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Operator`s Manual (model M1066H)

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5. SENSOR 941 16 2 418 CODLANT BLACK d 414A 416 YELLE TEMP 003 OL PRESSURE NS SENDER gt 461 129 0 80 amp 1 TA LOWS py 7 tgo So RAIL PRESS 427 Purr 427 ps PUN Ed lt 475 Tr BI dy E OK DEN RI v1 947 96 PURPLE t ENGNE TENP lt lt RE ES aX ope 5 Y3 amp muc A 1 x D 25DF Q220 p6 RED B2 t2 GREEN 22 22 e 495 MB LT BLU AWG 2 0 BATTERY CABLE MAX LENGTH ENGINE 8 EACH SIDE 10 BLACK ALTERNATOR 12V 140A 22 4D282 12VUC STARTER MOTOR 22 41647 OR Ur 20 BURN oon D C Wiring 12 Volt Isolated Ground for M1064H amp M1066H Drawing D 3829 ium 4420 14th Ave NW Seattle WA 98107 Tel 206 789 3880 1 800 762 0165 www northern lights com pacem Northern Lights and Lugger are registered trademarks of Northern Lights Inc NORTHERN LIGHTS 2013 All rights reserved Litho USA
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7. 13 Shutdown Procedures 13 Break In Period eren 14 SERVICING SCHEDULE CHART 15 SERVICING Lubrication 16 81544180 16 16 Changing OI Filtet sc 16 Air 16 Valve 17 18 Fuels 18 Crankshaft Vibration Damper 6 Cyl 19 Bue CS 19 The S VS efu secs 20 21 High Pressure Common Rail 20 21 21 Turbo BOOS 21 Cooling System 21 Engine Coolant 1 22 23 Cooling System Flushing 23 24 Heat Exchanger Cleaning 24 Zine 24 Raw Water 24 25 Electrical System General 5 Booster Dattetie 25 Battery 25 Winterizing 1 25 TROUBLESHOOTING 26 26 28 WIRING DIAGRAMS AC Electrical 29 DC Electrical 30 31 ON BOARD SPARE 32 P
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9. 0 0 0 0 0 0 0 0 7 RELAY BOARD e i ENGINE AWG 2 BATTERY CABLE MAX LENGIN TO_ENGINE FT EACH SIDE 022A 16 RED EC U X Q 6 T3558 REI 7L SLL BRUT Aa SEE NOTE i ae Gale 02 lt m d 16 QREY 2 EX S 0229 p mca n a cum OX GREEN UC lt Ei 4n ORN 4 9 d i 16 MOLT G3 LT BILE HU m PLUC 495 gb OX GREEN UG 474 716 YELLOW gt 51 1 lt OSDA gi H3 419 216 WHITE PSS 4713 EINE Di lt 22 939 pwi gt 02 PLUS o Sy Ji ge Hm 496 16 cREY E 2 lt PLUG 12 Dti ne 2 BLACK 9258 ORANGE SEE NOTE 5 50 n5 ETT ar BLK Dodd FD E K 90 A D i i aad 9940 29 YELLOW pora gaat m ECU X07 11 poe azo m dp Rap I onc 20 0 EEN 12 247 pb PyRP 953 116 ORANG Su lt 915 6 0K ORN 43g waite m lt DREY H LOSS OF COOLANT n 16 n 467 PURPI mus gt res HE BRONN RANK SENSOR 911 HE BROWNS ni qne 14 N3 3 T gt gt 1144 HB ELOR p3 pn 1B PURP o e 428 y20 CREY 475 479 916 DK CRN i emt FL UU Ir 92 4B BROWN 120 a 946 ALTA Ses T Put 24 0 STARTING MOTO
10. No 4 Piston at TDC Compression Stroke E Exhaust Valve Intake Valve Adjust valve clearance on No 2 and No 4 exhaust valves and No 3 and No 4 intake valves OM2 4 7 13 17 Servicing 6 CYLINDER ENGINES FUELS GENERAL continued Lock No 1 piston at TDC compression stroke Figure 9 B Adjust valve clearance on No 1 No 3 and No 5 exhaust valves and No 1 No 2 and No 4 intake valves Rotate flywheel 360 Lock No 6 piston at TDC compression stroke Figure 9 C 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 Fill the fuel tank at the end of each day s Note Firing Order is 1 5 3 6 2 4 operation This will reduce condensation 6 Biodiesel Biodiesel involves the transesterification of vegetable oils or animal fats Mainly in the U S soybean methyl ester is used SMB but in Europe mainly rapeseed canola methyl ester is made RME and in Asia palm methyl ester is made PME 100 biodiesel B100 is made in compliance with ASTM D6751 or EN14214 EU specifications Biodiesel may be used in a 5 blend 596 biodiesel 95 diesel from a BQ 9000 accredited producer 2096 biodiesel blends can only be used if they meet ASTM D6751 or EN14214 EU Reproduced by permission of Deere amp Company c2004 Deere amp Company specifications A 296 reduction in power and a 3 reduction in rights reserved RG121
11. A CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constitu ents are known to the State of California to cause cancer birth defects and other reproductive harm Northern Lights 4420 14th Avenue N W Seattle WA 98107 Tel 206 789 3880 Fax 206 782 5455 Copyright 2013 Northern Lights Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Northern Lights Inc Printed in U S A PART NO OM2 4 7 13 1 T RTHERN LIGHTS OPERATOR S MANUAL ZOM2 4 for Models M1064H and M1066H 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 2 Models Ineluded conce Debt erdt eerie tsarked 2 Model Numbers 2 Serial Numbers 0 4 0000 00000000000 2 2020 002020 5 3 SAFETY RULES etr ntu 3 7 LOCK OUT TAG OUT PROCEDURES 8 COMPONENT LOCATIONS M 10 RETE RR 11 ENGINE amp GENERATOR CONTROL PANELS eius 12 EMISSION RELATED INSTALLATION amp 13 OPERATING PROCEDURES Before SUITE
12. 4 Lube Oil Fill 11 Turbocharger 16 Fuel Manifold 22 Electronic Control Unit 5 Oil Filter 12 Heat Exchanger 17 Fuel Filter Secondary 6 Lube Oil Dipstick 13 Thermostat Cover 18 Aftercooler 7 Lube Oil Drain 2 4 7 13 10 Component Locations Figure 3 amp 4 M1066H 1 Coolant Fill 7 Lube Oil Drain 13 Optional Hydrolastic 18 Heat Shield 2 Expansion Tank 8 Starter Mounts 19 Junction Box 3 DC Alternator 9 Heat Exchanger Zinc 2 14 Drive Belt Cover 20 Electronic Control Unit 4 Lube Oil Fill 10 Turbocharger 15 Fuel Manifold 21 Optional PTO 5 Oil Filter 11 Heat Exchanger 16 Fuel Filter Secondary 6 Lube Oil Dipstick 12 Thermostat cover 17 Aftercooler 2 4 7 13 11 Northern Lights Control Panel Series 3 Generator Set Control Panel Shutdown Bypass Engine Control amp Preheat Swich Figure 5 Series 3B Generator Control Panel 1 SHUTDOWN BYPASS SWITCH This switch bypasses the safety shutdown feature during the starting process 2 ENGINE CONTROL SWITCH To start the engine hold this switch in the START position until the engine is running NOTE Excessive cranking of marine sets equipped with water lift muffler systems can cause engine damage After the engine starts release the switch and it will return to RUN position To stop the engine hold the switch in the STOP position 3 OIL PRESSURE GAUGE The oil pressure gauge shows the oil pressure in the engine lubricating system
13. OOS o 01 10S 5 SU oK m le Os ai HOLIMS AS 8 t 58 A l LON 0 IOHLNOO 3NI9N3 81507 02 Do am mp NAP D WIS 1915 Q a Ib I8 6 1 s om i 0b qui cm vid oe 9 Gu Mona 9 mA Passi 2 t Q38 M0113A ama ry ama u5 wr jay otto AV 13H o 13916 vet NM 7 an 8 SE TH 5901 zz d 7 Cs YOLDW 5315915 IDAZ ud anya a gg LLL LLL LLL LLL LLL 9 1 SION 1 ganz 9 au dif doi L 310N 338 MOVIE 101 5 1vN l1dO 50 S 308 HOV 13 ANIONS 01 SNIIIA 3 08 MDLYH3N3U 131 201 AB Tena JNIBN3 9 999 999 bi Av 13 lt TANVd 1041502 2 4 7 13 31 Board Spare Parts Safety at sea depends on careful preparation product knowledge and having the right tools and parts Below 1 a list of parts Northern Lights Inc recommends you carry onboard at all times Onboard Parts Kits are available from your dealer We consider these minimum quantities Your vessel s operating conditions may require more of a given part Consult your dealer Item Description Quantity 1 Lube Filter 4 2
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15. 4 5 cm below the filler cap sealing surface when the engine is cold When filling with coolant the venting cock on top of the turbocharger should be opened to ensure that no air pockets form in the cooling system see Service Point 14 CAUTION Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns The oil level should be between the waffled area and the Never allow the level to go below the Always add the same viscosity of oil as 1 already in the crankcase see Service Point 1 Check the fuel tank level and open any fuel valves Disengage clutch if equipped 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 l While holding the Shutdown Bypass switch in the ON position push the Engine Control switch to the START position As soon as the engine starts release both switches Do not crank the starter for more than 20 seconds If the engine fails to start the first time be sure the starter has stopped before re engaging Wait 2 min utes before starting engine again NOTE f there is a governor locked at a specific speed on the generator set there may not be a slow idle function so in tha
16. 5 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 m eben the waler from drain is clear free from SP20 RAW WATER PUMP discoloration and sediment close that drain When all drai losed flushing 1 lete j Heat exchanged cooled engines only 7 Fill the fresh water system by pouring the 1 Change the sea water pump impeller as needed recommended coolant mixture as described in previous sections 8 Close cooling system air vent on turbocharger 9 Open the seacock 10 Start the engine Check hoses and connections and a failed impeller W Clean the inside of the housing 4 Press in the new impeller and place the sealing washer in the outer end of the impeller center 1f this SP17 HEAT EXCHANGER CLEANING Cone 5 Replace the cover using a new gasket repair any leakage 1 Drain the cooling system Note Make sure there is always an extra impeller 2 Remove the cooling water pipes between the heat and cover gasket in reserve and on board exchanger and the water pump inlet 3 Disconnect hose to seawater pump DRIVEN EQUIPMENT 4 Unscrew the attaching bolts holding the heat Gears and PTO s exchanger to the expansion tank 5 Remove bolts holding heat exchanger cover 1 Manufacturer s service recommendations vary See 6 Wash the core inside and out If necess
