Northern Lights OLP LP445 User manual

OLP
For Models: LP445, LP455T, LP668D and LP668T
OPERATOR’S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators

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:
Northern Lights
4420 14th Avenue N.W.
Seattle, WA 98107
Tel: [phone]
Fax: [phone]
Copyright ©2000 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.: OLP 05/00

OLP 05/00
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
#OLP for Models
LP445D, LP445T, LP668D, and LP668T
INTRODUCTION ..................................................2
Models Included .................................................2
Model Numbers ..................................................2
Serial Numbers ...................................................2
WARRANTY .........................................................3
SAFETY RULES .......................................3
COMPONENT LOCATIONS .............................4
LUGGER CONTROL PANEL ...........................5
OPERATING PROCEDURES
Before Starting....................................................6
Idle Speeds..........................................................7
Shutdown Procedures .........................................7
Break-In Period...................................................7
SERVICING SCHEDULE CHART ................8
SERVICE RECORD ..........................................9
SERVICING
Lubrication - General....................................... 10
Checking Oil.................................................... 10
Oil Changes ..................................................... 10
Changing Oil Filter .......................................... 10
Air Filter .......................................................... 10
Valve Clearances...............................................11
Fuels - General..................................................11
Fuel Filters ....................................................... 12
Bleeding the Fuel System ................................ 12
Injector Service...........................................13-14
Injection Pump............................................14-16
Turbocharger.................................................... 17
Turbo Boost ..................................................... 17
Cooling System - General................................ 17
Engine Coolant Specications....................17-19
Cooling System Flushing................................. 19
Heat Exchanger Cleaning ................................ 19
Heat Exchanger Diagram................................. 26
Zinc Electrodes ................................................ 20
Raw Water Pump ............................................. 20
Electrical System - General ............................. 20
Booster Batteries.............................................. 21
Battery Care ..................................................... 21
Winterizing / Out-of-Service ........................... 21
TROUBLESHOOTING
Electrical .......................................................... 22
Engine .........................................................22-23
DATA SHEETS
Lugger Performance Specications................. 24
Propeller Recommendations............................ 24
Lugger Installation Data .................................. 25
WIRING DIAGRAMS
Lugger DC Electrical..................................27-30
ON-BOARD SPARE PARTS ....................... 31
Proprietary Information
This publication is the property of Alaska Diesel Electric, Inc.
It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc.
© Alaska Diesel Electric, Inc. All rights reserved. Litho U.S.A. Publication number OLP 05/00
Table of Contents
1

OLP 05/00
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 amplied when not corrected during rou-
tine 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
D & T
LP - Lugger marine propulsion engine Lugger model number
4 Cylinder 4.5 Liters
(John Deere model number)
4 Cylinder 4.5 Liters
Model Numbers
Model numbers give the unit's application, block model, aspiration, and RPM:
D - Naturally aspirated
T - Turbocharged
++
Lugger®turbocharged marine propulsion
engine with a John Deere Powertech 4045
engine block.
Lugger®naturally aspirated marine propulsion
engine with a John Deere Powertech 4045
engine block.
LP445T
LP445D
LP 445 (4045)
=
=
2
Serial Numbers
When referencing Alaska Diesel Electric equipment by serial number, please refer only to the number
stamped on the Northern Lights®or Lugger®serial number plate.
Lugger®turbocharged marine propulsion
engine with a John Deere Powertech 6068
engine block.
Lugger®naturally aspirated marine propulsion
engine with a John Deere Powertech 6068
engine block.
LP668T =
LP668D =

OLP 05/00
CAUTION: This symbol is used throughout
this book to alert you to possible danger areas.
Please take special notice of these sections.
A warranty registration certicate 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 lling
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 knowledge-
able, qualied 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 rst 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 re 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 uids 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.
Safety Rules
Warranty
3
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.

