Northern Light M1064A, M1064D, M1064T1, M1064T2, M1066A1 OPERATOR’S MANUAL

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Page 1

OM2-2

For Models: M1064A, M1064D, M1064T1, M1064T2,

M1066A1, M1066A2, M1066A3, M1066T, M40C2,

M55C2, M65C2, and M99C2

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

Page 2

— 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

Printed in U.S.A. PART NO.: OM2-2 06/10

Page 3

OPERATOR'S MANUAL

#OM2-2 for Models:

M1064A, M1064D, M1064T1, M1064T2, M1066A1, M1066A2,

M1066A3, M1066T, M40C2, M55C2, M65C2, and M99C2

Read this operator's manual thoroughly before starting to operate your equipment.

This manual contains information you will need to run and service your new unit.

Table of Contents

INTRODUCTION ....................................................2

Models Included .................................................2

Model Numbers ..................................................2

Serial Numbers ...................................................2

WARRANTY ............................................................3

SAFETY RULES .....................................................3

COMPONENT LOCATIONS

M1064 .................................................................4

M1066 .................................................................5

M40C2 ................................................................6

ENGINE & GENERATOR CONTROL PANELS

Series 3B & 4B .............................................8 - 9

OPERATING PROCEDURES

Before Starting .................................................10

Shutdown Procedures ...................................... 10

Break-In Period .................................................11

SERVICING SCHEDULE CHARTS .......... 12 - 13

SERVICING

Lubrication - General ....................................... 15

Checking Oil .................................................... 15

Oil Changes ..................................................... 15

Changing Oil Filter .......................................... 15

Air Filter .......................................................... 15

Valve Clearances .............................................. 16

Fuels - General ................................................. 17

Crankshaft Vibration Damper (6 Cyl.) ............ 17

Fuel Filters ............................................... 17 - 18

Bleeding the Fuel System ................................ 18

Injector Service ........................................ 18 - 20

Injection Pump ......................................... 20 - 22

Turbocharger .................................................... 23

Turbo Boost ..................................................... 23

Cooling System - General ................................ 23

Engine Coolant Speciﬁ cations .................23 - 24

Cooling System Flushing ................................. 25

Heat Exchanger Cleaning ................................ 25

Zinc Electrodes ........................................ 25 - 26

Raw Water Pump ............................................. 26

Generator Ends ................................................ 26

Electrical System - General ............................. 26

Booster Batteries .............................................. 27

Battery Care ..................................................... 27

Winterizing / Out-of-Service ........................... 27

TROUBLESHOOTING

Electrical .......................................................... 28

Engine ...................................................... 29 - 30

WIRING DIAGRAMS

AC Wiring ................................................ 31 - 32

DC Wiring ................................................ 33 - 50

ON-BOARD SPARE PARTS .............................. 51

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.

OM2-2 06/10

Page 4

Introduction

Servicing of marine engines and generator sets presents unique problems. In many cases boats cannot be moved to a repair facility. Marine engines cannot

Failures begin with minor problems that are overlooked and become ampliﬁ ed when not corrected during

routine maintenance. be compared to the servicing of automobiles, trucks or even farm equipment. Failures often occur in remote areas far from competent assistance. Marine engines are taxed far more severely than auto or truck engines; therefore, maintenance schedules must be adhered to more strictly.

As operator, it is your obligation to learn about your

equipment and its proper maintenance. This is not a

comprehensive technical service manual. Nor will it

make the reader into an expert mechanic. Its aim is to

aid you in maintaining your unit properly.

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:

M - Northern Lights marine generator set

M1064A

Northern Lights® aftercooled, 1800 RPM

marine diesel generator set with a John Deere Powertech Tier II 4045 engine block with an electronically controlled fuel system.

106 mm bore, 4 Cylinder

or 106 mm bore, 6 Cylinder

1064 or 1066

Model number

M1066T

Northern Lights® turbocharged marine generator set with a John Deere Powertech

Tier II 6068 engine block with an electronically controlled fuel system.

A, D, & T

A - Aftercooled D - Naturally aspirated

T - Turbocharged

M1064D

M1064T1

M1064T2

M1066A1

Northern Lights® naturally aspirated, 1800 RPM marine diesel generator set with a John

Deere Powertech Tier II 4045 engine block with a mechanically controlled fuel system.

Northern Lights® turbocharged marine generator set with a John Deere Powertech

Tier II 4045 engine block with a mechanically controlled fuel system.

Northern Lights® turbocharged marine generator set with a John Deere Powertech

Tier II 4045 engine block with an electronically controlled fuel system.

Northern Lights® aftercooled marine generator set with a John Deere Powertech Tier II 6068

series 1 engine block with an electronically controlled fuel system

MP40C2

MP55C2

MP65C2

MP99C2

40 kW Northern Lights® commercial marine generator set with a John Deere Powertech

Tier II 4045 engine block with a mechanically controlled fuel system.

55 kW Northern Lights® commercial marine

generator set with a John Deere Powertech Tier II 4045 engine block and a mechanically controlled fuel system.

65 kW Northern Lights® commercial marine generator set with a John Deere Powertech

Tier II 6068 engine block and an electronically controlled fuel system.

99 kW Northern Lights

generator with a John Deere Powertech Tier II 6068 engine block and an electronically controlled fuel system.

commercial marine

Serial Numbers

When referencing Northern Lights equipment by serial number, please refer only to the number stamped on the Northern Lights® serial number plate.

OM2-2 06/10

Page 5

Warranty

A warranty registration certiﬁ cate is supplied with your set. The extent of coverage is described in the Limited Warranty Statement. We recommend that you study the statement carefully.

NOTE: If the warranty is to apply, the servicing instructions outlined in this manual must be followed. If further information is needed, please contact an authorized dealer or the factory.

Safety Rules

CAUTION:

You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.

• Never leave engine without proper security.

• Turn the coolant tank cap slowly to relieve pressure before removing. Add coolant only when the engine is stopped and cool.

• Mount a ﬁ re extinguisher near engine.

• Always disconnect the battery ground strap before making adjustments.

• Operate engines in properly ventilated areas.

• Keep trash and other objects away from engine.

• Escaping ﬂ uids under pressure can penetrate your skin. Use a piece of cardboard or wood, not your hands, to search for leaks.

• Avoid wearing loose clothing when working around engines.

Accident reports show that careless use of engines causes a high percentage of accidents.

• Use caution in handling fuel. Never refuel a hot

or running engine. Do not smoke while ﬁ lling fuel tank or servicing fuel system.

• Keep your hands, feet, hair and clothing away from power-driven parts.

• Check for any loose electrical connections or faulty wiring.

• Engines should be operated only by knowledgeable, qualiﬁ ed personnel.

• Look completely around engine to make sure that everything is clear before starting.

• Do not operate an engine that isn't in proper working order. If an unsafe operating condition is noted, tag the set and control panel so others will also know about the problem.

• Do not oil or grease engine while it is running.

• Always disconnect the ECU (Electronic Control Unit) connectors and remove the ground connection for the engine control system-tomachine frame before welding on engine. Make sure no other electronic components are in the ground path also.

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.

• Provide ﬁ rst aid kits.

CAUTION: This symbol is used throughout this book to alert you to possible danger areas. Please take special notice of these sections.

OM2-2 06/10

Page 6

Component Locations

Figures 1 & 2: M1064T1 (Mechanically Controlled Fuel System)

1. Junction Box

2. Exhaust Elbow

3. Turbocharger

4. Air Cleaner

5. Fuel Filter

6. Fuel Lift Pump

7. Lube Oil Fill

8. Coolant Fill

9. Alternator

10. Raw Water Pump

11. Lube Oil Dipstick

12. Lube Oil Filter

13. Optional Hydrolastic Mount

14. Starter

15. Lube Oil Drain

16. Fuel Manifold

17. Expansion Tank

18. Thermostat Cover

19. Heat Exchanger Zincs

20. Heat Exchanger

21. Belt Guard

OM2-2 06/10

22. Injection Pump Drive Coupling Access Cover Plate

23. Engine Block Drain

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Component Locations

Figure 3 & 4: M1066T (Mechanically Controlled Fuel System)

1. Coolant Fill

2. Expansion Tank

3. DC Alternator

4. Lube Oil Fill

5. Lube Oil Filter

6. Fuel Lift Pump

7. Lube Oil Dipstick

8. Lube Oil Drain

9. Air Cleaner

10. DC Circuit Breaker

11. Turbocharger

12. Wet Exhaust Elbow

13. Exhaust Manifold Drain

14. Electric Starter

15. Engine Block Drain

16. Fuel Injection Pump

OM2-2 06/10

17. Heat Exchanger Zinc (2)

18. Heat Exchanger Drain

19. Heat Exchanger

20. Raw Water Pump

21. Fuel Injectors (6)

22. Thermostat cover

23. Optional Hydrolastic Mounts

24. Optional Governor Actuator

25. Drive Belt Cover

26. Fuel Manifold

27. A.V.R. Fuse

28. Fuel Filter

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Component Locations

Figure 5 & 6: M40C2 (Mechanically Controlled Fuel System)

1. Junction Box

2. Fuel Filter

3. Fuel Lift Pump

4. Air Cleaner

5. Alternator

6. Coolant Fill

7. Expansion Tank

8. Belt Guard

9. Coolant Pump

10. Centerbonded Mounts

11. Lube Oil Drain

12. Lube Oil Filter

13. Dipstick

14. Electric Starter

15. Closed Crankcase Vent

OM2-2 06/10

16. Exhaust Manifold

17. Injection Lines

18. Fuel Injection Pump

Page 9

Notes

OM2-2 06/10

Page 10

Northern Lights Control Panels

Figure 7: 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 mufﬂ er 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. 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°F (93.30C) or drops below 140°F (600C), 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.

