OPERATOR`S MANUAL
Contents
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3. OL844 03 10 5 Revised page 1 14 10 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 in 2 5 cm below the filler cap sealing surface when the engine is cold 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 Add Never allow the level to go below the Do not fill above the crosshatch pattern Oil levels within the crosshatch are considered in the acceptable operating range Always add the same viscosity of oil as is already in the crankcase see Service Point 1 Check the fuel tank level and open any fuel valves Check the oil level in the reverse gear Methods may vary from gear to gear See your Gear Owner s Manual Close the seacock check and clean the strainer and reopen the seacock Place the battery switch in the ON position NOTE The battery switch must always be kept ON while the engine is running If the switch is turned OFF while the engine is running the battery charging regulator could be ruined Starting 1 2 3 Put the gear control in the neutral position Move the throttle control to the idle position Turn the key switch to the first posi
4. 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 2010 Northern Lights Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Northern Lights Inc Printed in U S A PART NO OL844D 03 10 INORTHERN LIGHTS OPERATOR S MANUAL OL844 for Model L844D Read this operator s manual thoroughly before starting to operate your equipment This manual contains information you will need to run and service your new unit INTRODUCTION er 2 Cooling System General sss 13 Models Included 5 een 2 Engine Coolant Specifications 13 15 Model Numbers 2 Cooling System Flushing 15 Serial Nutnbets rient e P Renee 2 Heat Exchanger Cleaning 15 Zinc Electtodes aoreet 15 WARRANTY eerte 3 Raw Water Pump 16 SAFETY RULES 3 system General soinean 18 Booster Batteries 17 COMPONENT LOCATIONS Battery Cate sacaron innra i e erint 17 ERIA 4 Winterizing Out of Service 17 Instrumen
5. WHO Og A 7 3313NDH2V1 QU3N i MOTTA ANNO ndn S3SS3NHWM SHON 39nv9 JNISN3 5 kq IONINOO NOISN31X3 OL844 03 10 22 On Board Spare Parts Safety at sea depends on careful preparation product knowledge and having the right tools and parts Below is a list of parts Alaska Diesel Electric Inc recommends you carry onboard at all times Onboard Parts Kits are available from your dealer Standard Kits are suitable for inland and offshore cruising World Class Kits are for world cruising and trans ocean cruising We consider these minimum quantities Your vessel s operating conditions may require more of a given part Consult your dealer World Item Description Standard Class 1 Lube Oil Filter 4 2 Air Filter Element 1 1 3 Fuel Filter 2 2 4 Injector 0 5 Thermostat 2 2 6 Thermostat Ring 2 2 7 Relay 0 2 8 Valve Cover Gasket 1 2 9 Gasket Kit Top 0 1 10 Gasket Kit Bottom 0 1 11 Zinc 6 12 12 Raw Water Pump Impeller 2 2 13 Raw Water Pump Cover Gasket 2 2 14 Raw Water Pump 0 1 15 Workshop Manual 0 1 16 Set of Alternator Belts 1 1 17 Fuel Washer Kit Std 1 w c 1 Heat exchanger cooled engines only OL844 03 10 23 NORTHERN LIGHTS 4420 14th Ave NW Seattle WA 98107 NORTHERN HICHTE Tel 206 789 3880 1 800 762 0165 Fax 206 782 5455 Northern Lights and Lugger
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7. Volume Exhaust Gas Temperature Fuel System Minimum Suction Line Minimum Return Line Maximum Fuel Pump Suction Head Specific Fuel Consumption at Max Load Approximate Fuel Rate at Max Load Maximum Engine Operating Angle Continuous Operation More than 2 minutes requires use of a remote expansion tank Intermittent Operation Sustained up to two minutes 1 Based on SAE J816b 2 Based on EN ISO 8665 2006 Revised page 1 14 10 L844D Data 40 Hp 2800 RPM Lugger 4 cycle swirl chamber diese Inline 4 121in 1 995 liters 4 3 3 x 3 5 in 84 x 90 mm counter clockwise 22 1 2 1 gal 8 2 liter Natural SAE 4 C 107 40 Hp 29 6 kW 873 Ibs 396 kg 31 1 in 789 mm 19 75 in 502 mm 26 7 in 678 mm 1 4 gal 5 3 liter 3 4 in 20 mm 3 4 in 20 mm 3 4 in 20 mm 1567 BTU min 20 1 gpm 76 lpm 14 gpm 53 lpm 39 in 990 mm 6 feet 1 8 M 1 in 25 4 mm 1 25 in 31 5 mm 120 Amp Hour 1 12 Volt 101 cfm 2 86 M m 48 in 1219 mm H O 2 in 51 mm 238 cfm 6 7 M m 1022 F 550 C 5 16 3125 in 7 9 mm 5 16 3125 in 7 9 mm 39 in 990 mm 421 Ibs hp hr 2 37 US gph 8 9 Iph Front Down Rear Down 0 0 10 0 35 0 35 S e 5 o
8. of fuel for operating conditions OL844 03 10 Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer Excessive Fuel Consumption continued v Engine Emits White Smoke Engine overloaded Water to air aftercooler fails Reduce load on engine Remove and inspect water to air aftercooler Compression too low See your dealer Determine cause of low compression and v Engine idles Poorly repair Improper type of fuel Leaks in fuel supply Replace with correct fuel grade Locate source of leak and repair as required Air leak on suction side of air intake Abnormal Engine Noise Checkhose andpipe connections fortightness Worn main or connecting rod bearings repair as required Determine bearing clearance See your dealer Excessive crankshaft end play Check crankshaft end play See your dealer Loose main bearing caps Check bearing clearance replace bearings and bearing cap screws as needed See your dealer Worn connecting rod bushings and piston pins Inspect piston pins and bushings See your dealer Scored pistons Inspect pistons See your dealer Worn timing gears or excessive back lash Check timing gear back lash See your dealer Excessive valve clearance Check and adjust valve clearance See your dealer Worn camshaft lobes nspect camshaft See your dealer Worn rocker arm shafts Inspect rocker arm shaft
