Northern Lights Lugger OM944W User manual

OM944W
For Models: M944W and M30CW
OPERATOR’SMANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators

www.northern-lights.com
4420 14thAve. NW., Seattle WA98107
Tel: [phone] • 1-800-762-0165
• Fax: [phone]
Northern Lights and Lugger are registered
trademarks of Northern Lights, Inc.
© 2006 All rights reserved. Litho USA.
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.
— CALIFORNIA —
Proposition 65 Warning:

OM944W 06/06
3
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 OM944W 06/06
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.
OPERATOR'S MANUAL
for Northern Lights®M944W and M30CW Diesel Generator Sets
INTRODUCTION ....................................................2
Model Numbers..................................................2
Serial Numbers ...................................................2
WARRANTY ............................................................3
SAFETY RULES.....................................................3
COMPONENT LOCATIONS
M944W Generator Set .................................4 - 5
CONTROL PANELS
Northern Lights Generator Sets .........................6
OPERATING PROCEDURES
Break-in Period...................................................7
Before Starting....................................................7
Starting................................................................8
Operating ............................................................8
Stopping..............................................................8
Shutdowns and Alarms .......................................9
Spare Parts..........................................................9
SERVICING SCHEDULE CHART.............10 - 11
SERVICING
Lubrication - General....................................... 12
Checking Oil.................................................... 12
Oil Changes ..................................................... 12
Changing Oil Filter.......................................... 13
Air Filter .......................................................... 13
Table of Contents
SERVICING (Continued)
V-Belts............................................................. 13
Valve Clearances.............................................. 14
Fuels - General................................................. 15
Fuel Filters....................................................... 15
Bleeding the Fuel System................................ 16
Injector Service................................................ 17
Injection Pump................................................. 18
Cooling System ............................................... 19
Heat Exchanger................................................ 20
Raw Water Pump ............................................. 20
Zinc Electrodes................................................ 20
Electrical System - General............................. 21
Booster Batteries.............................................. 21
Battery Care..................................................... 22
Winterizing / Out-of-Service ........................... 22
TROUBLESHOOTING
Electrical.......................................................... 23
Engine...................................................... 24 - 26
WIRING DIAGRAMS
AC Electrical ................................................... 27
DC Electrical ........................................... 28 - 31

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OM944W 06/06
The 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 begin with minor problems that
are overlooked and become amplified when not corrected
during routine maintenance.
As operator, it is your obligation to learn about your
equipment and its proper maintenance. This is not a
comprehensive technical service manual. Nor will it make
the reader into an expert mechanic. Its aim is to aid you in
maintaining your unit properly.
Introduction
M - Northern Lights marine generator set Model number of engine block
Bore Cylinders
94 mm 4
Serial Numbers
MODELS INCLUDED
This manual covers the operating instructions for:
M944W marine generator sets, which use the 944 engine block.
Model Numbers
Model numbers give the unit's application, block model, aspiration, and RPM:
+
Unit Identification
Northern Lights marine diesel generator set with
a 944 engine and a PX-332K2 series generator end.
M944W
M 944
=
Your set has three serial numbers: 1an engine number stamped on
a plate attached to the valve cover, 2a generator end serial number,
and 3a generator set serial number.
NOTE: Always use the generator set serial number when ordering parts
or in correspondence. The generator set serial number plate is found on
the service side of the generator and resembles the drawing in Figure 1.
Figure 1: Generator set
serial number plate.
Northern Lights marine diesel generator set with a 944 engine and a
PX-332K2 series generator end; commercial unit, 30 kW.
M30CW =