OM2-2 06/10

Page 11

Northern Lights Control Panel

Figure 8: Series 4 B Generator Control Panel

1. SHUTDOWN BYPASS SWITCH

This switch bypasses the safety shutdown feature

during the starting process.

2. ENGINE CONTROL SWITCH

The control switch starts and stops the engine.

3. OIL PRESSURE GAUGE

The oil pressure gauge shows the oil pressure in

the engine lubricating system. If the pressure drops below 15 PSI at a speed higher than idling, stop the engine and investigate.

4. COOLANT TEMPERATURE GAUGE

Water temperature gauge shows the temperature of

the cooling water. If the gauge registers over 200° (93.30C) or drops below 140°(600C), 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.

7. AC VOLTMETER

The voltmeter shows the generator output

voltage, phase to phase. If the voltage ﬂ uctuates greatly from the normal reading, shut down the unit and investigate.

8. FREQUENCY METER

Indicates engine speed. The correct reading for

1800 and 1200 RPM sets is 60 Hz. For 1500 RPM sets, it is 50 Hz. If meter does not indicate correct hertz, stop and investigate.

9. AMMETER SELECTOR SWITCH

The ammeter switch is used for checking each

phase for load condition. Leave it in the ON

position while the engine is running.

10. AC AMMETER

The ammeter indicates the phase load. Check for

load unbalance. If the unbalance is greater than 30%, have an electrician balance the load properly. This will ensure longer generator life and better economy.

OM2-2 06/10

Page 12

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 1 3/4 in. (4-5 cm) below the ﬁ ller cap sealing surface when the engine is cold. When ﬁ lling 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 ﬁ ller 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 “wafﬂ ed area” and the “oo”. Never allow the level to go below the “oo”. Always add the same viscosity of oil as is already in the crankcase (see Service Point #1).

3. Check the fuel tank level and open any fuel valves.

4. Disengage clutch, if equipped.

5. Close the seacock, check and clean the strainer and reopen the seacock.

6. Place the battery switch in the ON position.

NOTE: The battery switch must always be kept ON

while the engine is running. If the switch is turned OFF while the engine is running, the battery charging regulator could be ruined.

Starting

1. While holding the Shutdown Bypass switch in the ON position, push the Engine Control switch to the START position.

2. As soon as the engine starts, release both switches.

Do not crank the starter for more than 20 seconds.

3. If the engine fails to start the ﬁ rst time, be sure the starter has stopped before re-engaging.

NOTE: If there is a governor locked at a speciﬁ c

speed on the generator set, there may not be a slow idle function, so in that case operate the engine at high idle for 1 to 2 minutes before adding load. If the stand-by generator set is loaded as soon as it reaches rated speed, this procedure would not apply.

Operating

1. Check Gauges Often: Oil pressure must be above 29 PSI (if not above 15 PSI within 5 seconds of

starting, the engine should be stopped and the problem should be explored). Normal oil pressure is 50 PSI at rated load speed (1800 to 2500 RPM). Oil temperature should be 1150C (2400F) 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. Let the unit run unloaded for a three to ﬁ ve minute warm-up period before applying load.

5. Do not add full electrical load until engine is at maximum operating temperature.

Shutdown

1. Turn the Engine Control Switch to the OFF

position.

2. Close the sea cock and fuel valves, and put the battery switch in the OFF position if the unit will be off for an extended period.

NOTE: Do not turn the battery switch to OFF while

the engine is running.

SHUTDOWNS AND ALARMS

1. Your unit is ﬁ tted with a system to protect it from high water temperature or low oil pressure.

a. Generator sets have shutdown systems to stop

the engine. They have no warning horns.

b. Other alarms and shutdowns are available as optional equipment.

NOTE: Do not rely on your warning or shutdown

system to the exclusion of careful gauge monitoring. Watching your gauges can prevent damage to the unit and dangerous power losses.

2. Do the following when your shutdown system is activated: a. Check the temperature gauge. If the temperature is above 205°F (97°C), shut off the engine immediately.

b. Use the Trouble Shooting Guide on pages 26- 28 to isolate the cause of the overheat.

OM2-2 06/10

Page 13

CAUTION: Do not remove the water ﬁ ll cap of an overheated engine. Escaping high temperature steam can cause severe burns. Allow the engine to cool and then remove the cap slowly, using protective clothing.

c. Make repairs and restart after the temperature gauge registers below 180°F (83°C).

d. Watch the temperature gauge regularly and

turn off the unit if the temperature rises above 200°F (93.3°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, ﬁ ll 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.

Operating Procedures

3. Oil consumption is greater during break-in as piston rings take time to seat.

4. Your engine comes equipped with break-in oil. Change engine oil and ﬁ lter at 50 hours using API Service Category CC, CD, or CE break-in oil. Change the oil and ﬁ lter again at 100 hours.

(Consult the lubricants section for oil recommendation.)

5. Frequently check the engine temperature and oil pressure gauges.

BREAK-IN PERIOD

1. Your engine is ready to be put into service. However, the ﬁ rst 100 hours on a new or reconditioned engine are critical to its life and performance. This is especially true of an engine that runs at a constant speed such as a generator engine.

2. Operate with an average of 75% load on your engine for the ﬁ rst 100 hours. Maintain no less than a 50% load to ensure proper seating of the piston rings.

OM2-2 06/10

Page 14

Revised 9-23-10

Service Schedule Chart, Mechanically Controlled Fuel System

The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your marine generator set. More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’ column.

DAILY:

SP1 Check oil level in engine SP8 Check primary fuel ﬁ lter SP15 Check cooling water level SP26 Check crankcase vent system ﬁ lter svc. indicator button

AFTER FIRST 50 HOURS:

SP2 Change engine oil SP3 Change lube oil ﬁ lter

EVERY 50 HOURS:

SP21 Check electrolyte in batteries

FIRST 100 HOURS:

SP2 Change engine oil SP3 Change lube oil ﬁ lter

EVERY 100 HOURS:

SP13 Check turbocharger air, oil & cooling lines for leakage

EVERY 250 HOURS:

SP2 Change engine oil SP3 Change lube oil ﬁ lter SP4 Check air cleaner SP9 Change primary fuel ﬁ lter element

SERVICE 50 100 250 500 2000 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours

ENGINE: SP1 15 Check oil level • SP2 15 Change engine oil 2) 1) 1) • SP3 15 Change lube oil ﬁ lters 2) 1) 1) • SP4 15 Check (replace) air cleaner 2) 4) • • SP5 Check belt condition 2) • SP6 16 Check valve clearances 2) • •

SP7 17 Check crankshaft vibration damper •

SP13 Check turbocharger air, oil & cooling lines for leakage SP19 Check zinc electrodes SP23 Test thermostats

AFTER FIRST 500 HOURS:

SP6 Check valve clearances

EVERY 500 HOURS / YEARLY:

SP4 Replace air cleaner SP5 Check belt condition SP7 Check crankshaft vibration damper SP10 Change secondary fuel ﬁ lter SP11 Check injectors SP14 Check turbocharger boost pressure SP16 Check cooling system SP20 Change impeller in raw water pump SP22 Check the state of the charge of the batteries SP26 Check crankcase vent system, change element at 500 hrs.