17. 7 2 i 2 Heat exchanger cooled engines only OM2 4 7 13 32 CONTROL PANEL gt INTERCONNECT WIRING 5 38 BY OTHERS YELLOW RED START ENGINE S f SWTC SHUTDOWN BYPASS SWITCH HOURME TER GIL PRESSURE CAUGE ENGINE TEMP GAUGE DC VOLTMETER la ad NOTES Ts 2 ALL A D E INSTALLATION CONDUCTORS ARE TO BE 14 TYPE MTW 600VAC 1D5 C MULTISTRAND EXCEPT AS NOTED UNLESS COLOR CODED ALL A D E INSTALLED CONDUCTORS ARE TO HE GREY AND MUST BE IDENTIFIED BY WIRE MARKER AT EACH CONNECTION POINT REMOVE AND DISCARD REMOTE ON OFF AND FUEL HEATER CONNECTORS WIRE AS SHOWN ALL ENGINE MANUFACTURER WIRE HARNESS CONDUCTORS CONNECTED TO A D E PROVIDED CIRCUITRY ARE TO BE IDENTIFIED BY WIRE MARKER AT INTERCONNECTION POINT W MFR S WIRE CODE NO ALL UNTERMINATED MANUFACTURER WIRE HARNESS CONDUCTORS ARE TO BE ISOLATED USING APROPRIATELY SIZED HEAT SHRINK TUBING PINCH END WITH PLIERS WHILE HOT TO SEAL TERMINATION LOCATED IN GENERATOR J Q0x ORCUII BREAKER Wid RED n 0220 12 RED H10 SR 10 YELLOW RED 422 12 R ale 012A RED 0506 112 BLK 0205 426 BLK SEE NOTE ENGINE TENP N O 2 AME EE UL PRESSURE 2 SWITCH BLACK GREY CASE GND 0 80 PSI CASE GND 0 25DF CAN DIAG CONNECTOR X07 MOUNTED ON J BOX QA PLUG 1 91 A so
18. High Pressure Fluids Relieve pressure prior to disconnecting pressurized lines Escaping fluid under pressure can penetrate the skin causing serious injury Always relieve pressure before disconnecting hydraulic or other pressurized lines Tighten all connections firmly before re applying pressure If searching for leaks use a piece of cardboard Always protect your hands and other body parts from high pressure fluids If an accident occurs see a doctor immediately Any high pressure spray injected into the skin must be removed within a few hours to prevent the risk of gangrene or other infection Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns and bodily injury Pressurized lines can rupture when heat goes beyond the immediate flame area Do not weld solder or use a torch or open flame near pressurized lines or other flammable fluids Do Not Open High Pressure Fuel System Many Northern Lights engines use high pressure fuel injection High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt any repair of fuel lines sensors or other 2 4 7 13 6 Added 6 11 12 Safety Rules Continued components between the high pressure fuel pump material containing asbestos Keep all bystanders and nozzles on engines with high pressure fuel away from any area where asbestos dust may be
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20. from below so avoid that area as well while in service Safe Battery Handling Prevent Battery Explosions Battery gas is highly flammable Battery explosions can cause severe injury or death To help prevent battery explosions keep sparks lighted matches and open flame away from the top of battery When checking battery electrolyte level use a flashlight Never check battery charge by contacting the posts with a metal object Use a volt meter or hydrometer Frozen batteries may explode if charged Never charge a battery that has not been allowed to warm to at least 16 C 60 F Always remove grounded battery clamp first and replace ground clamp last Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin eat holes into clothing and other materials and cause blindness if splashed into eyes To Avoid Hazards Fill batteries only in well ventilated areas Wear appropriate eye protection and rubber gloves e Never use air pressure to clean batteries Wear appropriate ventilation equipment to avoid inhaling fumes when adding electrolyte Do not spill or drip electrolyte Use correct jump start procedure if required LAU wa eter aom LLLI ree on a If acid is spilled on skin or in eyes 1 Flush skin with water 2 Apply baking soda or lime to help neutralize acid 3 Flush
21. of main battery To Remove Generator Set from Long Term Storage Take off all protective coverings and unseal all the openings that were covered up 2 Install batteries that are fully charged and connect the terminals 3 Install the fan and alternator belts 1f they had been removed 4 Fill the fuel tank Perform all pre start checks a 6 Crank the engine for 20 seconds with the starter without letting the engine start Wait 2 minutes Battery Booster Battery and crank the engine an additional 20 seconds to make sure all bearing surfaces are well coated Figure 18 Booster Battery Connections 7 Start the engine and run at no load in a low idle for several minutes Make sure the engine is warmed 4 Then connect negative terminal of booster battery up and check gauges before going under load to ground on the engine block see Figure 18 8 Check all gauges and check for leaks 5 Remove booster battery after starting engine 6 Sealed batteries see manufacturer charging and SP30 AFTERCOOLER booster instructions 1 The aftercooler should be removed and inspected for deposits and the air side cleaned every 2000 hours OM2 4 7 13 25 Servicing If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer DC ELECTRICAL SYSTEM v Battery Will Not Charge Loose or corroded connections Clean and tighten battery connections Sulfated or worn out batteries Check specif
22. off or unplugging it while it is being worked on does not give enough protection to others who are not performing the maintenance or repair Many serious accidents happen when someone thought the machine was turned off or all of its energy was safely blocked or released General Policy CAUTION To avoid dangerous or hazardous situations refrain from any of the following e Removing or bypassing a guard or other safety device Placing any part of your body in a position where you could be caught by moving machinery Cleaning or oiling machinery when in operation Adjusting circuits chillers pumps air handlers valves circuit breakers or fans while in operation Working on piping or high pressure systems Lock Out Tag Out Instructions Electrical Equipment Be sure the equipment s ON OFF switch is in the OFF position and is unplugged from any electrical source before attempting to perform any type of work on the equipment Obtain an electrical plug cap cover with a lockset Secure the plug terminal end using the electrical plug lockout cap Lock the cap and retain the key If the equipment is directly wired into an electrical box with a shut off switch obtain a lock pad and or the appropriate colored tags and place the lock and tag through the shut off lever Retain the key until the repair is completed and the machine is safe to start Be certain the shut off lever is in the OFF position before restarting
23. systems generated ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH Use Proper Lifting Equipment and Techniques PRESSURE FUEL INJECTION SYSTEMS Lifting heavy components incorrectly can cause severe injury or damage to machinery Avoid unbalanced Avoid Hot Exhaust loads Do not use lifting eyes Lift the A Avoid exposure to and physical ae ae generator set using lifting bars inserted contact with hot exhaust through the lifting holes on the skid gases Exhaust parts and streams can reach high Follow all recommended removal and installation temperatures during operation leading to burns or procedures in this and associated Northern Lights other serious injury manuals Cleaning exhaust filters can also lead to exposure to hot exhaust gas and the injury risk associated with Use Proper Tools it Avoid exposure to and physical contact with hot aeae exhaust gases when cleaning exhaust filters A AUTION During auto or manual stationary exhaust filter Makeshift tools and procedures cleaning operations engine will run at can create safety hazards elevated temperatures for an extended period of Always use appropriate tools for time Exhaust parts and streams can reach high the job temperatures during operation leading to burns or other serious injury Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware always use the correct sized tools Avoid
24. 7 Check air intake hoses FUEL SYSTEM SP8 15 Check primary filter Racor 3 SP9 15 Change primary filter element Racor 3 4 SP10 14 Change secondary fuel filter 2 4 o TURBOCHARGER SP13 17 Check air amp cooling water lines for leakage 2 14 17 Check boost pressure SP26 17 Check crankcase vent system 2 7 SP30 21 Check aftercooler clean air side COOLING SYSTEM SP15 19 Check coolant level 16 19 Check and flush cooling system 2 6 e SP17 20 Check and clean heat exchanger 2 5 19 20 Check zinc electrodes 2 4 SP20 20 Change impeller in raw water pump 2 4 ELECTRICAL SYSTEM SP21 21 Check electrolyte level in batteries 2 4 SP22 21 Check condition of batteries with hydrometer _2 e SP23 Test thermostats SP29 Check electrical ground connection 1 Change the oil and filter before the first 100 hours of operation during engine 5 Replace damper every 4500 hours or after 60 months break in 6 Check cooling system at 500 hours flush at 2000 hours 2 Perform all maintenance once a year even if hour level has not been reached 7 Check hoses and o rings on crankcase vent system change 3 Consult manufacturer s maintenance schedule note on chart element at 500 hours 4 Whenever necessary OM2 4 7 13 15 Servicing LUBRICATION Break in