OM944W 06/06
5
A warranty registration certificate is supplied with your
set. It entitles the original purchaser of our equipment
to a warranty covering material or assembly faults. The
extent of coverage is described in the Limited Warranty
Statement. We recommend that you study the statement
carefully.
NOTE: If the warranty is to apply, the servicing
instructions outlined in this manual must be followed.
If further information is needed, please contact an
authorized dealer or the factory.
CAUTION: 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.
• Use caution in handling fuel. Never refuel a hot or
running engine. Do not smoke while filling fuel tank
or servicing fuel system.
• Keep your hands, feet, hair and clothing away from
power-driven parts.
• Check for any loose electrical connections or faulty
wiring.
• Engines should be operated only by knowledgeable,
qualified personnel.
• Look completely around engine to make sure that
everything is clear before starting.
• Do not operate an engine that isn't in proper working
order. If an unsafe operating condition is noted, tag the
set and control panel so others will also know about the
problem.
• Provide first aid kits.
• Never leave engine without proper security.
• Turn the coolant tank cap slowly to relieve pressure
before removing. Add coolant only when the engine
is stopped and cool.
• Mount a fire extinguisher near engine.
• Always disconnect the battery ground strap before
making adjustments.
• Operate engines in properly ventilated areas.
• Keep trash and other objects away from engine.
• Escaping fluids under pressure can penetrate your
skin. Use a piece of cardboard or wood, not your
hands, to search for leaks.
• Avoid wearing loose clothing without a belt when
working around engines.
• Do not oil or grease engine while it is running.
• Remove the negative (-) battery terminal cable before
servicing electrical components or welding.
Safety Rules
CAUTION: This symbol is used throughout
this book to alert you to possible danger areas.
Please take special notice of these sections.
Warranty

6
OM944W 06/06
Figure 2: M944W Service Side with PX-300K2 series generator end.
M944W Generator Set Component Locations
1. Expansion Tank
2. Coolant Fill
3. Rocker Arm Cover
4. Intake Manifold
5. Lube Oil Fill
6. Air Filter
7. Junction Box
8. Fuel Filter
9. Vibration Mounts
10. Lube Oil Dipstick
11. Fuel Manifold
12. Oil Filter
13. Fuel Primer Pump
14. Injection Pump
15. Lube Oil Drain
16. Thermostat Housing
17. Heat Exchanger Raw Water
Drain and Zinc
1234567
8
9
1011
13 12
1415
16
17

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M944W Generator Set Component Locations
Figure 3: M944W Non-Service Side with PX-300K2 series generator end.
18. AC Circuit Breaker
19. DC Circuit Breaker
20. Wet Exhaust Elbow
21. Exhaust Manifold
22. Heat Exchanger
23. Raw Water Pump
24. Belt Guard
25. Oil Pan
26. Alternator
27. Starter
18 19 20 21
22
23
24
25
26
27

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OM944W 06/06
Control Panels
Figure 4-B: Series 3 Generator Control Panel
Figure 4-A: Series 1-B Generator Control Panel
1. PREHEAT/ SHUTDOWN BYPASS
This switch serves two functions:
1. Preheats air before beginning the starting process.
Press switch for 10-20 seconds before attempting
startup.
2. Bypasses the safety shutdown feature during the
starting process. Keep switch engaged while starting
engine, and for 2 to 3 seconds afterwards, allowing oil
pressure to build beyond shutdown setpoint.
2. ENGINE CONTROL SWITCH
To start the engine, hold this switch in the START
position until the engine is running. After the engine
starts, release the switch and it will return to RUN
position. To stop the engine, hold the switch in the
STOP position.
NOTE: The rocker switch is used on Series 1 panels
only, and has a light that glows when the set is
running.
3. HOUR METER
Keeps track of engine running time.
4. OIL PRESSURE GAUGE
Shows the oil pressure in the engine lubricating system.
5. WATER TEMPERATURE GAUGE
Registers the temperature of the cooling water.
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 alterna-
tor.
For Series 4 Control Panels only:
7. A.C. VOLTMETER
Shows the generator output voltage.
8. FREQUENCY METER (Hertz)
The frequency meter indicates alternating current
frequency: 60 Hz (1800 rpm) or 50 Hz (1500 rpm).
9. AMMETER/VOLTMETER SELECTOR
Used to check the voltage and current of each phase.
Return to “Amps Off” position when not monitoring.
10. A.C. AMMETER
Shows the generator load on each phase. The phase is
selected with the Ammeter Selector switch (#9).
Figure 4-C: Series 4 Generator Control Panel