9. seasonal change in temperature when a new viscosity of oil is required Marine Generator Sets a Remove plug from outlet in base frame Screw in owner supplied drain hose b Open valve at oil pan outlet After oil has been drained into suitable container close valve remove drain hose and replace plug in base frame outlet c Refill engine with recommended oil 4 Engine Lube Oil Capacity 844 2 1 gallons 8 2 liters ae CHANGING OIL FILTER Change the lube oil filter every 200 hours Use a filter wrench to remove old filter Dispose of filter in approved manner 3 Make sure the gasket from the old filter is removed and discarded 4 Lubricate the rubber gasket on the new filter and screw it on nipple until gasket meet the sealing surface 5 Using hands only no wrench tighten filter one half turn farther Overtightening can do damage to filter housing 6 Fill engine with recommended oil Start engine and check for leakage Stop engine and check oil level Add additional oil if necessary SP4 AIR CLEANER Inspect air cleaner every 100 hours Replace filter every 600 hours or yearly whichever comes first 2 Clean the rubber tube at the cleaner Loosen the hose clamp and the attaching strip for the cleaner 3 Make sure the rubber tube is in good condition and that new filter is absolutely clean and installed prop erly 4 Start the engine and check for leaks NOTE Make absolutely sure no imp
10. wearing loose clothing when working tag the set and control panel so others will also around engines know about the problem e Do not oil or grease engine while it is running Provide first aid kits CALIFORNIA Proposition 65 Warning CAUTION This symbol is used throughout Diesel engine exhaust and some of its constitu this book to alert you to possible danger areas ents are known to the State of California to cause Please take special notice of these sections cancer birth defects and other reproductive harm OL844 03 10 3 L844D Component Locations Figure 1 amp 2 L844D Coolant Fill 2 Expansion Tank Exhaust Manifold Heat Exchanger Tank Coolant Drain Wet Exhaust Elbow Starter U5 Alternator Belt Guard Raw Water Pump Oil Fill Top Fresh Water Pump Fuel Injector 4 Fuel Return Line AG AN 10 4 9 uU 47 13 Secondary Fuel Filter 20 Fuel Return Line 14 Coolant Recovery Tank 21 Fuel Inlet Line 15 Lube Oil Drain 16 Oil Filter 17 Oil Dipstick 18 Oil Fill Side 19 Injection Pump OL844 03 10 4 Added page 1 15 10 Instrument Panel Figure 4 Lugger Main Instrument Control Panel TACHOMETER The tachometer shows the engine speed in revolutions per minute RPM Numbers are multiples of 100 HOUR METER Keeps track of the engine running time D C VOLTMETER When the engine is stopped t
11. 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 coolant concentrate antifreeze normally DOES NOT contain the SCA chemical inhibitors needed to control liner pitting or ero sion rust scale and acidity WATER QUALITY 1 Distilled deionized soft water is preferred for use in cooling systems Bottled distilled water from a food store or water supplier is recommended Tap water often has a high mineral content Tap water should NEVER be put in a cooling system unless first tested by a water quality laboratory 2 Here are acceptable water quality specifications Parts Grains Contaminates per Million per Gallon Maximum Chlorides 40 2 5 Maximum Sulfates 100 5 9 Maximum Dissolved Solids 340 20 0 Maximum Total Hardness 170 10 0 PH Level 5 5 to 9 0 OL844 03 10 13 IMPORTANT 1 3 A If chlorides sulfates or total dissolved solids are higher than the above given specification the water must be distilled demine
12. 4 Replace air cleaner SP5 Check V belt condition SP6 Check valve clearances SP10 Check injectors SP15 Check and flush cooling system SP19 Change impeller in raw water pump SP21 Check the state of the charge of the batteries EVERY 2500 HOURS SP16 Check and clean heat exchanger SP17 Check and clean gear oil cooler SERVICE 50 200 600 2500 POINT PAGE OPERATION DAILY Hours Hours Hours Hours ENGINE SP1 10 Check oil level SP2 10 Change engine oil 1 SP3 10 Change lube oil filters 1 SP4 10 Check replace air cleaner 1 3 5 5 Check belt condition 1 d SP6 11 Check valve clearances 1 FUEL SYSTEM SP7 12 Check primary filter Racor 2 SP8 12 Change primary filter element Racor 2 3 SP9 12 Change secondary fuel filter 1 3 SP10 Check injectors 1 SP12 Check condition of exhaust elbow 4 COOLING SYSTEM SP14 15 Check cooling water level SP15 15 Check and flush cooling system 1 SP16 15 Check and clean heat exchanger 1 SP17 Check and clean gear oil cooler 1 SP18 15 Check zinc electrodes 1 3 bi SP19 16 Change impeller in raw water pump 1 3 SP24 Check sea water strainer ELECTRICAL SYSTEM SP20 17 Check electrolyte level in batteries 1 3 SP21 17 Check condition of batteries with hydrometer 1 OUT OF SERVICE SP22 17 Winterizing or out of service 3 1 Perform all maintenance once a year even if hour level has n