EVERY 2000 HOURS:

SP6 Check valve clearances, adjust if necessary SP12 Check fuel injection pump SP17 Check and clean heat exchanger

FUEL SYSTEM:

SP8 17 Check primary ﬁ lter (Racor) 3) • SP9 17 Change primary ﬁ lter element (Racor) 3) 4) • SP10 17 Change secondary fuel ﬁ lter 2) 4) • SP11 18-19 Check injectors 2) • SP12 20-22 Check fuel injection pump  •

TURBOCHARGER: SP13 23 SP14 23 Check boost pressure •

SP26 27 Check crankcase vent system  SP15 25 Check cooling water level • SP16 25 Check and ﬂ ush cooling system 2) • 5) SP17 25 Check and clean heat exchanger 2) • SP19 25-26 Check zinc electrodes 2) 4) • SP20 26 Change impeller in raw water pump 2) 4) •

ELECTRICAL SYSTEM: SP21 27 Check electrolyte level in batteries 2) 4) • SP22 27 Check condition of batteries with hydrometer 2) •  SP23 Test thermostats •

Check air, oil & cooling water lines for leakage

COOLING SYSTEM:

•

• 6) 

1) Change the oil and ﬁ lter at 50 hours, using break-in oil again, until changing it at 100 hours, then at every 250 hours.

2) Perform all maintenance once a year even if hour level has not been reached.

3) Consult manufacturer's maintenance schedule.

OM2-2 06/10

4) Or whenever necessary.

5) Check the cooling system at 500 hours, ﬂ ush at 2000 hours.

6) Check hoses and o-rings, replace element at 500 hours.

Page 15

Revised 9-23-10

Service Schedule Chart, Electronically Controlled Fuel System

DAILY:

SP1 Check oil level in engine SP8 Check primary fuel ﬁ lter SP15 Check cooling water level SP26 Check crankcase vent system ﬁ lter svc. indicator button

AFTER FIRST 50 HOURS:

SP2 Change engine oil SP3 Change lube oil ﬁ lter

EVERY 50 HOURS:

SP21 Check electrolyte in batteries AFTER FIRST 100 HOURS/ EVERY TWO WEEKS 5:

SP2 Change engine oil after ﬁ rst 100 hrs., then check every 2 wks. SP3 Change oil ﬁ lter after ﬁ rst 100 hrs., then check every 2 wks.

SP7 Check crankshaft vibration damper SP15 Check coolant level

EVERY 250 HOURS :

SP2 Change engine oil SP3 Change lube oil ﬁ lter SP4 Check air cleaner SP19 Check zincs

SERVICE 50 100 250 500 2000 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours

ENGINE: SP1 15 Check oil level • SP2 15 Change engine oil 2) 1) 1) • SP3 15 Change lube oil ﬁ lters 2) 1) 1) • SP4 15 Check air cleaner • • SP5 Check belt condition 2) • SP6 16 Check valve clearances 2) •

SP7 17 Check crankshaft vibration damper 5) •

SP25 Check engine mounts •

 SP27 Check air intake hoses •

FUEL SYSTEM:

SP8 17 Check primary ﬁ lter (Racor) 3) • SP9 17 Change primary ﬁ lter element (Racor) 3) 4) • SP10 17 Change secondary fuel ﬁ lter 2) 4) • SP11 18-19 Check injectors 2) SP12 20-22 Check fuel injection pump •

TURBOCHARGER:

SP13 23 SP14 23 Check boost pressure •

SP30 27 Check aftercooler, clean air side •

SP26 27 Check crankcase vent system

Check air, oil & cooling water lines for leakage

COOLING SYSTEM:

SP15 25 Check cooling water level • SP16 25 Check and ﬂ ush cooling system 2) 6) • SP17 25 Check and clean heat exchanger 2) • SP19 25-26 Check zinc electrodes 2) 4) •

SP20 26 Change impeller in raw water pump 2) 4) • ELECTRICAL SYSTEM:

SP21 27 Check electrolyte level in batteries 2) 4) • SP22 27 Check condition of batteries with hydrometer 2) •

 SP23 Test thermostats •  SP29 Check electrical ground connection •

EVERY 500 HOURS / YEARLY:

SP4 Replace air cleaner SP5 Check belt condition SP9 Change primary ﬁ lter element (Racor) SP10 Change secondary fuel ﬁ lter SP11 Check injectors SP14 Check turbocharger boost pressure SP16 Check cooling system SP20 Change impeller in raw water pump SP22 Check the state of the charge of the batteries

SP25 Check engine mounts SP26 Check crankcase vent system, change element at 500 hrs. SP27 Check air intake hoses SP29 Check electrical ground connection

EVERY 2000 HOURS:

SP6 Check & adjust valve clearance SP7 Check crankshaft vibration damper SP12 Check fuel injection pump SP16 Flush cooling system SP17 Check and clean heat exchanger SP23 Test thermostats SP30 Check aftercooler, clean air side

•

• 7)

1) Change the oil and ﬁ lter at 50 hours, using break-in oil again, until changing it at 100 hours, then at every 250 hours.

2) Perform all maintenance once a year even if hour level has not been reached.

3) Consult manufacturer's maintenance schedule.

4) Or whenever necessary.

OM2-2 06/10

5) Replace damper every 4500 hours or after 60 months.

6) Check cooling system at 500 hours, ﬂ ush at 2000 hours.

7) Check hoses, and o-rings on crankcase vent system, change element at 500 hours.

Page 16

Notes

OM2-2 06/10

Page 17

updated 6-7-10

Servicing

LUBRICATION

Break-in oil

1. Use one of the following during the ﬁ rst 100 hours of operation:

a. John Deere Engine Break-In Oil b. API Service Category CC, CD, or CE oil c. ACEA Speciﬁ cation E1

2. Do not use John Deere PLUS-50 oil or engine oils meeting API CG4, API CF4, ACEA E3, or ACEA E2 performance levels during the ﬁ rst 100 hours of operation of a new or rebuilt engine. These oils will not allow the engine to break-in properly.

Lubrication - General

1. Use only clean, high quality lubricants stored in clean containers in a protected area.

2. These oils are acceptable after the ﬁ rst 100 hours:

a. ACEA Oil Sequence E5 and E4 b. API Service Category CI-4 or CH-4. c. ACEA Oil Sequence E3 multi-viscosity oil.

3. Use the proper weight oil for your average operation temperature.

Air Single Multi Temperature Viscosity Viscosity

Above 32°F (0°C)

-10°F to 32°F (-23°C to 0°C)

SAE-30W SAE15-40W

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 ﬂ ushing 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 “Wafﬂ ed area” and the “oo”. Never allow the level to go below the “oo”.

3. Always add the same viscosity of oil as is already in the crankcase.

SP2. OIL CHANGES

1. Using the oil recommended above, change the engine oil and ﬁ lter after the ﬁ rst 50 hours of opera- tion, the ﬁ rst 100 hours and every 250 hours thereaf- ter.

SP2. OIL CHANGES continued

2. During intermittent cold weather operation, change oil every 100 hours or six weeks, whichever comes ﬁ rst.

3. Change oil at any seasonal change in temperature when a new viscosity of oil is required.

a. Remove plug from outlet in base frame. Screw in owner-supplied drain hose. b. Open valve at oil pan outlet. After oil has been drained into suitable container, close valve, remove drain hose and replace plug in base frame outlet. c. Reﬁ ll engine with recommended oil.

4. Engine Lube Oil Capacity:

M1064D & T1 15.5 qts. 14.7 liters M1064T2 M1064T2 M1064A & H 21.6 qts. 20.5 liters M40C2 15.5 qts. 14.7 liters M55C2 15.5 qts. 14.7 liters M65C2 15.5 qts. 14.7 liters M1066T 20.0 qts. 19.0 liters* M1066A1, A2, A3 34.3 qts. 32.5 liters M99C2 20.0 qts. 19.0 liters

*depending on oil pan size

(@60 Hz)

(@50 Hz)

15.5 qts. 14.7 liters

21.6 qts. 20.5 liters

SP3. CHANGING OIL FILTER

1. Change the lube oil ﬁ lter every 250 hours, after the initial 50 and 100 hour change.

2. Use a ﬁ lter wrench to remove old ﬁ lter. Dispose of ﬁ lter in approved manner.

3. Make sure the gasket from the old ﬁ lter is removed and discarded.

4. Lubricate the rubber gasket on the new ﬁ lter and screw it on nipple until gasket meet the sealing surface.

Using hands only, no wrench, tighten ﬁ lter one-half turn farther. Overtightening can do damage to ﬁ lter 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

1. Inspect air cleaner every 100 hours. Replace ﬁ lter every 500 hours, or yearly, whichever comes ﬁ rst for

mechanically controlled fuel system engines. For elec-

tronically controlled units - replace air cleaner element every 500 hours.

