Page 1
OPERATOR’S
OPERATOR’S
MANUAL
MANUAL
O6140
For Models
L6140A, L6140AL2,
M6140AL, M6140AL2
Page 2
— 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 ©2003 Alaska Diesel Electric, Inc.
All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Alaska Diesel Electric, Inc.
Printed in U.S.A.
PART NO.: O6140 03/03
Page 3
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
All rights reserved. Litho USA. Publication number O6140 03/03.
O6140 03/03
3
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 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
4
Page 5
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
5
Page 6
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
6
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
Page 7
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
7
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
Page 8
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:
o
is
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
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Page 9
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
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Page 10
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
o
(96
C). Check AC voltage and frequency meters.
o
F (16oC) ambient temperature.
o
F
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
o
(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.
o
F (16oC).
o
F
O6140 03/03
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Page 11
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.
o
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
o
F (82oC).
e. Watch the temperature gauge regularly and
turn off the unit if the temperature rises
above 205
o
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
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Page 12
SERVICING SCHEDULE CHART
The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your unit. 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
SP7 Check primary fuel filter
SP14 Check cooling water level
SP21 Check oil level in reverse gear
FIRST 50 HOURS:
SP2 Change engine oil
SP3 Change lube oil filter
EVERY 50 HOURS (or weekly):
SP5 Check V-belt tension
SP24 Check electrolyte in batteries
FIRST 100 HOURS:
SP2 Change oil
SP3 Change lube oil filter
SP6 Check valve clearances
FIRST 250 HOURS:
SP20 Change coolant filter
EVERY 250 HOURS (or every 6 months):
SP2 Change engine oil
SP3 Change lube oil filter
SP4 Check air filter
SERVICE 50 250 500 750 2400
POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours
SP1 12 Check oil level ●
SP2 12 Change engine oil 1) 4) ●
SP3 12&13 Change lube oil filter 1) 4) ●
SP4 13 Replace air filter 1) 3) ●
SP5 13 Check V-Belt tension 1) 4) ●
SP6 13 Check valve clearances 1) 5) ●
SP7 14 Check primary filter (Racor) 2) 3) ●
SP8 14 Change primary filter element 2) 3) ●
SP9 14 Change secondary filter 1) 3) ●
SP10 14&15 Check injectors 1) 3) ●
SP11 15 Check fuel injection pump ●
SP12 17 Check air lines, oil and cooling water lines for leakage 1) 3) ●
SP13 17 Check boost pressure ●
SP14 18&20 Check cooling water level ●
SP15 20&21 Check and flush cooling system 1) ●
SP16 21 Check and clean heat exchanger 1) ●
SP17 21 Check and clean gear oil cooler 1) ●
SP18 21 Check zinc electrodes-HE engines only 1) 3) ●
SP19 21 Change impeller in seawater pump 1) 3) ●
SP20 21 Change coolant filter 1) 3) ●
SP21 21 Check oil level in reverse gear ●
SP22 21 Change oil in reverse gear 2)
SP23 21 Clutch and PTO service 2)
SP24 22 Check electrolyte level in batteries 1) 3) ●
SP25 22 Check condition of batteries with hydrometer 1) 4) ●
SP26 22 Winterizing or out-of-service 3)
1) Perform all maintenance once a year even if hour level has not been reached.
2) Consult manufacturer's maintenance schedule, note on chart.
3) When necessary.
ENGINE:
FUEL SYSTEM:
TURBOCHARGER:
COOLING SYSTEM
DRIVEN EQUIPMENT:
ELECTRICAL SYSTEM:
OUT OF SERVICE:
O6140 03/03
EVERY 250 HOURS (Continued)
SP8 Change primary fuel filter element
SP12 Check turbocharger air, oil and cooling lines for leakage
SP18 Check zinc electrodes. HE engines only
FIRST 500 HOURS
SP20 Change coolant filter
EVERY 500 HOURS (or yearly):
SP20 Change coolant filter
EVERY 750 HOURS (or yearly):
SP4 Replace air filter
SP6 Check valve clearances
SP9 Change secondary fuel filter
SP10 Check injectors
SP13 Check turbocharger boost pressure
SP15 Check and flush cooling system
SP19 Change impeller in sea water pump
SP25 Check condition of batteries with hydrometer
EVERY 2400 HOURS:
SP11 Check fuel injection pump
SP16 Check and clean heat exchanger
SP17 Check and clean gear oil cooler
4) Change at first 50 and first 100 hours.
5) Adjust at first 100 hours.
12
Page 13
SERVICE RECORD
Service
Point
OPERATION HOURS/DATE
50 HOURS (or weekly)
SP5 Check V-belt tension
SP25 Check electrolyte in batteries
250 HOURS (or every 6 months)
SP2 Change engine oil
SP3 Change lubricating oil filter
SP4 Check air cleaner
SP8 Change primary fuel filter element
SP12 Check turbocharger air, oil & cooling lines for leakage
SP18 Check zinc electrodes - HE engines only
SP20 Change cooling system filter
SP4 Replace air cleaner
SP6 Check valve clearances
SP9 Change secondary fuel filter
SP10 Check injectors
SP13 Check turbocharger boost pressure
SP15 Check and flush cooling system
SP19 Change impeller in sea water pump
SP25 Check state of charge of batteries
SP11 Check fuel injection pump
500 HOURS (or annually)
750 HOURS (or annually)
2400 HOURS
SP16 Check and clean heat exchanger
SP17 Check and clean gear oil cooler
O6140 03/03
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Page 14
SERVICING
LUBRICATION - GENERAL
1. Use only clean, high quality lubricants
stored in clean containers in a protected area.
2. These lubricants are acceptable:
a. API Service CC/CD single viscosity oils.
b. API Service CC/CD/SF multi-viscosity
oils.
3. Use the proper weight oil for your average
operation temperature.