25. 70 Figure 9 fuel economy can be expected using a 20 blend and a fuel A Front of Engine Wes B No lPistonat TDC Compression Stroke conditioner is recommended Biodiesel blends must be used C No 4Piston at TDC Compression Stroke within 90 days of their manufacture Oil level leaking micro bial growth plugging and component degradation all must be checked more frequently using biodiesel blends Request a Adjust valve clearance on No 2 No 4 and No 6 certificate of analysis from an approved biodiesel fuel distribu exhaust valves and No 3 No 5 and No 6 intake tor to make sure the blend meets specifications valves NOTE Using raw pressed or partially refined vegetable oils or recycled greases as fuel which have not been through Install rocker arm cover and crankcase ventilator tube transesterification could cause engine failure Reconnect battery terminal SP8 10 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 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 b Use Grade No 1 at ambient temperatures below freezing and for all temperatures at an altitude of above 5 500 ft 1500 meter
26. Harmful Asbestos Dust Do not use US measurement tools on metric fasteners or vice versa Use only service parts that meet Northern Lights specifications Inhaling asbestos fibers may cause lung cancer Avoid breathing any dust that may be generated when handling components containing asbestos fibers including some gaskets CAUTION Disposing of waste improperly can threaten the Dispose of Waste Properly The asbestos used in these components is usually environment and lead to unsafe working conditions found in a resin or otherwise sealed Normal Potentially harmful waste used in Northern Lights handling of these components is not dangerous equipment can include oil fuel coolant filters and as long as airborne dust containing asbestos is not batteries generated Avoid creating dust Never use compressed air for Use leakproof containers to drain fluid Do not cleaning Avoid brushing or grinding materials use food or beverage containers that may mislead containing asbestos When servicing wear an someone into drinking from them approved respirator A special vacuum cleaner is recommended to clean asbestos If this vacuum 1 Do not pour waste onto the ground down a drain or not available apply a mist of oil or water on the into any water source OM2 4 7 13 7 Added 6 11 12 Lock Out Tag Out Procedures Scope During maintenance repairs or retooling of a Northern Lights generator set simply turning the machine
27. IN PERIOD 1 Your unit is fitted with a system to protect it from high water temperature or low oil pressure 1 Your engine is ready to be put into service How a Generator sets have shutdown systems to stop the ever the first 100 hours on a new or reconditioned engine They have no warning horns engine are critical to its life and performance b Other alarms and shutdowns are available as This is especially true of an engine that runs at a optional equipment constant speed such as a generator engine NOTE Do not rely on your warning or shutdown system to the exclusion of careful gauge monitoring 2 Operate the engine under various conditions Watching your gauges can prevent damage to the unit particularly heavy loads with minimal idling to and dangerous power losses help seat engine components properly 2 Dothe following when your shutdown system is 3 consumption is greater during break in as piston activated rings take time to seat a Check the temperature gauge If the temperature is above 205 F 97 C shut off the engine immediately Your engine comes equipped with break in oil b Use the Trouble Shooting Guide on pages 22 24 Change engine oil and filter at 50 hours using API to isolate the cause of the overheat Service Category CC CD or CE break in oil Change the oil and filter again at 100 hours CAUTION Do not remove the water fill cap of an sult the lubricants section for oil recommend
28. If the pressure drops below 15 PSI at a speed higher than idling stop the engine and investigate 4 COOLANT TEMPERATURE GAUGE Water temperature gauge shows the temperature of the cooling water If the gauge registers over 200 93 3 C or drops below 140 60 C stop the engine and investigate 5 HOUR METER Keeps track of the engine running time 6 DC VOLTMETER When the engine is running it indicates the voltage output of the alternator OM2 4 7 13 12 revised 3 19 13 Emission Related Installation amp Instructions Failing to follow these instructions when installing a certified engine in a vessel violates federal law 40 CFR 1068 105 b subject to fines or other penalties as described in the Clean Air Act The installed exhaust system should not create exhaust back pressure greater than 30 760 mm of water for a turbocharged engine and 48 1200 mm for a non turbocharged unit measured at the engine exhaust elbow If you install the engine in a way that makes the engine s emission control information label hard to read during normal engine maintenance you must place a duplicate label on the vessel as described 40 CFR 1068 105 Operating Procedures BEFORE STARTING l Check the oil level in the crankcase with the dipstick 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 1 3 4 in
29. NEVER give a lock out key to unauthorized personnel If the equipment is directly wired into an electrical box without a shut off switch and lock out capability then a circuit breaker lock out will be required Obtain a circuit lock and tag set Install the lock onto the circuit breaker box Ensure the unit ON OFF switch is in the OFF position before restarting Lock Out Tag Out Instructions Pneumatic and Hydraulic Equipment For servicing pneumatic and hydraulic equipment the following additional procedures must be implemented following completion of lock out tag out procedures for the unit to be serviced Shut off air water or supply valves at the equipment to be serviced Check the local bleed off point for completed release of pressurized air water or oil If shutting off of air water or other material cannot be achieved at the local supply valve shut off valves further back in the system and re check the bleed off point until complete shut off is achieved Affix a DO NOT OPERATE tag to each valve handle that requires shut off Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment Lock Out Tag Out Instructions Air Hose Connected Pneumatic Equipment Equipment connected to the compressed air system through an air hose with a detachable fitting must be shutdown and unplugged Excess air must be bled prior to removing the air hose prior to any maintenance or re
30. NTERCONNECTION POINT W MFR S WIRE CODE NO 9 ALL UNTERMINATED MANUFACTURER WIRE HARNESS CONDUCTORS ARE TO BE ISOLATED USING APROPRIATELY SIZED HEAT SHRINK TUBING PINCH ENO WITH PLIERS WHILE HOT SEAL TERMINATION REMOVE DISCARD REMOTE ON OFF AND FUEL HEATER CONNECTORS WIRE AS SHOWN OM2 4 10 04 31 CAN DIAG CONNECTOR X07 MOUNTED ON J BOX gt 918 LT 3 LT a4 lt 474 YELLOW 16 DK CREEN PLUS lt A mn lt mE e 7 419 16 WHITE _ oe 3 012 16 RED 0508 BLA gt C 2 475 116 ORANGE 0500 Pad DRANG gt al lt 424 1416 02 2 lt ma Grey s a 2 429 HE 23 018 ORANG E1 995 GRANGE 496 ontv Se T4 m 012 415 REG gt g K PLUG 0506 412 n zt REO 92 0129 318 RED SEE NOTE 5 12 8 Den nor 050 T poog a amp 8 SEE NOTE 5 EL 20 120 YELLOW uoc 749 9540 420 TENP ECU X07 DREY N v e BLACK ERES ELE gt nans 20 O PN uu 52 937 16 PURP N E 205 NE RNN ey ae 5 men H LOSS OF COOLANT 5 YELLOW 12 lt 467 PURPLE GREY 5 O K a PIG gt NS 381 16 BROWN CRANK SENSOR NC 911A 16 BROWN 447 20 PURPLE 447 are
31. R ENC v 6 BLK 1064 AT R D gt BLOCK 4 1005 E 4 BLK 1060 USED ON M1066 TD B 24 0 STARTER NOTOR 22 41648 9 IQ 33 CASE CND D C Wiring 24 Volt Standard Ground for M1064H amp M1066H Drawing D 3828 OM2 4 10 04 30 CONTROL PANEL Q RELAY BOARD _ gt 4 gt ENGINE pv Ommers 5 48 LOCATED GENERATOR J Bdx i CROUIT BREAKER i s C22 RED Enc Jeu queer T H1O RED 022D 12 RED ECU X06 FE d SA gt ni nuo SEE NOTE 6 22 09 5 REO 491 015 BROW gt 2 2K PLUG FUEL NERIA SR 217 Ai F3 E 954 YEU 493 ano K i H1O YELLOW RED 422 12 RED um lt o p eet o n NE m lt SHUTDOWN BYPASS SWITCH 870 RUN RELAY GAUCE n ENGINE CN GAUGE VOLTMETER NOTES 1 ALL A D E INSTALLATION CONDUCTORS ARE TO GE AWG 14 TYPE MTW 6OOVAC 105 C MULTISTRANG EXCEPT AS NOTED 2 UNLESS COLOR CODED ALL A D E INSTALLED CONDUCTORS ARE BE GREY AND MUST IDENTIFIED BY WIRE MARKER AT EACH CONNECTION POINT 3 TRANSIENT VOLTAGE PROTECTION INTEGRAL TO 65A ALTERNATOR 4 ALL ENGINE MANUFACTURER WIRE HARNESS CONDUCTORS CONNECTED TO A D E PROVIDED CIRCUITRY ARE TO BE IDENTIFIED BY WIRE MARKER AT I
32. SEQ 776 38 OL 5 1 SSINUVH O3IVNINS3INQ TIY 76 E la B a Xr 0319 3 4136 NO GASANN ZOX NOIO3NNOO v ap M NOILVM3dO ShONONH2OSI NMOHS SV 426 OL 116 123 02 ES INIOd 2 H2V3 HIANY 3MIM AB 3B LSNW 43X9 38 OL piece seni e ee D D pus SMO19n0NOO Q3TIVISNI 3 0v 03002 40709 5631 0 72 AJLON Sv ONY 43013 6 9315 SS3NHNVH 3MIM 3NION3 3HL 1d39X3 ONVYLSILIAW 72 50 2 009 MLN 3dAL 38 OL 3HV SYOLONGNOD NOLVTIVISNI TIV HILMO Old 231413313 DAZ NNauda WHO 002 F VAAVN 20 gt u zy ama 1 ow SALON LOX _YALSINNOD wz su avid A KING 81 S bl fle E U MalwH od amp LIE E 1 ir RN po ENT pue ty CNV A ndm _ mi 176 Wm Ad 56 me lt a aonva Ls Z nb 9 mansamod boe aD omes A lt VS Lu Y Lr T MOTTA 7