OLP 05/00
Figure 1: LP668D1 HE with gear (note: components of LP445 are in a similar location).
Lugger Component Locations
1. Heat Exchanger
2. Heat Exchanger Zinc (2)
3. Raw Water Pump
4. Optional Pulley
5. Oil Cooler
6. Lube Oil Fill
7. Lube Oil Dipstick
15. DC Alternator
16. Water Fill
17. Expansion Tank
18. Manifold Drain Cock
19. Starter
20. Block Drain Cock
21. Fuel Injection Pump
8. Lube Oil Drain
9. Lube Oil Filter
10. Secondary Fuel Filter
11. Marine Transmission
12. Air Cleaner
13. Crankcase Vent
14. DC Circuit Breaker
22. Heat Exchanger
23. Heat Exchanger Drain Cock
24. Fuel Injectors (6)
25. Thermostat Housing
26. Dry Exhaust Elbow
4

OLP 05/00
Lugger Control Panel
Figure 2: Lugger Instrument Control Panel
1. OIL PRESSURE GAUGE
The oil pressure gauge shows the oil pressure in
the engine lubricating system. If the pressure drops
below 15 PSI at a speed higher than idling, stop the
engine immediately.
2. TACHOMETER
The tachometer shows the engine speed in
revolutions per minute (RPM). Numbers are mul-
tiples of 100.
3. HOUR METER
Keeps track of the engine running time.
4. DC VOLTMETER
When the engine is stopped, the voltmeter shows
the condition of the battery, When the engine is
running, it indicates the voltage output of the
alternator.
5. KEY SWITCH
Turning the key clockwise to the rst position
will switch on the current. continue turning the
key clockwise to start the engine. When the
engine starts, immediately turn the key back to
the rst position while the engine is running.
5
The key must be kept in the on or rst position while
the engine is running.
Turn the key counterclockwise as far as possible to
stop the engine.
Note:
Optional ybridge panels have engine start switches instead of key
switches.
6. STOP BUTTON
Stops engine immediately.
7. INSTRUMENT PANEL LIGHTING
The switch turns on the instrument panel lights.
8. OIL PRESSURE FAULT LIGHT
Indicates low oil pressure.
9. ENGINE TEMPERATURE FAULT LIGHT
Indicates engine is over-heating. Activates in conjunction
with alarm horn.
10. ALARM HORN
Shut down engine if possible and investigate immediately.
11. COOLANT TEMPERATURE GAUGE
Water temperature gauge shows the temperature of the
cooling water. If the gauge registers over 200° or drops
below 140°, stop the engine and investigate.

OLP 05/00
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 room to expand, the level should be
about 1 3/4 in. (4-5 cm) below the ller cap sealing
surface when the engine is cold. When lling with
coolant, the venting cock on top of the turbocharger
should be opened to ensure that no air pockets form
in the cooling system (see Service Point #14).
CAUTION: Use protective clothing and open
the ller cap carefully when the engine is warm
to prevent burns.
2. Check the oil level in the crankcase with the dipstick.
The oil level should be between the “waed area”
and the “oo”. Never allow the level to go below
the “oo”. Always add the same viscosity of oil as is
already in the crankcase (see Service Point #1).
3. Check the fuel tank level and open any fuel valves.
4. Check the oil level in the reverse gear. Methods
may vary from gear to gear. See your Gear Owner's
Manual.
5. Close the seacock, check and clean the strainer and
reopen the seacock.
6. Place the battery switch in the ON position.
NOTE: The battery switch must always be kept ON
while the engine is running. If the switch is turned
OFF while the engine is running, the battery charging
regulator could be ruined.
6
Starting
1. Put the gear control in the neutral position.
2. Move the throttle control to the full speed position
and return back to idle.
3. Turn the key switch to the rst position. Check the
voltage meter to see the condition of the batteries.
For starting, the voltmeter should not read below 12
volts (24 volts for 24 volt systems).
4. Turn the key to the starting position and as soon as the
engine starts, release the key. Move the throttle up until
the engine is running at approximately 1000 RPM.
5. Do not crank the starter for more than 15 seconds
consecutively. If the engine fails to start with the rst
attempt, be sure that the starter has stopped
completely before re-engaging.
NOTE: Never race a cold engine. Operate at
1000 RPM for a 3 to 5 minute warm-up period.
Operating
1. Check oil pressure as soon as the engine has started.
Oil pressure should be above 15 PSI. The engine
must never be run if the oil pressure is below 15 PSI.
2. Check the voltmeter. It should read 13 to 14 volts
(26-28 volts, 24 volt systems) at 60°F (16°C).
3. Water temperature should not rise over 200°F (94°C).
If it does, shut down the engine and investigate the
cause of overheating.
4. Do not exceed 800 RPM when shifting marine gear.
Repeated shifts at higher engine speeds can damage
the reverse gear.