13. P15 FLUSHING THE COOLING SYSTEM A CAUTION The cooling water in the engine reaches extremely high temperatures You must use extreme caution when working on hot engines to avoid burns Allow the engine to cool before working on the cooling system Open the filler cap carefully using protective clothing when the engine is warm 1 Flush the cooling system and check for leaks and blockage every 600 hours or yearly The engine must be stopped and cold 2 Close the seacock 3 Remove the pressure cap from the expansion tank with caution If applicable open the cooling system air vent on top of turbocharger 4 Open the drains on the exhaust manifold and engine block Drain the fresh water system see Component Locations page 4 5 For vessels with keel cooling the vessel must be out of the water to allow draining of the keel cooler 6 With drains open pour clean water into the expansion tank When the water from drain is clear and free from discoloration and sediment close that drain When all drains are closed flushing is complete 7 Fill the fresh water system by pouring the recommended coolant mixture as described in previ ous sections 8 Open the seacock 9 Start the engine Check hoses and connections and repair any leakage SP16 HEAT EXCHANGER CLEANING 1 Clean the heat exchanger core once a year or after 2400 hours of operation 2 Drain expansion tank and heat exchanger 3 Remove heat exchanger end co
14. are registered trademarks of Northern Lights Inc www northern lights com 2010 All rights reserved Litho USA
15. atteries while the engine is running Regulator damage can result DO NOT reverse the polarity of battery cables when installing the battery When welding on the unit disconnect the regulator and battery Isolate the leads Disconnect battery cables when servicing the DC alternator Never test with a screwdriver etc against any ter minal to see if it emits sparks A DC circuit breaker protects your control panel and wiring harness OL844 03 10 16 BOOSTER BATTERIES SP22 WINTERIZING OUT OF SERVICE CAUTION Battery Gas Can Explode Keep all The following long term storage preparation guides flames and sparks away from batteries are good for storage up to one year after that the engine should be started warmed up and prepared again for 1 Before changing or using booster batteries check long term storage battery electrolyte level Add distilled water 2 Booster and main batteries must have the same volt 1 Change oil and replace filter Used oil will not give age rating adequate protection 3 First connect positive terminal of booster 2 Service the air cleaner battery to positive terminal of main battery 3 For storage less than a year it is not necessary to drain and flush the cooling system For a year or more of storage the cooling system should be drained flushed and refilled with appropriate cool ant 4 Remove the fan and alternator belts optional 5 Remove and clean the batterie
16. e tine maintenance compared to the servicing of automobiles trucks or even farm equipment Failures often occur in remote As operator it is your obligation to learn about your areas far from competent assistance Marine engines equipment and its proper maintenance This is not a are taxed far more severely than auto or truck engines comprehensive technical service manual Nor will it therefore maintenance schedules must be adhered to make the reader into an expert mechanic Its aim is to more strictly aid you in maintaining your unit properly Model Numbers Model numbers give the unit s application block model and aspiration L 844 D L Lugger propulsion engine Model number D Natural Aspirated 4 Cylinders 84 mm bore ee 18440 Northern Lights naturally aspirated propulsion engine with a 844 engine Serial Numbers When referencing Northern Lights Inc equipment by serial number please refer only to the number stamped on the Northern Lights or Lugger serial number plate LUGGER by NORTHERN LIGHTS Serial No Model No Northern Lights 4420 14th Ave NW Seattle WA 98107 OL844 03 10 2 A warranty registration certificate is supplied followed If further information is needed please with your set The extent of coverage is described contact an authorized dealer or the factory in the Limited Warranty Statement We recom
