant Level 20 Component Locations Flushing the Cooling System 20 Luge kp PrODUISIOPL a niis i pU E 4 Heat Exchanger Cleaning 21 Northern Lights Marine Generator Set
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8. rpm 2100 1400 1200 1050 840 700 600 Sft dia in 1 75 2 2 2 5 3 3 5 4 Medium Duty Rating 600 flywheel HP 579 SHP at 2100 RPM Speed Gear Ratios and Propellers Knots 1 51 1 75 1 2 1 2 5 1 3 1 3 51 41 9 11 34 22 39 24 43 26 48 30 52 34 11 13 34 24 39 26 43 28 48 32 52 36 13 15 32 20 34 26 39 28 43 32 48 38 52 42 15 17 28 20 32 22 34 28 39 30 43 36 48 44 52 48 17 19 28 22 32 24 34 30 39 34 43 40 48 48 19 21 28 24 32 26 34x32 39x38 43x44 48x52 21 23 32 28 34 34 39 42 43 43 Sft rpm 1400 1200 1050 840 700 600 525 Sft dia in 2 2 2 5 3 3 5 4 4 5 Continuous Duty Rating 500 flywheel HP 482 SHP at 1800 RPM Speed Gear Ratio and Propellers Knots 2 5 1 3 1 3 5 1 4 1 4 5 1 5 1 6 1 5 7 50 18 54 20 58 22 61 25 68 30 7 9 40 20 46 22 50 27 54 28 58 30 61 34 68 40 9 11 40 24 46 28 50x31 54x34 58x38 61 42 68 50 11 13 40x28 46x32 50x35 54 40 58 45 13 15 40 30 46 36 50 39 54 46 58 53 Sft rpm 720 600 514 450 400 360 300 Sft dia in 3 5 4 4 5 4 5 5 6 6 06140 03 03 25 LUGGER DATA Displacement 930 in 15 24 liters Bore x Stroke 5 51 in 140 mm x 6 49 in 165mm High Output 700HP 2100RPM Medium Duty 600HP 2100RPM Continuous Duty 500HP 1800RPM Approximate dry weight Keel cooled less
9. 8 Oil filter 16 Gear oil cooler 25 Raw water pump inlet 33 Turbocharger O6140 03 03 6 COMPONENT LOCATIONS M6140AL Northern Lights Marine Generator Set Starboard side Non service Late Model Raw Water Pump 2 Port side 8 9 Service Figure 2 M6140AL Generator Set 1 frame 8 Fuel manifold 16 DC alternator 24 Vibration isolation mounts 2 Coolant filter 9 Lube oil dipstick 17 Turbocharger 25 Expansion tank 3 Fresh water pump 10 Lube oil drain 18 Generator J box 26 Coolant system fill 4 Stop solenoid 11 Starter 19 Manifold drain 27 Heat exchanger 5 Lube oil fill 12 Air Cleaner 20 Air vents 28 Rocker arm cover 6 Generator fan 13 Crankcase vent 21 PTO optional 29 Cylinder head 7 Fuelfeed pump and manual 14 Secondary fuel filter 22 Block drain 30 Raw water pump priming pump 15 Lube oil filter 23 Fuel injection pump 06140 03 03 7 INSTRUMENT PANEL 1 OIL PRESSURE GAUGE The oil pressure gauge shows the oil pressure in the engine lubricating system If the oil pressure drops BELOW 15 PSI at a speed higher than idling stop engine immediately and investigate 2 WATER TEMPERATURE GAUGE This gauge shows the temperature of the cooling water If a temperature of over 205 is indicated stop engine and investigate immediately 3 TACHOMETER The tachometer shows the engine speed in revolutions per minute RPM
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11. HOURS or every 6 months SP2 Change engine oil SP3 Change lubricating oil filter SP4 Check air cleaner SP8 Change primary fuel filter element SP12 Check turbocharger air oil amp cooling lines for leakage ora 500 HOURS or annually SP20 Change cooling system filter 750 HOURS or annually SP4 Replace air cleaner SP6 Check valve clearances SP9 Change secondary fuel filter SP10 Check injectors SP13 Check turbocharger boost pressure SP15 Check and flush cooling system SP19 Change impeller in sea water pump SP25 Check state of charge of batteries 2400 HOURS SP11 Check fuel injection pump SP16 Check and clean heat exchanger SP17 Check and clean gear oil cooler 06140 03 03 13 SERVICING LUBRICATION GENERAL 1 Use only clean high quality lubricants stored in clean containers in a protected area 2 These lubricants are acceptable a API Service CC CD single viscosity oils b API Service CC CD SF multi viscosity oils 3 Use the proper weight oil for your average operation temperature Air Single Multi Temperature Viscosity Viscosity Above 32 F SAE 30W SAE 15 40W 10 to 32 F SAE 10W SAE 10 30W 23 to 0 C Below 10 F SAE 5W SAE 5 20W 23 C 4 Some increase in oil consumption may be expected when SAE 5W and SAE
12. Loosen the crosshead lock nut Fig 10 5 then the adjustment screw Fig 10 6 omes Te TT x 0 x xj Figure 9 Hold top of crosshead lightly and tighten adjustment screw until it contacts valve stem then tighten 20 more Then loosen nut see Fig 10 1 on valve adjustment screw Fig 10 2 insert feeler gauge between crosshead Fig 10 3 and rocker arm Fig 10 4 and adjust the clearance with the adjustment screw until the thickness gauge slides with a slight drag After the clearance is properly adjusted tighten the lock nut to secure the adjustment screw using 47 to 54 foot Ibs of torque 7 to 7 5 kgm 7 Valves should be set cold with the following clearances a Intake Valves 017 in 43mm b Exhaust Valves 031 in 80mm 8 Rotate the engine one full revolution Adjust valves marked to above clearances Intake Exhaust Figure 10 06140 03 03 15 SERVICING FUELS GENERAL 1 Use only clean high quality fuels of the follow ing specifications as defined by ASTM designation D975 for diesel fuels a Use grade No 2 diesel at ambient tempera tures above freezing 32 F 0 C b Use grade No 1 at ambient temperatures below freezing and for all temperatures at an altitude of above 5 500 ft 1500 meters Use fuel having less than 1 sulphur preferably less than 0 5 The cetane
13. Numbers are multiples of 100 4 VOLTMETER When the engine is stopped the voltmeter will indicate the condition of the battery When the engine is running it shows the alternator voltage output 5 HOUR METER The hour meter keeps track of the accumulated length of the engine s operating time 6 KEY SWITCH The key must be kept in ON position while the engine is running 7 STOP BUTTON Hold down until engine is completely stopped SO OO Figure 3 Main Panel Lugger Marine Propulsion Engine 8 INSTRUMENT LIGHTING DIMMER Adjust instrument panel lights On some panels this is an on off switch and not a dimmer 9 WARNING LIGHTS a Light comes on when oil pressure is too low b Light comes on when engine is too hot 10 ALARM HORN Will sound in case of overheating or low oil pressure Stop engine and investigate Remember horn will sound when key is in ON position with engine stopped because there is no oil pressure 11 START BUTTON Will start engine only if key on main panel is in ON position 12 EXHAUST Maximum temperature 975 F 510 C Figure 5 13 TURBO BOOST GAUGE Auxilliary Panel 14 GEAR PRESSURE GAUGE See Gear Manual for operating range m Figure 4 Flybridge Panel 06140 03 03 CONTROL PANELS Northern Lights Generator Sets SERIES 3 GENERATOR CONTROL PANEL 1 SHUTDOWN BYPASS PREH
14. Racor 2 SP8 14 Change primary filter element 2 3 5 9 14 Change secondary filter 1 3 SP10 14 amp 15 Check injectors 1 SP11 15 Check fuel injection pump TURBOCHARGER SP12 17 Check air lines oil and cooling water lines for leakage 1 SP13 17 Check boost pressure COOLING SYSTEM SP14 18820 Check cooling water level e SP15 20821 Check and flush cooling system 1 SP16 21 Check and clean heat exchanger 1 SP17 21 Check and clean gear oil cooler 1 SP18 21 Check zinc electrodes HE engines only 1 3 5 19 21 Change impeller seawater pump 1 3 5 20 21 Change coolant filter 1 DRIVEN EQUIPMENT SP21 21 Check oil level reverse gear 5 22 21 Change oil reverse gear 2 SP23 21 Clutch and PTO service 2 ELECTRICAL SYSTEM SP24 22 Check electrolyte level in batteries 1 3 5 25 22 Check condition of batteries with hydrometer 1 OUT OF SERVICE SP26 22 Winterizing or out of service 3 1 Perform all maintenance once a year even if hour level has not been reached 2 Consult manufacturer s maintenance schedule note on chart 3 When necessary 4 Change at first 50 and first 100 hours 5 Adjust at first 100 hours 06140 03 03 12 SERVICE RECORD Service Point OPERATION HOURS DATE 50 HOURS or weekly SP5 Check V belt tension SP25 Check electrolyte in batteries 250