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9
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 in. (2.5 cm) below the filler cap
sealing surface when the engine is cold.
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 between high and
low marks on the stick. Never allow the level to go
below this area. Always add the same viscosity of
oil as is already in the crankcase.
3. Check the fuel tank level and open any fuel valves
on the tank and at the secondary fuel filter.
4. Close the sea-cock, check and clean the sea strainer,
and reopen the sea-cock.
5. 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 alternator could be
damaged.
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 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 (consult Lubricants section for oil
recommendation).
Operating Instructions:
Maintain at least a 75% load on your generator
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 the rings.

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OM944W 06/06
OPERATING
1. Units with Series 3 and Series 4 Control Panels:
check gauges often. Oil pressure must be above
15 PSI. The D.C. voltmeter should read between
11 and 15 volts at 80° F (25° C) ambient temperature.
The water temperature gauge must be below 200°
F (94° C). Check the A.C. voltage and frequency
meters (Series 4 panel). If the gauges deviate from
normal levels, shut down the generator set and
investigate.
2. Let the unit run unloaded for a three to five minute
warm-up period.
3. Add electrical load.
STOPPING
1. Remove electrical load from the generator set.
2. Run the engine for a three to five minute cool-down
period.
3. Move the Engine Control switch to the STOP
position until the engine stops completely.
4. Shut off seacock, fuel valve, and battery switch.
Operating Procedures
STARTING
1. Hold the Shutdown Bypass switch in the ON
position.
2. While holding the Shutdown Bypass switch in the
ON position, push the Engine Control switch to the
START position.
3. As soon as the engine starts, release both switches.
Do not crank the starter for more than 20 seconds
consecutively. If the engine fails to start with the
first attempt, be sure that it has stopped completely
before re-engaging the starter.
NOTE: Excessive cranking of the starter on marine
sets equipped with a water lift muffler can
cause engine damage. If the engine does not
start after 3 consecutive 20-second cranks,
remove the impeller from the seawater
pump. This will prevent the muffler from
filling with water and backfilling the exhaust
line and engine. Once the engine starts, shut
if off immediately and reinstall the impeller.
Restart and check the exhaust overboard
outlet for gushes of water.

OM944W 06/06
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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. Other alarms and shutdowns are available as
optional equipment.
NOTE: If your unit is equipped with optional
shutdowns and alarms, 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 above 205° F
(96° C), shut off the engine immediately.
b. Use the Trouble Shooting Guide on page 25 to
isolate the cause of the overheat.
CAUTION: Do not remove the water fill
cap of an overheated engine. Escaping high
temperature steam can cause severe burns. Allow
the engine to cool and then remove the cap slowly
using protective clothing.
c. Make repairs and restart after the temperature
gauge registers below 200° F (94° C).
d. Watch the temperature gauge regularly and
turn off the unit if the temperature rises above
205° F (96° C). Repeat troubleshooting.
3. If 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 (20-60 PSI) after a
few seconds of operation.
c. If the oil level is normal, DO NOT restart the
engine. Call your dealer for assistance.
Operating Procedures
SPARE PARTS
1. ADE recommends that you keep the following spare
parts on hand for field service. The parts are
available from your local Northern Lights dealer.
Some marine models may already have “On-Board
Kits,” a handy box that contains the most common
parts you will need.
a. Primary and secondary fuel filter elements
b. Oil filters
c. Air filter elements
d. Alternator belt
e. Thermostat and gaskets
f. Seawater pump impeller and gaskets
g. Glow plugs
h. Injector and washer
2. If your set is operating a long distance from a
servicing dealer, add the following:
a. Complete set of injectors
b. Copper washers for injector change
c. Complete set of glow plugs
d. Fuel lift pump