17. earing clearance Determine bearing clearance See your dealer v High Oil Pressure Regulating valve not operating correctly Remove and inspect oil pressure regulating valve See your dealer Plugged piston spray jet Replace piston spray jet See your dealer Filter bypass valve stuck or damaged Remove and inspect filter bypass valve See your dealer High Oil Consumption Crankcase oil too low viscosity Drain crankcase and refill with correct oil Crankcase oil level too high Drain oil until level is correct External oil leak Check for leaks in lines around gaskets and drain plug Oil control rings worn or broken Replace piston rings See your dealer Scored cylinder liners or pistons Remove and inspect cylinders and liners replace as required See your dealer Worn valve guides or stems nspect and measure valve stems and valve guides repair as required See your dealer Piston grooves worn Remove and inspect pistons See your dealer Piston rings sticking in ring grooves Remove and inspect pistons See your dealer Insufficient piston ring tension Remove and inspect pistons See your dealer Piston ring gaps not staggered Remove and inspect pistons See your dealer Front and or rear crankshaft oil seal faulty Replace oil seals See your dealer Excessive Fuel Consumption Intake air restriction Service air cleaner Improper type of fuel Consult fuel supplier and use proper type
18. ery Replace battery Corroded or loose battery connections Clean battery terminals and connections Defective main switch or start safety switch Repair switch as required Starter solenoid defective Replace starter or solenoid Hard to Start or Will Not Start Poor fuel quality Drain fuel and replace with proper grade fuel Slow cranking speed Check for problems in the charging or starting system Engine Misfiring or Runs Irregularly Basic engine problem See your dealer Lack of Engine Power Poor fuel quality Drain fuel and replace correct grade fuel Intake air restriction Service air cleaner Clogged primary fuel filter Clean or replace filter element Clogged secondary fuel filter element Replace secondary filter element Crankcase oil too heavy Hil with oil of appropriate viscosity Low Oil Pressure Low crankcase oil level Fill crank case to proper level Clogged oil cooler or filter Remove and inspect oil cooler See your dealer High oil temperature Remove and inspect oil cooler See your dealer Defective oil pump Remove and inspect oil pump See your dealer Oil pressure regulating valve failure Remove and inspect oil pressure regulating valve See your dealer Broken piston spray jet Replace piston spray jet See your dealer Clogged oil pump screen or cracked pick up tube Remove oil pan and clean screen replace pick up tube Excessive main or connecting rod b
19. ese concentrates are not compatible with chemicals used in supplemental coolant addi tives Damage can occur to rubber seals on cylinder liners which are in contact with coolant DO NOT use an EGC containing sealer or stop leak additives DO NOT use EGC containing more than 0 1 anhydrous metasilicate This type of concentrate which is intended for use in aluminum engines may cause a gel like deposit to form that reduces heat transfer and coolant flow Check container label or consult with supplier OL844 03 10 14 A SP14 CHECKING COOLANT LEVEL CAUTION The cooling water in the engine reaches extremely high temperatures You must use extreme caution when working on hot engines to avoid burns Allow the engine to cool before working on the cooling system Open the filler cap carefully using protective clothing when the engine is warm Check the coolant level each day before starting the engine Remove the pressure cap from the expansion tank and check water level In order to give the coolant an opportunity to expand the level should be about 1 in 2 5 cm below the filler cap sealing surface when the engine is cold The pressure valve in the filler cap releases when the pressure is approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it is faulty The makeup coolant added to compensate for loss or leaks must meet engine coolant requirements outlined in previous section S
20. f an overheated engine Escaping high temperature steam can cause severe burns Allow the engine to cool and then remove the cap slowly using protective clothing c Make repairs and restart after the temperature gauge registers below 180 F 83 C d Watch the temperature gauge regularly and turn off the unit if the temperature rises above 200 F 94 C Repeat the troubleshooting process 3 If the shutdown is activated and the temperature gauge shows temperature within normal temperature range a Check the engine crankcase oil level b If the oil level is low fill with recommended lubricating oil and restart Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading after a few seconds of operation 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 Your engine is ready to be put into service However the first 100 hours on a new or reconditioned engine are critical to its life and performance This is especially true of an engine that runs at a constant speed such as a propulsion engine does 2 Operate with an averager of 75 load on your engine for the first 100 hours Maintain no less than a 50 load to ensure proper seating of the piston rings Operating Procedures 3 Oil consumption is greater during break in as piston rings take time to seat 4 Your engine comes equipped with brea