Air Single Multi-
Temperature Viscosity Viscosity
Above 32oF
o
C)
(0
-10 to 32
(-23 to 0
Below -10
o
C)
(-23
o
F
o
C)
o
F
SAE-30W SAE 15-40W
SAE-10W SAE10-30W
SAE-5W SAE 5-20W
4. Change oil when engine is warm.
5. Dispose of waste oil in an approved manner.
6. Propulsion Engines with Optional Drain Pump:
a. Your engine is fitted with a hand pump that
drains the engine crankcase and marine
gear.
b. Use a wrench to turn the selector valve to
drain the engine or gear. Use marks on the
valve stem as a guide. (See below).
c. Turn pump handle in clockwise direction
and pump oil into a suitable container.
When the engine is empty, switch the valve
and drain the gear oil.
d. Close valve. Refill engine and gear with
recommended oils.
NOTE: Make sure the valve is in the closed
position before starting engine. If it is left
open it is possible for crankcase oil to be
pumped into the reverse gear and out of
the gear dipstick and breather. This can
ruin the engine.
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 flushing oil in crankcase.
6. Propulsion Engines: See Gear Owner's Manual
for gear lubrication recommendations.
SP1. CHECK OIL LEVEL
1. Check oil in the crankcase daily with the
dipstick. The oil level must be in the waffled
area between the “L” and “H.” Never alow the
level to go below the “L.”
2. Always add the same viscosity of oil as is
already in the crankcase. (See above recommendations.)
SP2. OIL CHANGES
1. Using the oil recommended in the above
diagram, change the engine oil and filter after
the first 50 hours of operation, the first 100
hours of operation, and every 250 hours
thereafter.
2. During intermittent cold weather operation,
change oil every 100 hours or six weeks,
whichever comes first.
3. Change oil at any seasonal change in temperature when a new viscosity of oil is required.
To drain
crankcase
To drain
reverse gear
To close
valve
Hand pump selector valve
7. Marine Generator Sets:
a. Remove plug from outlet in base frame.
Screw in owner-supplied drain hose.
b. Open valve at oil pan outlet. After oil has
been drained into suitable container, close
valve, remove drain hose and replace plug
in base frame outlet.
c. Refill engine with recommended oil.
8. Engine capacity with new oil filter is 10
gallons (38 liters).
SP3. CHANGING OIL FILTER
1. Change the lube oil filter after the first 50
hours of operation, after the first 100 hours of
operation and every 250 hours thereafter.
2. Use a filter wrench to remove old filter.
Dispose of filter in approved manner.
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SERVICING
3. Make sure the gasket from the old filter is
removed and discarded.
4. Lubricate the rubber gasket on the new filter and
screw it on nipple until gasket meets the sealing
surface.
5. Using hands only, no wrench, tighten filter onehalf turn farther. Overtightening can do damage
to filter 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 FILTER
1. Inspect air cleaner every 250 hours, replace the
filter every 750 hours, or yearly, whichever
comes first.
2. After replacing element and cover, start engine
and check for air leaks.
NOTE: Make absolutely sure no impurities enter
the engine while changing the element. Do not
run the engine with the air cleaner removed.
SP5. V-BELTS
1. Check the tension and wear on the V-belts after
every 50 hours.
2. Use your thumb to press on the belt at the
midpoint between the crankshaft and alternator
pulleys. The tension is correct if the belts can be
depressed about 3/8 in. (10mm).
3. Belts that operate in pairs should both be replaced in pairs, even if only one of them needs to
be replaced.
SP6. VALVE CLEARANCES
1. Check the valve clearances after the first 100
hours, and every 750 hours thereafter.
2. Turn off battery switch.
3. Remove valve covers which are held by three
bolts.
4. Use a breaker bar, with a 19mm or 3/4" socket,
on the pulley that powers the alternator to rotate
the crankshaft in a clockwise direction. Align the
mark on the vibration damper with the pointer
according to data plate specifications. In this
position No. 1 cylinder is at top dead center of
the compression stroke, and No. 6 cylinder's
intake valves will start to move. (see figure 8.)
5. Adjust the valve clearance for valves marked
with an "X" in Fig. 9.
6. To adjust the valve clearance, first adjust the
crosshead. Loosen the crosshead lock nut (Fig.
10-5), then the adjustment screw (Fig. 10-6).
Figure 8.
Cylinder No. 123456
Intake Valve X X O X O O
Exhaust Valve X O X O X O
Figure 9.
Hold top of crosshead lightly and tighten adjustment screw until it contacts valve stem, then
tighten 20° more. Then loosen nut (see Fig. 10-1)
on valve adjustment screw (Fig. 10-2), insert
feeler gauge between crosshead (Fig. 10-3) and
rocker arm (Fig. 10-4) and adjust the clearance
with the adjustment screw until the thickness
gauge slides with a slight drag. After the clearance is properly adjusted, tighten the lock nut to
secure the adjustment screw using 47 to 54 foot
lbs. of torque (7 to 7.5 kgm).
7. Valves should be set cold with the following
clearances:
a. Intake Valves - .017 in (.43mm)
b. Exhaust Valves - .031 in (.80mm)
8. Rotate the engine one full revolution. Adjust
valves marked “O” to above clearances.
Figure 10.
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SERVICING
FUELS - GENERAL
1. Use only clean, high quality fuels of the following specifications, as defined by ASTM designation D975 for diesel fuels:
a. Use grade No. 2 diesel at ambient tempera-
tures above freezing 32
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. Use fuel having less than 1% sulphur (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.
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.
o
F (0oC).
SP7-9. FUEL FILTERS
1. Your engine or generator set should have a
primary fuel filter installed. We recommend the
Racor brand of fuel filter - water separators.
a. Check the primary fuel filter daily as recom-
mended by the filter manufacturer. Empty
the collection bowl as necessary.
b. Change the element every 250 hours or when
necessary.
c. If the bowl fills with water, change the
primary and secondary element immediately.
2. Change secondary fuel filter every 750 hours.
a. Remove the filter cartridge by turning it
counterclockwise with a filter wrench. Fill
the new cartridge with fuel and install it
after applying engine oil to gasket surface.
Screw on until the gasket surface comes into
contact with sealing surface of filter base.
Then, tighten it two-thirds of a turn by hand.
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, filter changed, etc.)
it should be bled.