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 ﬁ lter is absolutely clean and installed properly.

4. Start the engine and check for leaks.

NOTE: Make absolutely sure no impurities enter the

engine while changing the element. Do not run the engine with the air cleaner removed.

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Servicing

SP6. VALVE CLEARANCES

The following special tools will be needed: JDE 820 or JDE 83 Flywheel Turning Tool, JDE 81-4 Timing Pin.

1. Remove rocker arm cover with ventilator tube.

2. Remove plastic plugs in engine timing holes on front side of ﬂ ywheel.

3. Rotate ﬂ ywheel in clockwise direction (viewed from water pump) with the Flywheel Turning Tool until the Timing Pin engages timing hole in the ﬂ ywheel. Both rocker arms for No. 1 cylinder will be loose at Top Dead Center. If they are not, remove the timing pin and rotate the ﬂ ywheel one complete turn and reinstall the timing pin in the ﬂ ywheel.

4. Valve clearances must be checked with the engine cold.

Intake Valve: 0.012-0.015 in. (0.31-0.38 mm)

Exhaust Valve: 0.016-0.019 in. (0.41-0.48 mm)

5. If the valves need adjusting, loosen the jam nut (A

on Figure 9)

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 speciﬁ cations. Check the clearance again after tightening the jam nut. Re-adjust as needed.

NOTE: Firing order is 1 - 3 - 4 - 2

A - Front of Engine B - No. 1 Piston at TDC Compression Stroke C - No. 4 Piston at TDC Compression Stroke E - Exhaust Valve I - Intake Valve

Adjust valve clearance on No. 2 and No. 4 exhaust valves and No. 3 and No. 4 intake valves.

6-CYLINDER ENGINES:

NOTE: Firing order is 1 - 5 - 3 - 6 - 2 - 4

Figure 9

4-CYLINDER ENGINES:

Lock No. 1 piston at TDC compression stroke (B). Adjust valve clearance on No. 1 and No. 3 exhaust valves and No. 1 and No. 2 intake valves. Rotate ﬂ ywheel 360°. Lock No. 4 piston at TDC compression stroke (C).

A - Front of Engine B - No. 1 Piston at TDC Compression Stroke C - No. 6 Piston at TDC Compression Stroke E - Exhaust Valve I - Intake Valve

Lock No. 1 piston at TDC compression stroke (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 ﬂ ywheel 360°. Lock No. 6 piston at TDC compression stroke (C). Adjust valve clearance on No. 2, No. 4, and No. 6 exhaust valves and No. 3, No. 5, and No. 6 intake valves.

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Servicing

FUELS - GENERAL

1. Use only clean, high quality fuels of the following speciﬁ cations, as deﬁ ned by ASTM designation D975 for

diesel fuels: a. Use Grade No. 2 diesel at ambient temperatures above freezing 30°F (0°C). b. Use Grade No.1 at ambient temperatures below freezing and for all temperatures at an altitude of above 5,500 ft. (1500 meters).

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, b. Class B engine, c. Class D domestic fuels, d. Class E, F, G or H industrial

or marine fuels,

e. ASTM-D975-60T No. 4-D and higher

number fuels, f. JP4

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 operation. This

will reduce condensation.

6. Biodiesel: Biodiesel involves the transesteriﬁ cation of vegetable oils or animal fats.

Mainly in the U.S. soybean methyl ester is used (SME), but in Europe

mainly rapeseed (canola) methyl ester is made (RME), and in Asia palm

methyl ester is made (PME). 100% biodiesel (B100) is made in compli-

ance with ASTM D6751 or EN14214 (EU) speciﬁ cations. Biodiesel

may be used in a 5% blend (5% biodiesel/ 95% diesel) from a BQ-9000

accredited producer. 20% biodiesel blends can only be used if they meet

ASTM D6751 or EN14214 (EU) speciﬁ cations. A 2% reduction in power

and a 3% reduction in fuel economy can be expected using a 20% blend,

and a fuel conditioner is recommended. Biodiesel blends must be used

within 90 days of their manufacture. Oil level, leaking, microbial growth,

plugging, and component degradation all must be checked more frequently

using biodiesel blends. Request a certiﬁ cate of analysis from an approved

biodiesel fuel distributor to make sure the blend meets speciﬁ cations. NOTE: Using raw pressed or partially reﬁ ned vegetable oils or recycled

greases as fuel (which have not been through transesteriﬁ cation) could

cause engine failure.

SP8-10. FUEL FILTERS

1. Your engine or generator set should have a primary

fuel ﬁ lter installed. We recommend the Racor brand of fuel

ﬁ lter - water separators. a. Check the primary fuel ﬁ lter daily as recommended by the

ﬁ lter manufacturer. Empty the collection bowl as necessary. b. Change the element every 250 hours (500 for electroni-

cally controlled fuel system units) or whenever necessary. c. If the bowl ﬁ lls with water, change the primary and secondary elements immediately.

2. Change secondary fuel ﬁ lter every 500 hours.

NOTE: The fuel ﬁ lter on the engine is considered the “secondary fuel ﬁ lter”. The engine will be ﬁ tted with a quick change disposable secondary fuel ﬁ lter.

SP7. CRANKSHAFT VIBRATION DAMPER (6 Cylinder Engines Only)

1. Remove belts.

2. Try to turn the vibration damper in both directions while grasping it with both hands. If rotation can be felt, the damper is defective and should be replaced.

NOTE: The vibration damper assembly should be

replaced every 4500 hours or 60 months, whichever occurs ﬁ rst, as the vibration damper assembly is not repairable.

3. Place a dial indicator (Figure 13) so that the probe contacts the damper’s outer diameter in order to check the damper radial runout.

4. Make sure the engine is at operating temperature, then rotate the crankshaft using the JD281A,

JDE81-4, or the JDE83 Flywheel Turning Tool.

5. If the runout reading exceeds the below

speciﬁ cation, replace the vibration damper. Vibration Damper Maximum

Radial Runout ..........................1.50 mm (0.060 in.)

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Servicing

SP8-10. FUEL FILTERS (Continued)

a. Turn off the fuel. b. Open the ﬁ lter drain plug (Figure 14-A) and drain the ﬁ lter.

Figure 14: Secondary Fuel ﬁ lter

c. Remove the secondary fuel ﬁ lter by turning the ﬁ lter clamp (Figure 14-B) counter clockwise until the ﬁ lter cartridge (Figure 14-C) slides out.

NOTE: Before installing a new ﬁ lter cartridge make sure the surfaces where the cartridge comes in contact with the mounting plate are absolutely clean. Dirt can be washed into the fuel injection system. This may result in severe damage to the fuel injection pump or nozzles. Your generator set may have two secondary ﬁ lters, depend- ing on the fuel supply system. Do not “preﬁ ll” the new

fuel ﬁ lter as the fuel used may be contaminated and damage the fuel system components.

d. Install new ﬁ lter cartridge. e. Turn on the fuel.

BLEEDING THE FUEL SYSTEM

CAUTION: Escaping diesel fuel under pressure can penetrate the skin, causing serious personal injury. Before disconnecting lines be sure to relieve all pressure. Before applying pressure to the system be sure all connections are tight and the lines, pipes and hoses are not damaged. Fuel escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood rather than the hands to search for suspected leaks. If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately.

1. Whenever the fuel system has been opened for service, (lines disconnected, ﬁ lter changed, etc.) it will be necessary to bleed air from the system.

a. To bleed the fuel system, loosen the bleed plug (Figure 14-D) on the fuel ﬁ lter. Operate the primer pump lever on fuel transfer pump (see component locations) until most of the air bubbles are expelled and clear fuel escapes the bleed plug. Tighten the bleed plug. b. If the engine will not start, it may be necessary to loosen the fuel supply pipe at the pump. Operate primer lever of fuel supply pump until fuel ﬂ ow is free from air bubbles. Retighten fuel supply line to 22 ft. lb. (30 N•m). c. If engine still doesn't start, loosen fuel line connection at injection nozzle. Always use a back up wrench when loosening or tightening fuel lines at nozzles and injection pump to avoid damage. With throttle on full, crank the engine over with the starter until fuel without air ﬂ ows from the loose fuel pipe connection. Repeat procedure for remaining nozzles, if necessary, until engine starts or until air has been removed from system. Tighten the connections to 20 foot lb. (27 N•m). d. For models M1066A2 and M1066A3 bleed the fuel

system using the electronic transfer pump. The ignition should be on and allow 40 seconds for the pump to complete the priming. If additional system bleeding is needed, do it by loosening the fuel line connections at the injection nozzles.

