Northern Lights L1064D, L1064A, L1066T, L1066A Operator's Manual

OPERATOR’S

MANUAL

Publication #OL2-2 for models:

L1064D, L1064A, L1066T, and L1066A

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constituents

are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

Northern Lights

4420 14th Avenue N.W. P.O. Box 70543 Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455

Copyright ©2004 Alaska Diesel Electric, Inc. All rights reserved. Alaska Diesel Electric™, the Alaska Diesel Electric logo, Northern Lights™, and the Northern Lights logo are all trademarks of Alaska Diesel Electric, Inc.

Printed in U.S.A. PART NO.: OL2-2 01/05

OPERATOR'S MANUAL

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

#OL2-2 for Models

L1064D, L1064A, L1066T, and L1066A

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

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

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

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

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

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

COMPONENT LOCATIONS ..........................4 - 5

LUGGER CONTROL PANEL ............................. 6

OPERATING PROCEDURES

Before Starting .................................................. 7

Shutdown Procedures ........................................ 7

Break-In Period ................................................. 8

SERVICING SCHEDULE CHART .............. 9 - 10

SERVICE RECORD ............................................ 11

SERVICING

Lubrication - General ...................................... 12

Checking Oil ................................................... 12

Oil Changes ..................................................... 12

Changing Oil Filter.......................................... 12

Air Filter .......................................................... 12

Valve Clearances............................................. 13

Fuels - General ................................................ 14

Fuel Filters....................................................... 14

Crankshaft Vibration Damper ......................... 14

Bleeding the Fuel System................................15

Injector Service ....................................... 15 - 16

Injection Pump ........................................ 17 - 20

Turbocharger ................................................... 21

Turbo Boost..................................................... 21

Cooling System - General ............................... 21

Engine Coolant Specifications ................ 21 - 22

Cooling System Flushing ................................ 23

Heat Exchanger Cleaning................................ 23

Zinc Electrodes................................................23

Raw Water Pump ............................................ 24

Electrical System - General............................. 24

Booster Batteries ............................................. 25

Battery Care..................................................... 25

Winterizing / Out-of-Service........................... 25

TROUBLESHOOTING

Electrical.......................................................... 26

Engine...................................................... 27 - 28

WIRING DIAGRAMS

Lugger DC Electrical .............................. 29 - 36

ON-BOARD SPARE PARTS............................. 37

Proprietary Information

This publication is the property of Alaska Diesel Electric, Inc.

It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc.

OL2-2 01/05

Introduction

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

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

routine maintenance. 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:

L - Lugger marine propulsion engine

1064 or 1066

Lugger model number

106 mm bore, 4 cylinder

106 mm bore, 6 cylinder

D, T , or A

D - Naturally aspirated

T - Turbocharged

A - Aftercooled

L1064D

L1064A

Lugger® naturally aspirated marine propulsion

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

Lugger

aftercooled marine propulsion engine with a John Deere Powertech Tier II 4045 engine block, with a electronically controlled fuel system.

L1066T

L1066A

Lugger® turbocharged marine propulsion

engine with a John Deere Powertech Tier II 6068 engine block, electronically controlled fuel system.

Lugger

aftercooled marine propulsion engine with a John Deere Powertech Tier II 6068 engine block, electronically controlled fuel system.

Serial Numbers

When referencing Alaska Diesel Electric equipment by serial number, please refer only to the number stamped on the Northern Lights® or Lugger® serial number plate.

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Warranty

A warranty registration certificate is supplied with your set. It entitles the original purchaser of our equipment to a warranty covering material or assembly faults. The extent of coverage is

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. described in the Limited Warranty Statement. We recommend that you study the statement carefully.

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 fire extinguisher near engine.

• Always disconnect the battery ground strap

before making adjustments.

• Operate engines in properly ventilated areas.

• Keep trash and other objects away from engine.

• Escaping fluids under pressure can penetrate

your skin. Use a piece of cardboard or wood, not your hands, to search for leaks.

• Avoid wearing loose clothing without a belt

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 filling 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, qualified 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 constituents

are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

OL2-2 01/05

• Provide first aid kits.

