OM2-2R

For Models: M1064T2MCA

and M1066TMCA

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

 — CALIFORNIA —
Proposition 65 Warning:
Diesel engine exhaust and some of its constitu-
ents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.

Northern Lights
4420 14th Avenue N.W.
Seattle, WA 98107
Tel: (206) 789-3880
Fax: (206) 782-5455

Copyright ©2013 Northern Lights, Inc.

All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Northern LIghts, Inc.

Printed in U.S.A.
PART NO.: OM2-2R 01/13
 OPERATOR'S MANUAL
#OM2-2R for Model:
M1064T2CMA and M1066TMCA

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 Injection Pump ................................................. 22

Models Included .................................................2 Turbocharger .................................................... 23
Model Numbers ..................................................2 Turbo Boost ..................................................... 23
Serial Numbers ...................................................2 Cooling System - General ................................ 23
Engine Coolant Specifications ......................... 24
WARRANTY ..........................................................3 Cooling System Flushing ................................. 25
Radiator............................................................ 25
SAFETY RULES ...............................................3 - 7
Generator Ends ................................................ 26
Electrical System - General ............................. 26
LOCK OUT / TAG OUT PROCEDURES .......... 8
Booster Batteries .............................................. 26
COMPONENT LOCATIONS Battery Care ..................................................... 26
M1066TMCA ...........................................10 - 11 Winterizing / Out-of-Service ........................... 27

ENGINE & GENERATOR CONTROL PANELS TROUBLESHOOTING

Series 3A MCA ................................................ 12 Electrical .......................................................... 28
Engine ...................................................... 28 - 30
OPERATING PROCEDURES
Before Starting ................................................. 13 WIRING DIAGRAM
Break-In Period ................................................ 14 AC Wiring ................................................ 31 - 32
DC Wiring ........................................................ 33
SERVICING SCHEDULE CHART .................... 15

SERVICING
Lubrication - General ....................................... 16
Checking Oil .................................................... 16
Oil Changes ..................................................... 16
Changing Oil Filter .......................................... 16
Air Filter .......................................................... 16
Belt Tension ..................................................... 17
Valve Clearances .............................................. 18
Fuels - General ................................................. 19
Crankshaft Vibration Damper .......................... 19
Fuel Filters ....................................................... 20
Bleeding the Fuel System ................................ 20
Injectors ................................................... 20 - 21

Proprietary Information
This publication is the property of Northern Lights, Inc.
It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc.
© Northern Lights, Inc. All rights reserved. Litho U.S.A. Publication number OM2-2R 01/13

OM2-2R 1/13
1
 Introduction

Servicing of marine engines and generator sets Failures begin with minor problems that are overlooked
presents unique problems. In many cases boats cannot and become amplified when not corrected during
be moved to a repair facility. Marine engines cannot routine maintenance.
be compared to the servicing of automobiles, trucks or
even farm equipment. Failures often occur in remote As operator, it is your obligation to learn about your
areas far from competent assistance. Marine engines equipment and its proper maintenance. This is not a
are taxed far more severely than auto or truck engines; comprehensive technical service manual. Nor will it
therefore, maintenance schedules must be adhered to make the reader into an expert mechanic. Its aim is to
more strictly. aid you in maintaining your unit properly.

Model Numbers Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:
M 1066 T, MCA

Model number T - Turbocharged

M - Northern Lights marine generator set + 106 mm bore, 6 Cylinder + MCA - Marine & Coast
Guard Agency

Northern Lights® , 1800 RPM, 99 kW marine

M1066TMCA = diesel generator set with a John Deere 6068
engine block with an electronically controlled
fuel system and radiator cooled.

Serial Numbers

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

OM2-2R 1/13
2
 Revised 1-9-13

Warranty

A warranty registration certificate is supplied NOTE: If the warranty is to apply, the servicing
with your set. The extent of coverage is described instructions outlined in this manual must be
in the Limited Warranty Statement. We followed. If further information is needed, please
recommend that you study the statement carefully. contact an authorized dealer or the factory.

Safety Rules

NOTICE: Accident reports show that careless use of engines causes a high percentage of accidents.
You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.
IMPORTANT SAFETY INSTRUCTIONS. on parts and components from outside suppliers
Electromagnetic equipment, including generator sets that is not reproduced in this manual. Consult the
and their accessories, can cause bodily harm and suppliers for additional safety information.
life threatening injuries when improperly installed,
operated or maintained. To prevent accidents be aware Learn how to operate the machine and how to use
of potential dangers and act safely. the controls properly. Only trained personnel should
operate machines, or work on or around them.
READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUAL, Keep you machine in proper working condition.
PRIOR TO THE INSTALLATION UNAUTHORIZED MODIFICATIONS TO THE
OF ANY GENERATOR SET OR MACHINERY MAY IMPAIR ITS FUNCTION
ACCESSORY. KEEP THESE AND SAFETY PARAMETERS.
INSTRUCTIONS FOR FUTURE
REFERENCE.
Prevent Bypass and Accidental Starting
Recognize Safety Symbols and Instructions
In addition to the information found in this section, this
operator’s manual uses three different signal words to
outline potential dangers of a specific nature. Do not start engine by shorting
across start terminal. Engine will
DANGER indicates a hazardous situation which, if start if normal circuitry is bypassed,
not avoided, will result in death or serious injury. creating a hazard by runaway
WARNING indicates a hazardous situation which, if machinery.
not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation which, Start engine only from operator’s station.
if not avoided, could result in minor or moderate
injury.

Follow All Safety Instructions Handle Fuel Safely - Avoid Flames

Carefully read and understand
all safety messages in this
manual and on your machine’s
safety signs. Keep signs in good Diesel is highly flammable and should be treated
and clean condition. Replace with care at all times. Do do not refuel while
missing or damaged signs. Be smoking or when near sparks or open flame.
sure new equipment components and repair parts
include the current safety signs. For replacement signs, ALWAYS STOP ENGINE
proper placement of safety signs or clarification on any BEFORE FUELING
safety issue, consult your Northern Lights dealer or the MACHINE. Always fill
factory. portable fuel tank outdoors.
There can be additional safety information contained Never fuel a hot engine.

OM2-2R 1/13
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 Added 1-9-13

Safety Rules (Continued)

Prevent accidental discharge of starting fluids by Operating equipment requires the full attention of
storing all cans in a cool, safe place, away from sparks the operator. Do not use radio or music headphones
or open flame. Store with cap securely on container. while operating machinery.
Never incinerate or puncture a fuel container.

Prevent fires by keeping machine clean of accumulated Practice Safe Maintenance

trash, grease and debris. Always clean any spilled fuel
as swiftly as possible. Do not store oily rags, which
can ignite and burn spontaneously.
Understand all service procedures
Be prepared if a fire starts. Keep a first aid kit and fire before starting work. Keep area clean and dry.
extinguisher handy. Keep emergency contact numbers Never lubricate, service, or adjust machine while it is
for fire department, doctors, ambulance and hospital in operation.
near the telephone.
Keep hands, feet and clothing away from power-
driven equipment. When shutting down an engine,
Service Machines Safely disengage all power and operator controls. Allow
the engine to cool completely before beginning any
service work.

Do not wear a necktie, scarf, Securely support any machinery elements that must
necklace, rings or other be raised for service work with support or lifting
jewelry, or any loose clothing machinery specifically intended for that purpose.
when working near moving
parts. Tie long hair behind your head. If any of these Keep all parts in good conditions and properly
items get caught in moving machinery, severe injury or installed. Fix damage immediately. Replace any
death could result. worn or broken parts. Remove any build up of
grease, oil or debris.
Check for any loose electrical connections or faulty
wiring. Disconnect battery ground cable (-) before making
any adjustments or service work.
Look completely around engine to make sure that
everything is clear before starting.
Stay Clear of Rotating Drivelines

Wear Protective Clothing

Entanglement in rotating drivelines can cause serious

injury or death. Keep shields in place at all times.
To prevent catching anything in moving machinery, Make sure that rotating shields turn freely in pace
always wear close fitting clothes and safety equipment with the drivelines.
appropriate to the job.
Prolonged exposure to loud noise can cause hearing Do not wear loose fitting equipment around rotating
loss or impairment. drivelines. Stop the engine and make sure that all
Wear suitable authorized moving parts have stopped
hearing protection, such before making any adjustments,
as earmuffs or plugs to connections, or performing
protect against loud noises. any other type of service to
the engine or other driven
equipment.