15. Use an ethylene glycol coolant concentrate meet ing ASTM D 4985P SAEJ1941 General Motors Performance Specification GM1899M or formulated to GM6038M 2 4 This product is concentrated and should be mixed to the following specification Distilled EGC 96 Freezing Boiling Water Antifreeze Point Point Optimum 50 50 37 C 109 C M F 226 F Minimum 60 40 24 C 106 C 12 F 2220F Maximum 40 60 52 C 111 C 62 F 232 5 If additional coolant solution needs to be added to the engine due to leaks or loss the glycol concentration should be checked with a hydrometer to assure that the desired freeze point is maintained CAUTION EGC Antifreeze is flammable away from any open flame Avoid contact with eyes Avoid contact with skin Do not take internally In case of contact immediately wash skin with soap and water For eyes flush with large amounts of water for at least 15 minutes physician KEEP OUT OF REACH OF CHILDREN Follow all warnings on the container 6 IMPORTANT DO NOT use methyl alcohol or methoxy pro panol base EGC These concentrates are not compatible with chemicals used in supplemental coolant additives Damage can occur to rubber A seals on cylinder liners which are in contact with coolant DO NOT use an EGC containing sealer or stop leak additives DO NOT use EGC containing more than 0 1 anhydrous metasilicate This type of concen trate wh
16. battery Then connect negative terminal of booster battery to ground on the engine block see Fig Battery Booster Battery Figure 14 Booster Battery Connections 4 Remove booster battery after starting engine 5 Sealed batteries see manufacturer charging and booster instruction SP24 25 BATTERY CARE 1 Check electrolyte level every 50 hours or weekly Add distilled water to manufacturer s recommended level Batteries cables and cable terminals should be checked and cleaned every 100 hours Clean corrosion with a water and baking soda solution Flush with clean water Tighten terminals and grease them to inhibit corrosion Check the battery condition with a hydrometer every 750 hours or yearly SP26 WINTERIZING OUT OF SERVICE 9o MARINE Drain seawater cooling systems completely Remember to shut off sea cocks before opening drain cocks Drain seawater supply lines and wet exhaust line Loosen the seawater pump cover and drain pump Check freshwater antifreeze mixture If refilling run the engine up to operating temperature to circulate the antifreeze Fill fuel tank and add biocide as per manufactur er s instructions Seal air cleaner inlet exhaust opening crankcase breather pipe and fuel tank vent with plastic bags and tape Change the crankcase oil and filter Loosen drive belts Disconnect and clean battery Remove to warm storage place if possible 10 Clean outside
17. gear 3362 Ibs 1526 kg Heat exchanger cooling less gear 3505 16 1591 kg Cooling General Freshwater circulating flow at rated speed High Output 158 US gpm 600 Medium Duty 119 US gpm 450 Ipm Continuous Duty 106 US gpm 400 Ipm Heat rejection to jacket water Ehligh Output 16 066 BTU min Medium 13 776 BTU min Continuous Duty 11 180 BTU min Cooling Heat Exchanger Raw water intake diameter 3in 75 mm Raw water discharge diameter 3in 75 mm Raw water pump flow at rated speed 82 US gpm 310 Ipm 82 US gpm 310 Ipm 69 US gpm 265 Ipm 39 in 1 m Maximum raw water temperature at inlet 100 F 37 C High output Medium Duty Continuous Duty Raw water pump maximum suction head Freshwater system capacity engine only 10 US gal 38 ltr Cooling Keel Cooled Water hose inside diameter 2 87 in 73 mm Keel cooler head diameter 2 5 in NPT Turbo tube length High Output 110 ft 34 m Medium Duty rte tte 84 ft 26 m Continuous 70 ft 22 Skin cooler aluminum High Output 120 f 11 2 m Medium Duty 90 ft 8 4 n Continuous Duty 80 f 7 4 m Skin cooler steel High Output 360 ft 33 5
18. it is correct see Fig 12 g To adjust timing rotate the crankshaft 30 40 1 8 turn in counter clockwise direc tion from No 1 cylinder top dead center to remove gear lash h Align the injection timing line on the damper with the pointer by slowly rotating the crankshaft in the clockwise direction i Loosen two nuts see Fig 13 2 on the cou pling Rotate the coupling Fig 13 3 on the pump side little by little while operating the priming pump see Fig 11 10 until no fuel flows out of the delivery valve holder Fig 11 8 06140 03 03 19 SERVICING COOLING REQUIREMENTS 1 To meet cooling system protection requirements the coolant solution must consist of a Quality water b Ethylene glycol concentrate EGC com monly known as antifreeze c Supplemental coolant additives SCA s Acoolant solution of ethylene glycol concentrate EGC antifreeze quality water and supplemen tal coolant additives SCA s MUST be used YEAR ROUND to protect against freezing boil over liner erosion or pitting and to provide a stable noncorrosive environment for cooling system components Ethylene glycol coolant concentrate anti freeze normally DOES NOT contain the SCA chemical inhibitors needed to control liner pitting or erosion rust scale and acidity Your engine is equipped with a spin on coolant filter conditioner element which provides the SCA s to protect your cylinder liners
19. may cause black 2 Delivery Valve Method exhaust smoke and soot Use delivery valve method when a repaired or 2 Listen along air line while engine is running A replaced injection pump is installed whistling or hissing sound indicates leakage a Disconnect fuel injection line from the No 3 Leakage on the pressure side between turbo and 1 cylinder delivery valve on the injection engine can be found by applying soapy water to pump see Fig 11 8 the air line b Remove delivery valve holder Remove 4 Tighten the hose clamps replace hose or gaskets spring and delivery valve and put valve as required holder back in injection pump 3 Check to see that the lubrication and cooling lines c Place the throttle Fig 11 9 in the full fuel thant ears forward position SP13 TURBO BOOST d Slowly rotate the crankshaft in a clockwise direction while operating the priming pump Fig 11 10 This is best done by two people 1 This check measures the amount of air the turbo is pushing into the engine It should be done by an authorized dealer every 750 hours e Stop rotating and pumping when fuel stops 2 Your engine can have a boost gauge permanently flowing out of the delivery valve holder Fig installed so you can monitor the turbo s output 11 8 from the control panel See page 6 f If the injection timing stamp line on the crankshaft damper is aligned with the pointer according to data plate specifica tions
20. necessary SP4 AIR FILTER 1 Inspect air cleaner every 250 hours replace the filter every 750 hours or yearly whichever comes first 2 After replacing element and cover start engine and check for air leaks NOTE Make absolutely sure no impurities enter the engine while changing the element Do not run the engine with the air cleaner removed 5 5 V BELTS 1 Check the tension and wear on the V belts after every 50 hours 2 Use your thumb to press on the belt at the midpoint between the crankshaft and alternator pulleys The tension is correct if the belts can be depressed about 3 8 in 10mm 3 Belts that operate in pairs should both be replaced in pairs even if only one of them needs to be replaced SP6 VALVE CLEARANCES 1 Check the valve clearances after the first 100 hours and every 750 hours thereafter 2 Turn off battery switch 3 Remove valve covers which are held by three bolts 4 Use breaker bar with a 19mm 3 4 socket on the pulley that powers the alternator to rotate the crankshaft in a clockwise direction Align the mark on the vibration damper with the pointer according to data plate specifications In this position No 1 cylinder is at top dead center of the compression stroke and No 6 cylinder s intake valves will start to move see figure 8 5 Adjust the valve clearance for valves marked with an X in Fig 9 6 adjust the valve clearance first adjust the crosshead