2. To bleed the fuel system, loosen the vent plug in
the top of the fuel filter housing. Unscrew the
hand primer knurled knob on the injection pump
and loosen until it can be pulled up by hand (see
Fig. 11,10).
Operate the hand primer up and down until most
of the air bubbles are expelled and clear fuel
escapes the vent plug. Push hand primer down
and tighten. Tighten the vent plug.
3. If the engine will not start, it may be necessary to
loosen the fuel pipes at the injectors. With the
throttle on full, crank the engine over with the
starter until fuel without air flows from the loose
fuel pipe connections. Tighten the connections.
SP10. INJECTORS
1. Fuel injectors should be checked by a LuggerNorthern Lights dealer or qualified fuel injection
shop after every 750 hours.
2. Injector Removal:
a. Thoroughly clean the area around injection
pump, fuel line connecting nuts and rocker
arm housing cover.
b. Remove rocker arm housing cover.
c. Remove fuel line nuts on fuel inlet connector
and injection pump. Remove fuel line
clamps. Pull fuel lines loose.
d. Remove fuel inlet connector. (Note: loosen
lock nut first, and then screw out connector.
Connector should be replaced.)
e. Remove injector hold down bolts.
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SERVICING
f. Using injector hold down and bolt, screw
bolt into top of injector and lift out.
3. Clean Injector Bore:
Injector seat in cylinder head can be cleaned by
wrapping a clean, lint-free rag around the
tapered end of a wooden rod and wiping the bore
and seat. Hardened carbon can be removed from
the seat by using a tapered wire brush to break
carbon free. Then clean the bore with rag and
rod.
4. Have injectors tested and rebuilt if necessary.
Or, take them to a Lugger-Northern Lights
dealer and use them as core exchange for rebuilt
injectors.
5. Injector Installation:
a. Install new o-ring in groove on injector.
b. Install new copper seat on end of injector.
c. Insert injector aligning fuel inlet hole with
fuel inlet connecting hole in rocker housing.
d. Install new fuel inlet connector.
e. Install injector hold down, ballwasher and
bolt. Torque to 48 ft. lbs. (6.75 kgm).
f. Torque inlet connector to 27 ft. lbs. (3.8
kgm) and lock nut to 29 ft. lbs. (4.0 kgm).
g. Install injector lines. Torque fuel line nuts to
17-18 ft. lbs. (2.3-2.5 kgm).
h. Bleed the fuel system, start the engine and
check the system for leaks using a piece of
cardboard.
SP11. INJECTION PUMP
1. The pump settings, maximum speed, idle speed
and exhaust smoke should be checked after
every 2400 hours of operation. Service of the
fuel injection pump should only be done if
checks indicate pump malfunction.
2. Low power and no smoke can indicate a fuel
injection pump malfunction. Check for full
throttle, proper solenoid adjustment and air filter
cleanliness before replacing pump. Black smoke
occasionally may indicate an injection pump
problem.
3. Any repair which involves disassembly of the
injection pump must be carried out by 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.
4. Injection Pump Removal:
a. Clean injection pump, hoses and area around
the pump with cleaning solvent or a steam
cleaner.
NOTE: Never steam clean or pour cold water
on an injection pump while the engine is
running or the pump is warm.
b. Remove line clamps (see Fig. 11-1) and fuel
injection lines (Fig. 11-2).
c. Remove feed lines (Fig. 11-3) and lubrica-
tion tubes (Fig. 11-4 & 11-5) and return line
(Fig. 11-6).
d. Remove coupling bolts (Fig. 13-2) between
the coupler (13-3) and the flange (Fig. 13-4)
on the pump drive.
e. Remove the four mounting bolts (Fig. 11-7)
which hold the injection pump on the
bracket.
6. Injection Pump Installation:
a. Position pump on bracket. Positioning
sleeves on two of the bolt holes help align
the pump.
b. Tighten four mounting bolts (see Fig. 11-7)
to 49-54 foot lbs (6.75-7.50 kgm).
c. Reinstall coupling (Fig. 13-2) bolts, but do
not tighten them until pump is timed as per
next section.
d. Reinstall feed lines (Fig. 11-3) and lubrica-
tion oil lines (Fig. 11-4 & 11-5) using new
gasket washers on both sides of banjo bolts.
• Torque nuts for line (Fig. 11-5):
18-31 foot lbs. (2.5-3 kgm)
• Torque nuts for line (Fig. 11-4):
11-14 foot lbs. (1.5-2 kgm)
e. Reinstall fuel injection lines (Fig. 11-2) and
line clamps (Fig. 11-1). Fuel delivery line
sleeve nuts (Fig. 11-8) torque to 16-18 foot
lbs. (2.4-2.5 kgm).
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TIMING INJECTION PUMP
1. The Match Mark Alignment Method:
This is used when the injection pump is installed
on the original engine and the pump has NOT
been repaired.
a. Turn the crankshaft by hand in clockwise
direction to bring the number one cylinder to
top dead center of the compression stroke.
The compression stroke can be determined
by removing the number one cylinder valve
cover and turning the engine until all valves
are closed.
b Rotate crankshaft in counter-clockwise
direction 30-40
lash.
c. Align the injection timing stamp line (27
±1o BTDC, 24o on 600HP Luggers) on No. 1
cylinder on the crankshaft damper with the
pointer by slowly rotating the crankshaft in
the clockwise direction
IMO certified engines, refer to the data plate
on the block for proper timing data.
o
(1/8 turn) to remove gear
(see Fig. 12). On
SERVICING
Figure 12. Pointer and Crankshaft Damper
o
d. Confirm that the stamped line "a" on the
injection pump is aligned with the stamped
line "b" on the coupling
(see Fig. 13-1).
e. If the stamped lines are out of alignment,
loosen nuts
lines by shifting the coupling
(Fig.13-2) and align the stamped
(see Fig. 13-3)
and re-tightening the nuts to 43-46 foot lbs.
torque (5.8-6.2 kgm).