OM2-2R 1/13
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 Added 1-9-13

Safety Rules (Continued)

Install all Safety Guards To Avoid Hazards:
• Fill batteries only in well-ventilated areas.
• Wear appropriate eye protection and rubber gloves.
• Never use air pressure to clean batteries.
Direct contact with rotating • Wear appropriate ventilation equipment to avoid
fans, belts, pulley and drives inhaling fumes when adding electrolyte.
can cause serious injury. • Do not spill or drip electrolyte.
• Use correct jump-start procedure if required.
Keep all guards in place at all
times during engine operation. If acid is spilled on skin or in eyes:
1. Flush skin with water.
Wear close-fitting clothes. Stop the engine and be 2. Apply baking soda or lime to
sure all fans, belts, pulleys and drives are stopped help neutralize acid.
before making adjustments, connections, or cleaning 3. Flush eyes with water for
near fans and their components. 15-30 minutes.
4. Get medical attention
Do not allow anything on your person to dangle into immediately.
or come in contact with a moving fan, belt, pulley or If acid is swallowed:
drive. Fans can act as vacuums and pull materials 1. DO NOT induce vomiting.
up from below, so avoid that area as well while in 2. Drink large amounts of
service. water or milk, without
exceeding 2 liters
(2 quarts)
Safe Battery Handling 3. Get medical attention immediately

Battery posts, terminals, and related accessories

Prevent Battery Explosions can contain lead and lead compounds, chemicals
Battery gas is highly known to the State of California to cause cancer and
flammable. Battery reproductive harm. Wash hands after handling.
explosions can cause severe
injury or death. To help
prevent battery explosions, keep sparks, lighted Handle Chemical Products Safely
matches and open flame away from the top of battery.
When checking battery electrolyte level, use a
flashlight.
Direct exposure to hazardous
Never check battery charge by contacting the posts chemicals can cause serious injury.
with a metal object. Use a volt-meter or hydrometer. Among the potentially hazardous
chemicals that may be used
Frozen batteries may explode if charged. Never with Northern Lights
charge a battery that has not been allowed to warm to products are lubricants,
at least 16oC (60oF). coolants, paints and adhesives.
Always remove grounded (-) battery clamp first and
replace ground clamp last. All potentially hazardous chemicals come with a Material
Safety Data Sheet (MSDS). The MSDS provides specific
Sulfuric acid in battery electrolyte is poisonous and details on chemical products, including physical hazards,
strong enough to burn skin, eat holes into clothing and safety procedures and emergency response techniques
other materials, and cause blindness if splashed into eyes.

OM2-2R 1/13
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 Added 1-9-13

Safety Rules (Continued)

Read and understand the MSDS for each chemical before engine has been shut off. Do not remove a filler cap
you start any job that includes it. Follow the procedures unless it is cool enough to comfortably grip with bare
and use appropriate equipment exactly as recommended. hands. Slowly loosen cap to relieve pressure before
opening fully.
Contact your Northern Lights dealer or Northern Lights
factory for MSDS’s used on Northern Lights products.
Avoid High Pressure Fluids

Work in Well Ventilated Areas

Relieve pressure prior to

disconnecting pressurized lines.
Exhaust fumes from engines contain carbon monoxide Escaping fluid under pressure
and can cause sickness or death. Work in well ventilated can penetrate the skin causing
areas to avoid prolonged exposure to engine fumes. If it serious injury. Always relieve pressure before
is necessary to run an engine in an enclosed area, route disconnecting hydraulic or other pressurized lines.
the exhaust fumes out of the area with an approved, leak Tighten all connections firmly before re-applying
proof exhaust pipe extension. pressure.

If searching for leaks, use a piece of cardboard.

Remove Paint Before Welding or Heating Always protect your hands and other body parts from
high-pressure fluids.

If an accident occurs, see a doctor immediately. Any

Hazardous fumes can be generated high pressure spray injected into the skin must be
when paint is heated by welding, removed within a few hours to prevent the risk of
soldering or using a torch. To avoid gangrene or other infection.
potentially toxic fumes and dust,
remove paint before heating.
Avoid Heating Near Pressurized Fluid Lines
• Remove paint a minimum of 100
mm (4 in.) from the
area that will be affected by heat.
• If paint cannot be removed, wear an approved respirator. Flammable spray can be generated
• If you sand or grind paint, use an approved respirator. by heating near pressurized fluid
• If you use solvent or paint stripper, remove stripper lines, resulting in severe burns and
with soap and water before welding. Remove bodily injury. Pressurized lines
solvent or paint stripper containers from the area. can rupture when heat goes beyond the immediate
• Allow at least 15 minutes for fumes to disperse flame area. Do not weld, solder or use a torch or
before welding or heating. open flame near pressurized lines or other flammable
fluids.
Do not use a chlorinated solvent in an area where welding
will occur. Work only in areas that are well ventilated.
Dispose of paint and solvent properly. Do Not Open High-Pressure Fuel System

Service Cooling System Safely

Many Northern Lights engines use high-pressure

fuel injection. High-pressure fluid remaining in fuel
Opening a pressurized cooling lines can cause serious injury. Do not disconnect or
system can release explosive attempt any repair of fuel lines, sensors, or other
fluids and causing serious burns.
Before opening any pressurized
cooling system, make sure the

OM2-2R 1/13
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 Added 1-9-13

Safety Rules (Continued)

components between the high-pressure fuel pump material containing asbestos. Keep all bystanders
and nozzles on engines with high pressure fuel away from any area where asbestos dust may be
systems. generated.

ONLY AUTHORIZED TECHNICIANS

CAN PERFORM REPAIRS ON AN HIGH Use Proper Lifting Equipment and Techniques
PRESSURE FUEL INJECTION SYSTEMS.

Avoid Hot Exhaust Lifting heavy components incorrectly

can cause severe injury or damage
to machinery. Avoid unbalanced
loads. Do not use lifting eyes. Lift the
Avoid exposure to and physical generator set using lifting bars inserted
contact with hot exhaust through the lifting holes on the skid.
gases. Exhaust parts and streams can reach high Follow all recommended removal and installation
temperatures during operation, leading to burns or procedures in this and associated Northern Lights
other serious injury. manuals.

Cleaning exhaust filters can also lead to exposure to

hot exhaust gas and the injury risk associated with Use Proper Tools
it. Avoid exposure to and physical contact with hot
exhaust gases when cleaning exhaust filters.

During auto or manual/stationary exhaust filter Makeshift tools and procedures

cleaning operations, the engine will run at can create safety hazards.
elevated temperatures for an extended period of Always use appropriate tools for
time. Exhaust parts and streams can reach high the job.
temperatures during operation, leading to burns or
other serious injury. Use power tools only to loosen threaded parts and
fasteners. For loosening and tightening hardware,
always use the correct sized tools.
Avoid Harmful Asbestos Dust
Do not use US measurement tools on metric
fasteners, or vice versa. Use only service parts that
meet Northern Lights specifications.
Inhaling asbestos fibers may cause
lung cancer. Avoid breathing any
dust that may be generated when Dispose of Waste Properly
handling components containing
asbestos fibers, including some
gaskets.
Disposing of waste improperly can threaten the
The asbestos used in these components is usually environment and lead to unsafe working conditions.
found in a resin or otherwise sealed. Normal Potentially harmful waste used in Northern Lights
handling of these components is not dangerous, equipment can include oil, fuel, coolant, filters and
as long as airborne dust containing asbestos is not batteries.
generated.
Avoid creating dust. Never use compressed air for Use leakproof containers to drain fluid. Do not
cleaning. Avoid brushing or grinding materials use food or beverage containers that may mislead
containing asbestos. When servicing, wear an someone into drinking from them.
approved respirator. A special vacuum cleaner is
recommended to clean asbestos. If this vacuum is Do not pour waste onto the ground, down a drain or
not available, apply a mist of oil or water on the into any water source.

OM2-2R 1/13
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 Added 1-9-13

Lock Out / Tag Out Procedures

Scope
During maintenance, repairs or retooling of a Northern Lights generator set, simply turning the machine off or unplugging
it while it is being worked on does not give enough protection to others who are not performing the maintenance or
repair. Many serious accidents happen when someone thought the machine was turned off, or all of its energy was
safely blocked or released.