21. question NOTE Some PTO and marine gears have rigid lubrication requirements Follow service recommendations closely 2 If you have a Northern Lights generator set the maintenance and operation recommendations for the generator end are in a separate Owner s Manual If you do not have one of these manuals contact your local Northern Lights dealer ph peu po po 4 Px O6140 03 03 23 SERVICING ELECTRICAL SYSTEM GENERAL 1 Never switch battery switch off or break the circuit between the alternator and batteries while the engine is running Regulator damage can result 2 Do NOT reverse the polarity of battery cables when installing the battery 3 When welding on the unit disconnect the regula tor and battery Isolate the leads 4 Disconnect battery cables when servicing the DC alternator 5 Never test with a screwdriver etc against any terminal to see if it emits sparks Do not polarize the alternator or regulator 7 ADC circuit breaker protects your control panel and wiring harness see Fig 1 5 for location BOOSTER BATTERIES CAUTION Battery Gas Can Explode Keep all flames and sparks away from batteries 1 Before changing or using booster batteries check battery electrolyte level Add distilled water if necessary 2 Booster and main batteries must have the same voltage rating 3 First connect positive terminal of booster battery to positive terminal of main
22. sororis 14 All Voltages Marine Gen Set 31 Bleeding the Puel Syste 14 Onboard Spare Parts i e rettet 32 jj 14 15 Inj ction PUMP etre 15 Proprietary Information This publication is the property of Alaska Diesel Electric Inc It may not be reproduced in whole or part without the written permission of Alaska Diesel Electric Inc Alaska Diesel Electric Inc All rights reserved Litho USA Publication number O6140 03 03 O6140 03 03 3 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 usually begin with minor problems that become amplified when not corrected during routine mainte nance As owner operator it is your obligation to learn about your equipment and its proper maintenance This manual is not a comprehen sive technical service manual Nor will it make the reader into an expert mechanic Its aim is to aid you in maintaining and servicing your equipment properly UNIT IDENTIFICATION MODEL NUMBER Model numbers give unit s
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25. 5 20W oils are used Check oil level frequently 5 Never put additives or flushing oil in crank case 6 Propulsion Engines See Gear Owner s Manual for gear lubrication recommendations SPI CHECK OIL LEVEL 1 Check oil in the crankcase daily with the dip stick The oil level must be in the waffled area between the L and H Never allow the level to go below the L 2 Always add the same viscosity of oil as is already in the crankcase See above recom mendations SP2 CHANGES 1 Using the oil recommended in the above dia gram change the engine oil and filter after the first 50 hours of operation the first 100 hours of operation and every 250 hours thereafter 2 During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes first 3 Change oil at any seasonal change in tempera ture when a new viscosity of oil is required 4 Change oil when engine is warm 5 Dispose of waste oil in an approved manner 6 Propulsion Engines with Optional Drain Pump a Your engine is fitted with a hand pump that drains the engine crankcase and marine gear b Use a wrench to turn the selector valve to drain the engine or gear Use marks on the valve stem as a guide See below c Turn pump handle in clockwise direction and pump oil into a suitable container When the engine is empty switch the valve and drain the gear oil d Close valve Refill engine an
26. Align the injection timing stamp line 27 injection pump is aligned with the stamped 1 BTDC 24 on 600HP Luggers on No line b on the coupling see Fig 13 1 1 cylinder on the crankshaft damper with e If the stamped lines are out of alignment the pointer by slowly rotating the crankshaft loosen nuts Fig 13 2 and align the stamped in the clockwise direction see Fig 12 On lines by shifting the coupling see Fig 13 3 IMO certified engines refer to the data plate and re tightening the nuts to 43 46 foot lbs on the block for proper timing data torque 5 8 6 2 kgm Figure 11 Injection Pump Servicing Points 1 Injection line clamps 4 Lubrication line inlet 7 Pump mounting bolts 10 Hand priming pump 2 Fuel injection line 5 Lubrication line outlet 8 No 1 delivery line 11 Air vent point 3 Fuel feed line 6 Fuel return line 9 Throttle 06140 03 03 18 SERVICING j Tighten two nuts see Fig 13 2 Now re check the injection timing to see it is properly adjusted by repeating steps e through g k Ifline b on coupling does not align with the line a on the pump re stamp coupling with new line 1 Reassemble the delivery valve and reinstall fuel lines see Fig 11 2 and clamps Fig 11 1 m Bleed fuel system cm o n auis SP12 TURBOCHARGER Figure 13 Pointer and Crankshaft Damper 1 Check for air leaks every 250 hours Air leakage will lower engine output and
27. EAT SWITCH Two functions are built into this switch The preheating of the engine and bypassing of the engine safety shutdown circuit enabling a quicker start Hold switch in up position 10 20 seconds before starting engine and continue holding in up position while starting engine Holding the switches on too long can burn out the heater elements ENOINE HOURS TOR 2 ENGINE CONTROL SWITCH To start the engine hold switch in start position until the engine is running After the engine starts release switch and it will return to the center position To stop engine move switch to stop position and release 3 OIL PRESSURE GAUGE The oil pressure gauge shows the oil pressure in the engine lubricating system 4 WATER TEMPERATURE GAUGE Registers temperature of cooling water 5 HOUR METER SERIES 4 GENERATOR CONTROL PANEL Mack OF 6 D C VOLTMETER When the engine is stopped the voltmeter indicates the condition of the battery When the engine is running the voltmeter indicates the voltage output of the alternator Figure 6 For Series 4 Control Panels Only Series 4 m 7 A C VOLTMETER Generator Set Control Panel Shows the generator output voltage 8 FREQUENCY METER HERTZ The frequency meter indicates the frequency of alternating current 1200 or 1800 RPM 60 Hz 1500 RPM 50 Hz 9 AMMETER SELECTOR SWITCH Used to check each phase for load condition You must always leave th
28. GZ ZH OG 2 9 7 0 2 ZH 09 OF 2 022 221 2 OS ec OvAOZZ LCI 2 08 ei 02 001 ZH ei OVA00Z 00 ZH 09 ec DvASLv Ovz ZH 06 OF 2 00 21 ZH 09 OVABOZ OZ ZH OG 2 9 IZH 09 OWAOBE E1Z ZH OG 2 08 6 2 ZH 09 2 061 011 ZH 09 2 061 011 as 992 912 5915 5915 82 92 33 1 10538 E ee TEMA n i a 1 N H 3SV110A w 8 E 32018 3NION3 6 N39 1 310N 335 1 L x IVNOI1d0 1222 fst E 0 9 310 335 s 2 1 20 201 ne Siow3s Z C NHO i 06140 03 03 33 ONBOARD SPARE PARTS Safety at sea depends on careful preparation product knowledge and having the right tools and parts Below is a list of parts Alaska Diesel Electric Inc recommends you carry onboard at all times Onboard Parts Kits are available from your dealer Standard Kits are suitable for inland and offshore cruising World Class Kits are for world cruising and trans ocean cruising We consider these minimum quantities Your vessel s operating condi tions may require more of a given part Consult your dealer mm 17 Item Description Quantity m LubeOilFilter Oil Filter dE 1b loRmg Ring H
29. S OLA HOLIMS LEM sarl f 71051405 3NI9N3 AVES 06 BOIS HOV3 13 Wes 1 3NION3 01 HION31 ove Wad CERVON d 318 2 00 SS3NYVH NOISN31X3 3313A0H2V1 X mm TJNVd NVW em 06140 03 03 30 MM HOA 107197 8 29 Oq E u 4 ONIN OYIN 9n d ON3W OYIN 301VW3J 39NVWO ITVN 4 9 18 JWA YOVI TiNVd 0 1 1 0319 15 38 NVO 3NION3 0350 LON 3l HOLIMS ALSSVS IV3103N Q031903NNOO2 03114405 YSWOLSND E quee Ouen INIOd NOILO3NNOO HOV3 LV pe YIAYYN AG OJHILNJAI 38 ISAW ONY 349 38 OL 3 SYOLONGNOS Q3TIVISNI TIv 93909 80105 SSFINN 22 G3LON SV 1432 3 ONVUYLSILIAN 09 184 462 3dAL 38 OL SYOLONGNOD NOLVTIVISNI TIV 1 410 1 ef 97 oF OF oF aF aF OF V 51 3 373 1
30. V ONIN JYIN 50199409 31VNW34 JONVYO JWW JWW33 2v18 TANVd eee ee e NI 0315715 38 NVO 3NION3 0350 LON 4l EU in 1 5 134 5 WHYLNSAN QO3103NNOO 03119905 YSWOLSNO ao 5 0559 1735 OL LOH T N3HM QN3 6 0344 ANY OH3N i WE ACUTA 9 XOMJdv 112 38 Ol SYOLONGNOD 553 Q3SnNO Tiv i NOILO3NNOO_HOV3_ 1Y x Ag 0313034 38 ISMN 4349 38 OL rms SYOLONGNOD Q3TIVISNI 93909 80102 SS3IND ERE Fl Q310N SV 1430 3 ONVYLSILINW OvAOOS 3 MIN vl Ol SHOLONGNOD NOLVTIVISNI TIV 2 2 S31ON 3 X18 T 30991 0 E ef ef 87 8 oF sr otto 7 soma 220 SIN3W313 MHd 338 1 ra 39NV8O 3onvo A 77 77 1 0 7 Sus gt lt a 1 rra T m 3UHA lt E 4 x 2 8 lt 223 NEWS 127 lt 2 lt ul I ES ere N3385 M MOJINVN i 39NVHO ANIANI i 9 _ lt NMOYB 3LIHM di s lt Q NMOSB 3IIHM Ze