33. ainer label or consult with supplier PPLEMENTAL 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 Important heat exchanger cooled engines Additional SCA s should NOT be added to the mixture of EGC H 0 on initial fill up of engines with a coolant conditioner filter A high SCA concentration will result and can cause silicate dropout When this happens a gel type deposit is created in the cooling system which retards heat transfer and coolant flow If additional SCA s are needed prepare a mixture of 50 quality water and 5096 EGC antifreeze Add liquid SCA at a rate of 3 by volume Example 30 mL of SCA per liter of H O EGC mixture 1 0 fl oz of SCA per qt of Add the resulting mixture to the cooling system in quart increments Run the engine for 2 hours and retest the coolant Continue process until SCA concentration meets recommended levels SCA is available from your Northern Lights dealer in the following sizes Pint Part Number 20 00002 1 2 gallon Part Number 20 00003 DO NOT use any coolant system additives containing soluble oil CO 1 B OLANT TESTING Coolan
34. an cause sickness or death Work in well ventilated areas to avoid prolonged exposure to engine fumes If it is necessary to run an engine in an enclosed area route the exhaust fumes out of the area with an approved leak proof exhaust pipe extension Remove Paint Before Welding or Heating Hazardous fumes can be generated when paint is heated by welding soldering or using a torch To avoid 5 potentially toxic fumes and dust remove paint before heating Remove paint a minimum of 100 mm 4 in from the area that will be affected by heat f paint cannot be removed wear an approved respirator f you sand or grind paint use an approved respirator f you use solvent or paint stripper remove stripper With soap and water before welding Remove solvent or paint stripper containers from the area Allow at least 15 minutes for fumes to disperse before welding or heating Do not use a chlorinated solvent in an area where welding Will occur Work only in areas that are well ventilated Dispose of paint and solvent properly Service Cooling System Safely Opening a pressurized cooling system can release explosive fluids and causing serious burns Before opening any pressurized lt cooling system make sure the engine has been shut off Do not remove a filler cap unless it is cool enough to comfortably grip with bare hands Slowly loosen cap to relieve pressure before opening fully Avoid
35. ary chemical your Owner s Manual for service information If you agents can be used Also clean the accessible parts of do not have a manual see your local dealer for the the heat exchanger housing equipment in question 7 Reassemble using new gaskets and sealing rings NOTE Some PTO and marine gears have SP19 ZINC ANODES rigid lubrication requirements Follow service recommendations closely 1 Zincs are installed in the cooling system to protect your engine from electrolysis Check them faithfully Generator Ends every 250 hours If you are in warm salt water or where electrolysis is a known problem check them 2 The maintenance and operation recommendations more often for the generator end are in a separate Owner s Heat exchanger cooled engine Manual If you do not have one of these manuals a Drain the raw water from heat exchanger contact your local Northern Lights dealer see Component Locations OM2 4 7 13 24 2 Remove the pump end cover Remove impeller with water pump pliers Be sure you remove all pieces of Servicing ELECTRICAL SYSTEM GENERAL SP21 22 BATTERY CARE LEAD ACID TYPE BATTERIES 1 Never switch battery switch off or break the circuit 1 Check electrolyte level every 50 hours between the alternator and batteries while the engine or once per month Add distilled water to is running Regulator damage can result manufacturer s recommended level 2 DO reverse the polarity of battery cables wh
36. as Disconnect the water sensor wiring if equipped while grasping it with both hands If rotation can be felt the damper is defective and should be replaced Reproduced by permission of Deere amp Company c2004 Deere amp Company All rights reserved a g RG8018 Figure 10 A NOTE The vibration damper assembly should be j a REIN DEEP replaced every 4500 hours or 60 months whichever A Mule occurs first as the vibration damper assembly is not 2 ET repairable Place a dial indicator Figure 11 so that the probe contacts the damper s outer diameter in order to check the damper radial runout Make sure the engine is at operating temperature then rotate the crankshaft using the JD281A JDESI 4 or the JDE83 Flywheel Turning Tool c Loosen the filter drain plug on the bottom and drain the filters d Remove the filter by turning the filter clamp on the top while lifting up on the clamp while it 1s turning counter clockwise until the filter RAN uem sip ty a M N Figure 12 Filters If the runout reading exceeds the below specification replace the vibration damper Vibration Damper Maximum Radial BUHOUE 1 50 mm 0 060 in cartridge slides out NOTE Before installing a new filter cartridge make sure the surfaces where the cartridge comes in contact with the mounting plate are absolutely c
37. ation overheated engine Escaping high temperature steam can cause severe burns Allow the engine to cool and then remove the cap slowly using 5 Frequently check the engine temperature and oil protective clothing pressure gauges c Make repairs and restart after the temperature gauge registers below 180 F 83 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 Ifthe oil level 1 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 was normal DO NOT restart the engine Call your Northern Lights or Lugger dealer for assistance OM2 4 7 13 14 Updated 9 23 10 Service 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 EVERY 500 HOURS YEARLY SP1 Check oil level in engine SP4 Replace air cleaner SP8 Check primary fuel filter SP5 Check belt condition SP15 Check coolant water level SP9 Change primary filter eleme
38. cleaner Service air cleaner Improper valve clearance e See your dealer Electronic fuel system problem See your dealer Engine not at proper temperature Check your thermostats Check water temperature with thermometer and replace gauge if necessary Below Normal Engine Temperature Thermostats not working properly Check thermostats Temperature gauge not working properly Check water temperature with thermometer Low Oil Pressure Low oil level e Fill crankcase to proper level Improper type of oil e Drain and fill crankcase with correct oil Partially plugged oil filter Replace filter High Oil Consumption Break in period Oil consumption decreases after break in Crankcase oil too light Use proper viscosity oil Oil leaks Check for leaks in lines around gaskets and drain plug Engine Emits Black or Gray Exhaust Smoke Clogged or dirty air cleaner Service air cleaner Clogged aftercooler e Service aftercooler Defective muffler back pressure too high Have dealer check back pressure Improper fuel Use correct fuel for temperature Engine overloaded Reduce load OM2 4 7 13 28 e See your dealer Turbocharger not functioning e See your dealer Engine timing off e See your dealer Engine Emits White Smoke Improper fuel Use correct fuel for temperature Cold engine Warm up engine to normal operating temperature Defective thermostat Remove and check thermosta
39. contact numbers for fire department doctors ambulance and hospital near the telephone Service Machines Safely Do not wear a necktie scarf necklace rings or other jewelry or any loose clothing when working near moving parts Tie long hair behind your head If any of these items get caught in moving machinery severe injury or death could result Check for any loose electrical connections or faulty wiring Look completely around engine to make sure that everything is clear before starting Wear Protective Clothing To prevent catching anything in moving machinery always wear close fitting clothes and safety equipment appropriate to the job Prolonged exposure to loud noise can cause hearing loss or impairment Wear suitable authorized ED hearing protection such as earmuffs or plugs to 4 protect against loud noises CO E 6 A moving parts have stopped Operating equipment requires the full attention of the operator Do not use radio or music headphones while operating machinery Practice Safe Maintenance CAUTION Understand all service procedures before starting work Keep area clean and dry Never lubricate service or adjust machine while it is in operation Keep hands feet and clothing away from power driven equipment When shutting down an engine disengage all power and operator controls Allow the engine to cool completely before beginning any service work Se
40. cosity of oil is required a Remove plug from outlet in base frame Screw in owner supplied drain hose b Open valve at oil pan outlet After oil has been drained into suitable container close valve remove drain hose and replace plug in base frame outlet c Refill engine with recommended oil Engine Lube Oil Capacity M1064H 20 5 liters 31 5 liters M1066H SP3 CHANGING OIL FILTER Change the lube oil filter every 250 hours Use a filter wrench to remove old filter Dispose of filter in approved manner Make sure the gasket from the old filter is removed and discarded Lubricate the rubber gasket on the new filter and screw it on nipple until gasket meet the sealing surface Using hands only no wrench tighten filter one half turn farther Overtightening can do damage to filter housing Fill engine with recommended oil Start engine and check for leakage Stop engine and check oil level Add additional oil if necessary 4 AIR CLEANER oil level frequently 1 Inspect air cleaner every 100 hours Replace filter 5 Never put additives or flushing oil in crankcase every 500 hours or yearly whichever comes first 2 Clean the rubber tube at the cleaner Loosen the hose SP1 CHECK ENGINE OIL LEVEL clamp and the attaching strip for the cleaner 1 Check the oil level in the crankcase with the oil 3 Make sure the rubber tube is in good condition and that dipstick daily the new filter is absolutely clean and ins