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

Lugger Component Locations

Figure 1 & 2: L1064D

1. Expansion Tank

2. Coolant Fill

3. Exhaust Manifold

4. Air Cleaner

5. Dry Exhaust Elbow

6. Marine Gear

7. Oil Pan

8. Injection Pump

9. Mounting Foot

10. Heat Exchanger Zincs

11. Heat Exchanger

12. Rocker Arm Cover

13. Alternator

14. Raw Water Pump

15. Dipstick

16. Starter

17. Secondary Oil Filter

18. Primary Oil Filter

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Lugger Component Locations

Figure 3 & 4: L1066T

1. Expansion Tank

2. Coolant Fill

3. Dry Exhaust Elbow

4. Turbocharger

5. Air Cleaner

6. Gear Filter

7. Gear Output Flange

8. Gear Dipstick

9. Marine Gear

10. Mounting Foot

11. Starter

12. ECU (Electronic Control Unit)

13. Second Alternator (Optional)

14. Gear Oil Cooler

15. Exhaust Manifold

16. Alternator

17. Belt Guard (2nd Alternator optional)

OL2-2 01/05

18. Oil Pan

19. Dipstick

20. Primary Oil Filter

21. Secondary Oil Filter

22. Intake Manifold

Lugger Control Panel

Figure 5: Lugger Powerview Control Panel

1. TACHOMETER

The tachometer shows the engine speed in revolutions per minute (RPM). Numbers are multiples of

100.

2. HOUR METER

Keeps track of the engine running time.

3. DC VOLTMETER

When the engine is stopped, the voltmeter shows the condition of the battery, When the engine is running, it indicates the voltage output of the alternator.

4. KEY SWITCH

Turning the key clockwise to the first position will switch on the current. continue turning the key clockwise to start the engine. When the engine starts, immediately turn the key back to the first position while the engine is running.

The key must be kept in the on or first position while the engine is running. Turn the key counterclockwise as far as possible to stop the engine.

Note: Optional flybridge panels have engine start switches instead of key switches.

5. POTENTIOMETER

Dims the panel lights.

6. ALARM HORN

Shut down engine if possible and investigate immediately.

7. COOLANT TEMPERATURE GAUGE

Water temperature gauge shows the temperature of the cooling water. If the gauge registers over 200° or drops below 140°, stop the engine and investigate.

8. 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 immediately.

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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 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 #13).

CAUTION: Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns.

2. Check the oil level in the crankcase with the dipstick. The oil level should be between the “waffled area” and the “oo”. Never allow the level to go below the “oo”. Always add the same viscosity of oil as is already in the crankcase (see Service Point #1).

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

4. Disengage clutch, if equipped.

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

6. Place the battery switch in the ON position.

Operating

1. Check oil pressure as soon as the engine has started. Oil pressure should be above 15 PSI. The engine must never be run if the oil pressure is below 15 PSI.

2. Check the voltmeter. It should read 13 to 14 volts (26 to 28 volts for 24 volt systems) at 60°F (16°C).

3. Water temperature should not rise over 200°F (94°C). If it does, shut down the engine and investigate the cause of overheating.

4. Do not exceed 800 RPM when shifting marine gear. Repeated shifts at higher engine speeds can damage the reverse gear.

5. If the proper propeller is used, the engine should reach its approximate RPM’s at full throttle. If the maximum rated RPMs for your engine application is exceeded at full throttle, then your propeller is too small. If you cannon reach your maximum rated RPMs at full throttle, either your propeller is too large or bottom growth is slowing the boat.

6. To establish maximum cruising RPM: establish the RPM at full throttle and subtract 200-300 RPM. This will promote engine life and reduce fuel consumption.

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. Put the gear control in the neutral position.

2. Move the throttle control to the full speed position and return back to idle.

3. Turn the key switch to the first position. Check the voltage meter to see the condition of the batteries. For starting, the voltmeter should not read below 12 volts (24 volts for 24 volt systems).

4. Turn the key to the starting position and as soon as the engine starts, release the key. Move the throttle up until the engine is running at approximately 1000 RPM.

5. Do not crank the starter for more than 15 seconds consecutively. If the engine fails to start with the first attempt, be sure that the starter has stopped completely before re-engaging.

NOTE: Never race a cold engine. Operate at 1000 RPM for a 3 to 5 minute warm-up period.