31. a year or after 2400 hours of operation 2 Drain expansion tank and heat exchanger 3 Remove heat exchanger covers Clean the inside of exchanger core tubes using a metal rod 5 Re assemble using new gaskets Fill the cooling system start the engine and check for leaks 5 17 CLEANING GEAR OIL COOLERS For propulsion engines only 1 Drain fresh water cooling circuit 2 Remove end covers of gear oil cooler 3 Wash the core in diesel fuel and blow it dry with compressed air Clean the end covers of the core with a steel brush and use a metal rod to clean inside of tubes Re assemble using new gaskets Fill the cooling system start the engine and check for leaks SP18 ZINC ELECTRODES 1 Zincs are installed in the heat exchanger cooling system to protect your engine from electrolysis Check them faithfully every 250 hours If you are in warm salt water or where electrolysis is a known problem check them more often Keel cooled engines do not have zincs 2 Heat exchanger cooled engines Drain the raw water from heat exchanger Fig s 1 amp 4 13 then drain the expansion tank Fig s 1 amp 4 1 Remove zinc holders Fig s 1 amp 4 18 from back end of heat exchanger and raw water pipe elbow 3 Scrape or steel brush the zinc electrode clean If more than 50 of the electrode is corroded away replace it with a new one The electrode screws out of the holder Re install the zinc holders Be sure the threads are cle
32. an for good metal to metal contact 5 Refill cooling system start engine check for leaks SP19 RAW WATER PUMP 1 Heat exchanger cooled engines only Change the the sea water pump impeller every year or as needed 2 Remove the pump end cover Pry out the impeller with the help of two screwdrivers Be sure you remove all pieces of a failed impeller NOTE Place some kind of protection under the screwdrivers in order not to damage the housing 3 Clean the inside of the housing Press in the new impeller and place the sealing washers in the outer end of the impeller center if this has not already been done 5 Replace the cover using a new gasket NOTE Make sure that there is always an extra impeller and cover gasket in reserve on board SP20 COOLANT FILTER 1 Change coolant filter after the first 250 hours the first 500 hours and every 500 hours thereafter Shut off both valves on filter body Use filter wrench to remove filter Make sure old gasket is removed Lubricate new filter gasket and screw on new filter until gasket meets housing Hand tighten two thirds of a turn more Open valves on filter body Start the engine and check for leaks Stop engine and check water level in expansion tank SP21 22 23 GEARS PTOS AND GENERATORS 1 Manufacturer s service recommendations vary See your Owner s Manual for service informa tion If you do not have a manual see your local dealer for the equipment in
33. and performance 2 Constantly check the engine temperature and oil pressure gauges 3 Oil consumption is greater during break in as piston rings and cylinder liners take time to seat 4 Break In Oil Changes Change engine oil and filter at 50 hours Change oil and filter again at 100 hours See Gear Owner s Manual for break in oil change procedures Consult Lubricants Section for oil recommendation Operating Instructions 1 Propulsion engines Never run full speed for more than 5 minutes during the first 50 hours Run engine at 50 to 75 of maximum working speed for the first 20 hours with as little idling time as possible Extended idling can inhibit ring seating causing cylinder walls to glaze 2 Generator Sets Maintain at least a 75 load on your set for the first 100 hours If this is not possible maintain no less than a 50 load to ensure proper seating of the piston rings Vary the load to help seat rings 06140 03 03 11 SERVICING SCHEDULE CHART The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your unit More detailed coverage of each Service Point SP is listed on the page noted in the page column DAILY SP1 Check oil level in engine SP7 Check primary fuel filter SP14 Check cooling water level SP21 Check oil level in reverse gear FIRST 50 HOURS SP2 Change engine oil SP3 Change lube oil filter EVERY 50 HOURS or weekly SP5 Check V be
34. application block model aspiration and RPM L M NL L Lugger marine propulsion engine M Northern Lights marine generator set NL Northern Lights industrial generator set Komatsu engine block 6 cylinder 140 mm bore 6140 Model number of A Aftercooled turbo AL2 Aftercooled turbo low profile D Naturally aspirated L6140AL2 Lugger turbocharged aftercooled marine propulsion engine Komatsu 6140 block low profile L6140A Lugger turbocharged aftercooled marine propulsion engine Komatsu 6140 block high profile Northern Lights turbocharged 1500 or 1800 RPM marine diesel generator set Komatsu 6140 block SERIAL NUMBERS T Turbocharged QA 1200 RPM Aftercooled Northern Lights aftercooled turbocharged 1200 RPM marine diesel generator set Komatsu 6140 M6140QA block Northern Lights turbocharged aftercooled 1500 or NL6140A 1800 RPM industrial diesel generator set Komatsu 6140 block When referencing Alaska Diesel Electric equipment by serial number refer only to the number stamped on the Lugger or Northern Lights serial number plate 5 Serial N ALASKA DIESEL ELECTRIC Inc 4420 14TH AVE NW SEATTLE WA U S A NORTHERN LIGHTS LUGGER Serial No Model No N ALASKA DIESEL ELECTRIC Inc 4420 14TH AVE NW SEATTLE WA U S A O6140 03 03 4 LL Alaska Dies
35. arly The engine must be stopped and cold Remove the filler cap with caution Open cooling system air vents on top of the turocharger at the front and rear of the aftercooler and for heat exchanged units on top of heat exchanger see Fig 1 Drain the jacket fresh water circuit of the cooling system HE heat exchanger cooled units KC keel cooled units a Exhaust manifold Drain is under manifold near rear of engine for both HE amp KC b Engine block Drains are on the water pump outlet and turbo coolant line see Fig 1 c Gear oil cooler Bottom of right gear oil cooler elbow propulsion engines only d Remote expansion tank Remove hose from bottom of tank To drain the raw water circuit of HE engine open the drain in the starboard end cap of the heat exchanger see Fig 1 With drains open pour clean water into the filler cap When the water from each drain is clear and free from discoloration and sediment close that drain When all drains are closed flushing is complete 06140 03 03 22 SERVICING FLUSHING THE COOLING SYSTEM cont 6 Re drain the engine and refill the jacket fresh water circuit with coolant mixture as described in previous section 7 Close cooling system air vent 8 Open sea cock 9 Start engine Monitor temperature gauge care fully and check cooling system for leaks SP16 HEAT EXCHANGER CLEANING 1 Clean the heat exchanger core once
36. as 7 4 Impeller Gasket 12 0 2 14 15 12 16 s PN 2 17 Fuel WasherKit Jaf i esas 19 Workshop Manua 1 2 ofi 21 GasketKitBotom 1 4 Note Heat exchanger cooled engines only Note Double this quantity if engine is keel cooled 06140 03 03 34 NORTHERN LIGHTS 4420 14th Ave NW Seattle WA 98107 NORTHERN HONT Tel 206 789 3880 1 800 762 0165 Fax 206 782 5455 Z Northern Lights and Lugger are registered trademarks of Northern Lights Inc www northern lights com 2003 All rights reserved Litho USA