General Policy If shutting off of air, water or other material cannot be

achieved at the local supply valve, shut off valves further
back in the system and re-check the bleed-off point until
To avoid dangerous or hazardous situations, refrain from complete shut-off is achieved.
any of the following:
• Removing or bypassing a guard or other safety device Affix a DO NOT OPERATE tag to each valve handle that
• Placing any part of your body in a position where you requires shut off. Each DO NOT OPERATE tag must be
could be caught by moving machinery. signed and dated by the authorized technician servicing
• Cleaning or oiling machinery when in operation. the equipment.
• Adjusting circuits, chillers, pumps, air handlers, valves,
circuit breakers or fans while in operation. Lock Out/Tag Out Instructions -
• Working on piping or high pressure systems. Air Hose Connected Pneumatic Equipment

Lock Out/Tag Out Instructions - Equipment connected to the compressed air system
Electrical Equipment through an air hose with a detachable fitting must be
shutdown and unplugged. Excess air must be bled prior
to removing the air hose, prior to any maintenance or
Be sure the equipment’s ON/OFF switch is in the OFF repair activities.
position and is unplugged from any electrical source before
attempting to perform any type of work on the equipment. Affix a DO NOT OPERATE tag to the air hose near the
Obtain an electrical plug cap cover with a lockset. Secure detachable fitting. Each DO NOT OPERATE tag must be
the plug terminal end using the electrical plug lockout cap. signed and dated by the authorized technician servicing
Lock the cap and retain the key. the equipment. Check that the equipment cannot be
operated by activating the ON switch.
If the equipment is directly wired into an electrical box with
a shut off switch, obtain a lock pad and/or the appropriate Stored Energy
colored tags and place the lock and tag through the shut
off lever. Retain the key until the repair is completed and
the machine is safe to start. Be certain the shut off lever Immediately after applying Lock Out or Tag Out devices,
is in the OFF position before restarting. NEVER give a ensure that all potentially hazardous stored or residual
lock out key to unauthorized personnel. energy is relieved, disconnected, restrained and otherwise
rendered safe.
If the equipment is directly wired into an electrical box
without a shut off switch and lock out capability, then a Verification of Isolation
circuit breaker lock out will be required. Obtain a circuit
lock and tag set. Install the lock onto the circuit breaker
box. Ensure the unit ON/OFF switch is in the OFF position Verify the machinery or equipment is actually isolated and
before restarting. de-energized prior to beginning work on a machine or on
equipment that has been locked out.
Lock Out/Tag Out Instructions -
Pneumatic and Hydraulic Equipment Restarting Procedures

For servicing pneumatic and hydraulic equipment, the Follow the procedures below prior to restoring energy:
following additional procedures must be implemented, • Ensure that all machinery or equipment is properly
following completion of lock out/tag out procedures for reassembled. Inspect the machinery or equipment to
the unit to be serviced: verify non-essential items have been removed.
• Ensure that all personnel are safely outside danger
Shut off air, water or supply valves at the equipment to zones. Notify personnel that lock out/tag out devices have
be serviced. been removed and energy will be reapplied.
• Only authorized personnel may remove lock out/tag out
Check the local bleed-off point for completed release of devices or notices.
pressurized air, water or oil.
OM2-2R 1/13
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 Notes

OM2-2R 1/13
9
 Component Locations

4 5 6
1 2 3

11
10 9

8
7
12 13

18
17
14
16
Figures 1 & 2: M1064T2MCA (for illustrative
15
purposes only - your model may vary)

1. Junction Box 7. Vibration Mount 13. Turbocharger

2. Air Cleaner 8. Lube Oil Filter 14. Generator End
3. Fuel Filter 9. Lube Oil Dipstick 15. & 16. Pressure Switch & Sender
4. Intake Manifold 10. Oil Level Switch/Gauge 17. Starter
5. Alternator 11. Fuel Manifold 18. ECU
6. Radiator Shroud 12. Exhaust Manifold

OM2-2R 1/13
10
 Component Locations
1 2 3 4 5 6

11
10 9
8
7
12 13

19
18
17 16 14
Figures 1 & 2: M1066TMCA (for illustrative purposes only - your 15
model may vary)

1. Junction Box 7. Vibration Mount 13. Turbocharger

2. Air Cleaner 8. Lube Oil Filter 14. Generator End
3. Fuel Filter 9. Lube Oil Dipstick 15. & 16. Pressure Switch & Sender
4. Intake Manifold 10. Oil Level Switch/Gauge 17. Starter
5. Alternator 11. Fuel Manifold 18. Alarm Tank
6. Radiator Shroud 12. Exhaust Manifold 19. ECU

OM2-2R 1/13
11
 Control Panel

1 2 3

4 5 6

Figures 3: Series 3 Autostart Control Panel

1. OIL PRESSURE GAUGE 5. SAFETY SHUTDOWN BUTTON

The oil pressure gauge shows the oil pressure in Push this button down to disable the safety shut-
the engine lubricating system. If the pressure drops downs (for emergency use), pull it up to enable the
below 15 PSI at a speed higher than idling, stop the safety shutdowns to work.
engine and investigate.
6. AUTO OR MANUAL SELECTOR SWITCH
2. COOLANT TEMPERATURE GAUGE
This switch allows the engine to be controlled
Water temperature gauge shows the temperature of
manually or by a different source.
the cooling water. If the gauge registers over 200°
(93.30C) or drops below 140°(600C), stop the engine
and investigate.

3. DC VOLTMETER
When the engine is running, it indicates the voltage
output of the alternator.

4. HOUR METER
Keeps track of the engine running time.

OM2-2R 1/13
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 Operating Procedures

BEFORE STARTING Operating

1. Check the water level by removing the pressure 1. Check Gauges Often: Oil pressure must be above
cap from the top of the radiator. In order to give the 29 PSI (if not above 15 PSI within 5 seconds of
cooling water room to expand, the level should be starting, the engine should be stopped and the
about 1 3/4 in. (4-5 cm) below the filler cap sealing problem should be explored). Normal oil pressure
surface when the engine is cold. When filling with is 50 PSI at rated load speed (1800 to 2500 RPM).
coolant, the venting cock on top of the turbocharger Oil temperature should be 1150C (2400F) for normal
should be opened to ensure that no air pockets form operating temperature. The D.C. voltmeter should
in the cooling system (see Service Point #14). read between 13 and 14 volts (26-28 volts, 24 volt
systems).
CAUTION: Use protective clothing and open
2. Check belt for good alignment.
the filler cap carefully when the engine is warm
to prevent burns. 3. Let the unit run unloaded for a three to five minute
warm-up period before applying load.
2. Check the oil level in the crankcase with the dipstick. 4. Do not add full electrical load until engine is at
The oil level should be between the “waffled area” maximum operating temperature.
and the “oo”. Never allow the level to go below Shutdown
the “oo”. Always add the same viscosity of oil as is 1. Turn the Engine Control Switch to the OFF
already in the crankcase (see Service Point #1). position.
3. Check the fuel tank level and open any fuel valves. 2. Close the fuel valves, and put the battery switch
4. Place the battery switch in the ON position. in the OFF position if the unit will be off for an
NOTE: The battery switch must always be kept ON extended period.
while the engine is running. If the switch is turned NOTE: Do not turn the battery switch to OFF while
OFF while the engine is running, the battery charging the engine is running.
regulator could be ruined.
SHUTDOWNS AND ALARMS
1. Your unit is fitted with a system to protect it from
high water temperature or low oil pressure, but only if
the shutdowns are enabled (with the button pulled up
on the control panel - see page 5.)
a. Other alarms and shutdowns are available as
optional equipment.
NOTE: Do not rely on your warning or shutdown
system to the exclusion of careful gauge monitoring.
Watching your gauges can prevent damage to the unit
and dangerous power losses.

2. Do the following when your shutdown system is

activated:
a. Check the temperature gauge. If the temperature
is above 220°F (104°C), shut off the engine
immediately.
b. Use the Trouble Shooting Guide on pages 22- 24
to isolate the cause of the overheat.

OM2-2R 1/13
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 Revised 1/9/13

Operating Procedures

CAUTION: Do not remove the water fill cap of an 3. Oil consumption is greater during break-in as piston
overheated engine. Escaping high temperature rings take time to seat.
steam can cause severe burns. Allow the engine to
cool and then remove the cap slowly, using protective
4. Your engine comes equipped with break-in oil.
clothing.
Change engine oil and filter at 50 hours using API
Service Category CC, CD, or CE break-in oil.
c. Make repairs and restart after the temperature
Change the oil and filter again at 100 hours.
gauge registers below 180°F (83°C).
(Consult the lubricants section for oil
d. Watch the temperature gauge regularly and
recommendation.)
turn off the unit if the temperature rises above
220°F (104°C). Repeat the troubleshooting
5. Frequently check the engine temperature and oil
process.
pressure gauges.
3. If the shutdown is activated and the temperature
Cold Weather Operation
gauge shows temperature within normal temperature
range:
1. Cold weather starting aids are required for air
temperatures below 0°C (32°F). These might
a. Check the engine crankcase oil level.
include intake air heaters, coolant heaters, or fuel
b. If the oil level is low, fill with recommended
heaters. Additional starting aids may be needed in
lubricating oil and restart. Watch the oil pressure
temperatures below -30°C (-22°F).
gauge carefully and shut off the engine if it does
not show a normal reading after a few seconds of
operation.
c. If the oil level was normal, DO NOT restart the
engine. Call your Northern Lights or Lugger
dealer for assistance.