Figure 11. Injection Pump Servicing Points
1. Injection line clamps
2. Fuel injection line
3. Fuel feed line
4. Lubrication line (inlet)
5. Lubrication line (outlet)
6. Fuel return line
7. Pump mounting bolts
8. No. 1 delivery line
9. Throttle
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18
10. Hand priming pump
11. Air vent point.
Page 19
Figure 13. Pointer and Crankshaft Damper
2. Delivery Valve Method:
Use delivery valve method when a repaired or
replaced injection pump is installed.
a. Disconnect fuel injection line from the No. 1
cylinder delivery valve on the injection
pump
(see Fig. 11-8).
b. Remove delivery valve holder. Remove
spring and delivery valve and put valve
holder back in injection pump.
c. Place the throttle
(Fig. 11-9) in the full fuel
(forward) position.
d. Slowly rotate the crankshaft in a clockwise
direction while operating the priming pump
(Fig. 11-10). This is best done by two people.
e. Stop rotating and pumping when fuel stops
flowing out of the delivery valve holder
11-8).
f. If the injection timing stamp line on the
crankshaft damper is aligned with the
pointer, according to data plate specifications, it is correct.
(see Fig. 12).
g. To adjust timing, rotate the crankshaft 30
o
40
(1/8 turn) in counter-clockwise direction
from No. 1 cylinder top dead center to
remove gear lash.
h. Align the injection timing line on the damper
with the pointer by slowly rotating the
crankshaft in the clockwise direction.
i. Loosen two nuts
coupling. Rotate the coupling
(see Fig. 13-2) on the
(Fig.13-3) on
the pump side little by little while operating
the priming pump (see Fig. 11-10) until no
fuel flows out of the delivery valve holder
(Fig. 11-8).
SERVICING
SP12. TURBOCHARGER
1. Check for air leaks every 250 hours. Air leakage
2. Listen along air line while engine is running. A
3. Leakage on the pressure side, between turbo and
4. Tighten the hose clamps, replace hose or gaskets
5. Check to see that the lubrication and cooling lines
SP13. TURBO BOOST
1. This check measures the amount of air the turbo is
2. Your engine can have a boost gauge permanently
(Fig.
o
-
j. Tighten two nuts (see Fig. 13-2). Now re-check
the injection timing to see it is properly
adjusted by repeating steps e through g.
k. If line "b" on coupling does not align with the
line "a" on the pump, re-stamp coupling with
new line.
l. Reassemble the delivery valve and reinstall
fuel lines
(see Fig. 11-2) and clamps (Fig. 11-1).
m. Bleed fuel system.
will lower engine output and may cause black
exhaust smoke and soot.
whistling or hissing sound indicates leakage.
engine, can be found by applying soapy water to
the air line.
as required.
are tight and without leaks.
pushing into the engine. It should be done by an
authorized dealer every 750 hours.
installed so you can monitor the turbo's output
from the control panel. (See page 6).
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SERVICING
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, boilover, 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.
4. Your engine is equipped with a spin-on coolant
filter conditioner element which provides the
SCA's to protect your cylinder liners.
5. The coolant filter conditioner element performs
two functions at once:
• The outer paper element filters out rust, scale
or dirt particles in the coolant.
• The inner element releases chemicals into the
coolant to maintain a proper acid/alkaline
balance, inhibit corrosion and suppress erosion
pitting which is discussed below.
LINER EROSION (PITTING)
1. Cylinder liner walls (A) which are in contact
with engine coolant
(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.
2. Vapor bubbles
(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.
4. Unprotected engines with low quality water as
coolant can have liner failure in as few as 500
hours.
5. The SCA's released by the filter will significantly reduce erosion and pitting. The chemicals
in the additives reduce the quantity of vapor
bubbles. It also forms a protective film on the
metal engine parts which act as a barrier against
collapsing vapor bubbles.
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 first tested by a water
quality laboratory.
the reverse osmosis method unless it has been
PH neutralized.
2. Here are acceptable water quality specifications
Do not use water made by
A - Cylinder Liner Walls
B - Engine Coolant
C - Vapor Bubbles
Contaminates Parts Per Grains Per
Million Gallon
Maximum Chlorides 40 2.5
Maximum Sulfates 100 5.9
Max Dissolved Solids 340 20
Max Total Hardness 170 10
PH level 5.5 to 9.0
3. If chlorides, sulfates or total dissolved solids are
higher than the above given specification, the
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SERVICING
water must be distilled, demineralized, or
deionized before it is used in a cooling system.
4. If total hardness is higher than 170 ppm and all
other parameters are within the given specifications, the water must be softened before it is
used to make coolant solution.
ETHYLENE GLYCOL CONCENTRATE -
EGC (ANTIFREEZE)
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 Specification GM1899M,
or formulated to GM6038M.
4. This product is concentrated and should be
mixed to the following specification.
Distilled EGC % Freeze Boiling
Water % Antifreeze Point Point
Optimum 50% 50% –37°C +109°C
–34° F +226° F
Minimum 60% 40% –24°C +106°C
–12° F +222° F
Maximum 40% 60% –52°C +111°C
–62° F +232° F
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.
CAUTION: EGC (Antifreeze) is flammable.
!
Keep it away from any open flame. Avoid
contact with eyes. Avoid contact with skin. Do
not take internally. In case of contact, immediately
wash skin with soap and water. For eyes, flush with
large amounts of water for at least 15 minutes. Call a
physician. KEEP OUT OF REACH OF
CHILDREN. Follow all warnings on the container.
6. IMPORTANT
DO NOT use methyl alcohol or methoxy
propanol base EGC. These concentrates are not
compatible with chemicals used in supplemental
coolant additives. Damage can occur to rubber
seals on cylinder liners which are in contact with
coolant.
DO NOT use an EGC containing sealer or stopleak additives.
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 flow.
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, flush with large
amounts of water for at least 15 minutes. Call a
physician. KEEP OUT OF REACH OF
CHILDREN. Follow all warnings on the container.
1. Your engine is equipped with a spin-on coolant
filter conditioner element which provides the
SCA's to protect your cylinder liners. The inner
element releases chemicals into the coolant to
maintain a proper acid/alkaline balance, inhibit
corrosion and suppress erosion pitting.
2. Important: All engines.
ALWAYS change the coolant conditioner-filter
element according to the service chart in this
manual.
3. Important: Radiator and heat exchanger cooled
engines.