37. d gear with recommended oils NOTE Make sure the valve is in the closed position before starting engine If it is left open it is possible for crankcase oil to be pumped into the reverse gear and out of the gear dipstick and breather This can ruin the engine To drain To drain To close crankcase reverse gear valve Hand pump selector valve 7 Marine Generator Sets a Remove plug from outlet in base frame Screw in owner supplied drain hose b Open valve at oil pan outlet After oil has been drained into suitable container close valve remove drain hose and replace plug in base frame outlet c Refill engine with recommended oil 8 Engine capacity with new oil filter is 10 gallons 38 liters SP3 CHANGING OIL FILTER 1 Change the lube oil filter after the first 50 hours of operation after the first 100 hours of operation and every 250 hours thereafter Use a filter wrench to remove old filter Dispose of filter in approved manner Make sure the gasket from the old filter is removed and discarded Lubricate the rubber gasket on the new filter and screw it on nipple until gasket meets the sealing surface 06140 03 03 14 SERVICING 5 Using hands only no wrench tighten filter one half turn farther Overtightening can do damage to filter housing 6 Fill engine with recommended oil Start engine and check for leakage Stop engine and check oil level Add additional oil if
38. ection pump on the bracket Injection Pump Installation a Position pump on bracket Positioning sleeves on two of the bolt holes help align the pump b Tighten four mounting bolts see Fig 11 7 to 49 54 foot lbs 6 75 7 50 kgm c Reinstall coupling Fig 13 2 bolts but do not tighten them until pump is timed as per next section d Reinstall feed lines Fig 11 3 and lubrica tion oil lines Fig 11 4 amp 11 5 using new gasket washers on both sides of banjo bolts Torque nuts for line Fig 11 5 18 31 foot Ibs 2 5 3 kgm Torque nuts for line Fig 11 4 11 14 foot Ibs 1 5 2 kgm e Reinstall fuel injection lines Fig 11 2 and line clamps Fig 11 1 Fuel delivery line sleeve nuts Fig 11 8 torque to 16 18 foot Ibs 2 4 2 5 kgm 06140 03 03 SERVICING TIMING INJECTION PUMP 1 The Match Mark Alignment Method This is used when the injection pump is installed on the original engine and the pump has NOT been repaired a Turn the crankshaft by hand in clockwise direction to bring the number one cylinder to top dead center of the compression stroke The compression stroke can be determined by removing the number one cylinder valve cover and turning the engine until all valves are closed b Rotate crankshaft in counter clockwise Figure 12 Pointer and Crankshaft Damper direction 30 40 1 8 turn to remove gear lash d Confirm that the stamped line a on the c
39. ective film on the metal engine parts which act as a barrier against collapsing vapor bubbles WATER QUALITY 1 Distilled deionized soft water is preferred for use in cooling systems Bottled distilled water from a food store or water supplier is recom mended Tap water often has a high mineral content Tap water should NEVER be put in a cooling system unless first tested by a water quality laboratory Do not use water made by the reverse osmosis method unless it has been PH neutralized 2 Here are acceptable water quality specifications Contaminates Parts Per Grains Per Million Gallon Maximum Chlorides 40 2 5 Maximum Sulfates 100 5 9 Max Dissolved Solids 340 20 Max Total Hardness 170 10 PH Level 5 5 to 9 0 3 If chlorides sulfates or total dissolved solids are higher than the above given specification the water must be distilled demineralized or de ionized before it is used in a cooling system 06140 03 03 20 SERVICING 4 If total hardness is higher than 170 ppm and all other parameters are within the given specifica tions the water must be softened before it is used to make coolant solution ETHYLENE GLYCOL CONCENTRATE EGC ANTIFREEZE 1 Ethylene glycol coolant concentrate is com monly mixed with water to produce an engine coolant with a low freeze point and high boiling point A low silicate form of ethylene glycol coolant is recommended for all diesel engines 3
40. el Electric 4420 14th Ave N W Seattle WA 98107 206 789 3880 o Generator Set Data o Set Serial No Set Model warranty registration certificate is supplied with your set It entitles the original purchaser of this equipment to a warranty covering mate rial or assembly faults The extent of coverage We recommend that you study the statement carefully is described in the Limited Warranty Statement If the warranty is to apply the servicing instruc tions outlined in this manual must be followed If further information is needed please contact an authorized dealer or the factory SAFETY RULES Accident reports show that careless use of engines cause a high percentage of accidents You can avoid accidents by observing these safety rules Study these rules carefully and enforce them on the job Never leave engine without proper security e Turn the coolant tank cap slowly to relieve pressure before removing Add coolant only when the engine is idling or stopped Mount fire extinguisher near engine Always disconnect the battery ground strap before making adjustments Operate engines in properly ventilated areas Keep trash and other objects away from engine Escaping fluids under pressure can penetrate your skin Use a piece of cardboard or wood not your hands to search for leaks Avoid wearing loose clothing without a belt wh
41. en working around engines Do notoil or grease engine while it is running Use caution in handling fuel Never refuel a hot or running engine Do not smoke while fill ing fuel tank or servicing fuel system Keep your hands feet hair and clothing away from power driven parts Check for any loose electrical connections or faulty wiring Engines should be operated only by knowl edgeable qualified personnel e Walk completely around engine to make sure that everything is clear before starting the engine Do not operate an engine that isn t in proper working order If an unsafe operating condition is noted tag the engine so others will also know about it Provide first aid kits O6140 03 03 COMPONENT LOCATIONS Lugger Propulsion L6140AL Low Profile Starboard Side Non service Port Side Service Figure 1 L6140AL 1 Cooling system vent 9 Injection pump 17 Heat exchanger 26 Jacket water block drain 2 Coolant filter 10 Fuel feed pump amp 18 Cooling system fill 27 Gear oil filter 3 Stop solenoid manual priming pump 19 Air cleaner 28 Starter 4 Lube oil fill 11 Lube oil dipstick 20 Crankcase vent outlet 29 Gear oil dipstick 5 DC circuit breaker amp relays 12 Raw water pump 21 Aftercooler vent 2 30 Manifold drain 6 Fuel system bleed plug 13 Expansion tank 23 DC Alternator 31 Cylinder head 7 Fuel filter 15 Zinc 2 24 Jacket water pump 32 Rocker arm cover
42. eter v Low oil pressure Low oil level Improper type of oil Drain and fill crankcase with correct oil Partially plugged oil filter Replace filter v High oil consumption Break in period Crankcase oil too light Use proper viscosity oil Oil leaks Check for leaks in lines around gaskets and drain plug Engine overheats See Engine Overheats v Engine emits black or gray exhaust smoke Clogged or dirty air cleaner Service air cleaner Defective muffler back pressure too high Improper fuel Engine overloaded Reduce load Check propeller size Injection nozzles dirty See your dealer Engine out of time See your dealer v Engine emits white smoke Improper fuel Cold engine Warm up engine to normal operating temperature Defective thermostat Remove and check thermostat Engine out of time See your dealer O6140 03 03 29 4 8 8 y a T os 40 UJ On O ool PUNOIE 15 HOA 1 0 191 959 98629 9 ureJDeiq 211 9019 IYIN OYIN
43. gm h Bleed the fuel system start the engine and check the system for leaks using a piece of cardboard SPU INJECTION PUMP 1 The pump settings maximum speed idle speed and exhaust smoke should be checked after every 2400 hours of operation Service of the fuel injection pump should only be done if checks indicate pump malfunction Low power and no smoke can indicate a fuel injection pump malfunction Check for full throttle proper solenoid adjustment and air filter cleanliness before replacing pump Black smoke occasionally may indicate an injection pump problem Any repair which involves disassembly of the injection pump must be carried out by 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 Injection Pump Removal a Clean injection pump hoses and area around the pump with cleaning solvent or a steam cleaner NOTE Never steam clean or pour cold water on an injection pump while the engine is running or the pump is warm b Remove line clamps see Fig 11 1 and fuel injection lines Fig 11 2 c Remove feed lines Fig 11 3 and lubrica tion tubes Fig 11 4 amp 11 5 and return line Fig 11 6 d Remove coupling bolts Fig 13 2 between the coupler 13 3 and the flange Fig 13 4 on the pump drive e Remove the four mounting bolts Fig 11 7 which hold the inj