21. he voltmeter shows the condition of the battery When the engine is running it indicates the voltage output of the alternator KEY SWITCH Turning the key clockwise to the first position will switch on the current Continue turning the key clockwise to preheat the engine then again to start the engine When the engine starts immediately turn the key back to the first position while the engine is run ning The key must be kept in the or first position while the engine is running Turn the key counter clockwise as far as possible to stop the engine Note Optional flybridge panels have engine start switches instead of key switches COVER Stop button not used for this application 11 12 INSTRUMENT PANEL LIGHTING The switch turns on the instrument panel lights OIL PRESSURE FAULT LIGHT Indicates low oil pressure Activates in conjunction with alarm horn ENGINE TEMPERATURE FAULT LIGHT Indicates engine is over heating Activates in conjunction with alarm horn ALARM HORN Shut down engine if possible and investigate immediately WIRE HARNESS COOLANT TEMPERATURE GAUGE Water temperature gauge shows the temperature of the engine coolant If the gauge registers over 200 F or drops below 140 F stop the engine and investigate OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system If the pressure drops below 15 PSI at a speed higher than idling stop the engine immediately
22. k in oil Change engine oil and filter at 50 hours using API Service Category CC CD or CE break in oil Change the oil and filter again at 100 hours Consult the lubricants section for oil recommendations 5 Frequently check the engine temperature and oil pressure gauges OPERATING INSTRUCTIONS 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 OL844 03 10 7 Servicing Schedule Chart The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your marine engine or generator set More detailed coverage of each Service Point SP is listed on the page noted in the page column DAILY SP1 Check oil level in engine SP7 Check primary fuel filter SP14 Check cooling water level SP24 Check sea water strainer AFTER FIRST 50 HOURS SP2 Change engine oil SP3 Change lube oil filter EVERY 50 HOURS SP20 Check electrolyte in batteries FIRST 100 HOURS SP2 Change engine oil SP3 Change lube oil filter EVERY 200 HOURS SP2 Change engine oil SP3 Change lube oil filter SP4 Check air cleaner SP8 Change primary fuel filter element SP9 Change secondary fuel filter SP12 Check condition of exhaust elbow SP18 Check zinc electrodes EVERY 600 HOURS YEARLY SP
23. mary Fuel Complete Unit Filter Part Number 24 50002 Part Number Element 24 50012 Figure 5 Primary Fuel filter d Operate the hand primer until the fuel filter pops up If this does not happen use a small screw driver and carefully pry under the filter flange e Install new filter cartridge do not reuse the old one A stalled engine could result from air bubbles in the old filter cartridge causing fuel to overflow from the housing f Ensure that the fuel level is between the minimum and maximum marks on the center tube in the middle of the filter housing If the fuel is below the minimum level use the hand primer to add more fuel Fuel level below the minimum could cause the engine to stall because of trapped air in the new filter Fuel level above the maximum could cause the fuel to overflow from the filter housing when the fuel filter is installed g Install new filter replace cap restart engine and run for five minutes minimum h Remove and clean the water separator bowl by first disconnecting the wiring connector from the water in fuel sensor i Drainthe fuel from the separator bowl Use a strap wrench close to the top of the bowl while gripping bowl and twisting it with the other hand to remove it Clean and dry the bowl Reinstall and hand tighten Reconnect sensor BLEEDING THE FUEL SYSTEM A CAUTION Escaping diesel fuel under pressure can penetrate the skin causing serious perso
24. mend that you study the statement carefully NOTE If the warranty is to apply the servicing instructions outlined in this manual must be Safety Rules CAUTION Accident reports show that careless use of engines causes a high percentage of accidents You can avoid accidents by observing these safety rules Study these rules carefully and enforce them on the e Never leave engine without proper security e Use caution in handling fuel Never refuel a hot or running engine Do not smoke while filling Turn the coolant tank cap slowly to relieve pres M E 7 fuel tank or servicing fuel system sure before removing Add coolant only when the engine is stopped and cool e Keep your hands feet hair and clothing away from power driven parts Mount a fire extinguisher near engine P Check for any loose electrical connections or Always disconnect the battery ground strap before making adjustments T e Engines should be operated only by knowledge Operate engines in properly ventilated areas able qualified personnel e Keep trash and other objects away from engine e Escaping fluids under pressure can penetrate that everything is clear before starting your skin Use a piece of cardboard or wood Do not operate an engine that isn t in proper work not your hands to search for leaks P prope ing order If an unsafe operating condition is noted Avoid