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OM944W 06/06
The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your generator set.
More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’column.
DAILY:
SP1 Check oil level in engine
SP8 Check primary fuel filter
SP14 Check cooling water level
Check sea strainer
AFTER FIRST 50 HOURS:
SP2/3 Change engine oil and filter
SP5 Check V-belt tension
SP7 Adjust valves
SP19 Check electrolyte level in batteries
EVERY 50 HOURS:
SP5 Check V-belt tension
SP19 Check electrolyte level in batteries
AFTER FIRST 100 HOURS:
SP2/3 Change engine oil and filter
EVERY 250 HOURS:
SP2/3 Change engine oil and filter
SP4 Check air cleaner
SP18 Check zinc electrodes
EVERY 500 HOURS:
SP6 Check valve clearances
SP9 Change primary fuel filter element
SP10 Change secondary fuel filter
SP12 Check injectors
SP15 Check cooling system
SP17 Change impeller
SP20 Check state of charge of batteries
EVERY 2000 HOURS or as needed:
SP13 Check fuel injection pump
SP16 Check and clean heat exchanger
SP24 Inspect starter and alternator
Servicing Schedule Chart
SERVICE 50 100 250 500 2000
POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours
ENGINE:
SP1 12 Check oil level
SP2 12 Change engine oil1, 5 
SP3 13 Change lube oil filters1, 5 
SP4 13 Check air cleaner1, 4 
SP5 13 Check V-belt tension1
SP7 14 Check valve clearances5
FUEL SYSTEM:
SP8 15 Check primary filter2
SP9 15 Change primary filter element2, 3
SP10 15 Change secondary fuel filter1, 3
SP11 16 Bleed the fuel system3
SP12 17 Check injectors1, 7
SP13 18 Check fuel injection pump
COOLING SYSTEM:
SP14 20 Check cooling water level
SP15 20 Check and flush cooling system8
SP16 21 Check and clean heat exchanger
SP17 21 Change impeller in raw water pump1, 3
SP18 21 Check zinc electrodes4
ELECTRICAL SYSTEM:
SP19 23 Check electrolyte level in batteries1, 4
SP20 23 Check condition of batteries with hydrometer1
SP24 24 Inspect alternator and starter
OUT OF SERVICE:
SP23 23 Winterizing or out-of-service3
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) Whenever necessary.
4) More often if necessary.
5) After first 50 hours.
6) Adjust at first 100 hours.
7) Fuel inj. valve opening pressure: 11.77 MPa (120 kgf/cm2) 1710 PSI
8) Or every 1 year

OM944W 06/06
13
Service
Point HOURS/ DATE
Service Record
OPERATION
50 HOURS
SP5 Check V-belt tension
SP19 Check electrolyte
in batteries
250 HOURS
SP2 Change engine oil
SP3 Change lubricating oil filters
SP4 Check air cleaner
SP18 Check zinc electrodes
EVERY 500 HOURS
SP7 Check valve clearances
SP8 Change primary filter element
SP10 Change secondary fuel filter
SP12 Check injectors
SP15 Check cooling system
SP17 Change impeller in seawater pump
SP20 Check condition of batteries with hydrometer
2000 HOURS or as required
SP13 Check fuel injection pump
SP15 Flush cooling system
SP16 Check and clean heat exchanger
Service Notes:

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OM944W 06/06
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 CD, CE, and CF-4 single viscosity
oils.
b. API Service CD, CE, and CF-4 multi-viscosity oils.
3. Use the proper weight oil for your average
operation temperature.
Air Single Multi-
Temperature Viscosity Viscosity
Above 32° F SAE 30W SAE 15-40W
(0° C)
-10° to 32° F SAE 10W SAE 10-30W
(-23° to 0° C)
Figure 5: Lube Oils
4. Never put additives or flushing oil in crankcase.
SP1. CHECKING OIL LEVEL
1. While the engine is stopped, check the oil
level in the crankcase with the dipstick daily.
The oil level must be between the high and low
marks on the stick. Fill with the recommended
oil, and fill only to the high mark on the dipstick.
Follow the lubrication recommendations in
Figure 5.
SP2. OIL CHANGES
1. The set is delivered with special break-in
oil. Change the engine oil and oil filter after
50 hours of operation. Use Service CC30
weight oil during the first 100 hours.
2. Change the oil and filter again at 100 hours
using the oil recommended in the above
diagram. After this, change oil and filter
every 250 hours.
3. During intermittent cold weather operation,
change oil every 100 hours or six weeks,
whichever comes first.
4. Change oil at any seasonal change in
temperature when a new viscosity of oil
is required.
5. Change oil when engine is warm but not
hot.
6. Dispose of waste oil in an approved manner.
7. Never use a flushing oil.
8. Loosen clamp on oil change tube. Remove
cap. Drain oil. Replace cap and tube.
9. Refill engine with recommended oil.
10. Engine capacity with new oil filter is:
Model 944W.....................2.64 gallons (10
liters)

OM944W 06/06
15
SP3. CHANGING LUBE OIL FILTER
1. Change the lube oil filter every 250 hours.
2. Use a filter wrench to remove old filter. Dispose of
filter in approved manner.
3. Make sure the gasket from the old filter is
removed and discarded. Clean mount face.
4. Spread a thin film of engine oil on 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
one-half turn farther. Overtightening can do
damage to filter housing.
6. Fill engine with recommended oil. Start engine
and check for leakage. Stop engine, wait 3 minutes,
and check oil level. Add additional oil if necessary.
7. Oil filter part number is:
Model 944W.......................................#24-01201
SP4. AIR CLEANER
1. Visually inspect air cleaner every 250 hours. In
dusty conditions, check more often.
2. Remove the plate on the bottom of the air intake
manifold. Remove and inspect the foam element.
If dirty, wash element in soapy water. Rinse and
dry thoroughly before reinstalling.
Note: Make absolutely sure no impurities enter
the engine while changing the element, and
do not run the engine with the air cleaner
removed.
Do not clean the filter with diesel fuel,
solvent, or gasoline. Serious engine damage
can result.
SP5. V-BELTS
1. Check the tension and wear on the V-belt 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 belt can be
depressed about .39 to .47 in. (10 - 12 mm) with
22 lbs. (10 kg) force.
Servicing

16
OM944W 06/06
Servicing
SP7. VALVE CLEARANCES
1. Readjust valve clearance after first 50 hours of
operation. Check valves every 500 hours thereafter.
2. Check the valves when the engine is cold.
3. Rotate the crankshaft in a clockwise direction in the
front 1800 to bring each piston to the top dead center
on the compression stroke. Top dead center (TDC) is
when notch on the pulley aligns with the pointer and
the two valves on cylinder No. 1“rock”. Rocking is
when the rocker arms (for the two valves on a given
cylinder) are moving in opposite directions, one up
closing the valve and one down opening the other
valve. The moment when the two rocker arms are
exactly aligned with each other is when they “rock”.
Figure 6: Timing Mark
4. Measure the valve clearance for each of the valves,
with a feeler gauge, in the firing order (1-3-4-2).
Standard valve clearances for a cold engine are:
Intake (IN)........................0.0098 in. (0.25 mm)
Exhaust (EX)....................0.0098 in. (0.25 mm)
5. To adjust valve clearance, loosen the lock nut on the
adjustment screw. Insert a feeler gauge between the
rocker arm and the valve stem cap. Adjust, while
measuring the clearance, until the feeler gauge slides
with a slight drag. Tighten the lock nut and recheck
the clearance (Figure 7).
Figure 7: Valve Adjustment
6. Adjust the remaining valves.
7. Replace the rocker arm cover.