SP11. INJECTORS

1. Fuel injectors should be checked by a Lugger-Northern Lights dealer or qualiﬁ ed fuel injection shop every 500 hours.

2. Injector Removal:

You will need the following special tools: JDE38A-Injection Nozzle Puller JDE39-Nozzle Bore Cleaning Tool, JD258-Pilot Tool a. Before removal, carefully remove all dirt from the cylinder head around fuel injection nozzles. Clean with compressed air to prevent dirt from entering the cylinders or valve seats. Plug the bore in the cylinder head after each fuel injection nozzle has been removed. Cap fuel line openings as soon as they are disconnected. b. Immediately ﬁ t protective caps over the nozzle tips and the line connections to avoid handling

damage.

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Servicing

c. Do not bend the fuel delivery lines. When loosening the fuel pressure lines, hold male union of nozzle line stationary with a backup wrench. d.

Loosen nuts to remove leak-off lines and T-ﬁ ttings

and disconnect fuel injection line from nozzle.

NOTE: When all fuel injection nozzles have to be

removed, disconnect leak-off line assembly at fuel tank, at injection pump, and at each nozzle T-ﬁ tting. Lift off complete leak-off line as an assembly.

e. Remove cap screw, clamp and spacer. f. Pull injection nozzle out of cylinder head with JDE38A Injection Nozzle Puller.

NOTE: Do not use screwdrivers, pry bars, or similar tools for this as they might damage the injection nozzle.

3. Clean Injector Bore: Always turn the tool clockwise through the bore

even when removing from bore, otherwise tool may

become dull. a. Clean nozzle bore with JDE39 Nozzle Bore Cleaning Tool. Blow debris from bore with compressed air and plug the bore to prevent entry of foreign material.

4. Clean injection nozzles: a. Remove carbon stop seal (Figure 15-A) and upper sealing washer (Figure 15-B), using a needle-nose pliers. Discard seals. b. Clean exterior of nozzle by soaking in clean solvent or diesel fuel. Clean tip with brass wire brush.

This coating will become discolored during normal

operation, but this is not harmful. Do not use a motor driven brush to clean up nozzle body.

Figure 16

5. Install seals on injection nozzle.

NOTE: Each time an injection nozzle is removed

from the cylinder head, replace carbon stop seal (B) with a new one.

a. Position JD258 (ROS16477) Pilot Tool (Figure

16-C) over nozzle tip. If Pilot Tool (included in

cleaning kit) is not available, use a No. 16189 Nozzle Protector Cap found on every new or re placement nozzle. b. Position a new carbon stop seal (Figure 16-B) on pilot tool. Use a new seal washer (Figure 16-A) to help slide the carbon seal into place until it seats in its groove on nozzle body. c. Continue to slide upper sealing washer onto nozzle body until it seats against inlet ﬁ tting.

6. Install injection nozzles:

NOTE: Before installing injection nozzles, make sure

nozzles are clean and free from oil or grease. Do not grease or oil the nozzles.

Figure 15

NOTE: Do not scrape or disturb the teﬂ on

coating on the nozzle body above the carbon stop

seal groove.

a. Remove plug (if installed previously) from nozzle bore in cylinder head and blow out bore with compressed air. b. Make sure that the sealing surface of the cylinder head (on which the seal washer will be resting) is smooth and free of damage or dirt. This could prevent proper sealing. Dirt and roughness could also cause distortion to nozzle when the attaching screw is tightened, making the valve stick. c. Install nozzle in cylinder head using a slight twisting motion as nozzle is seated in bore. d. Install spacer and cap screw. Do not tighten capscrew at this stage.

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Servicing

Install injection nozzles (continued):

Figure 17: Shows relationship of parts required for

installation.

e. Connect fuel pressure line to nozzle. Leave connection slightly loose until air is bled from system. f. Tighten nozzle hold-down cap screws to 27 foot lb. (37 N• m). g. Install leak-off assembly. h. Bleed air from loose injection line connection. Tighten connection using two wrenches.

DB4 AND DB2 INJECTION PUMPS – REMOVAL

All Stanadyne DB2 and DB4 injection pumps will

have a retained drive shaft (shaft stays in pump when pump is removed from engine).

1. Clean the fuel injection pump, lines, and area around the pump with cleaning solvent or a steam cleaner.

IMPORTANT: Never steam clean or pour cold water

on a fuel injection pump while the pump is running or while it is warm. Doing so may cause seizure of internal rotating pump parts.

2. Disconnect shutoff cable and speed control linkage or cold start switch, if equipped. Disconnect electrical connection to shutoff solenoid or throttle positioning solenoid. Tag electrical wires for correct reassembly.

IMPORTANT: Always use a backup wrench when

loosening or tightening fuel lines at injection pump

so that discharge ﬁ ttings are not altered which will

prevent internal pump damage.

3. Disconnect fuel return line (Figure 18-A) and fuel supply line (Figure 18-C).

SP12. INJECTION PUMP

1. Since operating conditions may vary considerably, it is difﬁ cult to give a deﬁ nite service interval. But, as a rule, the pump settings, maximum speed, idle speed and exhaust smoke should be checked by your dealer after every 2000 hours of operation. Service of the fuel injection pump should only be done if checks indicate pump malfunction.

2. Black smoke can be an indication of pump

malfunctions. Before servicing pump, check the

other possible causes.

a. Check cleanliness of air ﬁ lter. b. Check valve clearances. c. Clean and check injectors.

Any repair which involves disassembly of the injection pump must be carried out by specially-trained

mechanics with the proper tools and test devices. NOTE: All warranties on the engine become null and

void if the injection pump seals are broken by unauthorized persons.

RG5659

4. Disconnect all fuel delivery (pressure) lines (Figure

18-B) from injection pump using a suitable 17 mm

deep-well crowsfoot socket.

5. Remove injection pump drive gear cover. Remove drive gear retaining nut and washer from end of pump shaft. Be careful not to let washer fall inside timing gear cover.

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Servicing

NOTE: The injection pump drive gear ﬁ ts snugly onto

a tapered drive shaft and indexed by a hollow pin or Woodruff key installed in drive shaft.

6. Attach JDG670A Drive Gear Puller (Figure 19-A) to injection pump drive gear as shown.

NOTE: Replace 6mm Grade 12.9 cap screws (C) as

needed.

7. Evenly tighten the two 6mm, Grade 12.9 screws (threaded in drive gear) and snugly tighten center forcing screw (Figure 19-B) against end of pump shaft.

RG7757

8. Tighten center forcing screw until pump drive gear is free from tapered shaft. Remove JDG670A puller

(Figure 19-A) and screws from drive gear.

9. Check to make sure that timing marks on back side of front plate (Figure 20-A) and injection pump ﬂ ange

(Figure 20-B) are present and properly aligned. This

assures that repaired or replacement pump can be properly timed to engine when installed.

IMPORTANT: Injection pump mounting ﬂ ange timing

mark (Figure 20-A ) and front plate timing mark (Figure 20-B) presence and alignment MUST be veriﬁ ed before removing pumps from engine. DO NOT reference internal timing marks (on pump cam ring and governor weight retainer). If timing mark is not clearly visible on front plate, make a visible reference mark as accurately as possible in-line with mark on pump ﬂ ange

10. Remove three injection pump mounting stud nuts. Remove injection pump from mounting studs.

11. Plug or cap all openings on injection pump and take pump to dealer for service

DB4 & DB2 INJECTION PUMP – INSTALLATION

1. Lubricate a new square sealing ring with clean engine oil. Install ring into groove on front face of pump mounting ﬂ ange. Slide injection pump onto mounting studs while inserting pump shaft into drive gear.

2. Check pump shaft and index pin for proper

alignment with pump drive gear key slot.

IMPORTANT: Shaft roll pin may be easily damaged

if improperly assembled. Pump drive gear should not move when initially installing pump index pin into drive gear key slot.

3. Install injection pump partially onto mounting studs without engaging pump pilot hub into engine front plate.

IMPORTANT: DO NOT tighten hex nuts more than

three full turns on mounting studs. Pump drive shaft index pin may be damaged if pin is not properly aligned with drive gear key slot and if the nuts are tightened more than three turns.

RG6293

OM2-2 06/10

4. Install three ﬂ at washers, lock washers, and hex nuts onto pump mounting studs. Tighten nuts three turns only so that pump will not fall off mounting studs.

NOTE: The pump drive gear should begin to move

forward (away from engine front plate) with the pump when ﬂ ange is approximately 1/8 in. (3.2 mm) away from engine front plate.