25. nal 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 The fuel system is self bleeding However any system may need manual bleeding when a Anew fuel filter is installed b The engine has run out of fuel c The fuel lines injection pump or any other fuel system component has been removed and installed Loosen bleed bolt A figure 6 on top of the filter Pump hand primer B on fuel lift pump until pure fuel no bubbles escapes from bleed bolt Tighten bleed screw A Loosen bleed screw Pump hand primer until pure fuel no bubbles escapes Then tighten bleed screw OL844 03 10 12 4 If the engine does not start after the above bleed ing process loosen a fuel line at the injector while cranking the engine with the starter motor until pure fuel escapes Then tighten the connection Do each line one at a time 5 After the engine has started use a piece of cardboard to look for fuel leaks Figure 6 COOLING REQUIREMENTS
26. nt temperatures below freezing and for all temperatures at an altitude of above 5 500 ft 1500 meters 2 Sulphur content should not exceed 0 5 preferably less than 0 5 3 The cetane number should be a minimum of 45 4 DO NOT use these unsuitable grades of fuel a Domestic heating oils all types Class B engine Class D domestic fuels Class E E G or H industrial or marine fuels ASTM D975 60T No 4 D and higher number fuels f JP4 5 Storing fuel a Keep dirt scale water and other foreign matter out of fuel b Avoid storing fuel for long periods of time c Hill the fuel tank at the end of each day s operation This will reduce condensation onan c OL844 03 10 11 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 200 hours or whenever necessary c If the bowl fills with water change the primary and secondary elements immediately Change secondary fuel filter every 200 hours NOTE The fuel filter on the engine is considered the secondary fuel filter a Turn off the fuel b Be sure area around fuel filter assembly is clean c Remove the cap from the fuel filter housing A wrench or pliers may be needed Pri
27. ot been reached 2 Consult manufacturer s maintenance schedule note on chart 3 Whenever necessary OL844 03 10 8 Service Record poi OPERATION HOURS DATE 50 HOURS SP20 Check electrolyte in batteries 200 HOURS SP2 Change engine oil SP3 Change lubricating oil filters 5 4 Check air cleaner SP7 Change primary fuel filter element SP9 Change secondary fuel filter SP12 Check turbocharger air oil amp cooling lines for leakage SP18 Check zinc electrodes 600 HOURS SP4 Replace air cleaner SP5 Check belt condition SP6 Check valve clearances SP10 Check injectors SP13 Check turbocharger boost pressure SP15 Check and flush cooling system SP19 Change impeller in raw water pump SP21 Check state of charge of batteries 2500 HOURS SP16 Check and clean heat exchanger SP17 Check and clean reverse gear oil cooler SP23 Check crankshaft damper OL844 03 10 9 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 CC CD oil c ACEA Specification E1 2 Do not use John Deere PLUS 50 oil or engine oils meeting API CF 4 API CG 4 API CH 4 API 4 ACEA E2 ACEA ACEA ACEA E5 performance levels during the first 100 h
28. ours 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 API Service CH 4 CI 4 multi viscosity oils b API Service CD CG 4 CF 4 multi viscosity oils c ACEA Specification E3 d ACEA Specification E4 E5 3 Use the proper weight oil for your average operation temper ature Air Single Multi Temperature Viscosity Viscosity SAE 30W SAE15 40W 0 C 10 F to 32 F 23 C to 0C SAE 10W SAE10 30W Below 10 F 23 C SAE 5W SAE5 20W 4 Some increase in oil consumption may be expected when SAE 5W and SAE 5 20W oils are used Check oil level frequently 5 Never put additives or flushing oil in crankcase SP1 CHECK ENGINE OIL LEVEL 1 Check the oil level in the crankcase with the oil dipstick daily 2 The oil level must be between the Waffled area and the Never allow the level to go below the Add 3 Always add the same viscosity of oil as is already in the crankcase SP2 OIL CHANGES Using the oil recommended above change the engine oil and filter after the first 50 hours of operation and every 200 hours thereafter During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes first Change oil at any
29. ralized or deionized before it is used in a cooling system If total hardness is higher than 170 ppm and all other parameters are within the given specifications the water must be softened before it is used to make coolant solution EGC ETHYLENE GLYCOL CONCENTRATE ANTIFREEZE CAUTION EGC Antifreeze is flammable Keep it away from any open flame Avoid contact with eyes Avoid contact with skin Do not take inter nally In case of contact immediately wash skin with soap and water For eyes flush with large amounts of water for at least 15 minutes Call a physician KEEP OUT OF REACH OF CHILDREN Follow all warnings on the container Ethylene glycol coolant concentrate is commonly mixed with water to produce an engine coolant with a low freeze point and high boiling point A low silicate form of ethylene glycol coolant is recommended for all diesel engines Use an ethylene glycol coolant concentrate meeting ASTM D 6210 D4985P and D5345 This product is concentrated and should be mixed to the following specification If additional coolant solution needs to be added to the engine due to leaks or loss the glycol concentration should be checked with a hydrometer to assure that the desired freeze point is maintained Distilled EGC Freeze Boiling Water Antifreeze Point Point Optimum 50 50 p je Minimum 60 40 p s Maximum 40 60 po pe DO NOT use methyl alcohol or methoxy propanol base EGC Th
