Northern Lights L6125, M6125 Operator's Manual

OPERATOR’S

MANUAL

L6125 and M6125

O6125

For Models

— 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. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455

Printed in U.S.A. PART NO.: O6125 03/03

O6125

OPERATOR'S MANUAL FOR MODELS

L6125 and M6125

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

Unit Identification

Model Designation........................................ 2

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

Warranty ............................................................... 3

Safety Rules ......................................................... 3

Component Locations

Lugger Propulsion ........................................ 4

Northern Lights Marine Generator Set ...... 5

Panels

Lugger Propulsion Engine........................... 6

Series 3 & 4 Generator Sets .......................... 7

Operating Procedures

Before Starting ............................................... 8

Generator........................................................ 8

Propulsion Engine.................................... 8 - 9

Shutdown Procedures .................................. 9

Shutdowns & Alarms ................................... 9

Break-in Period .............................................. 9

Servicing Schedule Chart................................ 10

Service Record................................................... 11

Servicing

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

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

Changing Oil Filter ..............................12 - 13

Air Filter ....................................................... 13

V-Belts........................................................... 13

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

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

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

Bleeding the Fuel System ........................... 14

Injectors..................................................14 - 15

Injection Pump............................................. 15

Servicing (cont.)

Injection Pump Timings ............................. 16

Turbocharger ............................................... 17

Turbo Boost .................................................. 17

Cooling System Requirements ...........18 - 20

Checking Coolant Level ............................. 20

Flushing the Cooling System..................... 20

Heat Exchanger Cleaning .......................... 21

Cleaning Gear Oil Coolers ......................... 21

Zinc Electrodes ............................................ 21

Raw Water Pump ........................................ 21

Coolant Filter ............................................... 21

Gears, PTOs, and Generators .................... 21

Electrical System - General ........................ 22

Booster Batteries .......................................... 22

Battery Care ................................................. 22

Winterizing - Out-of-Service ..................... 22

Propeller Sizing Chart ..................................... 23

Data Sheets

Lugger........................................................... 24

Northern Lights Marine ............................. 25

Troubleshooting

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

Engine ........................................................... 27

DC Wiring Diagrams

12 Volt Lugger Engine................................ 28

24 Volt Lugger Engine................................ 29

12 Volt Marine Generator Set .................... 30

24 Volt Marine Generator Set .................... 31

Onboard Spare Parts ........................................ 32

Proprietary Information

in whole or part without the written permission of Alaska Diesel Electric, Inc. ©Alaska Diesel Electric, Inc.

This publication is the property of Alaska Diesel Electric, Inc. It may not be reproduced

O6125 03/03

INTRODUCTION

Servicing of marine engines and generator sets presents unique problems. In many cases boats cannot be moved to a repair facility. Marine engines cannot be compared to the servicing of automobiles, trucks or even farm equipment. Failures often occur in remote areas far from competent assistance. Marine engines are taxed far more severely than auto or truck engines; therefore, maintenance schedules must be adhered to more strictly.

Failures usually begin with minor problems that become amplified when not corrected during routine maintenance.

As owner-operator, it is your obligation to learn about your equipment and its proper maintenance. This manual 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 and servicing your equipment properly.

UNIT IDENTIFICATION

MODEL NUMBER

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

L - M - NL 6125 A, H, T, QA, QT

L - Lugger marine propulsion engine Model number of A - Aftercooled (turbo) M - Northern Lights marine generator set Komatsu engine block H - High Output NL - Northern Lights industrial generator set 6 cylinder, 125 mm bore T - Turbocharged

QA - (1200 RPM), Aftercooled QT - (1200 RPM), Turbo-

charged

Examples:

L6125A

M6125T

M6125QT

Lugger turbocharged-aftercooled marine propulsion engine. Komatsu 6125 block.

Northern Lights turbocharged 1800 or 1500 RPM marine diesel generator set. Komatsu 6125 block.

Northern Lights turbocharged 1200 RPM marine diesel generator set. Komatsu 6125 block.