Additional SCA's should NOT be added to the
mixture of EGC/H
with a coolant conditioner-filter. A high SCA
concentration will result and can cause silicatedropout. When this happens, a gel-type deposit
is created in the cooling system which retards
heat transfer and coolant flow.
4. Important: Engines with Keel Cooling.
The SCA in the spin-on filter may not be able to
treat the large volume of coolant in a vessel's
keel cooling system. The operator must use a test
kit strip to determine the amount of additional
SCA's that need to be added to the cooling
system.
0 on initial fill up of engines
2
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SERVICING
SCA'S CONTINUED
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 H
mixture. (1.0 fl oz of SCA per qt of H
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.
5. SCA is available from your Northern Lights/
Lugger dealer in the following sizes.
Pint - Part Number...............20-00002
1/2 gallon - Part Number.....20-00003
6. DO NOT use any coolant system additives
containing soluble oil.
O/EGC
2
O/EGC).
2
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
SP14. 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
filler cap carefully, using protective clothing when
the engine is warm.
1. Check the coolant level each day before starting
the engine. Check the coolant level by removing
the pressure cap from the expansion tank. In
order to give the coolant an opportunity to
expand, the level should be about 1 3/4 in. (4-5
cm) below the filler cap sealing surface when the
engine is cold. When filling with coolant, the
venting cock on top of the turbocharger should
be opened to ensure that no air pockets form in
the cooling system.
2. The pressure valve in the filler 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.
SP15. 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 filler cap carefully, using protective clothing
when the engine is warm.
IMPORTANT
Be sure to close the sea cock before working on the
engine cooling system.
1. Flush the cooling system and check for leaks and
blockage every 750 hours, or yearly.
2. The engine must be stopped and cold. Remove
the filler cap with caution. Open cooling system
air vents on top of the turocharger, at the front and
rear of the aftercooler and for heat exchanged units
on top of heat exchanger.
3. Drain the jacket (fresh) water circuit of the
cooling system.
HE = heat exchanger cooled units
KC = keel cooled units
a. Exhaust manifold: Drain is under manifold
near rear of engine for both HE & KC.
b. Engine block: Drains are on the water pump
outlet and turbo coolant line
c. Gear oil cooler: Bottom of right gear oil
cooler elbow (propulsion engines only).
d. Remote expansion tank: Remove hose from
bottom of tank.
4. To drain the raw water circuit of HE engine,
open the drain in the starboard end cap of the
heat exchanger
5. With drains open, pour clean water into the filler
cap. When the water from each drain is clear
and free from discoloration and sediment, close
that drain. When all drains are closed, flushing
is complete.
(see Fig. 1).
(see Fig. 1)
(see Fig. 1).
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SERVICING
FLUSHING THE COOLING SYSTEM (cont.)
6. Re-drain the engine and refill the jacket (fresh)
water circuit with coolant mixture as described
in previous section.
7. Close cooling system air vent.
8. Open sea cock.
9. Start engine. Monitor temperature gauge carefully and check cooling system for leaks.
SP16. HEAT EXCHANGER CLEANING
1. Clean the heat exchanger core once a year or
after 2400 hours of operation.
2. Drain expansion tank and heat exchanger.
3. Remove heat exchanger covers.
4. Clean the inside of exchanger core tubes using a
metal rod.
5. Re-assemble using new gaskets. Fill the cooling
system, start the engine and check for leaks.
SP17. CLEANING GEAR OIL COOLERS
For propulsion engines only:
1. Drain fresh water cooling circuit.
2. Remove end covers of gear oil cooler.
3. Wash the core in diesel fuel and blow it dry with
compressed air. Clean the end covers of the core
with a steel brush and use a metal rod to clean
inside of tubes.
4. Re-assemble using new gaskets. Fill the cooling
system, start the engine and check for leaks.
SP18. ZINC ELECTRODES
1. Zincs are installed in the heat exchanger 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. Keel
cooled engines do not have zincs.
2. Heat exchanger cooled engines: Drain the raw
water from heat exchanger
drain the expansion tank
zinc holders
exchanger and raw water pipe elbow.
3. Scrape or steel brush the zinc electrode clean. If
more than 50% of the electrode is corroded
away, replace it with a new one. The electrode
screws out of the holder.
4. Re-install the zinc holders. Be sure the threads
are clean for good metal-to-metal contact.
5. Refill cooling system, start engine, check for
leaks.
(Fig's 1&4,18) from back end of heat
(Fig's. 1&4,13), then
(Fig's 1&4,1). Remove
SP19. RAW WATER PUMP
1. Heat exchanger cooled engines only. Change the
the sea water pump impeller every year, or as
needed.
2. Remove the pump end cover. Pry out the
impeller with the help of two screwdrivers. Be
sure you remove all pieces of a failed impeller.
NOTE: Place some kind of protection under the
screwdrivers in order not to damage the
housing.
3. Clean the inside of the housing.
4. Press in the new impeller and place the sealing
washers 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 that there is always an extra
impeller and cover gasket in reserve on board.
SP20. COOLANT FILTER
1. Change coolant filter after the first 250 hours, the
first 500 hours and every 500 hours thereafter.
2. Shut off both valves on filter body.
3. Use filter wrench to remove filter.
4. Make sure old gasket is removed.
5. Lubricate new filter gasket and screw on new
filter until gasket meets housing.
6. Hand tighten two-thirds of a turn more.
7. Open valves on filter body.
8. Start the engine and check for leaks.
9. Stop engine and check water level in expansion
tank.
SP21,22,23. GEARS, PTOS AND
GENERATORS
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
recommendations closely.
2. If you have a Northern Lights generator set, 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.
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SERVICING
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. Do not polarize the alternator or regulator.
7. A DC circuit breaker protects your control panel
and wiring harness
(see Fig. 1,5 for location).
4. Remove booster battery after starting engine.
5. Sealed batteries: see manufacturer charging and
booster instruction.
SP24,25. BATTERY CARE
1. Check electrolyte level every 50 hours or
weekly. 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 750 hours or yearly.
BOOSTER BATTERIES
CAUTION: Battery Gas Can Explode. Keep
!
all flames and sparks away from batteries.