44. heats Engine overloaded Reduce load generator sets Check propeller size propulsion Low coolant level tank to proper level Check hoses for loose connections and leaks Keel cooling tubes have been painted Cooling system needs flushing Defective thermostat Remove and check thermostat Defective temperature gauge sender Check water temperature with thermometer and replace gauge or sender if necessary Water pump impeller worn broken HE Engine v Engine knocks Insufficient oil Check dipstick Call your dealer Injection pump out of time Call your dealer Below normal engine temperature Check your thermostats Check water temperature to see if temperature gauge is working properly Engine overheating See Engine Overheating section v High fuel consumption Improper type of fuel Clogged or dirty air cleaner Service air cleaner Engine overloaded Reduce load Check proper propeller size Grass etc on bottom of boat Improper valve clearance See your dealer Injection nozzles dirty See your dealer Injection pump out of time See your dealer Engine not at proper temperature Check your thermostats Check water temp with thermometer to see if tempera ture gauge is working properly v Below normal engine temperature Thermostats not working properly Check thermostats Temperature gauge not working properly Check water temperature with thermom
45. ich is intended for use in aluminum engines may cause a gel like deposit to form that reduces heat transfer and coolant flow Check container label or consult with supplier SUPPLEMENTAL COOLANT ADDITIVE SCA CAUTION Supplemental coolant additive contains alkali Avoid contact with eyes Avoid contact with skin Do not take internally In case of contact immediately wash skin with soap and water For eyes 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 Your engine is equipped with a spin on coolant filter conditioner element which provides the SCA s to protect your cylinder liners The inner element releases chemicals into the coolant to maintain a proper acid alkaline balance inhibit corrosion and suppress erosion pitting Important All engines ALWAYS change the coolant conditioner filter element according to the service chart in this manual Important Radiator and heat exchanger cooled engines Additional SCA s should NOT be added to the mixture of EGC H 0 on initial fill up of engines with a coolant conditioner filter A high SCA concentration will result and can cause silicate dropout When this happens a gel type deposit is created in the cooling system which retards heat transfer and coolant flow Important Engines with Keel Cooling The SCA in the spin on filter may not be able to treat the large volume of coola
46. is switch in the ON posi tion while the unit is running 10 A C AMMETER Shows the generator load on each phase The phase is selected on the Ammeter Selector Switch Figure 7 switch 9 above 06140 03 03 9 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 an opportunity to expand the level should be about 1 3 4 in 4 5 cm below the filler cap sealing surface when the engine is cold When filling with coolant all the venting cocks should be opened to ensure that no air pockets form in the cooling system See Service Point 14 page 20 CAUTION Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns 2 Check the oil level in the crankcase with the dipstick The oil level must be in the waffled area between the L and H Never allow the level to go below the L Always add the same viscosity of oil as is already in the crankcase See Service Point 1 page 12 3 Check the fuel tank level and open any fuel valves 4 Propulsion Only Check the oil level in the reverse gear Methods may vary from gear to gear See your Gear Owner s Manual 5 Close the sea cock check and clean the strainer and reopen the sea cock 6 Place the battery switch in the ON position NOTE The battery switch must always be kept ON while the engine is running If the swi
47. lt tension SP24 Check electrolyte in batteries FIRST 100 HOURS SP2 Change oil SP3 Change lube oil filter SP6 Check valve clearances FIRST 250 HOURS SP20 Change coolant filter EVERY 250 HOURS or every 6 months SP2 Change engine oil SP3 Change lube oil filter SP4 Check air filter EVERY 250 HOURS Continued SP8 Change primary fuel filter element SP12 Check turbocharger air oil and cooling lines for leakage SP18 Check zinc electrodes HE engines only FIRST 500 HOURS SP20 Change coolant filter EVERY 500 HOURS or yearly SP20 Change coolant filter EVERY 750 HOURS or yearly SP4 Replace air filter SP6 Check valve clearances SP9 Change secondary fuel filter SP10 Check injectors SP13 Check turbocharger boost pressure SP15 Check and flush cooling system SP19 Change impeller in sea water pump SP25 Check condition of batteries with hydrometer EVERY 2400 HOURS SP11 Check fuel injection pump SP16 Check and clean heat exchanger SP17 Check and clean gear oil cooler SERVICE 50 250 500 750 2400 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours ENGINE SP1 12 Check oil level SP2 12 Change engine oil 1 4 SP3 12813 Change lube filter 1 4 5 4 13 Replace air filter 1 3 e SP5 13 Check V Belt tension 1 5 6 13 Check valve clearances 1 5 FUEL SYSTEM SP7 14 Check primary filter
48. m Medium Duty 300 ft 27 9 m Continuous Duty 250 ft 23 2 m Note DC Electrical Voltage 24 volt standard 12 volt optional 2 x 225 amp hrs 1150 cca 00 up to 10 ft run 20 ft 6 m Minimum battery capacity Battery cable size Standard instrument harness length Air Intake and Exhaust Engine air consumption at rated speed High Output 1500 42 5 m min Medium Duty 1250 f min 35 4 m min Continuous Duty 1045 f min 29 6 m min Minimum engine room intake vent area High Output Medium Duty Continuous Duty 400 in 0 26 335 in 0 22 m 280 in 0 18 m Exhaust gas flow at rated speed High Output ees Medium Duty Continuous Duty 3380 95 7 m min 2900 82 1 m min 2740 77 6 m min Maximum exhaust gas temperature at rated speed Mish O tp t 875 F 472 C Medium Duty 800 F 430 C Continuous Duty 750 F 402 C 30 in 760 mm H O Maximum exhaust back pressure Suggested dry exhaust 500 amp 600 hp 6 inch 700 hp 8 in Suggested wet exhaust I D 500 amp 600 hp 8 inch 700 hp 10 in Fuel and Oil Minimum fuel line Suction return 1 2 12 mm 3 8 10 mm 39 in 1 m 40 US qts 38 Itr Maximum fuel pump head Crankcase oil capacity Gear PTO Engine Angle Engine rotation facing flywheel Co
49. n when working on hot engines to avoid burns Allow the engine to cool before working on the cooling system Open the filler cap carefully using protective clothing when the engine is warm 1 Check the coolant level each day before starting the engine Check the coolant level by remov ing the pressure cap from the expansion tank In order to give the coolant an opportunity to expand the level should be about 1 3 4 in 4 5 cm below the filler cap sealing surface when the engine is cold When filling with coolant the venting cock on top of the turbocharger should be opened to ensure that no air pockets form in the cooling system 2 pressure valve in the filler cap releases when the pressure is approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it is faulty The makeup coolant added to compensate for loss or leaks must meet engine coolant requirements outlined in previous section SP15 FLUSHING THE COOLING SYSTEM CAUTION The cooling water in the engine reaches extremely high temperatures You must use extreme caution when working on hot engines to avoid burns Allow the engine to cool before working on the cooling system Open the filler cap carefully using protective clothing when the engine is warm IMPORTANT Be sure to close the sea cock before working on the engine cooling system 1 Flush the cooling system and check for leaks and blockage every 750 hours or ye