Page 24

Servicing

5. Install pump mounting ﬂ ange ﬂ ush to engine front plate with drive gear held ﬂ ush against front side of engine front plate.

IMPORTANT: Do not use tightening force of pump mount-

ing stud nuts to pull pump shaft into drive gear I.D.

With the pump shaft index pin properly engaged in the drive gear key slot, ﬁ nger tighten mounting stud nuts.

Push pump drive gear ﬁ rmly onto shaft taper. Install washer and retaining nut (Figure 21-C) onto end of shaft. Tighten retaining nut to 90 lb-ft. (122 N•m) for DB2, 150 lb-ft. (203 N•m) for DB4.

RG7630

RG5664

IMPORTANT: Do not overtighten cap screws on pump cover plate to avoid damage to O-ring.

8. Install access cover plate using a new gasket. Apply LOCITE 242 (TY9370) to cap screw threads and tighten to 1.7 lb-ft. (2 N•m).

Align timing mark on the pump ﬂ ange (Figure 22-B) with timing mark on the cylinder block front plate (A).

RG6278

10. Tighten the three hex nuts securing the pump to the front plate to 20 foot lbs. (27 N•m).

11. Connect injection pump pressure lines (Figure 23-E). Beginning with outlet connection to #1 cylinder (Figure

24-B) and continue around the pump head in counter-

clockwise direction, attaching lines in same order as engine ﬁ ring (1-5-3-6-2-4 on 6-cylinder engines and 1-3-4-2 on 4-cylinder engines).

RG9089

12. Tighten fuel delivery (pressure) lines to 20 foot lbs. (27 N•m), using a suitable 17 mm deep-well crowsfoot socket.

IMPORTANT: Always use a backup wrench when

loosening or tightening fuel delivery lines at fuel injection pump, so that the pump discharge ﬁ ttings are not altered. This prevents possible internal pump damage.

13. Connect fuel supply line (Figure 23-C) and fuel return line (Figure 23-D).

14. Connect fuel shutoff cable and speed control linkage, if equipped. Install and securely tighten electrical connections to shutoff solenoid and throttle positioning solenoid, if equipped. Connect cold start switch, if equipped.

15. Bleed air from fuel system as outlined on page 18. Start engine and run for several minutes. Check the entire system for leaks.

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Servicing

SP13. TURBOCHARGER

1. Check for air leaks every 100 hours. Air leakage will lower engine output and may cause black

exhaust smoke and soot.

2. Listen along air line while engine is running. A whistling or hissing sound indicates leakage.

3. Leakage on the pressure side, between turbo and engine, can be found by applying soapy water to the air line.

4. Tighten the hose clamps, replace hose or gaskets as required.

5. Check to see that the lubrication and cooling lines are tight and without leaks.

SP14. TURBO BOOST

1. This check measures the amount of air the turbo is pushing into the engine. It should be done by an authorized dealer every 500 hours.

2. On the inlet manifold there is a 1/8" NPT threaded port. Remove the plug and install the boost gauge hose. Refer to your engine speciﬁ cations for correct pressure.

2. Vapor bubbles (Figure 25-C) are formed when the piston's impact causes the liner walls to vibrate, sending pressure waves into the coolant.

3. These tiny vapor bubbles collect on the surface

of metal parts. As the bubbles collapse (pop) a

microscopic piece of metal is eroded from the

metal part. Over a period of time, this pitting may

progress completely through the cylinder liner of a wet-sleeve, heavy-duty diesel engine. This allows coolant to enter the combustion chamber. Engine failure or other serious damage will result.

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. A coolant 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, 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 25-A) which are in contact with engine coolant (Figure 25-B) can be eroded or pitted unless the proper concentration and type of SCA's are present in the coolant. Water pump impellers are also susceptible to pitting.

A - Cylinder Liner Walls B - Engine Coolant C - Vapor Bubbles

Figure 25

4. Unprotected engines with low quality water as coolant can have liner failure in as few as 500 hours.

WATER QUALITY

1. Distilled, deionized, soft water is preferred for use in cooling systems. Bottled distilled water from a food store or water supplier is recommended. Tap water often has a high mineral content. Tap water should NEVER be put in a cooling system unless ﬁ rst 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 speciﬁ cations:

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

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PH Level 5.5 to 9.0

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Servicing

3. If chlorides, sulfates or total dissolved solids are higher than the above given speciﬁ cation, 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 speciﬁ cations, the water must be softened before it is used to make coolant solution.

EGC: ETHYLENE GLYCOL CONCENTRATE (ANTIFREEZE)

CAUTION: EGC (Antifreeze) is ﬂ ammable. Keep it away from any open ﬂ ame. 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, ﬂ ush with large amounts of water for at least 15 minutes. Call a physician. KEEP OUT OF REACH OF CHILDREN. Follow all warnings on the container.

1. Ethylene glycol coolant concentrate is commonly mixed with water to produce an engine coolant with a low freeze point and high boiling point.

2. A low silicate form of ethylene glycol coolant is recommended for all diesel engines.

3. Use an ethylene glycol coolant concentrate

meeting ASTM D 4985P, SAEJ1941, General

Motors Performance Speciﬁ cation GM1899M,

or formulated to GM6038M.

4. This product is concentrated and should be mixed

to the following speciﬁ cation.

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

Optimum 50% 50%

-34°F +226°F

Minimum 60% 40%

-12°F +222°F

Maximum 40% 60%

-62°F +232°F

-37°C +109°C

-24°C +106°C

-52°C +111°C

IMPORTANT

1. 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.

2. DO NOT use an EGC containing sealer or stop-leak additives.

3. DO NOT use EGC containing more than 0.1% anhydrous metasilicate. This type of concentrate, which is intended for use in aluminum engines, may cause a gel-like deposit to form that reduces heat transfer and coolant ﬂ ow. Check container label or consult with supplier.

SUPPLEMENTAL COOLANT ADDITIVE (SCA)

CAUTION: Supplemental coolant additive contains alkali. Avoid contact with eyes. Avoid contact with skin. Do not take internally. In case of contact immediately wash skin with soap and water. For eyes, ﬂ ush 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. Important for heat exchanger cooled engines:

Additional SCA's should NOT be added to the

mixture of EGC/H20 on initial ﬁ ll up of engines

with a coolant conditioner-ﬁ lter. 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 ﬂ ow.

2. If additional SCA's are needed, prepare a mixture

of 50% quality water and 50%EGC (antifreeze). Add liquid SCA at a rate of 3%, by volume. Example: 30 mL of SCA per liter of H2O/EGC mixture (1.0 ﬂ oz of SCA per qt of H2O/EGC). Add the resulting mixture to the cooling system in

quart increments. Run the engine for 2 hours and retest the coolant. Continue process until SCA concentration meets recommended levels.

3. SCA is available from your Northern Lights dealer in the following sizes.

Pint - Part Number...............20-00002

1/2 gallon - Part Number.....20-00003

4. DO NOT use any coolant system additives

containing soluble oil.

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Servicing

COOLANT TESTING

1. Coolant test kits are available to allow on-site evaluation of the coolant condition.

2. The kits use small strips of paper which are dipped into the coolant. The paper changes color and indicates the SCA concentration. It also indicates the amount of EGC (antifreeze).

3. Test kits are available through your Northern Lights or Lugger Dealer.

4 Pack - Part Number.......................20-00005

50 Pack - Part Number.....................20-00010

SP15. CHECKING COOLANT LEVEL

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 ﬁ ller cap carefully, using protective clothing when the engine is warm.

1. Check the coolant level each day before starting the engine.

2. Remove the pressure cap from the expansion tank and check water level. In order to give the coolant

an opportunity to expand, the level should be about 1 3/4 in. (4-5 cm) below the ﬁ ller cap sealing surface

when the engine is cold. When ﬁ lling with coolant, the venting cock on top of the turbocharger (for engines ﬁ tted with turbocharger) should be opened to ensure that no air pockets form in the cooling system.

2. The pressure valve in the ﬁ ller 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.

4. The makeup coolant, added to compensate for loss or leaks, must meet engine coolant requirements outlined in previous section.

SP16. FLUSHING THE COOLING SYSTEM

CAUTION: The cooling water in the engine reaches extremely 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 ﬁ ller cap carefully, using protective clothing when the engine is warm.

1. Flush the cooling system and check for leaks and blockage every 2000 hours. 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, pages 4 - 6).

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, ﬂ ushing is complete.

7. Fill the fresh water system by pouring the

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 repair any leakage.