BREAK-IN PERIOD

1. Your engine is ready to be put into service. How-

ever, the first 100 hours on a new or reconditioned
engine are critical to its life and performance. This
is especially true of an engine that runs at a constant
speed such as a generator engine.

2. Operate the engine under various conditions,

particularly heavy loads with minimal idling, to help
seat engine components properly.

OM2-2R 1/13
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 Service Schedule Chart
The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your marine
generator set. More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’ column.
DAILY: EVERY 500 HOURS / YEARLY:
SP1 Check oil level in engine SP4 Replace air cleaner
SP8 Check primary fuel filter SP5 Check belt condition
SP15 Check cooling water level, visually inspect radiator SP9 Change primary filter element (Racor)
AFTER FIRST 50 HOURS: SP10 Change secondary fuel filter
SP2 Change engine oil SP11 Check injectors
SP3 Change lube oil filter SP14 Check turbocharger boost pressure
EVERY 50 HOURS: SP16 Check cooling system
SP21 Check electrolyte in batteries SP22 Check the state of the charge of the batteries
AFTER FIRST 100 HOURS/ EVERY TWO WEEKS 5: SP25 Check engine mounts
SP2 Change engine oil after first 100 hrs., then check every 2 wks. SP27 Check air intake hoses
SP3 Change oil filter after first 100 hrs., then check every 2 wks. SP29 Check electrical ground connection
SP7 Check crankshaft vibration damper7 EVERY 2000 HOURS:
SP15 Check coolant level SP6 Check & adjust valve clearance
EVERY 250 HOURS : SP7 Check crankshaft vibration damper
SP2 Change engine oil SP12 Check fuel injection pump
SP3 Change lube oil filter SP16 Flush cooling system
SP4 Check air cleaner SP17 Check and clean radiator
SP23 Test thermostats

SERVICE 50 100 250 500 2000

POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours
ENGINE:
SP1 10 Check oil level •
SP2 10 Change engine oil 2) 1) 1) •
SP3 10 Change lube oil filters 2) 1) 1) •
SP4 10 Check air cleaner • •
SP5 Check belt condition 2)    •
SP6 12 Check valve clearances 2)   •
SP7 13 Check crankshaft vibration damper 5)   •
SP25 Check engine mounts •
 SP27 Check air intake hoses •
FUEL SYSTEM:
SP8 13 Check primary filter (Racor) 3) •
SP9 13 Change primary filter element (Racor) 3) 4)   •
SP10 13 Change secondary fuel filter 2) 4) •
SP11 14-15 Check injectors 6)
SP12 16 Check fuel injection pump •
TURBOCHARGER:
SP13 17 Check air, oil & cooling water lines for leakage 2) •
SP14 17 Check boost pressure     •

COOLING SYSTEM:
SP15 19 Check cooling water level, visually inspect radiator •
SP16 19 Check and flush cooling system 2) 7) •
SP17 19 Check and clean radiator 2)    •

ELECTRICAL SYSTEM:
SP21 20 Check electrolyte level in batteries 2) 4) •
SP22 20 Check condition of batteries with hydrometer 2) •
 SP23 Test thermostats    •
 SP29 Check electrical ground connection   •

1) Change the oil and filter at 50 hours, using break-in oil again, until changing it 5) Replace damper every 4500 hours or after 60 months.
at 100 hours, then at every 250 hours. 6) Check at 5000 hours.
2) Perform all maintenance once a year even if hour level has not been reached. 7) Check cooling system at 500 hours, flush at 2000 hours.
3) Consult manufacturer's maintenance schedule.
4) Or whenever necessary.

OM2-2R 1/13
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 Servicing
LUBRICATION SP2. OIL CHANGES
Break-in oil 1. Using the oil recommended above, change the engine
1. Use one of the following during the first 100 hours oil and filter after the first 50 hours of operation, the first
of operation: 100 hours and every 250 hours thereafter.
a. John Deere Engine Break-In Oil 2. During intermittent cold weather operation, change oil
b. API Service Category CC, CD, or CE oil every 100 hours or six weeks, whichever comes first.
c. ACEA Specification E1 3. Change oil at any seasonal change in temperature when
2. Do not use John Deere PLUS-50 oil or engine oils a new viscosity of oil is required.
meeting API CG4, API CF4, ACEA E3, or ACEA a. Remove plug from outlet in base frame. Screw in
E2 performance levels during the first 100 hours of owner-supplied drain hose.
operation of a new or rebuilt engine. These oils will b. Open valve at oil pan outlet. After oil has been
not allow the engine to break-in properly. drained into suitable container, close valve, remove
Lubrication - General drain hose and replace plug in base frame outlet.
1. Use only clean, high quality lubricants stored in c. Refill engine with recommended oil.
clean containers in a protected area. 4. Engine Lube Oil Capacity:
2. These oils are acceptable after the first 100 hours:
a. ACEA Oil Sequence E5 and E4 M1064T2 @ 60 Hz 15.5 qts. 14.7 liters
b. API Service Category CI-4 or CH-4. M1064T2 @ 50 Hz 21.6 qts. 20.5 liters
c. ACEA Oil Sequence E3 multi-viscosity oil. M1066T 20.1 qts. 19.0 liters
3. Use the proper weight oil for your average operation SP3. CHANGING OIL FILTER
temperature. 1. Change the lube oil filter every 250 hours, after the
initial 50 and 100 hour change.
2. Use a filter wrench to remove old filter. Dispose of filter
Air Single Multi
Temperature Viscosity Viscosity in approved manner.
3. Make sure the gasket from the old filter is removed and
Above 32°F discarded.
SAE-30W SAE15-40W 4. Lubricate the rubber gasket on the new filter and screw it
(0°C)
on nipple until gasket meet the sealing surface.
-10°F to 32°F 5. Using hands only, no wrench, tighten filter one-half turn
SAE-10W SAE10-30W
(-23°C to 0°C) farther. Overtightening can do damage to filter housing.
Below -10°F 6. Fill engine with recommended oil. Start engine and
SAE-5W SAE5-20W check for leakage. Stop engine and check oil level. Add
(-23°C)
additional oil if necessary.
4. Some increase in oil consumption may be expected SP4. AIR CLEANER
when SAE 5W and SAE 5-20W oils are used. Check 1. Inspect air cleaner every 100 hours. Replace air cleaner
oil level frequently. element every 500 hours.
5. Never put additives or flushing oil in crankcase. 2. Clean the rubber tube at the cleaner. Loosen the hose
clamp and the attaching strip for the cleaner.
SP1. CHECK ENGINE OIL LEVEL 3. Make sure the rubber tube is in good condition and that
1. Check the oil level in the crankcase, with the oil new filter is absolutely clean and installed properly.
dipstick, daily. 4. Start the engine and check for leaks.
2. The oil level must be between the “Waffled area” and NOTE: Make absolutely sure no impurities enter the
the “oo”. Never allow the level to go below the “oo”. engine while changing the element. Do not run the engine
3. Always add the same viscosity of oil as is already in with the air cleaner removed.
the crankcase.

OM2-2R 1/13
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 Servicing

SP5. BELT TENSION Note: If an automatic spring tensioner is used, a

belt tension gauge will not give an accurate
measure of the belt’s tension. Measure the spring
1. Inspect the belt for cracks, stretched out areas, or tensioner’s tension instead, as follows.
frays and replace if needed. 1. Using a torque wrench, remove the belt from the
2. Twist the belt in the middle of a 10 to 12 inch span pulleys using a breaker bar and socket on the ten-
(254- 305 mm) with two fingers. It should turn 75 sion arm.
to 85 degrees if it is properly tensioned. If it turns 2. Check the pulleys and bearings while the belt is off.
more it needs to be tightened, if it can not turn that See dealer if replacements are needed.
much it needs to be loosened. 3. Release the tension on the tension arm and remove
3. Loosen Capscrews shown (A & B, Figure 4) the breaker bar.
4. Using torque wrench as shown in Figure 4, Rotate 4. Mark a line as shown (Figure 5A).
tensioner until a reading of 100 lb is reached. Hold 5. Measure 21 mm (.83 in.) down from (A) and put a
in position and retighten fasteners A & B. line (B) on the tensioner mounting base.
Note: Do not pry against the alternator rear frame. 6. Install a torque wrench (Figure 6C) and align the
5. Pry outward on the tension bracket or the alternator center of the pulley and tensioner, aligning marks.
front frame to stretch the belt, until the specified 7. Record the torque wrench measurement and com-
tension is achieved. pare it with the below specification.