Shutdown

1. Run engine three to five minutes in neutral at 1000 RPM, for cool down period.

2. Return engine to low idle.

3. Turn the key switch counterclockwise as far as possible to stop the engine.

4. Close the sea cock and fuel valves and put the battery switch in OFF position.

NOTE: Do not turn the battery switch to OFF while the engine is running.

SHUTDOWNS AND ALARMS

1. Your unit is fitted with a warning system to indicate high water temperature or low oil pressure. Propulsion engines have warning horns to sound and warn you of a problem. Remember - when the engine is not running the horn will sound when key is in the “ON” position because there is no oil pressure.

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.

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Operating Procedures

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.

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

protective clothing.

c. Make repairs and restart after the temperature

gauge registers below 180°F (83°C).

d. Watch the temperature gauge regularly and turn

off the unit if the temperature rises above 200°F (94°C). Repeat the troubleshooting process.

3. If the shutdown is activated and the temperature gauge shows temperature within normal temperature range:

a. Check the engine crankcase oil level. b.

If the oil level is low, fill with recommended lubricating oil and restart. Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading after a few seconds of operation.

c. If the oil level was normal, DO NOT restart the

engine. Call your Northern Lights or Lugger dealer for assistance.

BREAK-IN PERIOD

1. The first 100 hours on a new or reconditioned engine are critical to its life and performance.

2. Constantly check the engine temperature and oil pressure gauges.

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

4. Break-In Oil Changes: Change engine oil and filter at 50 hours. Change oil and filter again at 100 hours (See Gear Owner's Manual for break-in oil change procedures. Consult Lubricants Section for oil recommendation).

Operating Instructions

Never run full speed for more than 5 minutes during the first 50 hours. Run engine at 50% to 75% of maximum working speed for the first 20 hours with as little idling time as possible. Extended idling can inhibit ring seating, causing cylinder walls to glaze.

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Service Schedule Chart, Mechanically Controlled Fuel System

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

DAILY:

SP1 Check oil level in engine SP8 Check primary fuel filter SP15 Check cooling water level

AFTER FIRST 50 HOURS:

SP2 Change engine oil SP3 Change lube oil filter

EVERY 50 HOURS:

SP21 Check electrolyte in batteries

FIRST 100 HOURS:

SP2 Change engine oil SP3 Change lube oil filter

EVERY 250 HOURS:

SP2 Change engine oil SP3 Change lube oil filter SP4 Check air cleaner SP9 Change primary fuel filter element SP13 Check turbocharger air, oil & cooling lines for leakage SP19 Check zinc electrodes

SERVICE 50 250 600 1200 2400

POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours

ENGINE:

SP1 15 Check oil level ● SP2 15 Change engine oil 1) 2) ● SP3 15 Change lube oil filters 1) 2) ● 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 ●

FUEL SYSTEM:

SP8 17 Check primary filter (Racor) 3) ● SP9 17 Change primary filter element (Racor) 3) 4) ●

SP10 17 Change secondary fuel filter 2) 4) ●

SP11 18-19 Check injectors 2) ● SP12 20-22 Check fuel injection pump ●

TURBOCHARGER:

SP13 23 SP14 23 Check boost pressure ●

Check air, oil & cooling water lines for leakage

COOLING SYSTEM:

SP15 25 Check cooling water level ● SP16 25 Check and flush cooling system 2) ● SP17 25 Check and clean heat exchanger 2) ● SP18 Check and clean gear oil cooler 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 ●

OUT OF SERVICE:

SP24 27 Winterizing or out-of-service 4)

SP23 Test thermostats

AFTER FIRST 600 HOURS:

SP6 Adjust valves

EVERY 600 HOURS / YEARLY:

SP4 Replace air cleaner SP5 Check V-belt condition SP7 Check crankshaft vibration damper SP10 Change secondary fuel filter SP11 Check injectors SP14 Check turbocharger boost pressure SP16 Check and flush cooling system SP20 Change impeller in raw water pump SP22 Check the state of the charge of the batteries

EVERY 1200 HOURS:

SP6 Adjust valves

EVERY 2400 HOURS:

SP12 Check fuel injection pump SP17 Check and clean heat exchanger SP18 Check and clean gear oil cooler

●

1) Change the oil and filter before the first 100 hours of operation during engine break-in.

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

3) Consult manufacturer's maintenance schedule, note on chart.

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4) Whenever necessary.

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