30. rated RPMs at full throttle either your propeller is too large or bottom growth is slowing the boat To establish Maximum Cruising RPM Establish the RPM at full throttle and subtract 200 300 RPM This will promote engine life and reduce fuel consumption Shutdown 1 Run engine three to five minutes in neutral at 1000 RPM for cool down period 2 Return engine to low idle Turn the key switch counterclockwise as far as pos sible to stop the engine Close the sea cock and fuel valves and put the battery switch in OFF position NOTE Do not turn the battery switch to OFF while the engine is running ALARMS 1 Your unit is fitted with a warning system to indi cate high water temperature or low oil pressure Propulsion engines have warning horns to sound and warn you of a problem Remember when the engine is not running the horn will sound when the key is in the ON position because there is no oil pressure OL844 03 10 6 NOTE Do not rely on your warning or shutdown system to the exclusion of careful gauge monitoring Watch ing your gauges can prevent damage to the unit and dangerous power losses 2 Do the following when your shutdown system is acti vated a Check the temperature gauge If the temperature is above 205 F 97 C shut off the engine immediately b Use the Trouble Shooting Guide on pages 18 19 to isolate the cause of the overheat CAUTION Do not remove the water fill cap o
31. s See your dealer Engine Emits Black or Gray Exhaust Smoke Clogged or dirty air cleaner Service air cleaner Defective muffler back pressure too high Have dealer check back pressure Improper fuel e Use correct fuel for temperature Engine Emits White Smoke Engine compression too low Determine cause see dealer Defective thermostat does not close Remove and check thermostats replace if needed Coolant entering combustion chamber maybe a failed cylinder head gasket or cracked cylinder head Repair see your dealer OL844 03 10 19 Hp RPM General Information Engine Type Cylinders Displacement Cycles Bore x Stroke Rotation Facing Flywheel Compression Ratio Crankcase Capacity including Oil Filter Aspiration Flywheel Housing Size Flywheel Drive Size Rated Crankshaft Hp Rated Crankshaft kW Dry Weight w Heat Exchanger Single Phase Length Width Height Cooling System Approx Coolant Cap Minimum Through Hull Diameter Sea Water Pump Inlet Hose ID Minimum Sea Water Discharge Heat Rejection to Jacket Coolant Fresh Water Pump Cap Seawater Pump Cap Maximum Seawater Pump Suction Head Keel Cooler TurboTube Length Keel Cooler Head Diameter Keel Cooler Water Hose ID D C Electrical Minimum Battery Capacity Battery Cable Size Starting Voltage Negative Ground Air Intake and Exhaust Air Consumption Maximum Exhaust Backpressure Wet Exhaust Elbow OD Exhaust Gas
32. s Store them in a cool dry place and be sure they are fully charged 6 Disengage the clutch to engine drivelines 7 Clean the exterior of the engine with salt free water and touch up painted surfaces with good paint 8 Coat all exposed machined metal surfaces with grease or corrosion inhibitors if they cannot be painted Figure 7 Booster Battery Connections 9 Sealall openings with plastic bags and tape 10 Store the engine in a dry protected place If the 4 Then connect negative terminal of booster battery engine must be outside cover with waterproof to ground on the engine block see Figure 7 canvas or other protective material and use strong 5 Remove booster battery after starting engine waterproof tape 6 Sealed batteries see manufacturer charging and booster instructions SP20 21 BATTERY CARE LEAD ACID TYPE BATTERIES 1 Check electrolyte level every 50 hours or once per month Add distilled water to manufacturer s recommended level 2 Batteries cables and cable terminals should be checked and cleaned every 100 hours Clean corro sion with a water and baking soda solution Flush with clean water Tighten terminals and grease them to inhibit corrosion 3 Check the battery condition with a hydrometer every 750 hours OL844 03 10 17 Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer v Engine Will Not Crank Weak batt
33. saty y won Old TIONIS zage REB 2212313 WNOUdO E 1 2 m m uz ONn039 3592 35v 3 502 9385 NYOH onnos dl 3NON3 19 Tye NMOMG 3LIHM Vi HOLIMS 31155309 10 Oif o fo EEN mamani lt on remy 4 3092 0 ve 2 uirum ONNOY _ 35v 30435 ANIL INNI AYTAY VIHJAA 7 lt ssim NO T r 3108 335 ZA JION 335 dz 350 ATS SUR LL aBidmungn E XB OF ESI OF T 3 B d e lt EOS ida ANT f lt H21UAS YILIN LIDA Tidind vid _ le 390vo 0 AY 38 NAY AW 3mg IHIN vil 1 3mB xa exo fo ANNOYS 390 amaos vi 7 K ae 3NI N3 5 of vsu 038 af E Ves SOLON HIS NET Jia vil g K 038 M0113A WS 55388 10 ee w L zt IND L S D E L O eu NOWIB ARIO viH lt HOLIMS NM p le IOJINOO 3NION3 Hd smod mee i id mu IILINIVN 2m pr X JovB Avg Mrs 1 S3SSINUWH NI9N3 71919 ONY NYd IOHINOO NOISN31X3 OL844 03 10 21