New Belt Tension .........470 -650 N (105-145 lb.-force) Spring Tension Torque .........18 -22 N•m (13-16 lb.-ft.)

Used Belt Tension.........400 -580 N (90- 130 lb.-force) Note: The belt tensioner roller capscrew threads are
Left-Hand threads.
Note: New belts are considered used after ten
Reproduced by permission of Deere & Company,
minutes of running time. c2005. Deere & Company. All rights reserved.
RG7977 Figure 5
6. Re-tighten capscrews B & C, run engine for ten
minutes and re-check belt tension.

Reproduced by per-
mission of Deere &
A Company, c2005. Deere
& Company. All rights
B reserved. RG12065
Figure 6

Figure 4

OM2-2R 1/13
17
 Servicing
SP6. VALVE CLEARANCES NOTE: Firing order is 1 - 3 - 4 - 2

The following special tools will be needed:

JDE 820 or JDE 83 Flywheel Turning Tool,
JDE 81-4 Timing Pin.
1. Remove rocker arm cover with ventilator tube.
2. Remove plastic plugs in engine timing holes on front
side of flywheel.
3. Rotate flywheel in clockwise direction (viewed from
water pump) with the Flywheel Turning Tool until
the Timing Pin engages timing hole in the flywheel.
Both rocker arms for No. 1 cylinder will be loose at
Top Dead Center. If they are not, remove the timing
pin and rotate the flywheel one complete turn and Reproduced by permission of Deere & Company, c2004. Deere & Company.

reinstall the timing pin in the flywheel. All rights reserved. RG4776 Figure 10
4. Valve clearances must be checked with the engine
A - Front of Engine
cold. B - No. 1 Piston at TDC Compression Stroke
Intake Valve: 0.012-0.015 in. (0.31-0.38 mm) C - No. 4 Piston at TDC Compression Stroke
E - Exhaust Valve
Exhaust Valve: 0.016-0.019 in. (0.41-0.48 mm) I - Intake Valve
5. If the valves need adjusting, loosen the jam nut (A
on Figure 9) on the rocker arm adjusting screw. Turn Adjust valve clearance on No. 2 and No. 4 exhaust
the adjusting screw until you feel a slight drag when valves and No. 3 and No. 4 intake valves.
the feeler gauge slips. With a screwdriver, hold the
adjusting screw from turning while tightening the 6-CYLINDER ENGINES:
jam nut to specifications. Check the clearance again
after tightening the jam nut. Re-adjust as needed. NOTE: Firing order is 1 - 5 - 3 - 6 - 2 - 4

Reproduced by permission of Deere & Company, c2004. Deere & Company. All rights

reserved. RG4777 Figure 11

Reproduced by permission of Deere & Company, c2004. Deere & Com-
pany. All rights reserved. RG7409
A - Front of Engine
Figure 9 B - No. 1 Piston at TDC Compression Stroke
C - No. 6 Piston at TDC Compression Stroke
4-CYLINDER ENGINES: E - Exhaust Valve
I - Intake Valve
Lock No. 1 piston at TDC compression stroke
(B). Lock No. 1 piston at TDC compression stroke (B).
Adjust valve clearance on No. 1 and No. 3 Adjust valve clearance on No. 1, No. 3, and No. 5 exhaust
exhaust valves and No. 1 and No. 2 intake valves and No. 1, No. 2, and No. 4 intake valves.
valves. Rotate flywheel 360°. Lock No. 6 piston at TDC
Rotate flywheel 360°. Lock No. 4 piston at compression stroke (C). Adjust valve clearance on No. 2,
TDC compression stroke (C). No. 4, and No. 6 exhaust valves and No. 3, No. 5, and No.
6 intake valves.
OM2-2R 1/13
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 Servicing
FUELS - GENERAL 2. Change secondary fuel filter every 500 hours.
1. Use only clean, high quality fuels of the following NOTE: The fuel filter on the engine is considered the
specifications, as defined by ASTM designation D975 for “secondary fuel filter”. The engine will be fitted with a
diesel fuels: quick change disposable secondary fuel filter.
a. Use Grade No. 2 diesel at ambient temperatures
above freezing 30°F (0°C). SP7. CRANKSHAFT VIBRATION DAMPER
b. Use Grade No.1 at ambient temperatures below (6 Cylinder Engines Only)
freezing and for all temperatures at an altitude of 1. Remove belts.
above 5,500 ft. (1500 meters). 2. Try to turn the vibration damper in both directions
2. Sulphur content should not exceed 0.5% (preferably less while grasping it with both hands. If rotation can be
than 0.5%). felt, the damper is defective and should be replaced.
3. The cetane number should be a minimum of 45.
4. DO NOT use these unsuitable grades of fuel:
a. Domestic heating oils, all types, b. Class B engine,
c. Class D domestic fuels, d. Class E, F, G or H industrial
or marine fuels, e. ASTM-D975-60T No. 4-D and higher
number fuels, f. JP4
5. Storing fuel:
a. Keep dirt, scale, water and other foreign matter
out of fuel.
b. Avoid storing fuel for long periods of time. Reproduced by permission of Deere & Company, c2004. Deere & Company. All rights

c. Fill the fuel tank at the end of each day's reserved. RG8018 Figure 9
operation. This will reduce condensation. NOTE: The vibration damper assembly should be
6. Biodiesel: replaced every 4500 hours or 60 months, whichever
Biodiesel involves the transesterification of vegetable oils or animal fats. occurs first, as the vibration damper assembly is not
Mainly in the U.S. soybean methyl ester is used (SME), but in Europe repairable.
mainly rapeseed (canola) methyl ester is made (RME), and in Asia palm 3. Place a dial indicator (Figure 10) so that the probe
methyl ester is made (PME). 100% biodiesel (B100) is made in compli- contacts the damper’s outer diameter in order to
ance with ASTM D6751 or EN14214 (EU) specifications. Biodiesel check the damper radial runout.
may be used in a 5% blend (5% biodiesel/ 95% diesel) from a BQ-9000 4. Make sure the engine is at operating temperature,
accredited producer. 20% biodiesel blends can only be used if they meet then rotate the crankshaft using the JD281A,
ASTM D6751 or EN14214 (EU) specifications. A 2% reduction in power JDE81-4, or the JDE83 Flywheel Turning Tool.
and a 3% reduction in fuel economy can be expected using a 20% blend, 5. If the runout reading exceeds the below
and a fuel conditioner is recommended. Biodiesel blends must be used specification, replace the vibration damper.
within 90 days of their manufacture. Oil level, leaking, microbial growth, Vibration Damper Maximum
plugging, and component degradation all must be checked more frequently Radial Runout ..........................1.50 mm (0.060 in.)
using biodiesel blends. Request a certificate of analysis from an approved
biodiesel fuel distributor to make sure the blend meets specifications.
NOTE: Using raw pressed or partially refined vegetable oils or recycled
greases as fuel (which have not been through transesterification) could
cause engine failure.
SP8-10. 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 recommended by the
filter manufacturer. Empty the collection bowl as necessary.
b. Change the element every 500 hours or whenever
necessary. Reproduced by permission of Deere & Company, c2004. Deere & Company. All rights
reserved. RG7508 Figure 10
c. If the bowl fills with water, change the primary and
secondary elements immediately.
OM2-2R 1/13
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 Servicing
SP8-10. FUEL FILTERS (Continued) 1. Whenever the fuel system has been opened for service,
(lines disconnected, filter changed, etc.) it will be
a. Turn off the fuel. necessary to bleed air from the system.
b. Open the filter drain plug (Figure 11-A) and drain a. To bleed the fuel system, loosen the bleed plug
the filter. (Figure 11-D) on the fuel filter.
Operate the primer pump lever on fuel transfer
pump (see component locations) until most of the
air bubbles are expelled and clear fuel escapes the
bleed plug. Tighten the bleed plug.
b. If the engine will not start, it may be necessary to
loosen the fuel supply pipe at the pump. Operate
primer lever of fuel supply pump until fuel flow
is free from air bubbles. Retighten fuel supply
line to 22 ft. lb. (30 N•m).
c. If engine still doesn't start, loosen fuel line
connection at injection nozzle. Always use a back
up wrench when loosening or tightening fuel lines
at nozzles and injection pump to avoid damage.
With throttle on full, crank the engine over with
Figure 11: Secondary Fuel filter the starter until fuel without air flows from the
c. Remove the secondary fuel filter by turning the loose fuel pipe connection. Repeat procedure for
filter clamp (Figure 11-B) counter clockwise until remaining nozzles, if necessary, until engine
the filter cartridge (Figure 11-C) slides out. starts or until air has been removed from system.
Tighten the connections to 20 foot lb. (27 N•m).
NOTE: Before installing a new filter cartridge make sure
the surfaces where the cartridge comes in contact with the SP11. INJECTORS
mounting plate are absolutely clean. Dirt can be washed 1. Fuel injectors should be checked by a Lugger-Northern
into the fuel injection system. This may result in severe Lights dealer or qualified fuel injection shop every 5000
damage to the fuel injection pump or nozzles. Your hours.
generator set may have two secondary filters, depend- 2. Injector Removal:
ing on the fuel supply system. Do not “prefill” the new You will need the following special tools:
fuel filter as the fuel used may be contaminated and JDE38A-Injection Nozzle Puller
damage the fuel system components. JDE39-Nozzle Bore Cleaning Tool, JD258-Pilot Tool
a. Before removal, carefully remove all dirt from
d. Install new filter cartridge. the cylinder head around fuel injection nozzles.
e. Turn on the fuel. Clean with compressed air to prevent dirt from
entering the cylinders or valve seats. Plug the
BLEEDING THE FUEL SYSTEM bore in the cylinder head after each fuel injection
CAUTION: Escaping diesel fuel under pressure nozzle has been removed. Cap fuel line openings
can penetrate the skin, causing serious personal as soon as they are disconnected.
injury. Before disconnecting lines be sure to b. Immediately fit protective caps over the nozzle
relieve all pressure. Before applying pressure to tips and the line connections to avoid handling
the system be sure all connections are tight and damage.
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.

