Northern Lights L6140A, L6140AL2, M6140AL, M6140AL2 Operator's Manual

OPERATOR’S

MANUAL

O6140

For Models

L6140A, L6140AL2,

M6140AL, M6140AL2

— 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

Printed in U.S.A. PART NO.: O6140 03/03

O6140

OPERATOR'S MANUAL FOR MODELS L6140A,

L6140AL2, M6140AL, & M6140AL2

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 ........................................... 25

Troubleshooting

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

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

DC Wiring Diagrams

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

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

24 Volt Standard Marine Gen Set ............. 30

AC Wiring Diagram

All Voltages Marine Gen 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

O6140 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 6140 AL, D, T, & Q

L - Lugger marine propulsion engine Model number of A - Aftercooled (turbo) M - Northern Lights marine generator set Komatsu engine block AL2 - Aftercooled (turbo- NL - Northern Lights industrial generator set 6 cylinder, 140 mm bore low profile)

D - Naturally aspirated T - Turbocharged QA - 1200 RPM (Aftercooled)

L6140AL2

L6140A

M6140AL2

Lugger turbocharged-aftercooled marine propulsion engine. Komatsu 6140 block. (low profile)

Lugger turbocharged-aftercooled marine propulsion engine. Komatsu 6140 block. (high profile)

Northern Lights turbocharged 1500 or 1800 RPM marine diesel generator set. Komatsu 6140 block.

M6140QA

NL6140A

Northern Lights aftercooled-turbocharged 1200 RPM marine diesel generator set. Komatsu 6140 block.

Northern Lights turbocharged-aftercooled 1500 or 1800 RPM industrial diesel generator set. Komatsu 6140 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.

O6140 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.

O6140 03/03

COMPONENT LOCATIONS

Lugger Propulsion L6140AL - Low Profile

Figure 1. L6140AL

1. Cooling system vent

2. Coolant filter

3. Stop solenoid

4. Lube oil fill

5. DC circuit breaker & relays

6. Fuel system bleed plug

7. Fuel filter

8. Oil filter

9. Injection pump

10. Fuel feed pump & manual priming pump

11. Lube oil dipstick

12. Raw water pump

13. Expansion tank

15. Zinc (2)

16. Gear oil cooler

17. Heat exchanger

18. Cooling system fill

19. Air cleaner

20. Crankcase vent outlet

21. Aftercooler vent (2)

23. DC Alternator

24. Jacket water pump

25. Raw water pump inlet

O6140 03/03

26. Jacket water block drain

27. Gear oil filter

28. Starter

29. Gear oil dipstick

30. Manifold drain

31. Cylinder head

32. Rocker arm cover

33. Turbocharger

COMPONENT LOCATIONS

M6140AL Northern Lights Marine Generator Set

Figure 2. M6140AL Generator Set

1. Base frame

2. Coolant filter

3. Fresh water pump

4. Stop solenoid

5. Lube oil fill

6. Generator fan

7. Fuel feed pump and manual priming pump

8. Fuel manifold

9. Lube oil dipstick

10. Lube oil drain

11. Starter

12. Air Cleaner

13. Crankcase vent

14. Secondary fuel filter

15. Lube oil filter

16. DC alternator

17. Turbocharger

18. Generator "J" box

19. Manifold drain

20. Air vents

21. PTO (optional)

22. Block drain

23. Fuel injection pump

O6140 03/03

24. Vibration isolation mounts

25. Expansion tank

26. Coolant system fill

27. Heat exchanger

28. Rocker arm cover

29. Cylinder head

30. Raw water pump

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.

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.

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.

12. EXHAUST TEMPERATURE:

Maximum temperature: 975°F (510°C).

13. TURBO BOOST GAUGE.

Figure 5 Auxilliary Panel

14. GEAR PRESSURE GAUGE:

See Gear Manual for operating range.

Figure 3 - Main Panel Figure 4 - Flybridge Panel

O6140 03/03

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).

O6140 03/03

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 750 RPM. Maximum working engine speed is: 2100 RPM for pleasure craft, 2100 RPM for light commercial craft and 1800 RPM for continuous duty applications.

F (16oC).

O6140 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 200-300 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 engine immediately.

b Use the Trouble Shooting Guide on page 26-

27 to isolate the cause of the overheat.

F (96oC), shut off the

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 (82oC).

e. Watch the temperature gauge regularly and

turn off the unit if the temperature rises above 205

F (96oC). Repeat the troubleshoot-

ing 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.

O6140 03/03

+ 23 hidden pages