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17
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 temperatures
above freezing 32° F (0° C).
b. Use grade No. 1 at ambient temperatures below
freezing.
c. International fuel specifications:
JIS K2204
ISO-8217-DMA
BS 2869 Part 1 Class A1
BS 2869 Part 2 Class A2
2. Use fuel having less that .2% sulphur of weight (less
than 0.05% recommended).
3. The cetane number should be 45 or higher.
4. Particulate contaminate should be 5.0 mg/l (0.00018
oz/U.S. gal) or lower.
5. 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.
6. 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.
SP8-10. FUEL FILTER
1. Your generator set should have a fuel filter installed.
We recommend the Northern Lights brand of fuel
filters.
a. Check the primary fuel filter daily as
recommended by the filter manufacturer.
b. Change the filter as often as necessary or
every 250 hours.
c. Remove the fuel filter with a filter wrench.
d. Apply a coating of fuel to the o-ring of the new
fuel filter.
e. Tighten the new filter by hand, do not use a filter
wrench for tightening.
f. The filter should be dry.
g. Do not add fuel to the fuel filter before
installation, as this could cause unfiltered fuel to
enter the fuel pump.
h. Bleed the air out of the filter.
The fuel filter part number is:
944W.........................24-51201
Servicing

18
OM944W 06/06
SP11. BLEEDING THE FUEL SYSTEM
CAUTION: Escaping diesel fuel under pressure
can penetrate skin causing serious personal injury.
Before disconnecting lines be sure to relieve all
pressure. Before applying pressure, be sure all
connections are tight and lines, pipes and hoses
aren't damaged. Fuel escaping from a very small
hole can be almost invisible. Use a piece of card-
board or wood, rather than 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. Fuel system air bleeding may be needed when:
a. After fuel has been added to a newly installed
engine.
b. A new fuel filter is installed.
c. The engine has run out of fuel.
d. The fuel lines, injection pump, or any other fuel
system component has been removed and
installed.
2. After changing the fuel filter, air only needs to be bled
from the fuel filter. To do this:
a. Loosen the air vent plug (#1 on Figure 8) on the fuel
filter by about 1-1/2 turns. (Be sure to cover the
vent with a cloth to prevent fuel from splashing.)
b. Turn the priming pump cap on the fuel feed pump
counterclockwise to unlatch it. Move the priming
pump plunger
(#2 on Figure 8) up and down. To
close the pump turn the cap clockwise while
depressing it.
c. Close the air vent plug when no more air bubbles
can be seen in the fuel flowing from the air vent
plug hole.
Servicing
Figure 8 Fuel Feed Pump
3. To bleed air at the fuel injection pump:
a. Turn the air vent plug (#3 on Figure 8) about 1-1/2
turns to loosen it. (Cover the vent with a cloth to
prevent fuel from splashing.)
b. Pump the feed pump cap up and down.
c. When there are no air bubbles to be seen in the
fuel flowing from the air vent plug hole, push
down the priming pump cap and turn it clockwise
to lock it in place.
NOTE:
Do not close the air vent plug before locking the
priming pump cap in place, because the internal
pressure in the pump will prevent the priming
pump cap from returning to the original
position.
4. If the engine does not start after this bleeding
process, loosen a fuel line at the injector while
cranking the engine with the starter motor until
pure fuel escapes. Then tighten the connections.
Do each line one-at-a-time. After the engine has
started, use a piece of cardboard to look for fuel
leaks.