OLP 05/00
Operating Procedures
CAUTION: Do not remove the water ll 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 180°F (83°C).
d. Watch the temperature gauge regularly and turn
o the unit if the temperature rises above 200°F
(94°C). Repeat the troubleshooting process.
3. If the 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, ll with recommended lubricating
oil and restart. Watch the oil pressure gauge carefully
and shut o the engine if it does not show a normal
reading after a few seconds of operation.
c. If the oil level is normal, DO NOT restart the
engine. Call your Northern Lights or Lugger
dealer for assistance.
BREAK-IN PERIOD
1. The rst 100 hours on a new or reconditioned engine
are critical to its life and performance.
2. Constantly check the engine temperature and oil pres-
sure gauges.
3. Oil consumption is greater during break-in as piston
rings and cylinder liners take time to seat.
4. Break-In Oil Changes: Change engine oil and lter
at 50 hours. Change oil and lter again at 100 hours
(See Gear Owner's Manual for break-in oil change
procedures. Consult Lubricants Section for oil
recommendation).
OPERATING INSTRUCTIONS
Never run full speed for more than 5 minutes
during the rst 50 hours. Run engine at 50% to
75% of maximum working speed for the rst 20
hours with as little idling time as possible. Extended
idling can inhibit ring seating, causing cylinder walls
to glaze.
7
5. LP445 – Low idle is 700 RPM. Maximum working
engine speed is: 2500 RPM for pleasure craft, 2400 RPM
for light commercial craft, 2200 RPM for continuous duty
applications.
LP668 – Low idle is 700 RPM. Maximum working
engine speed is 2400 RPM for pleasure craft, 2400 RPM
for light commercial craft, 2200 RPM for continuous duty
applications.
6. If the proper propeller is used, the engine should reach its
appropriate maximum RPM's at full
throttle. If the maximum rated RPM's for your engine
application is exceeded at full throttle, then your propel-
ler is too small. If you cannot reach your maximum rated
RPM's at full throttle, either your propeller is too large or
bottom growth is slowing the boat (see Prop Chart, page
25).
7. To establish Maximum Cruising RPM: Establish the
RPM at full throttle and subtract 200-300 RPM. This will
promote engine life and reduce fuel consumption.
Shutdown
1. Run engine three to ve minutes in neutral at 1000 RPM,
for cool down period.
2. Return engine to low idle.
3. Turn the key switch counterclockwise as far as possible to
stop the engine.
4. Close the sea cock and fuel valves and put the battery
switch in OFF position.
NOTE: Do not turn battery switch to OFF while engine is
running.
ALARMS
1. Your unit is tted with a warning system to indicate high
water temperature or low oil pressure.
Propulsion engines have warning horns to sound and
warn you of a problem. Remember - when engine is
not running the horn will sound when key is in the
"ON" position because there is no oil pressure.
NOTE: Do not rely on your warning system to the exclu-
sion 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 acti-
vated:
a. Check the temperature gauge. If the temperature is
above 205°F (97°C), shut o the engine immediately.
b. Use the Trouble Shooting Guide on pages 23 - 24
to isolate the cause of the overheat.