M6125QA

Northern Lights aftercooled 1200 RPM marine diesel generator set. Komatsu 6125 block.

SERIAL NUMBERS

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

O6125 03/03

WARRANTY

A warranty registration certificate is supplied with your set. It entitles the original purchaser of this equipment to a warranty covering material or assembly faults. The extent of coverage is described in the Limited Warranty Statement. We recommend that you study the statement carefully.

SAFETY RULES

Accident reports show that careless use of engines cause a high percentage of

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

• Never leave engine without proper security.

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

• Mount fire extinguisher near engine.

• Always disconnect the battery ground strap before making adjustments.

• Operate engines in properly ventilated areas.

• Keep trash and other objects away from engine.

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

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.

• Avoid wearing loose clothing without a belt when working around engines.

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

• 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.

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

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

• Provide first aid kits.

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COMPONENT LOCATIONS

Lugger Propulsion L6125A

Figure 1. L6125A

1. Coolant Filter

2. Raw Water Pump

3. Jacket Water Drain

4. Raw Water Zincs (2)

5. Heat Exchanger End Cover

6. Expansion Tank

7. Jacket Water Filler Cap

8. Jacket Water Zinc (2)

9. Lube Oil Fills (2)

10. Lube Oil Dipstick

11. Aftercooler

12. DC Circuit Breaker & Relays

13. Air Cleaner

14. Lube Oil Drain Pump (opt.)

15. DC Harness Plug-Ins

16. Lube Oil Filter

17. Secondary Fuel Filter

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18. Injection Pump

19. Manual Fuel Prime Pump

20. Raw Water Drain

21. DC Alternator

22. Starboard Oil Dipstick (opt.)

23. Gear Oil Cooler Drain

24. Gear Oil Cooler

25. Block Drain (behind Gear Oil Cooler)

26. Engine Oil Cooler

27. Starter

28. Gear Oil Dipstick

29. Manifold Drain

30. Turbocharger

31. Jacket Water Vents (2)

32. Rocker Arm Cover

33. Fuel Injector

COMPONENT LOCATIONS

M6125A Northern Lights Marine Generator Set

Figure 2. M6125A Generator Set

1. Coolant Filter

2. Raw Water Pump

3. Jacket Water Drain

4. Raw Water Zincs (2)

5. Heat Exchanger End Cover

6. Expansion Tank

7. Jacket Water Filler Cap

8. Jacket Water Zinc (2)

9. Lube Oil Fills (2)

10. Lube Oil Dipstick

11. Aftercooler

12. Crankcase Vent

13. Injection Pump

14. Air Cleaner

15. Lube Oil Drain

16. Electronic Governor (opt.)

17. Primary Fuel Filter (opt.)

18. Lube Oil Filter

19. Secondary Fuel Filter

20. Fuel Manifold

21. Manual Fuel Prime Pump

22. Raw Water Drain

23. DC Alternator

24. Jacket Water Pump

25. Base Frame

26. Oil Pan

27. Block Drain

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28. Engine Oil Cooler

29. Starter

30. Data Plate

31. Manifold Drain

32. Dry Exhaust Elbow

33. Turbocharger

34. Jacket Water Vents (2)

35. Rocker Arm cover

36. Fuel Injector

INSTRUMENT PANEL

Lugger Marine Propulsion Engine

1. OIL PRESSURE GAUGE:

The oil pressure gauge shows the oil pressure in the engine lubricating system. If the oil pressure drops BELOW 15 PSI at a speed higher than idling, stop engine immediately and investigate.

2. WATER TEMPERATURE GAUGE:

This gauge shows the temperature of the cooling water. If a temperature of over 205 indicated, stop engine and investigate immediately.

3. TACHOMETER:

The tachometer shows the engine speed in revolutions per minute (RPM). Numbers are multiples of 100.

4. VOLTMETER:

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

5. HOUR METER:

The hour meter keeps track of the accumulated length of the engine's operating time.

6. KEY SWITCH:

The key must be kept in "ON" position while the engine is running.