1. Before changing or using booster batteries,
check battery electrolyte level. Add distilled water if necessary.
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.
Then, connect negative (-) terminal of booster
battery to ground on the engine block
14).
(see Fig.
SP26. WINTERIZING, OUT-OF-SERVICE
MARINE
1. Drain seawater cooling systems completely.
Remember to shut off sea cocks before opening
drain cocks.
2. Drain seawater supply lines and wet exhaust
line.
3. Loosen the seawater pump cover and drain
pump.
4. Check freshwater antifreeze mixture. If refilling,
run the engine up to operating temperature to
circulate the antifreeze.
5. Fill fuel tank and add biocide as per
manufacturer's instructions.
6. Seal air cleaner inlet, exhaust opening, crankcase
breather pipe and fuel tank vent with plastic bags
and tape.
7. Change the crankcase oil and filter.
8. Loosen drive belts.
9. Disconnect and clean battery. Remove to warm
storage place if possible.
10. Clean outside of unit. Paint any scratched or
chipped surfaces. Put corrosion preventative on
all exposed metal surfaces.
Figure 14. Booster Battery Connections.
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THREE BLADED PROPELLER SIZING CHART
Use this chart to find aproximate propeller sizes for boats
with single engine using
with a 3% loss factor.
NOTE: Prop size is influenced by many factors (hull
design, load, boat use). It is impossible to make an
absolute recommendation. For more accurate recommendations, contact your dealer.
a three blade
propeller and gears
1)Find the boat speed your boat builder expects from
an engine of this horsepower in the left column.
2)Locate the gear ratio desired on the top line.
3)Find where two columns intersect for an approximate propeller size. See the column bottom for
shaft RPM and shaft diameter.
Example: 700 HP rating; 20 knot boat with 2:1 gear
needs a 35 x 32 three blade propeller.
High Output Rating: 700 flywheel HP, 675 SHP at 2100 RPM
Speed Gear Ratios and Propellers
Knots 1:1 1.5:1 1.75:1 2:1 2.5:1 3:1 3.5:1
11 - 13 –– –35x24 40x26 44x28 48x32
13 - 15 ––32x20 35x26 40x28 44x32 48x38
15 - 17 – 28x20 32x22 35x28 40x32 44x36 48x44
17 - 19 23x15 28x22 32x24 35x30 40x34 44x40 48x48
19 - 21 23x16 28x24 32x26 35x32 40x38 44x44 48x52
21 - 23 23x17 28x25 32x28 35x34 40x42 44x48 –
23 - 25 23x19 28x28 32x30 35x38 –––
25 - 27 23x20 28x30 32x32 35x40 –––
27 - 29 23x22 28x32 32x35 35x42 –––
29 - 31 23x24 28x34 32x38 35x44 –––
Sft. rpm 2100 1400 1200 1050 840 700 600
Sft. dia. in 1.75 2 2 2.5 3 3.5 4
Medium Duty Rating: 600 flywheel HP, 579 SHP at 2100 RPM
Speed Gear Ratios and Propellers
Knots 1.5:1 1.75:1 2:1 2.5:1 3:1 3.5:1 4:1
9 - 11 ––34x22 39x24 43x26 48x30 52x34
11 - 13 ––34x24 39x26 43x28 48x32 52x36
13 - 15 – 32x20 34x26 39x28 43x32 48x38 52x42
15 - 17 28x20 32x22 34x28 39x30 43x36 48x44 52x48
17 - 19 28x22 32x24 34x30 39x34 43x40 48x48 –
19 - 21 28x24 32x26 34x32 39x38 43x44 48x52 –
21 - 23 – 32x28 34x34 39x42 43x43 ––
Sft. rpm 1400 1200 1050 840 700 600 525
Sft. dia. in 2 2 2.5 3 3.5 4 4.5
Continuous Duty Rating: 500 flywheel HP, 482 SHP at 1800 RPM
Speed Gear Ratio and Propellers
Knots 2.5:1 3:1 3.5:1 4:1 4.5:1 5:1 6:1
5 - 7 ––50x18 54x20 58x22 61x25 68x30
7 - 9 40x20 46x22 50x27 54x28 58x30 61x34 68x40
9 - 11 40x24 46x28 50x31 54x34 58x38 61x42 68x50
11 - 13 40x28 46x32 50x35 54x40 58x45 ––
13 - 15 40x30 46x36 50x39 54x46 58x53 ––
Sft. rpm 720 600 514 450 400 360 300
Sft. dia. in 3.5 4 4.5 4.5 5 6 6
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LUGGER DATA
Displacement................................... 930 in3 (15.24 liters)
Bore x Stroke ....... 5.51 in (140 mm) x 6.49 in (165mm)
High Output ........................................700HP/2100RPM
Medium Duty ......................................600HP/2100RPM
Continuous Duty.................................500HP/1800RPM
Approximate dry weight:
Keel cooled, less gear..................... 3362 lbs (1526 kg)
Heat exchanger cooling, less gear.. 3505 lbs (1591 kg)
Cooling (General)
Freshwater circulating flow at rated speed
High Output ..............................158 US gpm (600 lpm)
Medium Duty............................119 US gpm (450 lpm)
Continuous Duty .......................106 US gpm (400 lpm)
Heat rejection to jacket water
High Output ....................................... 16,066 BTU/min
Medium Duty..................................... 13,776 BTU/min
Continuous Duty ................................ 11,180 BTU/min
Cooling (Heat Exchanger)
Raw-water intake diameter............................3 in (75 mm)
Raw-water discharge diameter ...................... 3 in (75 mm)
Raw-water pump flow at rated speed
High output .................................82 US gpm (310 lpm)
Medium Duty..............................82 US gpm (310 lpm)
Continuous Duty .........................69 US gpm (265 lpm)
Raw-water pump maximum suction head ........ 39 in (1 m)
Maximum raw-water temperature at inlet .. 100° F (37° C)
Freshwater system capacity-engine only 10 US gal (38 ltr)
Cooling (Keel Cooled)*
Water hose inside diameter ......................2.87 in (73 mm)
Keel cooler head diameter ................................ 2.5 in NPT
Turbo tube length, High Output .................. 110 ft (34 m)
Medium Duty............................................. 84 ft (26 m)