OLP 05/00
The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your marine engine
or 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
SP7 Check primary fuel lter
SP14 Check cooling water level
AFTER FIRST 50 HOURS:
SP2 Change engine oil
SP3 Change lube oil lter
EVERY 50 HOURS:
SP22 Check electrolyte in batteries
AFTER FIRST 100 HOURS:
SP2 Change engine oil
SP3 Change lube oil lter
EVERY 200 HOURS:
SP2 Change engine oil
SP3 Change lube oil lter
SP4 Check air cleaner
SP8 Change primary fuel lter element
SP12 Check turbocharger air, oil & cooling lines for leakage
SP18 Check zinc electrodes
AFTER FIRST 600 HOURS:
SP6 Adjust valves
EVERY 600 HOURS / YEARLY:
SP4 Replace air cleaner
SP5 Check V-belt condition
SP9 Change secondary fuel lter
SP10 Check injectors
SP13 Check turbocharger boost pressure
SP15 Check and ush cooling system
SP19 Change impeller in raw water pump
SP23 Check the state of the charge of the batteries
EVERY 1200 HOURS:
SP6 Adjust valves
EVERY 2400 HOURS:
SP11 Check fuel injection pump
SP16 Check and clean heat exchanger
SP17 Check and clean gear oil cooler
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.
Servicing Schedule Chart
SERVICE 50 200 600 1200 2400
POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours
ENGINE:
SP1 7 & 11 Check oil level •
SP2 11 Change engine oil 1)
SP3 11 Change lube oil lters 1) •
SP4 11 Check (replace) air cleaner 1) 3) • •
SP5 Check belt condition 1) •
SP6 12 Check valve clearances 1) •
FUEL SYSTEM:
SP7 13 Check primary lter (Racor) 2) •
SP8 13 Change primary lter element (Racor) 2) 3) •
SP9 13 Change secondary fuel lter 1) 3) •
SP10 14 -15 Check injectors 1) •
SP11 15 -17 Check fuel injection pump •
TURBOCHARGER:
SP12 18 Check air, oil & cooling water lines for leakage 1) •
SP13 18 Check boost pressure •
COOLING SYSTEM:
SP14 7 & 18 Check cooling water level •
SP15 20 Check and ush cooling system 1) •
SP16 20 Check and clean heat exchanger 1) •
SP17 26 Check and clean gear oil cooler 1) •
SP18 21 Check zinc electrodes 1) 3) •
SP19 21 Change impeller in raw water pump 1) 3) •
DRIVEN EQUIPMENT:
SP20 27 Check oil level in reverse gear •
SP21 27 Change oil in reverse gear 2)
ELECTRICAL SYSTEM:
SP23 22 Check electrolyte level in batteries 1) 3) •
SP23 22 Check condition of batteries with hydrometer 1) •
OUT OF SERVICE:
SP24 22 Winterizing or out-of-service 3)
8

OLP 05/00
Service
Point HOURS/DATE
Service Record
OPERATION
9
50 HOURS
SP23 Check electrolyte
in batteries
200 HOURS
SP2 Change engine oil
SP3 Change lubricating oil lters
SP4 Check air cleaner
SP7 Change primary fuel lter element
SP12 Check turbocharger air, oil & cooling lines for leakage
SP18 Check zinc electrodes
600 HOURS
SP4 Replace air cleaner
SP5 Check belt condition
SP9 Change secondary fuel lter
SP10 Check injectors
SP13 Check turbocharger boost pressure
SP15 Check and ush cooling system
SP19 Change impeller in raw water pump
SP23 Check state of charge of batteries
EVERY 1200 HOURS
SP6 Check valve clearances
2400 HOURS
SP11 Check fuel injection pump
SP16 Check and clean heat exchanger
SP17 Check and clean reverse gear oil cooler