7. STOP BUTTON:

Hold down until engine is completely stopped.

8. INSTRUMENT LIGHTING DIMMER :

Adjust instrument panel lights. (On some panels this is an on/off switch and not a dimmer.)

9. WARNING LIGHTS:

a. Light comes on when oil pressure is too low. b. Light comes on when engine is too hot.

10. ALARM HORN:

Will sound in case of overheating or low oil pressure. Stop engine and investigate. Remember horn will sound when key is in "ON" position with engine stopped because there is no oil pressure.

11. START BUTTON:

Will start engine only if key on main panel is in "ON" position.

12. EXHAUST TEMPERATURE:

Maximum temperature: 975°F (510°C).

13. TURBO BOOST GAUGE:

See page 17 for boost range.

14. GEAR PRESSURE GAUGE:

See Gear Manual for operating range.

Auxilliary Panel

Figure 5 -

Figure 3 - Main Panel Figure 4 - Flybridge Panel

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CONTROL PANELS

Northern Lights Generator Sets

SERIES 3 GENERATOR CONTROL PANEL

1. SHUTDOWN BYPASS PREHEAT SWITCH:

Two functions are built into this switch: The preheating of the engine, and bypassing of the engine safety shutdown circuit, enabling a quicker start. Hold switch in up position 10-20 seconds before starting engine, and continue holding in up position while starting engine. Holding the switches on too long can burn out the heater elements.

2. ENGINE CONTROL SWITCH:

To start the engine, hold switch in start position until the engine is running. After the engine starts, release switch and it will return to the center position. To stop engine, move switch to stop position and release.

3. OIL PRESSURE GAUGE:

The oil pressure gauge shows the oil pressure in the engine lubricating system.

Figure 6.

SERIES 4 GENERATOR CONTROL PANEL

4. WATER TEMPERATURE GAUGE:

Registers temperature of cooling water.

5. HOUR METER:

Keeps track of engine running time.

6. D.C. VOLTMETER:

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

For Series 4 Control Panels Only:

7. A.C. VOLTMETER:

Shows the generator output voltage.

8. FREQUENCY METER (HERTZ):

The frequency meter indicates the frequency of alternating current: 1200 or 1800 RPM (60 Hz), 1500 RPM (50 Hz).

9. AMMETER SELECTOR SWITCH:

Used to check each phase for load condition. You must always leave this switch in the "ON" position while the unit is running.

Figure 7.

10. A.C. AMMETER

Shows the generator load on each phase. The phase is selected on the Ammeter Selector Switch (switch #9 above).

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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 an opportunity to expand, the level should be about 1 3/4 in. (4-5 cm) below the filler cap sealing surface when the engine is cold. When filling with coolant, all the venting cocks should be opened to ensure that no air pockets form in the cooling system. (See Service Point 14,

page 20)

CAUTION: Use protective clothing and open

the filler cap carefully when the engine is warm to prevent burns.

2. Check the oil level in the crankcase with the dipstick. The oil level must be in the waffled area between the "L" and "H." Never allow the level to go below the "L." Always add the same viscosity of oil as is already in the crankcase. (See Service Point 1, page 12)

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

4. Propulsion Only: Check the oil level in the reverse gear. Methods may vary from gear to gear. See your Gear Owner's Manual.

5. Close the sea cock, check and clean the strainer and reopen the sea cock.

6. Place the battery switch in the ON position.

NOTE: The battery switch must always be kept ON

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

GENERATOR

Starting

1. While holding the Shutdown Bypass-Preheat switch in ON position, push the Engine Control switch to START position. As soon as the engine starts, release both switches. Do not crank the starter for more than 20 seconds. If the engine fails to start the first time be sure the starter has stopped before reengaging.

2. Cold Weather: Hold Shutdown Bypass-Preheat switch in the ON position for 30 seconds before starting. This will warm the air heater elements and will ease starting. This is not necessary if engine is warm. A longer preheat time may be required in extremely cold weather.