OM2-2R 1/13
20
 Servicing

c. Do not bend the fuel delivery lines. When This coating will become discolored during normal
loosening the fuel pressure lines, hold male union operation, but this is not harmful. Do not use a motor
of nozzle line stationary with a backup wrench. driven brush to clean up nozzle body.
d. Loosen nuts to remove leak-off lines and T-fittings
and disconnect fuel injection line from nozzle.

NOTE: When all fuel injection nozzles have to be

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

e. Remove cap screw, clamp and spacer. Figure 13

f. Pull injection nozzle out of cylinder head with
JDE38A Injection Nozzle Puller. 5. Install seals on injection nozzle.

NOTE: Do not use screwdrivers, pry bars, or similar NOTE: Each time an injection nozzle is removed
tools for this as they might damage the injection nozzle. from the cylinder head, replace carbon stop seal (B)
with a new one.
3. Clean Injector Bore:
Always turn the tool clockwise through the bore a. Position JD258 (ROS16477) Pilot Tool (Figure
even when removing from bore, otherwise tool may 13-C) over nozzle tip. If Pilot Tool (included in
become dull. cleaning kit) is not available, use a No. 16189
a. Clean nozzle bore with JDE39 Nozzle Bore Nozzle Protector Cap found on every new or re-
Cleaning Tool. Blow debris from bore with placement nozzle.
compressed air and plug the bore to prevent entry b. Position a new carbon stop seal (Figure 13-B) on
of foreign material. pilot tool. Use a new seal washer (Figure 13-A) to
4. Clean injection nozzles: help slide the carbon seal into place until it seats
a. Remove carbon stop seal (Figure 12-A) and upper in its groove on nozzle body.
sealing washer (Figure 12-B), using a needle-nose c. Continue to slide upper sealing washer onto
pliers. Discard seals. nozzle body until it seats against inlet fitting.
b. Clean exterior of nozzle by soaking in clean
solvent or diesel fuel. Clean tip with brass wire 6. Install injection nozzles:
brush.
NOTE: Before installing injection nozzles, make sure
nozzles are clean and free from oil or grease. Do not
grease or oil the nozzles.

a. Remove plug (if installed previously) from nozzle

bore in cylinder head and blow out bore with
compressed air.
b. Make sure that the sealing surface of the cylinder
head (on which the seal washer will be resting) is
smooth and free of damage or dirt. This could
Reprinted by permission of Deere & Company, 2004. All rights reserved. RG6300 prevent proper sealing. Dirt and roughness could
Figure 12 also cause distortion to nozzle when the attaching
screw is tightened, making the valve stick.
NOTE: Do not scrape or disturb the teflon c. Install nozzle in cylinder head using a slight
coating on the nozzle body above the carbon stop twisting motion as nozzle is seated in bore.
seal groove. d. Install spacer and capscrew. Do not tighten
capscrew at this stage.

OM2-2R 1/13
21
 Servicing
Install injection nozzles (continued):

Figure 14: Shows relationship of parts required for

installation.

e. Connect fuel pressure line to nozzle. Leave

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

SP12. INJECTION PUMP

1. Since operating conditions may vary considerably,
it is difficult to give a definite service interval. But,
as a rule, the pump settings, maximum speed, idle
speed and exhaust smoke should be checked by your
dealer after every 2000 hours of operation. Service
of the fuel injection pump should only be done if
checks indicate pump malfunction.
2. Black smoke can be an indication of pump
malfunctions. Before servicing pump, check the
other possible causes.
a. Check cleanliness of air filter.
b. Check valve clearances.
c. Clean and check injectors.
3. Any repair which involves disassembly of the injection
pump must be carried out by specially-trained
mechanics at an authorized dealer with the proper tools
and test devices. Special tools are needed to re-install
the injection pump and match the engine timing.
NOTE: All warranties on the engine become null and
void if the injection pump seals are broken by
unauthorized persons.

OM2-2R 1/13
22
 Servicing

SP13. TURBOCHARGER
2. Vapor bubbles (Figure 15-C) are formed when the
1. Check for air leaks every 100 hours. Air leakage
piston's impact causes the liner walls to vibrate,
will lower engine output and may cause black
sending pressure waves into the coolant.
exhaust smoke and soot.
3. These tiny vapor bubbles collect on the surface
2. Listen along air line while engine is running.
of metal parts. As the bubbles collapse (pop) a
A whistling or hissing sound indicates leakage.
microscopic piece of metal is eroded from the
3. Leakage on the pressure side, between turbo and
metal part. Over a period of time, this pitting may
engine, can be found by applying soapy water to the
progress completely through the cylinder liner of a
air line.
wet-sleeve, heavy-duty diesel engine. This allows
4. Tighten the hose clamps, replace hose or gaskets as
coolant to enter the combustion chamber. Engine
required.
failure or other serious damage will result.
5. Check to see that the lubrication and cooling lines
are tight and without leaks.

SP14. TURBO BOOST

1. This check measures the amount of air the turbo
is pushing into the engine. It should be done by an
authorized dealer every 500 hours.
2. On the inlet manifold there is a 1/8" NPT threaded
port. Remove the plug and install the boost gauge
hose. Refer to your engine specifications for correct
pressure.
A - Cylinder Liner Walls B - Engine Coolant C - Vapor Bubbles
COOLING REQUIREMENTS
1. To meet cooling system protection requirements, the Figure 15
coolant solution must consist of:
a. Quality water 4. Unprotected engines with low quality water as
b. Ethylene glycol concentrate (EGC ) commonly coolant can have liner failure in as few as 500 hours.
known as antifreeze.
c. Supplemental coolant additives (SCA's). WATER QUALITY
2. A coolant solution of ethylene glycol concentrate 1. Distilled, deionized, soft water is preferred for use in
(EGC-antifreeze), quality water and supplemental cooling systems. Bottled distilled water from a food
coolant additives (SCA's) MUST be used YEAR store or water supplier is recommended. Tap water
ROUND to protect against freezing, boil-over, liner often has a high mineral content. Tap water should
erosion or pitting and to provide a stable, noncorro- NEVER be put in a cooling system unless first tested
sive environment for cooling system components. by a water quality laboratory. Do not use water
3. Ethylene glycol coolant concentrate (antifreeze) made by the reverse osmosis method unless it has
normally DOES NOT contain the SCA chemical been PH neutralized.
inhibitors needed to control liner pitting or erosion, 2. Here are acceptable water quality specifications:
rust, scale, and acidity.
Parts Grains
Contaminates per Million per Gallon
LINER EROSION (PITTING)
1. Cylinder liner walls (Figure 15-A) which are in contact Maximum Chlorides 40 2.5
with engine coolant (Figure 15-B) can be eroded or
Maximum Sulfates 100 5.9
pitted unless the proper concentration and type of
SCA's are present in the coolant. Water pump Maximum Dissolved Solids 340 20.0
impellers are also susceptible to pitting. Maximum Total Hardness 170 10.0