OLP 05/00
LUBRICATION
Break-in oil
1. Use one of the following during the rst 100 hours
of operation:
a. John Deere Engine Break-In Oil
b. API Service CE oil
c. ACEA Specication E1
2. Do not use John Deere PLUS-50 oil or engine oils
meeting API CG4, API CF4, ACEA E3, or ACEA
E2 performance levels during the rst 100 hours of
operation of a new or rebuilt engine. These oils will
not allow the engine to break-in properly.
Lubrication - General
1. Use only clean, high quality lubricants stored in
clean containers in a protected area.
2. These oils are acceptable after the rst 100 hours:
a. API Service CC/CD single viscosity oils.
b. API Service CD/CG-4/CF-4 multi-viscosity oils.
c. ACEA Specication E3/E2 multi-viscosity oils.
3. Use the proper weight oil for your average operation
temperature.
4. Some increase in oil consumption may be expected
when SAE 5W and SAE 5-20W oils are used. Check
oil level frequently.
5. Never put additives or ushing oil in crankcase.
SP1. CHECK ENGINE OIL LEVEL
1. Check the oil level in the crankcase, with the oil
dipstick, daily.
2. The oil level must be between the “Waed area” and
the “oo”. Never allow the level to go below the “oo”.
3. Always add the same viscosity of oil as is already in
the crankcase.
SP2. OIL CHANGES
1. Using the oil recommended above, change the
engine oil and lter after the rst 50 hours of
operation, the rst 100 hours and every 200 hours
thereafter.
Marine Generator Sets:
a. Remove plug from outlet in base frame. Screw in
owner-supplied drain hose.
b. Open valve at oil pan outlet. After oil has been
drained into suitable container, close valve, remove
drain hose and replace plug in base frame outlet.
c. Rell engine with recommended oil.
4. Engine Lube Oil Capacity:
SP3. CHANGING OIL FILTER
1. Change the lube oil lter every 200 hours.
2. Use a lter wrench to remove old lter. Dispose of
lter in approved manner.
3. Make sure the gasket from the old lter is removed
and discarded.
4. Lubricate the rubber gasket on the new lter and screw
it on nipple until gasket meet the sealing surface.
5. Using hands only, no wrench, tighten lter one-half turn
farther. Overtightening can do damage to lter housing.
6. Fill engine with recommended oil. Start engine and
check for leakage. Stop engine and check oil level.
Add additional oil if necessary.
SP4. AIR Cleaner
1. Inspect air cleaner every 100 hours. Replace lter
every 600 hours, or yearly, whichever comes rst.
2. Clean the rubber tube at the cleaner. Loosen the hose
clamp and the attaching strip for the cleaner.
3. Make sure the rubber tube is in good condition and
that new lter is absolutely clean and installed prop-
erly.
4. Start the engine and check for leaks.
NOTE: Make absolutely sure no impurities enter
the engine while changing the element. Do not
run the engine with the air cleaner removed.
Air Single Multi
Temperature Viscosity Viscosity
Above 32°F
(0°C) SAE-30W SAE15-40W
-10°F to 32°F
(-23°C to 0°C) SAE-10W SAE10-30W
Below -10°F
(-23°C) SAE-5W SAE5-20W
445 Series 14 qts. 13.2 liters
668 Series 18 qts. 17.0 liters
10
Servicing
2. During intermittent cold weather operation, change oil
every 100 hours or six weeks, whichever comes rst.
3. Change oil at any seasonal change in temperature when
a new viscosity of oil is required.
Propulsion Engines w/Optional Drain Pump:
a. Remove dipstick.
b. Unscrew dipstick tube and insert the hand pump to
the bottom of the oil pan. Drain by pumping.
c. Replace dipstick tube and dipstick.
d Rell engine with recommended oil.