Operating

1. Check Gauges Often: Oil pressure must be

above 29 PSI. The DC voltmeter should read between 13 and 14 volts (26-28 volts, 24 volt systems) at 60 Water temperature gauge must be below 205

(96

C). Check AC voltage and frequency meters.

F (16oC) ambient temperature.

If gauges deviate from normal levels, shut down the set and investigate.

2. Let the unit run unloaded for a three to five minute warm-up period.

3. Do not add full electrical load until the engine has reached normal operating temperature.

PROPULSION ENGINE

Starting

1. Put the gear control in the neutral position.

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

3. Turn the key switch to the first position. Check the 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. In cold weather, turn the key to the preheat position and hold there for 20-30 seconds.

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

6. Do not crank the starter for more than 20 seconds consecutively. If the engine fails to start with the first attempt, be sure that the starter has stopped completely before re-engaging.

NOTE: Never race a cold engine. Operate at 1000

RPM for a 3-5 minute warm-up period.

Operating

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

2. Check the voltmeter. It should read 13 to 14 volts (26-28 volts, 24 volt systems) at 60

3. Water temperature should not rise over 205

(96

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. Low Idle is 650 RPM. Maximum working engine speed is: 2300 RPM for pleasure craft, 2300 RPM for light commercial craft and 2100 RPM for continuous duty applications.

F (160C).

O6125 03/03

OPERATING PROCEDURES

6. If the proper propeller is used, the engine should reach its appropriate maximum speed at full throttle. If at full throttle the maximum speed is exceeded, then the propeller is too small. If maximum speed cannot be attained, then the propeller is too large or bottom growth may be slowing the boat. (See Prop Chart, page 23.)

7. To Establish Maximum Cruising RPM: Establish the RPM at full throttle and subtract 200300 RPM. This will promote engine life and reduce fuel consumption.

SHUTDOWN PROCEDURES

1. Run for three to five minute cool down period.

a. Propulsion engines in neutral at 1000 RPM,

then return throttle to low idle.

b. Generators unloaded.

2. Push STOP button until the engine has completely stopped. Turn key switch to OFF position.

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

NOTE: Do not turn battery switch to OFF while

engine is running.

SHUTDOWNS AND ALARMS

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

a. Generator sets have shutdown systems to stop

the engine. They have no warning horns.

b. Propulsion engines have warning horns to

sound and warn you of a problem. Remember: when engine is not running the horn will sound when key is in the "ON" position because there is no oil pressure. Propulsion engines do not have shutdown systems.

c. Other alarms and shutdowns are available as

optional equipment.

NOTE: Do not rely on your warning 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 warning or shutdown system is activated.

a. Check the temperature gauge. If the tempera-

ture is above 205 immediately.

b. Use the Trouble Shooting Guide on page 26 to

isolate the cause of the overheat.

F (960C), shut off the engine

CAUTION: Do not remove the water fill

cap of an overheated engine. Escaping high temperature steam can cause severe burns.

c. Allow the engine to cool and then remove

the cap slowly using protective clothing.

d. Make repairs and restart after the tempera-

ture gauge registers below 180

F (820C).

e. Watch the temperature gauge regularly and

turn off the unit if the temperature rises

above 205

F (960C). Repeat the

troubleshooting process.

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

a. Check the engine crankcase oil level. b. If the oil level is low, fill with recommended

lubricating oil and restart. Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading after a few seconds of operation.

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

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

BREAK-IN PERIOD

1. The first 100 hours on a new or reconditioned engine are critical to its life 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 breakin oil change procedures. Consult Lubricants Section for oil recommendation.)

Operating Instructions

1. Propulsion engines: Never run full speed for more than 5 minutes during the first 50 hours.

Run engine at 50 to 75% of maximum working speed for the first 20 hours with as little idling time as possible. Extended idling can inhibit ring seating, causing cylinder walls to glaze.

2. Generator Sets: Maintain at least a 75% load on your set for the first 100 hours. If this is not possible, maintain no less than a 50% load to ensure proper seating of the piston rings. Vary the load to help seat rings.

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