SP17. HEAT EXCHANGER CLEANING

1. Drain the cooling system.

2. Remove the cooling water pipes between the heat exchanger and the water pump inlet.

3. Disconnect hose to seawater pump.

4. Unscrew the attaching bolts holding the heat exchanger to the expansion tank.

5. Remove bolts holding heat exchanger cover.

6. Wash the core inside and out. If necessary, chemical agents can be used. Also clean the accessible parts of the heat exchanger housing.

7. Reassemble, using new gaskets and sealing rings.

SP19. ZINC ANODES

1. Zincs are installed in the cooling system to protect your engine from electrolysis. Check them faithfully every 250 hours. If you are in warm salt water or where electrolysis is a known problem, check them more often.

OM2-2 06/10

Page 28

Servicing

Heat exchanger cooled engine:

a. Drain the raw water from heat exchanger (see Component Locations). b. Remove zinc holders from back of the tank and from front and port side of the heat exchanger (see Component Locations).

Keel Cooled engines.

a. Drain expansion tank and remove zinc holder from tank (see Component Locations).

2. Scrape or steel brush the zinc electrode clean. If more than 50% of the electrode has eroded away, replace it with a new one. The electrode screws out of the holder.

3. Reinstall the zinc holders. Be sure the threads are clean and have good metal to metal contact.

SP20. RAW WATER PUMP

Heat exchanged cooled engines only.

1. Change the sea water pump impeller as needed.

2. Remove the pump end cover. Remove impeller with water pump pliers. Be sure you remove all pieces of a failed impeller.

3. Clean the inside of the housing.

4. Press in the new impeller and place the sealing washer in the outer end of the impeller center if this has not already been done.

5. Replace the cover using a new gasket.

Note: Make sure there is always an extra impeller

and cover gasket in reserve and on-board.

DRIVEN EQUIPMENT

Gears and PTO's

1. Manufacturer's service recommendations vary. See your Owner's Manual for service information. If you do not have a manual, see your local dealer for the equipment in question.

NOTE: Some PTO and marine gears have

rigid lubrication requirements. Follow service recom-

mendations closely.

Generator Ends

2. The maintenance and operation recommendations for the generator end are in a separate Owner's Manual. If you do not have one of these manuals, contact your local Northern Lights dealer.

ELECTRICAL SYSTEM - GENERAL

1. Never switch battery switch off or break the circuit between the alternator and batteries while the engine is running. Regulator damage can result.

2. DO NOT reverse the polarity of battery cables when installing the battery.

3. When welding on the unit, disconnect the regulator and battery. Isolate the leads.

4. Disconnect battery cables when servicing the DC alternator.

5. Never test with a screwdriver, etc., against any terminal to see if it emits sparks.

6. A DC circuit breaker protects your control panel and wiring harness.

OM2-2 06/10

Page 29

Servicing

BOOSTER BATTERIES

CAUTION: Battery Gas Can Explode. Keep all

ﬂ ames and sparks away from batteries.

1. Before changing or using booster batteries, check battery electrolyte level. Add distilled water.

2. Booster and main batteries must have the same voltage rating.

3. First, connect positive (+) terminal of booster

battery to positive (+) terminal of main battery.

Figure 26: Booster Battery Connections

4. Then, connect negative (-) terminal of booster battery to ground on the engine block (see Figure 26).

5. Remove booster battery after starting engine.

6. Sealed batteries: see manufacturer charging and booster instructions.

SP21-22. 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 corrosion 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 500 hours.

1. Change the engine oil and replace the ﬁ lter. Service the air cleaner.

2. Drain, ﬂ ush, and reﬁ ll the cooling system.

3. Crank the engine a few times with a starter, without starting the engine.

4. Remove and clean batteries.

5. All engine openings should be sealed with plastic bags and tape.

6. Store in a dry protected place.

To Remove Generator Set from Long-Term Storage:

1. Take off all protective coverings and unseal all the openings that were covered up.

2. Install batteries that are fully charged and connect the terminals.

3. Install the fan and alternator belts if they had been removed.

4. Fill the fuel tank.

5. Perform all pre-start checks.

6. Crank the engine for 20 seconds with the starter, without letting the engine start. Wait 2 minutes and crank the engine an additional 20 seconds to make sure all bearing surfaces are well coated.

7. Start the engine and run at no load in a low idle for several minutes. Make sure the engine is warmed up and check gauges before going under load.

8. Check all gauges and check for leaks.

SP26. CRANKCASE VENT SYSTEM

1. For sea water aftercooled units the crankcase vent system is a good option, and now standard equipment for M1064A, M1066A1, M1066A2, and M1066A3 units as of July 2008.

Check the red ﬁ lter service indicator button daily -

if it pops up the ﬁ lter 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 ﬁ lter canister because of engine operation may make it difﬁ cult to take apart.

Normally, the ﬁ lter element should be changed

every 750 hours.

SP24. WINTERIZING, OUT-OF-SERVICE

If the generator set will not be used for more than 6 months the following preparations should be taken for long term storage.

OM2-2 06/10

SP30. AFTERCOOLER

1. The aftercooler should be removed and inspected for deposits and the air side cleaned every 2000 hours.

Page 30

Troubleshooting

If you cannot correct problems with these procedures, see your Lugger or Northern Lights dealer.

DC ELECTRICAL SYSTEM

 Battery Will Not Charge

Loose or corroded connections:

• Clean and tighten battery connections. Sulfated or worn out batteries:

• Check speciﬁ c 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.

• Increase the engine RPM when there is a heavy electrical load.

Poor electrical connections on battery, ground strap,

starter, or alternator.

• Inspect 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:

• If the 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 speciﬁ c gravity of each battery cell.

• Check electrolyte level of each battery cell.

Defective electrical system ground wire:

• Repair or replace.

 Starter Cranks Slowly

Low battery output:

• Battery is too small.

• Battery cables are too small.

Check speciﬁ c gravity of each battery cell:

• Replace battery if necessary.

Check electrolyte level of each battery cell:

• If low, ﬁ ll cells with distilled water.

Crankcase oil too heavy:

• Fill with oil of appropriate viscosity. Loose or corroded connections:

• Clean and tighten loose connections.

 Starter and Hour Meter Function but rest of

Electrical System Does Not Function

Blown fuse on magnetic switch.

• Replace fuse.

 Entire Electrical System Does Not Function

Check DC circuit breaker:

• If breaker is tripped, reset it. Faulty connection:

• Clean and tighten battery and harness plug connections. Sulfated or worn out batteries:

• Check speciﬁ c gravity and electrolyte level of each battery cell.

ENGINE

 Engine Hard to Start or Will Not Start

Engine starting under load.

• Disengage PTO if applicable. Improper starting procedure:

• See starting section of this manual. Take special note of Bypass Switch operation. No fuel:

• Check level of fuel in fuel tank. Low battery output:

• Check electrolyte level and condition. Excessive resistance in starting circuit:

• Clean and tighten all battery connections. Crankcase oil too heavy:

• Use oil of proper viscosity. Improper type of fuel:

• Consult fuel supplier and use proper type of fuel for operating condition. Water, dirt or air in fuel system:

• Drain, ﬂ ush, ﬁ ll and bleed system. Clogged primary fuel ﬁ lter element:

• Clean or replace ﬁ lter element. Clogged secondary fuel ﬁ lter element:

• Replace ﬁ lter element. Dirty or faulty injection nozzles:

• Have your dealer check injection nozzles. Electronic Fuel System problem (if equipped):

• See your dealer. Injection pump not getting fuel or air in fuel system.

• Check fuel ﬂ ow at supply pump or bleed fuel system.

OM2-2 06/10

Page 31

Troubleshooting

If you cannot correct problems with these procedures, see your Lugger or Northern Lights dealer.

 Engine Runs Irregularly or Stalls

Frequently

Below normal engine temperature:

• Remove and check thermostat. Clogged primary fuel ﬁ lter element:

• Clean or replace ﬁ lter element. Clogged secondary fuel ﬁ lter element:

• Replace secondary ﬁ lter element. Water or dirt in the fuel system:

• Drain, ﬂ ush, ﬁ ll and bleed system. Dirty or faulty injection nozzles:

• Have your dealer check injection nozzles. Air in fuel system:

• Inspect clamps and hoses on suction side of fuel pump for air leak, bleed fuel system. Improper type of fuel:

• Consult fuel supplier and use proper type of fuel for operating condition.

 Lack of Engine Power

Intake air restriction:

• Service air cleaner.

• Service aftercooler. Clogged primary fuel ﬁ lter element:

• Clean or replace ﬁ lter element. Clogged secondary fuel ﬁ lter element:

• Replace ﬁ lter 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. Injection pump out of time.

• See your dealer. Electronic fuel system problem.