41. curely support any machinery elements that must be raised for service work with support or lifting machinery specifically intended for that purpose Keep all parts in good conditions and properly installed Fix damage immediately Replace any worn or broken parts Remove any build up of grease oil or debris Disconnect battery ground cable before making any adjustments or service work Stay Clear of Rotating Drivelines Entanglement in rotating drivelines can cause serious injury or death Keep shields in place at all times Make sure that rotating shields turn freely in pace with the drivelines Do not wear loose fitting equipment around rotating drivelines Stop the engine and make sure that all before making any adjustments connections or performing any other type of service to the engine or other driven equipment Oy p 2 4 7 13 Added 6 11 12 Safety Rules Continued Install all Safety Guards Direct contact with rotating fans belts pulley and drives can cause serious injury Keep all guards in place at all times during engine operation Wear close fitting clothes Stop the engine and be sure all fans belts pulleys and drives are stopped before making adjustments connections or cleaning near fans and their components Do not allow anything on your person to dangle into or come in contact with a moving fan belt pulley or drive Fans can act as vacuums and pull materials up
42. dded to compensate for loss or leaks must meet engine coolant requirements outlined in previous section SP16 FLUSHING THE COOLING SYSTEM 2 4 7 13 23 CAUTION The cooling water 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 Servicing SP16 FLUSHING THE COOLING SYSTEM CONTINUED 1 Flush the cooling system and check for leaks and b Remove zinc holders from back of the tank and from front and port side of the heat exchanger L blockage every 2000 hours engine must be see Component Locations stopped and cold 2 Close the seacock 3 Remove the pressure cap from the expansion tank Keel Cooled engines a Drain expansion tank and remove zinc holder f k Locati with caution If applicable open the cooling system rom tank see Component Locations air vent on top of turbocharger 2 Scrape or steel brush the zinc electrode clean If more than 50 of the electrode has eroded away replace it with a new one The electrode screws out of the holder 3 Reinstall the zinc holders Be sure the threads are clean and have good metal to metal contact 4 Open the drains on the exhaust manifold and engine block Drain the fresh water system see Component Locations pages 4
43. dealer Improper valve clearance Reset valves Best done by dealer OM2 4 7 13 27 v Engine Overheats Engine overloaded Reduce the load Low coolant level Hil tank or radiator to proper level Check hoses for loose connections and leaks Keel cooling tubes have been painted marine Remove paint from tubes Stretched belt or defective belt tensioner Check automatic belt tensioner and check belts for stretching Replace as required Low engine oil level Check oil level add oil as needed Incorrect grade of fuel e Use correct grade of fuel Cooling system needs flushing e Flush cooling system Defective thermostat e Remove and check thermostat Defective temperature gauge Check water temperature with thermometer and replace gauge if necessary Water pump impeller worn broken Check impeller and replace if necessary Engine Knocks Low oil level e Add oil to engine crankcase Below normal engine temperature Check your thermostats Check water temperature to see if temperature gauge is working properly Engine overheating See Engine Overheating section Troubleshooting If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer v High Fuel Consumption Electronic fuel system problem Engine overloaded Reduce load Air in fuel system Bleed fuel system Improper type of fuel Use correct fuel for temperature Clogged or dirty air
44. e flywheel one complete turn and reinstall the timing pin in the flywheel 4 Valve clearances Intake Valve 0 014 in 0 36 mm Exhaust Valve 0 018 in 0 46 mm 5 Ifthe valves need adjusting loosen the jam nut A on Figure 7 on the rocker arm adjusting screw Turn the adjusting screw until you feel a slight drag when the feeler gauge slips With a screwdriver hold the adjusting screw from turning while tightening the jam nut to specifications Check the clearance again after tightening the jam nut Re adjust as needed Valve Clearance Adjustment Specifications Intake Valve Adjustment Clearance Rocker arm to bridge 0 36 mm 0 014 in Exhaust Valve Adjustment Clearance Rocker arm to bridge 0 46 mm 0 018 in Rocker Arm Adjusting Screw Jam Nut te deseos ies 27 Nem 20 lb ft Reproduced by permission of Deere amp Company c2004 Deere amp Company All rights reserved RG12169 Figure 7 4 CYLINDER ENGINES Lock No 1 piston at TDC compression stroke Figure 8 B Adjust valve clearance on No 1 and No 3 exhaust valves and No 1 and No 2 intake valves Rotate flywheel 360 Lock No 4 piston at TDC compression stroke Figure 8 Note Firing Order is 1 3 4 2 Reproduced by permission of Deere amp Company c2004 Deere amp Company All rights reserved RG12357 Figure 8 A Frontof Engine No 1Piston at TDC Compression Stroke
45. en 2 Batteries cables and cable terminals should be installing the battery checked and cleaned every 100 hours Clean corro 3 When welding on the unit disconnect the regulator sion with a water and baking soda solution Flush and battery Isolate the leads with clean water Tighten terminals and 4 Disconnect battery cables when servicing the DC grease them to inhibit corrosion alternator 3 Check the battery condition with a hydrometer 5 Never test with a screwdriver etc against any every 500 hours terminal to see if it emits sparks 6 A DC circuit breaker protects your control panel and SP24 WINTERIZING OUT OF SERVICE wiring harness If the generator set will not be used for more than 6 months the following preparations should be taken for BOOSTER BATTERIES long term storage 1 Change the engine oil and replace the filter A CAUTION Battery Gas Can Explode Keep all Service the air cleaner flames and sparks away from batteries 2 Drain flush and refill the cooling system 3 Crank the engine a few times with a starter 1 Before changing or using booster batteries check without starting the engine battery electrolyte level Add distilled water 4 Remove and clean batteries 2 Booster and main batteries must have the same 5 Allengine openings should be sealed with plastic voltage rating bags and tape 3 First connect positive terminal of booster 6 Store in a dry protected place battery to positive terminal
46. ensor 15 D measures the temperature of the pump housing Fuel outlets 15 C are on the top and bottom of the pump Reproduced by permission of Deere amp Company c2004 All rights reserved RG12459C Figure 16 High Pressure Common Rail Operation Two high pressure pump delivery lines Figure 16 A deliver fuel to the high pressure common rail Fuel is transported to the electronic injectors through the high pressure common rail delivery lines 16 E The fuel pressure inside the rail is detected by the fuel rail pressure sensor 16 B The ECU uses this sensor in monitoring the fuel pressure to determine timing of the pump control valve on the high pressure fuel pump If unusually high pressure occurs within the HPCR the pressure limiter 16 C is used to release the excess pressure and drain fuel back to the tank The maximum fuel flow to the electronic injectors is controlled by the flow dampers 16 D and help prevent damage if the electronic injector fails or a high pressure leak develops by shutting off fuel to the electronic injector in trouble SP13 TURBOCHARGER 1 Check for air leaks every 100 hours Air leakage will lower engine output and may cause black exhaust smoke and soot 2 Listen along air line while engine is running A whistling or hissing sound indicates leakage 3 Leakage on the pressure side between turbo and engine can be found by applying soapy water to the air line 4 Tighten the hose clamps
47. eproduced in this manual Consult the suppliers for additional safety information Learn how to operate the machine and how to use the controls properly Only trained personnel should operate machines or work on or around them Keep you machine in proper working condition UNAUTHORIZED MODIFICATIONS TO THE MACHINERY MAY IMPAIR ITS FUNCTION AND SAFETY PARAMETERS Prevent Bypass and Accidental Starting Do not start engine by shorting across start terminal Engine will start if normal circuitry is bypassed creating a hazard by runaway machinery Start engine only from operator s station Handle Fuel Safely Avoid Flames Diesel is highly flammable and should be treated with care at all times Do not refuel while smoking or when near sparks or open flame S ALWAYS STOP ENGINE BEFORE FUELING MACHINE Always fill portable fuel tank outdoors Never fuel a hot engine 2 4 7 13 3 Added 6 11 12 Safety Rules Prevent accidental discharge of starting fluids by storing all cans in a cool safe place away from sparks or open flame Store with cap securely on container Never incinerate or puncture a fuel container Prevent fires by keeping machine clean of accumulated trash grease and debris Always clean any spilled fuel as swiftly as possible Do not store oily rags which can ignite and burn spontaneously Be prepared if a fire starts Keep a first aid kit and fire extinguisher handy Keep emergency