Continuous Duty ........................................ 70 ft (22 m)
Skin cooler-aluminum, High Output ...... 120 ft2 (11.2 m2)
Medium Duty.......................................... 90 ft2 (8.4 m2)
Continuous Duty ..................................... 80 ft2 (7.4 m2)
Skin cooler-steel, High Output ............... 360 ft2 (33.5 m2)
Medium Duty...................................... 300 ft2 (27.9 m2)
Continuous Duty ................................. 250 ft2 (23.2 m2)
DC Electrical
Voltage ..........................24 volt standard, 12 volt optional
Minimum battery capacity........ 2 x 225 amp hrs/1150 cca
Battery cable size................................."00" up to 10 ft run
Standard instrument harness length.................. 20 ft (6 m)
Air Intake and Exhaust
Engine air consumption at rated speed
High Output .........................1500 f3/min (42.5 m3/min)
3
Medium Duty.......................1250 f
Continuous Duty ..................1045 f
/min (35.4 m3/min)
3
/min (29.6 m3/min)
Minimum engine room intake vent area
High Output ........................................ 400 in
Medium Duty...................................... 335 in
Continuous Duty ................................ 280 in2 (0.18 m2)
Exhaust gas flow at rated speed
High Output ........................ 3380 f3/min (95.7 m3 /min)
Medium Duty.......................2900 f3/min (82.1 m3/min)
Continuous Duty ..................2740 f3/min (77.6 m3/min)
Maximum exhaust gas temperature at rated speed
High Output ........................................... 875°F (472°C)
Medium Duty......................................... 800°F (430°C)
Continuous Duty .................................... 750°F (402°C)
Maximum exhaust back pressure ...... 30 in (760 mm) H2O
Suggested dry exhaust I.D.
500 & 600 hp: 6 inch. 700 hp: 8 in.
Suggested wet exhaust I.D.
500 & 600 hp: 8 inch. 700 hp: 10 in.
Fuel and Oil
Minimum fuel line:
Suction (return)..................... 1/2 "-12 mm (3/8"-10 mm)
Maximum fuel pump head................................ 39 in (1 m)
Crankcase oil capacity ............................ 40 US qts (38 ltr)
Gear, PTO, Engine Angle
Engine rotation (facing flywheel)
Counter-clockwise
Flywheel housing size
SAE #1 14" (SAE 0, 18" optional)
Front PTO size (optional)
SAE #4 10", SAE #3 11.5"
Max. operating angle:
Any direction 35° for less than 2 minutes
Max. installed operating angle
10° rear down, 0° front down
*Note:
Based on 70° F (21°C) seawater temperature and minimum boat speed of 8knots at full rpm. Return water 120-165°F (50-75°C).
2
(0.26 m2)
2
(0.22 m2)
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NORTHERN LIGHTS MARINE SPECIFICATIONS
Model Number M6140AL
AC Output
1800 RPM, 60 Hz 330 kW
1500 RPM, 50 Hz 280 kW
Phase (Optional Phase) 3
RPM/ Hz Available in 1800 RPM/60 Hz and 1500 RPM/ 50 Hz
Voltages 60 Hz 120/208, 120/240, 127/220, 139/240, 220/380, 240/416, 254/440 and 277/480
Voltages 50 Hz 110/190, 110/220, 115/230, 120/208, 127/220, 220/380, 240/416
Engine
Aspiration Turbo/AC
Cylinders Inline 6
Displacement cu. in. (l) 930 (15.24)
Bore in (mm) 5.51 (140)
Stroke in (mm) 6.49 (165)
1
Specific Fuel Rate
Fuel Rate-Full Load
Fuel Rate-1/2 Load
(3)
lb/bhp/hr 0.331
(4)
gal/hr(lph 23.1 (87.4)
(4)
gal/hr(lph) 12.0 (45.4)
Model Number M6140QA
AC Output
1200 RPM, 60 Hz 200 kW
50 Hz ––
Phase (Optional Phase) 3
Voltages 60 Hz 120/208, 120/240, 127/220, 139/240, 220/380, 240/416, 254/440 and 277/480
Engine
Aspiration Turbo/AC
Cylinders Inline 6
Displacement cu. in. (l) 930(15.24)
Bore in (mm) 5.51 (140)
Stroke in (mm) 6.49 (165)
Specific Fuel Rate
Fuel Rate-Full Load
Fuel Rate-1/2 Load
1
(3)
lb/bhp/hr 0.350
(4)
gal/hr(lph) 14.8 (56)
(4)
gal/hr(lph) 7.7 (29.14)
1. Prime kW rating. 1 kW equals 1000 watts. 0.8 power factor.
2. Net flywheel hp rating for fully equipped engine at RPM under SAE J816b.
3. Based on prime HP rating at rated (1800 or 1200) RPM.
4. Based on prime kW rating at rated (1800 or 1200) RPM. Fuel rate may vary depending on operating conditions.
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If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer.
ELECTRICAL
✓
Battery will not charge
Loose or corroded connections:
• Clean and tighten battery connections.
Sulfated or worn out batteries:
• Check specific gravity of each battery.
• Check electrolyte level of each battery.
Loose or defective alternator belt:
• Adjust belt tension.
• Replace belt.
• Defective alternator
✓
Starter inoperative
Check DC circuit breaker.
Loose or corroded connections:
• Clean and tighten loose battery and harness plug
connection.
Low battery output:
• Check specific gravity of each battery.
• Check electrolyte level of each battery.
Defective electrical system ground wire:
✓
• Repair or replace.
Starter cranks slowly
Low battery output:
• Batteries too small.
• Battery cables too small.
Check specific gravity of each battery.
Check electrolyte level of each battery.
Crankcase oil too heavy.
Loose or corroded connections:
• Clean and tighten loose connections.
✓
Entire electrical system does not function
Check DC circuit breaker.
Faulty connection:
• Clean and tighten battery and harness plug connections.
Sulfated or worn out batteries:
• Check specific gravity and electrolyte level of each
battery.