50. nt in a vessel s keel cooling system The operator must use a test kit strip to determine the amount of addi tional SCA s that need to be added to the cooling system O6140 03 03 21 SERVICING SCA S CONTINUED If additional SCA s are needed prepare a mix ture of 50 quality water and 5076 EGC anti freeze Add liquid SCA at a rate of 396 by volume Example 30 mL of SCA per liter of HO EGC mixture 1 0 fl oz of SCA per qt of Add the resulting mixture to the cooling system in quart increments Run the engine for 2 hours and retest the coolant Continue process until SCA concentration meets recommended levels 5 SCA is available from your Northern Lights Lugger dealer in the following sizes Pint Part Number 20 00002 1 2 gallon Part Number 20 00003 6 DO NOT use any coolant system additives con taining soluble oil COOLANT TESTING 1 Coolant test kits are available to allow on site evaluation of the coolant condition 2 kits use small strips of paper which are dipped into the coolant The paper changes color and indicates the SCA concentration It also indicates the amount of EGC antifreeze 3 Test kits are available through your Northern Lights or Lugger Dealer 4 Pack Part Number 20 00005 SP14 CHECKING COOLANT LEVEL A CAUTION The cooling water in the engine reaches extremely high temperatures You must use extreme cautio
51. number should be a minimum of 45 DO NOT use these unsuitable grades of fuel a Domestic heating oils all types Class B engine Class D domestic fuels Class E F G or H industrial or marine fuels ASTM D975 60T No 4 D and higher number fuels 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 SP7 9 FUEL FILTERS 1 Your engine or generator set should have a primary fuel filter installed We recommend the Racor brand of fuel filter water separators a Check the primary fuel filter daily as recommended by the filter manufacturer Empty the collection bowl as necessary b Change the element every 250 hours or when necessary c If the bowl fills with water change the pri mary and secondary element immediately 2 Change secondary fuel filter every 750 hours a Remove the filter cartridge by turning it counterclockwise with a filter wrench Fill the new cartridge with fuel and install it after applying engine oil to gasket surface Screw on until the gasket surface comes into contact with sealing surface of filter base Then tighten it two thirds of a turn by hand BLEEDING THE FUEL SYSTEM CAUTION Escaping diesel fuel under pressure can penetrate the skin causing serious personal injury Before disconnecting lines be su
52. of unit Paint any scratched or chipped surfaces Put corrosion preventative on all exposed metal surfaces O6140 03 03 24 THREE BLADED PROPELLER SIZING CHART Use this chart to find aproximate propeller sizes for boats 1 Find the boat speed your boat builder expects from with single engine using a three blade propeller and gears an engine of this horsepower in the left column with a 3 loss factor 2 Locate the gear ratio desired on the top line NOTE Prop size is influenced by many factors hull 3 Find where two columns intersect for an approxi design load boat use It is impossible to make an mate propeller size See the column bottom for absolute recommendation For more accurate shaft RPM and shaft diameter recommendations contact your dealer Example 700 HP rating 20 knot boat with 2 1 gear needs a 35 x 32 three blade propeller High Output Rating 700 flywheel HP 675 SHP at 2100 RPM Speed Gear Ratios and Propellers Knots 1 1 1 51 1 75 1 2 1 2 5 1 3 1 3 5 1 11 13 35 24 40 26 44 28 48 32 13 15 32 20 35 26 40 28 44 32 48 38 15 17 28 20 32 22 35 28 40 32 44 36 48 44 17 19 23 15 28 22 32 24 35x30 40x34 44 40 48 48 19 21 23x16 28x24 32x26 35x32 40x38 44 44 48 52 21 23 23 17 28 25 32 28 35 34 40 42 44 48 23 25 23 19 28 28 32 30 35 38 25 27 23 20 28 30 32x32 35x40 27 29 23 22 28 32 32x35 35x42 29 31 23 24 28 34 32x38 35x44 Sft
53. pe of fuel Consult fuel supplier and use proper type of fuel for operating condition v Lack of engine power Engine overloaded Reduce load Intake air restriction Service air cleaner Clogged primary fuel filter element Clean or replace filter element Clogged secondary fuel filter element Replace filter element Improper type of fuel Consult fuel supplier and use proper type of fuel for operating conditions Overheated engine See Engine Overheats in next category Below normal engine temperature Remove and check thermostat Improper valve clearance See your local dealer Dirty or faulty injection nozzles See your local dealer O6140 03 03 28 TROUBLESHOOTING If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer Lack of engine power cont Injection pump out of time See your local dealer Improper propeller Consult your dealer and prop chart Grass etc on bottom of boat Clean hull Turbocharger malfunction Stop the engine Remove the air cleaner Make sure the compressor wheel is stationary and then rotate it with your hand to see whether it is stiff to rotate First rotate the wheel under light pressure then by lightly pulling axially If the wheel is stiff to rotate blades are damaged or blades hit housing the turbocharger should be replaced as soon as possible v Engine over
54. r shut down system to the exclusion of careful gauge monitoring Watching your gauges can prevent damage to the unit and dangerous power losses 2 Do the following when your warning or shutdown system is activated a Check the temperature gauge If the temperature is above 205 F 96 C shut off the engine immediately b Use the Trouble Shooting Guide on page 26 27 to isolate the cause of the overheat CAUTION Do not remove the water fill A cap of an overheated engine Escaping high temperature steam can cause severe burns c Allow the engine to cool and then remove the cap slowly using protective clothing d Make repairs and restart after the temperature gauge registers below 180 F 82 C e Watch the temperature gauge regularly and turn off the unit if the temperature rises above 205 F 96 C Repeat the troubleshooting process 3 If the warning or shutdown is activated and the temperature gauge shows temperature within normal temperature range a Check the engine crankcase oil level b If the oil level is low fill with recommended lubricating oil and restart Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading after a few seconds of operation c If the oil level is normal DO NOT restart the engine Call your Northern Lights or Lugger dealer for assistance BREAK IN PERIOD 1 The first 100 hours on a new or reconditioned engine are critical to its life
55. re 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 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 should be bled To bleed the fuel system loosen the vent plug in the top of the fuel filter housing Unscrew the hand primer knurled knob on the injection pump and loosen until it can be pulled up by hand see Fig 11 10 Operate the hand primer up and down until most of the air bubbles are expelled and clear fuel escapes the vent plug Push hand primer down and tighten Tighten the vent plug If the engine will not start it may be necessary to loosen the fuel pipes at the injectors With the throttle on full crank the engine over with the starter until fuel without air flows from the loose fuel pipe connections Tighten the connections SP10 INJECTORS 1 Fuel injectors should be checked by a Lugger Northern Lights dealer or qualified fuel injection shop after every 750 hours 2 Injector Removal a Thoroughly clean the area around injection pump fuel line connecting n