48. eyes with water for 15 30 minutes 4 Get medical attention immediately If acid is swallowed 1 DO NOT induce vomiting 2 Drink large amounts of water or milk without exceeding 2 liters 2 quarts 3 Get medical attention immediately tant a 441 AL H i o um E Battery posts terminals and related accessories can contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injury Among the potentially hazardous chemicals that may be used with Northern Lights products are lubricants coolants paints and adhesives All potentially hazardous chemicals come with a Material Safety Data Sheet MSDS The MSDS provides specific details on chemical products including physical hazards safety procedures and emergency response techniques OM2 4 7 13 5 Added 6 11 12 Safety Rules Continued Read and understand the MSDS for each chemical before you start any job that includes it Follow the procedures and use appropriate equipment exactly as recommended Contact your Northern Lights dealer or Northern Lights factory for MSDS s used on Northern Lights products Work in Well Ventilated Areas CAUTION Exhaust fumes from engines contain carbon monoxide and c
49. ft water is preferred for use in cooling systems Bottled distilled water from a food store or water supplier is recommended Tap water often has a high mineral content Tap water should NEVER be put in a cooling system unless first tested by a water quality laboratory Do not use water made by the reverse osmosis method unless it has been PH neutralized 2 Here are acceptable water quality specifications 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 3 If chlorides sulfates or total dissolved solids are higher than the above given specification the water must be distilled demineralized or deionized before it is used in a cooling system 4 If total hardness is higher than 170 ppm and all other parameters are within the given specifications the water must be softened before it is used to make coolant solution EGC ETHYLENE GLYCOL CONCENTRATE ANTIFREEZE CAUTION EGC Antifreeze is flammable A Keep it 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 Call a physician KEEP OUT OF REACH OF CHILDREN Follow all warnings on the container 1 Ethylene glycol coolant concentrate is commonly mi
50. hese procedures see your Lugger or Northern Lights dealer v Engine Runs Irregularly or Stalls Frequently Below normal engine temperature e Remove and check thermostat Clogged primary fuel filter element Clean or replace filter element Clogged secondary fuel filter element Replace secondary filter element Water or dirt in the fuel system Drain flush fill and bleed system Dirty or faulty injection nozzles Have your dealer check injection nozzles Air in fuel system nspect clamps and hoses on suction side of fuel pump for air leak bleed fuel system Improper type of fuel Consult fuel supplier and use proper type of fuel for operating condition Lack of Engine Power Intake air restriction Service air cleaner e Service aftercooler Clogged primary fuel filter element e 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 Electronic fuel system problem e See your dealer Turbocharger not functioning if equipped e See your dealer Leaking exhaust manifold gasket e See your dealer Defective aneroid control line e See your dealer Restricted fuel hose Clean or replace fuel hose Low fast idle speed e See your
51. hten loose connections Starter and Hour Meter Function but rest of Electrical System Does Not Function Blown fuse on magnetic switch Replace fuse Entire Electrical System Does Not Function Check DC circuit breaker e If breaker is tripped reset it Faulty connection e Clean and tighten battery and harness plug connections Sulfated or worn out batteries Check specific gravity and electrolyte level of each battery cell ENGINE v Engine Hard to Start or Will Not Start Engine starting under load Disengage PTO if applicable Improper starting procedure e See starting section of this manual Take special note of Bypass Switch operation No fuel Check level of fuel in fuel tank Low battery output e Check electrolyte level and condition Excessive resistance in starting circuit Clean and tighten all battery connections Crankcase oil too heavy Use oil of proper viscosity Improper type of fuel Consult fuel supplier and use proper type of fuel for operating condition Water dirt or air in fuel system Drain flush fill and bleed system Clogged primary fuel filter element Clean or replace filter element Clogged secondary fuel filter element Replace filter element Electronic Fuel System problem e See your dealer Injection pump not getting fuel or air in fuel system Check fuel flow at supply pump or bleed fuel system 2 4 7 13 Troubleshooting If you cannot correct problems with t
52. ic gravity of each battery cell Check electrolyte level of each battery cell Loose or defective alternator belt Adjust belt tension Replace belt Undercharged Electrical System Excessive electrical load from added accessories Take off accessories or install higher output alternator Engine idling excessively ncrease the engine RPM when there is a heavy electrical load Poor electrical connections on battery ground strap starter or alternator nspect connections and clean if necessary Defective battery Test battery Battery charging rate too high Test charging system Starter Inoperative PTO engaged Disengage PTO Check DC circuit breaker e Ifthe breaker is tripped reset it Faulty start circuit relay See dealer Blown main system fuse Replace fuse Loose or corroded connections Clean and tighten loose battery and harness plug connection Low battery output Check specific gravity of each battery cell e Check electrolyte level of each battery cell Defective electrical system ground wire Repair or replace Starter Cranks Slowly Low battery output e Battery is too small Battery cables are too small Check specific gravity of each battery cell Replace battery if necessary Check electrolyte level of each battery cell If low fill cells with distilled water Crankcase oil too heavy Hil with oil of appropriate viscosity Loose or corroded connections Clean and tig
53. ir accessories can cause bodily harm and life threatening injuries when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL PRIOR TO THE INSTALLATION OF ANY GENERATOR SET OR ACCESSORY KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE Recognize Safety Symbols and Instructions In addition to the information found in this section this operator s manual uses three different signal words to outline potential dangers of a specific nature T D ANGE DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a hazardous situation which A CA UTION if not avoided could result in minor or moderate injury Follow All Safety Instructions Carefully read and understand all safety messages in this manual and on your machine s safety signs Keep signs in good and clean condition Replace missing or damaged signs Be sure new equipment components and repair parts include the current safety signs For replacement signs proper placement of safety signs or clarification on any safety issue consult your Northern Lights dealer or the factory There can be additional safety information contained on parts and components from outside suppliers that is not r
54. lean Dirt can be washed into the fuel injection system This may result in severe damage to the fuel injection pump or nozzles Do not prefill the new fuel filter as the fuel used may be contaminated and damage the fuel system components e Install new filter cartridge f Filter cartridge numbers are 2nd number is water separator Reproduced by permission of Deere amp Company c2004 Deere amp Company rights M1064H 509031 and 509208 reserved M1066H 509032 and 509036 RG7508 Figure 11 g Turn on the fuel OM2 4 7 13 19 Servicing FUEL SYSTEM CAUTION DO NOT OPEN THE HIGH A PRESSURE FUEL SYSTEM Serious injury can be caused by the high pressure fluid in the fuel lines Do not disconnect or attempt to repair fuel lines sensors or any components between the high pressure fuel pump and nozzles on engines with High Pressure Common Rail HPCR fuel system See your dealer for qualified technicians to perform these repairs Reproduced by permission of Deere amp Company c2004 All rights reserved E RG12221 Figure 14 NOTE Altering or modifying the injection pump the injection pump timing or the fuel injectors in ways 2 Operate the fuel supply pump primer lever not recommended by the manufacturer will result Figure 14 B or primer button on fuel filter base in the termination of the warranty obligation to the if equipped until fuel flows out of bleed vent scre