34. t 5 TROUBLESHOOTING OPERATING PROCEDURES 18 19 Before Starting 6 Shutdown Procedures sss 6 7 DATA SHEETS Break In Period eese 7 Unit Specifications 20 SERVICING SCHEDULE CHART 8 WIRING DIAGRAMS SERVICE 9 12 and 24 Volt 21 22 SERVICING ON BOARD SPARE PARTS 23 Lubrication 10 Checking ires 10 Ol CHAM BES sc hee cess cares dde teens 10 Changing Oil Filter teas 10 Air ea 10 Valve Clearances 11 Fuels Generali eH 11 Fuel Filter zs oec tereti eene 12 Bleeding the Fuel System 12 13 Proprietary Information This publication is the property of Northern Lights Inc It may not be reproduced in whole or in part without the written permission of Northern Lights Inc Northern Lights Inc All rights reserved Litho U S A Publication number OL844 03 10 OL844 03 10 1 Revised page 3 2 10 Introduction Servicing of marine engines and generator sets pres Failures begin with minor problems that are overlooked ents unique problems In many cases boats cannot be and become amplified when not corrected during rou moved to a repair facility Marine engines cannot b
35. tion Check the voltage meter to see the condition of the batteries For starting the voltmeter should not read below 12 volts 24 volts for 24 volt systems Turn the key to the starting position and as soon as the engine starts release the key Move the throttle up until the engine is running at approximately 1000 RPM Do not crank the starter for more than 15 seconds consecutively If the engne fails to start with the first attempt be sure that the starter has stopped com pletely before re engaging NOTE Never race a cold engine Operate at 1000 RPM for a 3 to 5 minute warm up period Operating 1 Check oil pressure as soon as the engine has started Oil pressure should be above 15 PSI The engine must never be run if the oil pressure is below 15 PSI Check the voltmeter It should read 13 to 14 volts 26 28 volts 24 volt systems at 60 F 16 C Water temperature should not rise over 200 F 94 If it does shut down the engine and investigate the cause of overheating Do not exceed 800 RPM when shifting marine gear Repeated shifts at higher engine speeds can damage the reverse gear Low idle is 800 RPM Maximum working engine speed is 2800 RPM for 40 Hp 6 If the proper propeller is used the engine should reach its appropri ate maximum RPMs at full throttle If the maximum rated RPMs for your engine application is exceeded at full throttle then your propeller is too small If you cannot reach your maximum
36. urities enter the engine while changing the element Do not run the engine with the air cleaner removed OL844 03 10 10 SP6 VALVE CLEARANCES 1 Adjust valve clearance after the first 50 hours of operation and every 600 hours thereafter 2 Engine should be cold and NOT running 3 Watch the valves while turning the engine over by hand Turn until the inlet valve starts to open and the exhaust valve starts to close the valves are rocking Then turn the crankshaft one more full turn and adjust the clearance on both valves for this cylinder Flywheel QO OO OO Figure 3 844 Valve sequence 4 Loosen the lock nut and adjust the clearance between the rocker arm and valve guide of both the intake and exhaust valves with the adjustment screw Figure 4 Clearance on both intake and exhaust valves should be 0 008 inches 0 2 mm 5 Repeat steps 3 and 4 for each cylinder Each set of valves must be adjusted individually 6 Replace the rocker arm cover Tighten cover nuts to 5 8 ft Ibs 0 8 2 3 kg m LV lt Valve Adjustment Screw Rocker Arm 0 008 in Figure 4 Valve adjustment E t 0 200 mm FUELS GENERAL 1 Use only clean high quality fuels of the following specifications as defined by ASTM designation D975 for diesel fuels a Use grade no 2 diesel at ambient temperatures above freezing 30 F 0 C b Use grade No 1 at ambie
37. vers and remove core 4 Clean the inside of exchanger core tubes using a metal rod Flush inspect and clean again if necessary 5 Reassemble Fill the cooling system start the engine and check for leaks SP18 ZINC ANODES 1 Zincs are installed in the cooling system to protect your engine from electrolysis Check them faithfully every 200 hours If you are in warm salt water or where electrolysis is a known problem check them more often OL844 03 10 15 SP19 RAW WATER PUMP Heat exchanged cooled engines only 1 Change the sea water pump impeller as needed 2 Remove the pump end cover Remove impeller with water pump pliers Be sure you remove all pieces of a failed impeller 3 Clean the inside of the housing Press in the new impeller and place the sealing washer in the outer end of the impeller center if this has not already been done 5 Replace the cover using a new gasket Note Make sure there is always an extra impeller and cover gasket in reserve and on board DRIVEN EQUIPMENT Gears and PTO s Manufacturer s service recommendations vary See your Owner s Manual for service information If you do not have a manual see your local dealer for the equipment in question NOTE Some PTO and marine gears have rigid lubrication requirements Follow service recom mendations closely ELECTRICAL SYSTEM GENERAL Never switch battery switch off or break the circuit between the alternator and b
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