56. ropeller is used the engine should reach its appropriate maximum speed at full throttle If at full throttle the maximum speed is exceeded then the propeller is too small If maximum speed cannot be attained then the propeller is too large or bottom growth may be slowing the boat See Prop Chart page 23 7 To Establish Maximum Cruising RPM Establish the RPM at full throttle and subtract 200 300 RPM This will promote engine life and reduce fuel consumption SHUTDOWN PROCEDURES 1 Run for three to five minute cool down period a Propulsion engines in neutral at 1000 RPM then return throttle to low idle b Generators unloaded 2 Push STOP button until the engine has completely stopped Turn key switch to OFF position 3 Close the sea cock fuel valves and put the battery switch in OFF position NOTE Do not turn battery switch to OFF while engine is running SHUTDOWNS AND ALARMS 1 Your unit is fitted with a system to protect it from high water temperature or low oil pressure a Generator sets have shutdown systems to stop the engine They have no warning horns b Propulsion engines have warning horns to sound and warn you of a problem Remember when engine is not running the horn will sound when key is in the ON position because there is no oil pressure Propulsion engines do not have shutdown systems c Other alarms and shutdowns are available as optional equipment NOTE Do not rely on your warning o
57. tage meter to see the condition of the bat teries For starting the voltmeter should not read below 12 volts 24 volts for 24 volt systems 4 In cold weather turn the key to the preheat posi tion and hold there for 20 30 seconds 5 Turn the key to the starting position and as soon as the engine starts release the key Move the throttle up until the engine is running at approxi mately 1000 RPM 6 Do not crank the starter for more than 20 seconds consecutively If the engine fails to start with the first attempt be sure that the starter has stopped completely before re engaging NOTE Never race a cold engine Operate at 1000 RPM for a 3 5 minute warm up period Operating 1 Check oil pressure as soon as the engine has started Oil pressure should be above 15 PSI The engine must never be run if the oil pressure is below 15 PSI 2 Check the voltmeter It should read 13 to 14 volts 26 28 volts 24 volt systems at 60 F 16 3 Water temperature should not rise over 205 F 96 If it does shut down the engine and inves tigate the cause of overheating 4 Do not exceed 800 RPM when shifting marine gear Repeated shifts at higher engine speeds can damage the reverse gear 5 Low Idle is 750 RPM Maximum working engine speed is 2100 RPM for pleasure craft 2100 RPM for light commercial craft and 1800 RPM for continuous duty applications O6140 03 03 10 OPERATING PROCEDURES 6 If the proper p
58. tch is turned OFF while the engine is running the battery charging regulator could be damaged GENERATOR Starting 1 While holding the Shutdown Bypass Preheat switch in ON position push the Engine Control switch to START position As soon as the engine starts release both switches Do not crank the starter for more than 20 seconds If the engine fails to start the first time be sure the starter has stopped before reengaging 2 Cold Weather Hold Shutdown Bypass Preheat switch in the ON position for 30 seconds before starting This will warm the air heater elements and will ease starting This is not necessary if engine is warm longer preheat time may be required in extremely cold weather Operating 1 Check Gauges Often Oil pressure must be above 29 PSI The DC voltmeter should read between 13 and 14 volts 26 28 volts 24 volt systems at 60 F 16 C ambient temperature Water temperature gauge must be below 205 F 96 C Check AC voltage and frequency meters If gauges deviate from normal levels shut down the set and investigate 2 Let the unit run unloaded for a three to five minute warm up period 3 Do not add full electrical load until the engine has reached normal operating temperature PROPULSION ENGINE Starting 1 Put the gear control in the neutral position 2 Move the throttle control to the full speed position and return back to idle 3 Turn the key switch to the first position Check the vol
59. unction Check DC circuit breaker Faulty connection Clean and tighten battery and harness plug connections Sulfated or worn out batteries Check specific gravity and electrolyte level of each bat tery ENGINE v Engine hard to start or will not start Improper starting procedure No fuel Low battery output Check electrolyte level and specific gravity of battery Excessive resistance in starting circuit Clean and tighten all connections on batteries Crankcase oil too heavy Use oil of proper viscosity Improper type of fuel Consult fuel supplier and use proper type of fuel for operating condition Water dirt or air in fuel system Drain flush fill and bleed system Clogged primary fuel filter element Clean or replace filter element Clogged secondary fuel filter element Replace filter element Dirty or faulty injection nozzles Have your dealer check injection nozzles Fuel pump primer lever left on upward end of stroke v Engine runs irregularly or stalls frequently Below normal engine temperature Remove and check thermostat Clogged primary fuel filter element Clean or replace filter element Clogged secondary fuel filter element Replace secondary filter element Water or dirt in the fuel system Dirty or faulty injection nozzles Have your dealer check injection nozzles Air in fuel system nspect clamps and hoses on suction side of fuel pump for air leak Improper ty
60. unter clockwise Flywheel housing size SAE 1 14 SAE 0 18 optional Front PTO size optional SAE 4 10 3 11 5 Max operating angle Any direction 35 for less than 2 minutes Max installed operating angle 10 rear down 0 front down Based on 70 F 21 C seawater temperature and minimum boat speed of 8 knots at full rpm Return water 120 165 F 50 75 C 06140 03 03 26 NORTHERN LIGHTS MARINE SPECIFICATIONS Model Number M6140AL AC Output 1800 RPM 60 Hz 330 kW 1500 RPM 50 Hz 280 kW Phase Optional Phase 3 RPM Hz Available in 1800 RPM 60 Hz and 1500 RPM 50 Hz Voltages 60 Hz 120 208 120 240 127 220 139 240 220 380 240 416 254 440 and 277 480 Voltages 50 Hz 110 190 110 220 115 230 120 208 127 220 220 380 240 416 Engine Aspiration Turbo AC Oylinders Inline 6 Displacement cu in 1 930 15 24 Bore in mm 5 51 140 Stroke in mm 6 49 165 Specific Fuel Rate lb bhp hr 0 331 Fuel Rate Full Load gal hr ph 23 1 87 4 Fuel Rate 1 2 Load gal hr Iph 12 0 45 4 Model Number M6140QA AC Output 1200 RPM 60 Hz 200 kW 50 Hz Phase Optional Phase 3 Voltages 60 Hz 120 208 120 240 127 220 139 240 220 380 240 416 254 440 and 277 480 Engine Aspiration Turbo AC Oylinders Inline 6 Displacement cu in 930 15 24 Bore in mm 5 51 140 Stroke in mm 6 49 165 Specific Fuel Rate lb bhp hr 0 350 Fuel Rate Full Load gal hr ph 14 8 56
61. uts and rocker arm housing cover b Remove rocker arm housing cover c Remove fuel line nuts on fuel inlet connec tor and injection pump Remove fuel line clamps Pull fuel lines loose d Remove fuel inlet connector Note loosen lock nut first and then screw out connector Connector should be replaced 06140 03 03 16 SERVICING e Remove injector hold down bolts f Using injector hold down and bolt screw bolt into top of injector and lift out 3 Clean Injector Bore Injector seat in cylinder head can be cleaned by wrapping a clean lint free rag around the tapered end of a wooden rod and wiping the bore and seat Hardened carbon can be removed from the seat by using a tapered wire brush to break carbon free Then clean the bore with rag and rod Have injectors tested and rebuilt if necessary Or take them to a Lugger Northern Lights dealer and use them as core exchange for rebuilt injec tors Injector Installation a Install new o ring in groove on injector b Install new copper seat on end of injector c Insert injector aligning fuel inlet hole with fuel inlet connecting hole in rocker housing d Install new fuel inlet connector e Install injector hold down ballwasher and bolt Torque to 48 ft 156 6 75 kgm f Torque inlet connector to 27 ft 156 3 8 kgm and lock nut to 29 ft 165 4 0 kgm g Install injector lines Torque fuel line nuts to 17 18 ft 165 2 3 2 5 k
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