PH Level 5.5 to 9.0

OM2-2R 1/13
23
 Servicing
3. If chlorides, sulfates or total dissolved solids are IMPORTANT
higher than the above given specification, the water 1. DO NOT use methyl alcohol or methoxy propanol
must be distilled, demineralized, or deionized before base EGC. These concentrates are not compatible
it is used in a cooling system. with chemicals used in supplemental coolant
4. If total hardness is higher than 170 ppm and all additives. Damage can occur to rubber seals on
other parameters are within the given specifications, cylinder liners which are in contact with coolant.
the water must be softened before it is used to make 2. DO NOT use an EGC containing sealer or stop-leak
coolant solution. additives.
3. DO NOT use EGC containing more than 0.1%
EGC: ETHYLENE GLYCOL CONCENTRATE anhydrous metasilicate. This type of concentrate,
(ANTIFREEZE) which is intended for use in aluminum engines, may
cause a gel-like deposit to form that reduces heat
CAUTION: EGC (Antifreeze) is flammable.
transfer and coolant flow. Check container label or
Keep it away from any open flame. Avoid contact
consult with supplier.
with eyes. Avoid contact with skin. Do not take
internally. In case of contact, immediately wash
SUPPLEMENTAL COOLANT ADDITIVE (SCA)
skin with soap and water. For eyes, flush with
large amounts of water for at least 15 minutes.
CAUTION: Supplemental coolant additive contains
Call a physician. KEEP OUT OF REACH OF
alkali. Avoid contact with eyes. Avoid contact with
CHILDREN. Follow all warnings
skin. Do not take internally. In case of contact
on the container.
immediately wash skin with soap and water. For
1. Ethylene glycol coolant concentrate is commonly eyes, flush with large amounts of water for at
mixed with water to produce an engine coolant with least 15 minutes. Call a physician. KEEP OUT OF
a low freeze point and high boiling point. REACH OF CHILDREN. Follow all warnings on the
2. A low silicate form of ethylene glycol coolant is container.
recommended for all diesel engines.
3. Use an ethylene glycol coolant concentrate 1. Important for heat exchanger cooled engines:
meeting ASTM D 4985P, SAEJ1941, General Additional SCA's should NOT be added to the
Motors Performance Specification GM1899M, mixture of EGC/H20 on initial fill up of engines
or formulated to GM6038M. with a coolant conditioner-filter. A high SCA
4. This product is concentrated and should be mixed concentration will result and can cause
to the following specification. silicate-dropout. When this happens, a gel-type
5. If additional coolant solution needs to be added deposit is created in the cooling system which
to the engine due to leaks or loss, the glycol retards heat transfer and coolant flow.
concentration should be checked with a 2. If additional SCA's are needed, prepare a mixture
hydrometer to assure that the desired freeze point is of 50% quality water and 50%EGC (antifreeze).
maintained. Add liquid SCA at a rate of 3%, by volume.
Example: 30 mL of SCA per liter of H2O/EGC
Distilled EGC % Freeze Boiling mixture (1.0 fl oz of SCA per qt of H2O/EGC).
Water % Antifreeze Point Point Add the resulting mixture to the cooling system in
quart increments. Run the engine for 2 hours and
-37°C +109°C
Optimum 50% 50% retest the coolant. Continue process until SCA
-34°F +226°F
concentration meets recommended levels.
Minimum 60% 40%
-24°C +106°C 3. SCA is available from your Northern Lights dealer
-12°F +222°F in the following sizes.
-52°C +111°C
Pint - Part Number...............20-00002
Maximum 40% 60% 1/2 gallon - Part Number.....20-00003
-62°F +232°F
4. DO NOT use any coolant system additives
containing soluble oil.

OM2-2R 1/13
24
 Servicing
COOLANT TESTING 1. Flush the cooling system and check for leaks and
1. Coolant test kits are available to allow on-site blockage every 2000 hours. The engine must be
evaluation of the coolant condition. stopped and cold.
2. The kits use small strips of paper which are dipped 2. Remove the pressure cap from the radiator with
into the coolant. The paper changes color and indicates caution. If applicable, open the cooling system air
the SCA concentration. It also indicates the amount of vent on top of turbocharger.
EGC (antifreeze). 3. Open the drains on the exhaust manifold and engine
3. Test kits are available through your Northern Lights or block. Drain the fresh water system (see Component
Lugger Dealer. Locations, pages 4).
4 Pack - Part Number.......................20-00005 4. For vessels with keel cooling, the vessel must be out
50 Pack - Part Number.....................20-00010 of the water to allow draining of the keel cooler.
5. With drains open, pour clean water into the expansion
SP15. CHECKING COOLANT LEVEL
tank. When the water from drain is clear and free from
CAUTION: The cooling water in the engine reaches discoloration and sediment, close that drain. When all
extremely high temperatures. You must use extreme drains are closed, flushing is complete.
caution when working on hot engines to avoid 6. Fill the fresh water system by pouring the
burns. Allow the engine to cool before working on recommended coolant mixture as described in
the cooling system. Open the filler cap carefully, previous sections.
using protective clothing when the engine is warm. 7. Close cooling system air vent on turbocharger.
8. Start the engine. Check hoses and connections and
1. Check the coolant level each day before starting the repair any leakage.
engine.
2. Remove the pressure cap from the radiator and check SP17. RADIATOR
water level. In order to give the coolant an opportunity
to expand, the level should be about 1 3/4 in. (4-5 cm) 1. Check for leaks.
below the filler cap sealing surface when the engine 2. Remove debris from radiator fins daily.
is cold. When filling with coolant, the venting cock 3. In very dusty applications clean the radiator with
on top of the turbocharger (for engines fitted with compressed air or steam cleaner every 100 hours or
turbocharger) should be opened to ensure that no air as needed. Clean in reverse direction of airflow.
pockets form in the cooling system.
3. The pressure valve in the filler cap releases when the
pressure is approximately 10 PSI (.689 bar). Use a cap
pressure tester to check cap if you suspect it is faulty.
4. The makeup coolant, added to compensate for loss or
leaks, must meet engine coolant requirements outlined
in previous section.

SP16. FLUSHING THE COOLING SYSTEM

CAUTION: The cooling water in the engine reaches

extremely high temperatures. You must use extreme
caution when working on hot engines to avoid burns.
Allow the engine to cool before working on the
cooling system. Open the filler cap carefully, using
protective clothing when the engine is warm.

OM2-2R 1/13
25
 Servicing
GENERATOR ENDS BOOSTER BATTERIES

2. The maintenance and operation recommendations CAUTION: Battery Gas Can Explode. Keep all
for the generator end are in a separate Owner's flames and sparks away from batteries.
Manual. If you do not have one of these manuals,
contact your local Northern Lights dealer. 1. Before changing or using booster batteries, check
battery electrolyte level. Add distilled water.
ELECTRICAL SYSTEM - GENERAL 2. Booster and main batteries must have the same
voltage rating.
1. Never switch battery switch off or break the circuit 3. First, connect positive (+) terminal of booster
between the alternator and batteries while the engine battery to positive (+) terminal of main battery.
is running. Regulator damage can result.
2. DO NOT reverse the polarity of battery cables when
installing the battery.
3. When welding on the unit, disconnect the regulator
and battery. Isolate the leads.
4. Disconnect battery cables when servicing the DC
alternator.
5. Never test with a screwdriver, etc., against any
terminal to see if it emits sparks.
6. A DC circuit breaker protects your control panel and
wiring harness.

Figure 16: Booster Battery Connections

4. Then, connect negative (-) terminal of booster battery

to ground on the engine block (see Figure 16).
5. Remove booster battery after starting engine.
6. Sealed batteries: see manufacturer charging and
booster instructions.

SP21-22. BATTERY CARE - LEAD/ACID TYPE

BATTERIES

1. Check electrolyte level every 50 hours or once per

month. Add distilled water to manufacturer's
recommended level.
2. Batteries, cables and cable terminals should be
checked and cleaned every 100 hours. Clean
corrosion with a water and baking soda solution.
Flush with clean water. Tighten terminals and grease
them to inhibit corrosion.
3. Check the battery condition with a hydrometer
every 500 hours.

OM2-2R 1/13
26
 Servicing
SP24. WINTERIZING, OUT-OF-SERVICE

If the generator set will not be used for more than 6

months the following preparations should be taken for
long term storage.