OM944W 06/06
19
Servicing
SP12. INJECTOR SERVICE
1. Injectors should be checked every 500 hours. This
check should be made by a Northern Lights dealer
or local injection repair station.
CAUTION: Escaping diesel fuel under pressure
can have sufficient force to penetrate the skin
causing serious personal injury. If injured by
escaping fuel, see a doctor at once.
2. Injector removal:
a. Clean loose dirt from around the injectors and
the fuel lines.
b. Relieve high pressure in the fuel lines by
loosening the delivery line flare nuts at each
injector.
c. Remove delivery lines by disconnecting them
from the injectors and injection pump.
Remove all lines as an assembly; do not remove
the spacers. Cover the ends of the lines, the injector
inlets,andtheinjectionpumpoutletstokeepdirtout.
d. Remove the return line retaining bolts, washers,
and return line.
e. Loosen the injector retaining nuts at the same
time a little at a time. Remove the injector.
f. Remove the injector seat. Cover the holes to
prevent debris from entering the cylinders.
Note: Do not use pry bars to remove injectors
from the cylinder head.
3. Injector repair and cleaning:
a. Take injectors to your Northern Lights dealer
or local injection repair station for testing and
service.
4. Injector installation:
a. Install new injector seal washer seat and
injector. Evenly tighten the injector retaining
nuts to 39.1 to 47.7 ft/lbs (53.0 to 64.7 N•m), or
5.4 to 6.6 kgf•m. Do not overtighten.
b. Reinstall the return line using new sealing
washers. Tighten bolts to 13.0 to 15.9 ft/lbs
(17.7 to 21.6 N•m), or 1.8 to 2.2 kgf•m.
NOTE: Overtightening can damage injectors.
c. Reinstall injection lines. Tighten
flare nuts at injection pump to 19.5 to 23.9
ft/lbs (26.5 to 32.4 N•m), or 2.7 to 3.3 kgf•m.
Leave the lines loose at injectors for bleeding.
d. Bleed the injection lines. Crank the
engine to fill the lines. Tighten flare nuts at
injectors to 15.2 to 18.1 ft/lbs (20.6 to 24.5 N•m),
2.1 to 2.5 kgf•m.
e. Start the engine and check for leaks using a
piece of paper or cardboard. Do not use your
hand to check for leaks.

20
OM944W 06/06
SP13. INJECTION PUMP
1. Since operating conditions may vary considerably,
it is difficult to give a definite interval for checking
the injection pump. But as a rule, pump settings,
maximum speed, idle speed and exhaust smoke
should be checked 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
malfunction. Before servicing the pump, check other
possible causes:
a. Check cleanliness of the air filter.
b. Check valve clearances.
c. Clean and check injectors.
3. Any repair which involves disassembly of the injec-
tion pump must be carried out by specially trained
mechanics with the proper tools and test equipment.
NOTE: All warranties on the engine become null
and void if the injection pump seals are
broken by unauthorized persons.
4. Injection Pump Removal:
CAUTION: Escaping diesel fuel under pressure
can have sufficient force to penetrate the skin,
causing serious personal injury. If injured by
escaping diesel fuel, see a doctor at once.
a. Clean the injection pump, hoses, and area
around the pump with a cleaning solvent or 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 the injection lines from the
pump and injectors. Remove all lines as an
assembly. Do not remove the spacers. Cover the
ends of the lines, the injector inlets, and the
injection pump outlets to keep dirt out of the
injectors, lines, and pump.
c. Align timing marks on timing gears.
d. Remove the pump support bracket on rear of
pump.
e. Remove the 4 mounting nuts.
Servicing
5. Injection Pump Installation:
a. Install the fuel injection pump after having
aligned its gear alignment mark with that of
the idler gear alignment mark as shown in
Figure 9 above. When the alignment marks
of the timing gears align as in the diagram to
the right, the No. 1 piston is top dead center in
the compression stroke.
b. Install the injection pump to the side of the
engine first then put in the end bolts, and
then the tube with its bolts, and then the side
bracket.
c. Torque mounting bolts to 13.0 - 18.1 ft/lbs
(17.7 to 24.5 N•m), 1.8 to 2.5 kgf•m.
Figure 9: Timing Marks
f. Take the pump to your Northern Lights dealer or
an injection repair station for testing and service.