55. nt Racor SP26 Check crankcase vent system filter svc indicator button SP10 Change secondary fuel filter AFTER FIRST 50 HOURS SP14 Check turbocharger boost pressure SP2 Change engine oil SP16 Check cooling system SP3 Change lube oil filter SP20 Change impeller in raw water pump EVERY 50 HOURS SP22 Check the state of the charge of the batteries SP21 Check electrolyte in batteries SP25 Check engine mounts AFTER FIRST 100 HOURS EVERY TWO WEEKS SP26 Clean crankcase vent system change element at 500 hrs SP2 Change engine oil after first 100 hrs then check every 2 wks SP27 Check air intake hoses SP3 Change oil filter after first 100 hrs then check every 2 wks SP29 Check electrical ground connection SP7 Check crankshaft vibration damper SPIS SP6 Check amp adjust valve clearance EVERY 250 HOURS SP7 Check crankshaft vibration damper TP SP16 Flush cooling system SP2 Change engine oil SP17 Check and clean heat exchanger SP3 Change oil filter SP23 Test thermostats ea SP30 Check aftercooler clean air side SP19 Check zincs SERVICE 100 2000 POINT OPERATION DAILY Hours Hours ENGINE SP1 12 Check oil level SP2 12 Change engine oil 2 1 1 SP3 12 Change lube filters 2 1 1 5 4 12 Check air cleaner SP5 Check belt condition 2 SP6 13 Check valve clearances 2 e SP7 15 Check crankshaft vibration damper 5 25 Check engine mounts SP2
56. oil Use one of following during the first 100 hours of operation a John Deere Engine Break In Oil b API Service Category CC CD or CE oil ACEA Specification Do not use John Deere PLUS 50 oil or engine oils meeting API CG4 API CF4 ACEA or ACEA E2 performance levels during the first 100 hours of operation of a new or rebuilt engine These oils will not allow the engine to break in properly Lubrication General L 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 ACEA Oil Sequence E5 and E4 b API Service Category 4 or CH 4 c ACEA Oil Sequence multi viscosity oil 3 Use the proper weight oil for your average operation temperature Air Temperature Multi Viscosity Single Viscosity Above 32 F 0 C SAE 30W 10 to 32 F 23 C to 0 Below 10 F 23 C SAE15 40W SAE10 30W SAE 10W SAE 5W SAE5 20W Some increase in oil consumption may be expected when SAE 5W and SAE 5 20W oils are used Check SP2 OIL CHANGES 1 Using the oil recommended above change the engine oil and filter after the first 50 hours of operation the first 100 hours and every 250 hours thereafter During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes first Change oil at any seasonal change in temperature when new vis
57. pair activities Affix a DO NOT OPERATE tag to the air hose near the detachable fitting Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment Check that the equipment cannot be operated by activating the ON switch Stored E Immediately after applying Lock Out or Tag Out devices ensure that all potentially hazardous stored or residual energy is relieved disconnected restrained and otherwise rendered safe Verification of Isolation CAUTION Verify the machinery or equipment is actually isolated and de energized prior to beginning work on a machine or on equipment that has been locked out Restarting Procedures CAUTION Follow the procedures below prior to restoring energy Ensure that all machinery or equipment is properly reassembled Inspect the machinery or equipment to verify non essential items have been removed e Ensure that all personnel are safely outside danger zones Notify personnel that lock out tag out devices have been removed and energy will be reapplied Only authorized personnel may remove lock out tag out devices or notices 2 4 7 13 8 Notes OM2 4 7 13 9 Component Locations Figures 1 amp 2 M1064H 1 Coolant Fill 8 Electric Starter 14 Optional Hydrolastic 19 Heat Shield 2 Expansion Tank 9 Heat Exchanger Zinc 2 Mounts 20 Junction Box 3 DC Alternator 10 Oil Pan 15 Drive Belt Cover 21 Wet Exhaust Elbow
58. r set with a John Deere generator set with a John Deere Powertech Tier 4045 engine block with an Powertech Tier 6068 engine block with electronically controlled fuel system high an electronically controlled fuel system pressured common rail high pressured common rail Serial Numbers When referencing Northern Lights equipment by serial number please refer only to the number stamped on the Northern Lights serial number plate NORTHERN LIGHTS Serial No Model No NORTHERN LIGHTS Northern Lights Northern Lights 4420 14th Ave N W 4420 14th Ave NW Seattle WA 98107 206 789 3880 Seattle WA 98107 o o ooo Generator Set Data Set Serial No 2 4 7 13 Revised 7 10 13 Warranty A warranty registration certificate is supplied with your set The extent of coverage is described followed If further information is needed please contact an authorized dealer or the factory in the Limited Warranty Statement We recommend that you study the statement carefully NOTE If the warranty is to apply the SeNGaraty Rules instructions outlined 1 i NOTICE Accident reports show that careless use of engines causes a high percentage of accidents You can avoid accidents by observing these safety rules Study these rules carefully and enforce them on the job IMPORTANT SAFETY INSTRUCTIONS Electromagnetic equipment including generator sets and the
59. replace hose or gaskets as required 5 Check to see that the lubrication and cooling lines are tight and without leaks SP14 TURBO BOOST 1 This check measures the amount of air the turbo is pushing into the engine It should be done by an authorized dealer every 500 hours 2 On the inlet manifold there is a 1 8 NPT threaded port Remove the plug and install the boost gauge hose Refer to your engine specifications for correct pressure SP26 CRANKCASE VENT SYSTEM 1 For sea water aftercooled units the crankcase vent system is a good option and now standard equipment for M1064H and M1066H units as of July 2008 Check the red filter service indicator button daily if it pops up the filter element needs to be changed After changing the element unscrew the clear plastic cover on the button and push the indicator down to reset it then replace the cover Note This service should be performed with the engine shut down The vacuum in the filter canister because of engine operation may make it difficult to take apart Normally the filter element should be changed every 750 hours COOLING REQUIREMENTS 1 To meet cooling system protection requirements the coolant solution must consist of a Quality water b Ethylene glycol concentrate EGC commonly known as antifreeze c Supplemental coolant additives SCA s 2 Acoolant solution of ethylene glycol concentrate EGC antifreeze quality water and supplemental coolant additi
60. roprietary 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 OM2 4 7 13 OM2 4 7 13 1 Introduction Servicing of marine engines and generator sets pres Failures begin with minor problems that are overlooked ents unique problems In many cases boats cannot be and become amplified when not corrected during rou moved to a repair facility Marine engines cannot be tine maintenance compared to the servicing of automobiles trucks or even farm equipment Failures often occur in remote As operator it is your obligation to learn about your areas far from competent assistance Marine engines equipment and its proper maintenance This is not a are taxed far more severely than auto or truck engines comprehensive technical service manual Nor will it therefore maintenance schedules must be adhered to make the reader into an expert mechanic Its aim is to more strictly aid you in maintaining your unit properly Model Numbers Model numbers give the unit s application block model aspiration and RPM M 1064 or 1066 H High Powered M Northern Lights marine generator set 106 mm bore 4 Cylinder Or 106 mm bore 6 Cylinder Northern Lights turbocharged marine Mi066H Northern Lights turbocharged marine diesel generato
61. s 2 Sulphur content should not exceed 0 5 preferably less than 0 5 3 The cetane number should be a minimum of 45 DO NOT use these unsuitable grades of fuel a Domestic heating oils all types Class B engine Class D domestic fuels by the filter manufacturer Empty the collection bowl as necessary b Change the element every 500 hours or whenever necessary c If the bowl fills with water change the primary and secondary elements immediately 2 Change secondary fuel filter every 500 hours NOTE The fuel filter on the engine is considered the secondary fuel filter The engine will be fitted with a quick change disposable secondary fuel filter b c Class E F G or H industrial or marine fuels e ASTM D975 60T No 4 D and higher number fuels or JP4 OM2 4 7 3 18 Servicing SP7 CRANKSHAFT VIBRATION DAMPER SP8 10 FUEL FILTERS Continued 6 Cylinder Engines Only Remove belts A CAUTION Serious injury can result from escaping Try to turn the vibration damper in both directions high pressure fluid Relieve pressure before disconnecting fuel or other lines Before applying pressure tighten all connections Do not use your hand to search for leaks use a piece of cardboard or paper Gangrene could develop if fluid is accidentally injected into the skin a doctor needs to surgically remove the fluid within a few hours of the accident a Turn off the fuel b Clean filter assemblies and surrounding are
62. t Engine out of time e See your dealer d6cvL g SULMEJQT JojejnDeu Z L 90AV H990LIN HY90LIN BULIM O V SLINN ALNG 3NISVW 3043 Q31VOIGNI SV Q3838WfN OL 50 41 YSLVSH 519018 3MIM 9019 310d 338Hl 3AOW33 NOlLVM3dO NI SI 31IHM SH3IV3H 3ZI9H3N3 LON OG SNISN3S 3SvHd 3I9NIS 303 6 P9 SIVNIWH3L N33M138 sS3dWnf SAOWSY NOLLV HdO ALOWA 33dOSd 3SIMMOO TO ATINA YSLAWOILNALOd ISNPAV 39VL1OA TWNYSLNI 3HL NYNL 70450 SI LVLSOSHY 15 39VI1OA SLOWSY V dl Z ANY v STIVNINYSL NSSML98 3AOWGMH MOLOnQNOO WYLNSN ON LNIOd Hevised 6 11 12 AC Wiring Diagram SALON 33S dqaioatosd 2 2 671 2 0 2 002 OL 193NNOO 88 TWULASN 110 ONING LON OG Q3MIQO3M LON SI 39VIL1OA N 1 N3MOJ 3l CLL A8 ANVLIOA OL ONIGIAIG GNNOS WaLNAN N33M138 39VLIOA 740002 OlHIOd3l3 TWNOILWN dO 8 916 3ONVIIdWOO NI JONVYO Q3 NVW 38 OL 931 H9IH OML INN INIOd NOILO3NNOO HOV3 LV 38IM A8 Q3lJILN3GI LSNW ANY AVM9 38 OL 3MV SYOLONGNOO QG3TIVISNI NN dadoo SS3INn 72 Q3aNVMIS 5 501 dies OV ALON 33S 3024005 031931034 2 021 001 OL LOANNOO 2 009 MLW 3dAL SMV 38 OL SYOLONGNOD NOILWIIVLSNI dius cH LLYM 062 2 021