1. Change the engine oil and replace the filter.

Service the air cleaner.
2. Drain, flush, and refill the cooling system.
3. Crank the engine a few times with a starter,
without starting the engine.
4. Remove and clean batteries.
5. All engine openings should be sealed with plastic
bags and tape.
6. Store in a dry protected place.

To Remove Generator Set from Long-Term Storage:

1. Take off all protective coverings and unseal all the
openings that were covered up.
2. Install batteries that are fully charged and connect
the terminals.
3. Install the fan and alternator belts if they had been
removed.
4. Fill the fuel tank.
5. Perform all pre-start checks.
6. Crank the engine for 20 seconds with the starter,
without letting the engine start. Wait 2 minutes
and crank the engine an additional 20 seconds to
make sure all bearing surfaces are well coated.
7. Start the engine and run at no load in a low idle for
several minutes. Make sure the engine is warmed
up and check gauges before going under load.
8. Check all gauges and check for leaks.

OM2-2R 1/13
27
 Troubleshooting
If you cannot correct problems with these procedures, see your Lugger or Northern Lights dealer.
DC ELECTRICAL SYSTEM Loose or corroded connections:
 Battery Will Not Charge • Clean and tighten loose connections.
Loose or corroded connections:  Entire Electrical System Does Not Function
• Clean and tighten battery connections. Check DC circuit breaker:
Sulfated or worn out batteries: • If breaker is tripped, reset it.
• Check specific gravity of each battery cell. Faulty connection:
• Check electrolyte level of each battery cell. • Clean and tighten battery and harness plug
Loose or defective alternator belt: connections.
• Adjust belt tension. Sulfated or worn out batteries:
• Replace belt. • Check specific gravity and electrolyte level of
 Undercharged Electrical System each battery cell.
Excessive electrical load from added accessories: ENGINE
• Take off accessories or install higher output  Engine Hard to Start or Will Not Start
alternator. Engine starting under load.
Engine idling excessively. Improper starting procedure:
• Increase the engine RPM when there is a • See starting section of this manual. Take
heavy electrical load. special note of Bypass Switch operation.
Poor electrical connections on battery, ground strap, No fuel:
starter, or alternator. • Check level of fuel in fuel tank.
• Inspect connections and clean if necessary. Low battery output:
Defective battery. • Check electrolyte level and condition.
• Test battery. Excessive resistance in starting circuit:
Battery charging rate too high. • Clean and tighten all battery connections.
• Test charging system. Crankcase oil too heavy:
 Starter Inoperative • Use oil of proper viscosity.
Check DC circuit breaker: Improper type of fuel:
• If the breaker is tripped, reset it. • Consult fuel supplier and use proper type of
Faulty start circuit relay. fuel for operating condition.
• See dealer. Water, dirt or air in fuel system:
Blown main system fuse. • Drain, flush, fill and bleed system.
• Replace fuse. Clogged primary fuel filter element:
Loose or corroded connections: • Clean or replace filter element.
• Clean and tighten loose battery and harness Clogged secondary fuel filter element:
plug connection. • Replace filter element.
Low battery output: Dirty or faulty injection nozzles:
• Check specific gravity of each battery cell. • Have your dealer check injection nozzles.
• Check electrolyte level of each battery cell. Electronic Fuel System problem (if equipped):
Defective electrical system ground wire: • See your dealer.
• Repair or replace. Injection pump not getting fuel or air in fuel system.
 Starter Cranks Slowly • Check fuel flow at supply pump or bleed fuel
Low battery output: system.
• Battery is too small.
• Battery cables are too small.
Check specific gravity of each battery cell:
• Replace battery if necessary.
Check electrolyte level of each battery cell:
• If low, fill cells with distilled water.
Crankcase oil too heavy:
• Fill with oil of appropriate viscosity.
OM2-2R 1/13
28
 Troubleshooting

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

 Engine Runs Irregularly or Stalls  Engine Overheats

Frequently Engine overloaded.
Below normal engine temperature: • Reduce the load.
• Remove and check thermostat. Low coolant level:
Clogged primary fuel filter element: • Fill tank or radiator to proper level.
• Clean or replace filter element. • Check hoses for loose connections and leaks.
Clogged secondary fuel filter element: Stretched belt or defective belt tensioner.
• Replace secondary filter element. • Check automatic belt tensioner and check belts
Water or dirt in the fuel system: for stretching. Replace as required.
• Drain, flush, fill and bleed system. Low engine oil level.
Dirty or faulty injection nozzles: • Check oil level, add oil as needed.
• Have your dealer check injection nozzles. Incorrect grade of fuel.
Air in fuel system: • Use correct grade of fuel.
• Inspect clamps and hoses on suction side of Cooling system needs flushing:
fuel pump for air leak, bleed fuel system. • Flush cooling system.
Improper type of fuel: Defective thermostat:
• Consult fuel supplier and use proper type of • Remove and check thermostat.
fuel for operating condition. Defective temperature gauge:
 Lack of Engine Power • Check water temperature with thermometer
Intake air restriction: and replace gauge if necessary.
• Service air cleaner.  Engine Knocks
Clogged primary fuel filter element: Low oil level:
• Clean or replace filter element. • Add oil to engine crankcase.
Clogged secondary fuel filter element: Injection pump out of time:
• Replace filter element. • Call your dealer.
Improper type of fuel: Below normal engine temperature:
• Consult fuel supplier and use proper type of • Check your thermostats.
fuel for operating conditions. • Check water temperature to see if temperature
Overheated engine: gauge is working properly.
• See “Engine Overheats” in next category. Engine overheating:
Below normal engine temperature: • See “Engine Overheating” section.
• Remove and check thermostat.
Electronic fuel system problem.
• See your dealer.
Turbocharger not functioning (if equipped).
• See your dealer.
Leaking exhaust manifold gasket.
• See your dealer.
Restricted fuel hose.
• Clean or replace fuel hose.
Low fast idle speed.
• See your dealer.
Improper valve clearance:
• Reset valves. Best done by dealer.
Dirty or faulty injection nozzles:
• Replace injectors. Best done by dealer.
• See your local dealer.

OM2-2R 1/13
29
 Troubleshooting
If you cannot correct problems with these procedures, see your Lugger or Northern Lights dealer.
 High Fuel Consumption Turbocharger not functioning.
Engine overloaded. • See your dealer.
• Reduce load. Injection nozzles dirty:
Air in fuel system: • See your dealer.
• Bleed fuel system. Engine out of time:
Improper type of fuel: • See your dealer.
• Use correct fuel for temperature.  Engine Emits White Smoke
Clogged or dirty air cleaner: Improper fuel:
• Service air cleaner. • Use correct fuel for temperature.
Improper valve clearance: Cold engine:
• See your dealer. • Warm up engine to normal operating
Injection nozzles dirty: temperature.
• See your dealer. Defective thermostat:
Electronic fuel system problem. • Remove and check thermostat.
• See your dealer. Engine out of time:
Engine not at proper temperature: • See your dealer.
• Check your thermostats. Defective injection nozzles.
• Check water temperature with thermometer • See your dealer.
and replace gauge if necessary.
 Below Normal Engine Temperature
Thermostats not working properly:
• Check thermostats.
Temperature gauge not working properly:
• Check water temperature with thermometer.
 Low Oil Pressure
Low oil level:
• Fill crankcase to proper level.
Improper type of oil:
• Drain and fill crankcase with correct oil.
Partially plugged oil filter:
• Replace filter.
 High Oil Consumption
Break-in period:
• Oil consumption decreases after break in.
Crankcase oil too light:
• Use proper viscosity oil.
Oil leaks:
• Check for leaks in lines around gaskets and
drain plug.
 Engine Emits Black or Gray Exhaust Smoke
Clogged or dirty air cleaner:
• Service air cleaner.
Improper fuel:
• Use correct fuel for temperature.
Engine overloaded.
• Reduce load.
Electronic fuel system problem.
• See your dealer.

OM2-2R 1/13
30
31
OM2-2R 1/13
AC Wiring Diagram

A.C. Wiring - All voltages

with an AVC63-12
Drawing B-7429H
32
OM2-2R 1/13
AC Wiring Diagram

A.C. Wiring - All voltages

with an AVR SX460,
Stamford 4 & 12 Wire
Drawing B-5703G
33
OM2-2R 1/13
DC Wiring Diagram

D.C. Wiring - 24 Volt Isolated Ground

Drawing C-6605
4420 14th Ave. NW., Seattle WA 98107
Tel: (206) 789-3880 • 1-800-762-0165 • www.northern-lights.com
Northern Lights and Lugger are registered trademarks of Northern Lights, Inc.
© 2013 All rights reserved. Litho USA.