• See your dealer. Turbocharger not functioning (if equipped).

• See your dealer. Leaking exhaust manifold gasket.

• See your dealer. Defective aneroid control line.

• See your dealer. Restricted fuel hose.

• Clean or replace fuel hose. Low fast idle speed.

• See your dealer. Improper valve clearance:

• Reset valves. Best done by dealer.

Dirty or faulty injection nozzles:

• Replace injectors. Best done by dealer.

• See your local dealer.

 Engine Overheats

Engine overloaded.

• Reduce the load. Low coolant level:

• Fill tank or radiator to proper level.

• Check hoses for loose connections and leaks. Keel cooling tubes have been painted (marine):

• Remove paint from tubes. Stretched belt or defective belt tensioner.

• Check automatic belt tensioner and check belts for stretching. Replace as required.

Low engine oil level.

• Check oil level, add oil as needed.

Incorrect grade of fuel.

• Use correct grade of fuel.

Cooling system needs ﬂ ushing:

• Flush cooling system.

Defective thermostat:

• Remove and check thermostat.

Defective temperature gauge:

• Check water temperature with thermometer

and replace gauge if necessary. Water pump impeller worn/broken:

• Check impeller and replace if necessary.

 Engine Knocks

Low oil level:

• Add oil to engine crankcase.

Injection pump out of time:

• Call your dealer.

Below normal engine temperature:

• Check your thermostats.

• Check water temperature to see if temperature

gauge is working properly. Engine overheating:

• See “Engine Overheating” section.

OM2-2 06/10

Page 32

Troubleshooting

If you cannot correct problems with these procedures, see your Lugger or Northern Lights dealer.

 High Fuel Consumption

Engine overloaded.

• Reduce load. Air in fuel system:

• Bleed fuel system.

Improper type of fuel:

• Use correct fuel for temperature. Clogged or dirty air cleaner:

• Service air cleaner. Improper valve clearance:

• See your dealer. Injection nozzles dirty:

• See your dealer. Injection pump out of time:

• See your dealer. Electronic fuel system problem.

• See your dealer. Engine not at proper temperature:

• Check your thermostats.

• Check water temperature with thermometer and replace gauge if necessary.

 Below Normal Engine Temperature

Thermostats not working properly:

• Check thermostats. Temperature gauge not working properly:

• Check water temperature with thermometer.

 Low Oil Pressure

Low oil level:

• Fill crankcase to proper level. Improper type of oil:

• Drain and ﬁ ll crankcase with correct oil. Partially plugged oil ﬁ lter:

• Replace ﬁ lter.

 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:

• Service aftercooler. Defective mufﬂ er (back pressure too high):

• Have dealer check back pressure.

Improper fuel:

• Use correct fuel for temperature. Engine overloaded.

• Reduce load. Electronic fuel system problem.

• See your dealer. Turbocharger not functioning.

• See your dealer. Injection nozzles dirty:

• See your dealer. Engine out of time:

• See your dealer.

 Engine Emits White Smoke

Improper fuel:

• Use correct fuel for temperature. Cold engine:

• Warm up engine to normal operating temperature. Defective thermostat:

• Remove and check thermostat. Engine out of time:

• See your dealer. Defective injection nozzles.

• See your dealer.

OM2-2 06/10

Page 33

AC Wiring Diagram

Drawing B-5689D

A.C. Wiring - All voltages

with an APR63-5 (Non-PMG)

OM2-2 06/10

Page 34

A.C. Wiring Diagram

Drawing B-7429G

A.C. Wiring - All voltages

with an AVC63-12B1 (PMG)

OM2-2 06/10

Page 35

D.C. Wiring Diagram

D.C. Wiring - 12 Volt Standard

Ground for M1064D and M1064T1

Drawing C-5453J

OM2-2 06/10

Page 36

D.C. Wiring Diagram

Drawing C-5548J

Ground for M40C2 and M55C2

D.C. Wiring - 12 Volt Standard

OM2-2 06/10

Page 37

D.C. Wiring Diagram

M40C2, and M55C2

D.C. Wiring - 12 Volt Isolated

Ground for M1064D, M1064T1,

Drawing C-6062A

OM2-2 06/10

Page 38

D.C. Wiring Diagram

Drawing C-5545C

M1064D and M1064T1

D.C. Wiring - 24 Volt Standard Ground for

OM2-2 06/10

Page 39

D.C. Wiring Diagram

D.C. Wiring - 24 Volt Standard

Drawing C-5562B

Ground for M40C2 and M55C2

OM2-2 06/10

Page 40

D.C. Wiring Diagram

OM2-2 06/10

Drawing C-5759C

D.C. Wiring - 24 Volt Isolated

Ground for M1064D and M1064T1

Page 41

D.C. Wiring Diagram

Ground for M40C2, & M55C2

D.C. Wiring - 24 Volt Isolated

Drawing C-5623

OM2-2 06/10

Page 42

D.C. Wiring Diagram

Drawing C-5823C

D.C. Wiring - 12 Volt Standard Ground for

M1064T2, M1064A, M1066T, and M1066A1

OM2-2 06/10

Page 43

D.C. Wiring Diagram

D.C. Wiring - 12 Volt Standard Ground for

Drawing C-5808E

M65C2 and M99C2

OM2-2 06/10

Page 44

D.C. Wiring Diagram

Drawing C-6594

D.C. Wiring - 12 Volt Isolated Ground for

M10642, M1064A, M1066T, and M1066A1

OM2-2 06/10

Page 45

D.C. Wiring Diagram

D.C. Wiring - 12 Volt Isolated

Drawing C-6335A

Ground for M65C2 and M99C2

OM2-2 06/10

Page 46

D.C. Wiring Diagram

Drawing C-5910E

D.C. Wiring - 24 Volt Standard Ground for

M1064T2, M1064A, M1066T, and M1066A1

OM2-2 06/10

Page 47

D.C. Wiring Diagram

D.C. Wiring - 24 Volt Standard

Drawing C-5794C

Ground for M65C2 and M99C2

OM2-2 06/10

Page 48

D.C. Wiring Diagram

Drawing C-5809F

M65C2, and M99C2

M1064T2, M1064A, M1066T, M1066A1,

D.C. Wiring - 24 Volt Isolated Ground for

OM2-2 06/10

Page 49

OM2-2 01/10

Page 50

D.C. Wiring - 12 Volt Standard Ground for

M1066A2 and M1066A3

Drawing D-3769B

Page 51

D.C. Wiring - 12 Volt Isolated Ground

for M1066A2 and M1066A3

Drawing D-3770B

Page 52

OM2-2 01/10

Page 53

D.C. Wiring - 12 Volt Isolated Ground

for M1066A2 and M1066A3

Drawing D-3770B

Page 54

OM2-2 01/10

Page 55

D.C. Wiring - 24 Volt Standard Ground

for M1066A2 and M1066A3

Drawing D-3771B

OM2-2 01/10

Page 56

Page 57

D.C. Wiring - 24 Volt Isolated Ground for

M1066A2 and M1066A3

Drawing D-3772C

Page 58

OM2-2 01/10

Page 59

On Board Spare Parts

Safety at sea depends on careful preparation, product knowledge, and having the right tools and parts. Below is a list of parts Northern Lights, Inc. recommends you carry onboard at all times.

Onboard Parts Kits are available from your dealer.

We consider these minimum quantities. Your vessel's operating conditions may require more of a given part. Consult your dealer. The example below lists typical items for either heat exchanged or keel cooled engines.

Item Description Quantity

1 Lube Oil Filter 4 2 Air Filter Element 1 3 Fuel Filter 2 4 Fuel Filter Element 4 5 Fuel Lift Pump 1 6 Injector 1 7 Thermostat 2 8 Thermostat Seal Ring 2 9 Thermostat Cover Gasket 1 10 Rocker Cover Gasket 2 11 Engine Overhaul Gasket Kit 1 12 Zinc Anode* 6 13 Raw Water Pump Impeller* 2 14 Raw Water Pump Cover Gasket* 2 15 Raw Water Pump* 1 16 Raw Water Pump Bearing* 2 17 Coolant Pump Repair Kit 1 18 Coolant Pump Gasket 1 19 Drive Belt 1 20 Workshop Manual 1

*Heat exchanger cooled engines only

OM2-2 06/10

Page 60

www.northern-lights.com

4420 14th Ave. NW., Seattle WA 98107 Tel: (206) 789-3880 • 1-800-762-0165 • Fax: (206) 782-5455 Northern Lights and Lugger are registered trademarks of Northern Lights, Inc. © 2010 All rights reserved. Litho USA.