ENGINE
✓
Engine hard to start or will not start
Improper starting procedure.
No fuel.
Low battery output:
• Check electrolyte level and specific gravity of battery.
Excessive resistance in starting circuit:
• Clean and tighten all connections on batteries.
Crankcase oil too heavy:
• Use oil of proper viscosity.
TROUBLESHOOTING
Improper type of fuel:
• Consult fuel supplier and use proper type of fuel for
operating condition.
Water, dirt or air in fuel system:
• Drain, flush, fill and bleed system.
Clogged primary fuel filter element:
• Clean or replace filter element.
Clogged secondary fuel filter element:
• Replace filter element.
Dirty or faulty injection nozzles:
• Have your dealer check injection nozzles.
Fuel pump primer lever left on upward end of
stroke.
✓
Engine runs irregularly or stalls frequently
Below normal engine temperature:
• Remove and check thermostat.
Clogged primary fuel filter element:
• Clean or replace filter element.
Clogged secondary fuel filter element:
• Replace secondary filter element.
Water or dirt in the fuel system.
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.
Improper type of fuel:
• Consult fuel supplier and use proper type of fuel for
operating condition.
✓
Lack of engine power
Engine overloaded:
• Reduce load.
Intake air restriction:
• Service air cleaner.
Clogged primary fuel filter element:
• Clean or replace filter element.
Clogged secondary fuel filter element:
• Replace filter element.
Improper type of fuel:
• Consult fuel supplier and use proper type of fuel for
operating conditions.
Overheated engine:
• See "Engine Overheats" in next category.
Below normal engine temperature:
• Remove and check thermostat.
Improper valve clearance:
• See your local dealer.
Dirty or faulty injection nozzles:
• See your local dealer.
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If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer.
Lack of engine power (cont.)
✓
Injection pump out of time:
• See your local dealer.
Improper propeller:
• Consult your dealer and prop chart.
Grass, etc. on bottom of boat:
• Clean hull.
Turbocharger malfunction:
• Stop the engine.
• Remove the air cleaner.
• Make sure the compressor wheel is stationary and then
rotate it with your hand to see whether it is stiff to rotate.
• First rotate the wheel under light pressure, then by lightly
pulling axially. If the wheel is stiff to rotate, blades are
damaged or blades hit housing, the turbocharger should
be replaced as soon as possible.
Engine overheats
✓
Engine overloaded:
• Reduce load (generator sets).
• Check propeller size (propulsion).
Low coolant level:
• Fill tank to proper level.
• Check hoses for loose connections and leaks.
Keel cooling tubes have been painted.
Cooling system needs flushing.
Defective thermostat:
• Remove and check thermostat.
Defective temperature gauge/sender:
• Check water temperature with thermometer and replace
gauge or sender if necessary.
Water pump impeller worn/broken (HE Engine).
✓
Engine knocks
Insufficient oil:
• Check dipstick
• Call your dealer.
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.
✓
High fuel consumption
Improper type of fuel.
Clogged or dirty air cleaner:
• Service air cleaner.
Engine overloaded:
• Reduce load.
• Check proper propeller size.
• Grass, etc. on bottom of boat.
TROUBLESHOOTING (CONT.)
Improper valve clearance:
• See your dealer.
Injection nozzles dirty:
• See your dealer.
Injection pump out of time:
• See your dealer.
Engine not at proper temperature
• Check your thermostats.
• Check water temp. with thermometer to see if tempera-
ture gauge is working properly.
✓
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.
Improper type of oil:
• Drain and fill crankcase with correct oil.
Partially plugged oil filter:
• Replace filter.
✓
High oil consumption
Break-in period.
Crankcase oil too light:
• Use proper viscosity oil.
Oil leaks:
• Check for leaks in lines around gaskets and drain plug.
Engine overheats:
• See "Engine Overheats".
Engine emits black or gray exhaust smoke
✓
Clogged or dirty air cleaner:
• Service air cleaner.
Defective muffler (back pressure too high).
Improper fuel.
Engine overloaded:
• Reduce load.
• Check propeller size.
Injection nozzles dirty:
• See your dealer.
Engine out of time:
• See your dealer.
Engine emits white smoke
✓
Improper fuel.
Cold engine:
• Warm up engine to normal operating temperature.
Defective thermostat:
• Remove and check thermostat.
Engine out of time:
• See your dealer.
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DC Wiring Diagram C-5298
L6140AL 12 Volt Standard Ground
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DC Wiring Diagram C-5228
L6140AL 24 Volt Standard Ground
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DC Wiring Diagram C-5299
M6140AL 24 Volt Standard Ground
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AVC63-12, all voltages
AC Wiring Diagram B-7429C
M6140 with Voltage Regulator
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ONBOARD SPARE PARTS
Safety at sea depends on careful preparation, product knowledge, and
having the right tools and parts. Below is a list of parts Alaska Diesel
Electric, Inc. recommends you carry onboard at all times.
Onboard Parts Kits are available from your dealer. "Standard" Kits
are suitable for inland and offshore cruising. "World Class" Kits are
for world cruising and trans-ocean cruising.
We consider these minimum quantities. Your vessel's operating
conditions may require more of a given part. Consult your dealer.
Standard World
Item Description Quantity Class
1 Lube Oil Filter 4 4
2 Air Filter Element 1 1
3 Fuel Filter 2 2
➤
4 Water Filter 2 2
5 Injector 0 6
6 O-Ring 0 6
➤
7 O-Ring 0 12
8 Gasket 0 6
9 Impeller and Gasket ✶ 22
10 Thermostat 2 2
11 Thermostat Ring 2 2
12 Relay 0 2
13 Valve Cover Gasket 6 6
14 Alternator Drive Belt 1 2
15 Zinc ✶ 612
16 Drive Belt - Raw Water Pump ✶ 02
17 Fuel Washer Kit 1 1
18 Raw Water Pump ✶ 01
19 Workshop Manual 0 1
20 Gasket Kit Top 0 1
21 Gasket Kit Bottom 0 1
✶ Note: Heat exchanger cooled engines only.
➤ Note: Double this quantity if engine is keel cooled.
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