63. t case operate the engine at high idle for 1 to 2 minutes before adding load If the stand by generator set is loaded as soon as it reaches rated speed this procedure would not apply Operating Check Gauges Often Oil pressure must be above 20 PSI if not above 15 PSI within 5 seconds of starting the engine should be stopped and the problem should be explored Normal oil pressure is 50 PSI at rated load speed 1800 to 2500 RPM Oil temperature should be 115 C 240 F for normal operating temperature The D C voltmeter should read between 13 and 14 volts 26 28 volts 24 volt systems 2 Check AC voltage and frequency meters Series 4 Panel If gauges deviate from normal levels shut down the set and investigate 3 Check belt for good alignment 4 Letthe unit run unloaded for a three to five minute warm up period before applying load 5 Do not add full electrical load until engine is at maximum operating temperature NOTE If engine dies while under load immediately remove load and restart engine Turbocharger parts could overheat if the oil flow stopped Shutdown Turn the Engine Control Switch to the OFF position 2 Close the sea cock and fuel valves and put the battery switch in the OFF position if the unit will be for an extended period NOTE Do not turn the battery switch to OFF while the engine is running 2 4 7 13 13 Updated 3 19 13 Operating Procedures SHUTDOWNS AND ALARMS BREAK
64. t test kits are available to allow on site evalu ation of the coolant condition The kits use small strips of paper which are dipped into the coolant The paper changes color and indicates the SCA concentration It also indicates the amount of EGC antifreeze Test kits are available through your Northern Lights or Lugger Dealer 4 Pack Part Number 50 Pack Part Number 20 00005 20 00010 SP15 CHECKING COOLANT LEVEL CAUTION The cooling water the engine reaches extremely high temperatures You must use extreme caution when working on hot engines to avoid burns Allow the engine to cool before work ing on the cooling system Open the filler cap carefully using protective clothing when the engine is warm Check the coolant level each day before starting the engine Remove the pressure cap from the expansion tank and check water level In order to give the coolant an opportunity to expand the level should be about 1 3 4 in 4 5 cm below the filler cap sealing surface when the engine is cold When filling with coolant the venting cock on top of the turbocharger for engines fitted with turbocharger should be opened to ensure that no air pockets form in the cooling system The pressure valve in the filler cap releases when the pressure 15 approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it 1s faulty The makeup coolant a
65. talled properly 2 The oil level must be between the Waffled area and 4 Start the engine and check for leaks the Never allow the level to go below the NOTE Make absolutely sure no impurities enter the 3 Always add the same viscosity of oil as is already in engine while changing the element Do not run the the crankcase engine with the air cleaner removed 2 4 7 13 16 Servicing SP6 VALVE CLEARANCES A CAUTION Disconnect the negative battery terminal before starting valve adjustments to prevent accidentally starting the engine Valve clearance must be checked and adjusted with the engine cold The following special tools will be needed JDE 820 or JDE 83 Flywheel Turning Tool JDE 81 4 Timing Pin 1 Remove rocker arm cover with ventilator tube NOTE Inspect the valve tips bridges rocker arm wear pads and contact surfaces for cracks or excessive wear Replace parts that show damage 2 Remove plastic plugs or cover plate in engine timing holes on front side of flywheel Figure amp B Reproduced by permission of Deere amp Company c2004 Deere amp Company rights reserved RG12168 Figure 6 3 Rotate flywheel in clockwise direction viewed from water pump with the Flywheel Turning Tool until the Timing Pin engages timing hole in the flywheel Both rocker arms for No cylinder will be loose at Top Dead Center If not remove the timing pin and rotate th
66. u 2 gti ZH on Lan 03395 w Xvid TA 990 LIN 8 HEP9O0LIA 2 ere 1621 99012 1 900 HIXIL 3NONJ _ gu an Mitek MUR ote SSS CREE Le SONILLIS HOLIMS G3adSHIAO TVNOILdO WNOILdO M o o stc Pcr 1755 Od F 302 Hd3SNI NMOQGInHS 04 QE 7 HANS _____ __ ery AINO HOLIMS 15 HOLIMS N31VM 0 1003 TTT TTT TTT a 3380 71 hc O31VOIONI INIOd LV 9078 3NIO9N3 OL ONNOYD Rp E ERN NUNC EN MR DEN ie AINO QN3 030NnON 38 Ol SI GTFIHS Q31SIML 6 om M MM LE M MCN iovi a 310 Sv 1d39X3 A009 2 50 ONVMLSILINN 1X9 m c 912 9 OMY 38 OL 38 SYOLOMGNOD SS3NBVH 3BIM 3NION3 TIV 10 CEDE REC re 2 i 5 MAE Lamma H MIN 3dAL 9 38 OL SYOLONGNOD 73Nvd 1081 09 v S Z o Sa ee eS AE 58 a3sn m 3NON3 j 28 NOUVOIddV 3d 03123736 57 108109 0334 79 NOILVNINS3L 7 35 OL 10H STIHM SH3lld ON3 HONId SEXE ONIBQL NiBHS 03215 AlilvisdOSdv ONISN Q31v 10S p
67. ves 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 3 Ethylene glycol coolant concentrate antifreeze normally DOES NOT contain the SCA chemical inhibitors needed to control liner pitting or erosion rust scale and acidity LINER EROSION PITTING 1 Cylinder liner walls Figure 17 A which are in con tact with engine coolant Figure 17 B can be eroded or pitted unless the proper concentration and type of SCA s are present in the coolant Water pump impellers are also susceptible to pitting OM2 4 7 13 Servicing LINER EROSION PITTING CONTINUED 2 Vapor bubbles Figure 17 C are formed when the piston s impact causes the liner walls to vibrate sending pressure waves into the coolant 3 These tiny vapor bubbles collect on the surface of metal parts As the bubbles collapse pop a microscopic piece of metal is eroded from the metal part Over a period of time this pitting may progress completely through the cylinder liner of a wet sleeve heavy duty diesel engine This allows coolant to enter the combustion chamber Engine failure or other serious damage will result A Cylinder Liner Walls Engine Coolant C Vapor Bubbles Figure 17 4 Unprotected engines with low quality water as coolant can have liner failure in as few as 500 hours WATER QUALITY 1 Distilled deionized so
68. w Also tampering with the fuel system that alters 3 Tighten the bleed vent screw securely Con emission related equipment on engines could result tinue operating primer until pumping action is in fines or other penalties per EPA regulations or no longer felt other local emissions laws 4 See your dealer for qualified technicians to perform repairs on the injection pump or fuel injectors Denso HP3 High Pressure Fuel Pump Operation If the engine does not start repeat 1 4 The fuel inlet Figure 15 A is the location where the filtered fuel enters the high pressure pump After the fuel goes through the inlet it continues through a fuel inlet filter and then goes through an internal transfer pump Reproduced by permission of Deere amp Company c2004 rights reserved RG12220 Figure 13 Bleeding the Fuel System NOTE Four valve cylinder head engines are sensitive to fuel contamination Do not crack any fuel lines to bleed the fuel system Reproduced by permission of Deere amp Company c2004 All rights reserved RG12465B Figure 15 1 On the fuel filter base loosen the air bleed vent screw Figure 13 A by hand two full turns OM2 4 7 13 20 Servicing There is a chamber at the top of the pump and at the bottom that holds fuel This fuel is pressurized in each chamber when the pump camshaft rotates Excess fuel goes through the overflow orifice 15 B back to the fuel tank The fuel temperature s
69. xed with water to produce an engine coolant with a low freeze point and high boiling point 2 low silicate form of ethylene glycol coolant is recommended for all diesel engines 3 Use an ethylene glycol coolant concentrate meeting ASTM D 4985P SAEJ1941 General Motors Performance Specification GM1899M or formulated to GM6038M 4 This product is concentrated and should be mixed to the following specification 5 If additional coolant solution needs to be added to the engine due to leaks or loss the glycol concentration should be checked with a hydrometer to assure that the desired freeze point is maintained Distilled EGC Freeze Boiling Water Antifreeze Point Point E 37 109 Optimum 50 50 226 24 106 60 40 _12 222 52 111 Maximum 40 60 62 F 2325 2 4 7 13 Servicing IMPORTANT 1 50 1 4 DO NOT use methyl alcohol or methoxy propanol base EGC These concentrates are not compatible with chemicals used in supplemental coolant additives Damage can occur to rubber seals on cylinder liners which are in contact with coolant DO NOT use an EGC containing sealer or stop leak additives DO NOT use EGC containing more than 0 1 anhydrous metasilicate This type of concentrate which 15 intended for use in aluminum engines may cause a gel like deposit to form that reduces heat transfer and coolant flow Check cont

Operator`s Manual (model M1066H)

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