OLP 05/00
11
Servicing
SP6. VALVE CLEARANCES
The following special tools will be needed:
JDE 820 or JDE 83 Flywheel Turning Tool.
JDE 81-4 Timing Pin.
1. Check the valve clearances after the rst 600 hours, the
rst 1200 hours and every 1200 hours thereafter.
2. Remove rocker arm cover with ventilator tube.
3. Remove plastic plugs in engine timing holes on front
side of ywheel.
4. Rotate ywheel in clockwise direction (viewed from
water pump) with the Flywheel Turning Tool until the
Timing Pin engages timing hole in the ywheel. 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 ywheel one complete turn and reinstall the
timing pin in the ywheel.
5. Valve clearances must be checked with the engine cold.
Intake Valve: 0.012-0.015 in. (0.31-0.38 mm)
Exhaust Valve: 0.016-0.019 in. (0.41-0.48 mm)
4-CYLINDER ENGINES:
NOTE: Firing order is 1 - 3 - 4 - 2
Reproduced by permission of Deere & Company, c2000. Deere & Company.
All rights reserved.
A - Front of Engine
B - No. 1 Piston at TDC Compression Stroke
C - No. 4 Piston at TDC Compression Stroke
E - Exhaust Valve
F - Intake Valve
Lock No. 1 piston at TDC compression stroke (B).
Adjust valve clearance on No. 1 and No. 3 exhaust
valves and No. 1 and No. 2 intake valves.
Rotate ywheel 360°. Lock No. 4 piston at TDC
compression stroke (C).
Adjust valve clearance on No. 2 and No. 4 exhaust
valves and No. 3 and No. 4 intake valves.
6-CYLINDER ENGINES:
NOTE: Firing order is 1 - 5 - 3 - 6 - 2 - 4
Reproduced by permission of Deere & Company, c2000. Deere & Company. All rights reserved.
A - Front of Engine
B - No. 1 Piston at TDC Compression Stroke
C - No. 6 Piston at TDC Compression Stroke
E - Exhaust Valve
F - Intake Valve
Lock No. 1 piston at TDC compression stroke (B).
Adjust valve clearance on No. 1, No. 3, and No. 5 exhaust
valves and No. 1, No. 2, and No.4 intake valves.
Rotate ywheel 360°. Lock No. 6 piston at TDC
compression stroke (C).
Adjust valve clearance on No. 2, No. 4, and No. 6 exhaust
valves and No. 3, No. 5, and No. 6 intake valves.
FUELS - GENERAL
1. Use only clean, high quality fuels of the following
specications, as dened by ASTM designation
D975 for diesel fuels:
a. Use grade no. 2 diesel at ambient temperatures
above freezing 30°F (0°C).
b. Use grade No.1 at ambient temperatures below
freezing and for all temperatures at an altitude of
above 5,500 ft. (1500 meters).
2. Use fuel having less than 1% sulphur (preferably
less than 0.5%).
3. The cetane number should be a minimum of 45.
4. DO NOT use these unsuitable grades of fuel:
a. Domestic heating oils, all types.
b. Class B engine.
c. Class D domestic fuels.
d. Class E, F, G or H industrial or marine fuels.
e. ASTM-D975-60T No. 4-D and higher number
fuels.
f. JP4

OLP 05/00
SP7-9. FUEL FILTERS
1. Your engine or generator set should have a primary
fuel lter installed. We recommend the Racor brand
of fuel lter - water separators.
a. Check the primary fuel lter daily as recommended
by the lter manufacturer. Empty the collection
bowl as necessary.
b. Change the element every 200 hours or whenever
necessary.
c. If the bowl lls with water, change the primary
and secondary elements immediately.
2. Change secondary fuel lter every 600 hours.
NOTE: The fuel lter on the engine is considered the
“secondary fuel lter”. The engine will be tted with a
quick change disposable secondary fuel lter.
a. Turn o the fuel.
b. Open the lter drain plug (Figure 11-A) and drain
the lter.
Figure 11: Secondary Fuel lter
c. Remove the secondary fuel lter by turning the
lter clamp (Figure 11-B) counter clockwise until
the lter cartridge (Figure 11-C) slides out.
BLEEDING THE FUEL SYSTEM
CAUTION: Escaping diesel fuel under pressure
can penetrate the skin, causing serious personal
injury. Before disconnecting lines be sure to
relieve all pressure. Before applying pressure to
the system be sure all connections are tight and
the lines, pipes and hoses are not damaged. Fuel
escaping from a very small hole can be almost
invisible. Use a piece of cardboard or wood rather
than the hands to search for suspected leaks. If
injured by escaping fuel, see a doctor at once.
Serious infection or reaction can develop if proper
medical treatment is not administered immediately.
1. Whenever the fuel system has been opened for
service, (lines disconnected, lter changed, etc.) it
will be necessary to bleed air from the system.
a. To bleed the fuel system, loosen the bleed plug
(Figure 11-D) on the fuel lter.
Operate the primer pump lever on fuel transfer
pump (see component locations) until 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 ow
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
the starter until fuel without air ows from the
loose fuel pipe connection. Repeat procedure for
remaining nozzles, if necessary, until engine
starts or until air has been removed from system.
Tighten the connections to 20 foot lb. (27 N•m).
12
Servicing
5. Storing fuel:
a. Keep dirt, scale, water and other foreign matter
out of fuel.
b. Avoid storing fuel for long periods of time.
c. Fill the fuel tank at the end of each day's
operation. This will reduce condensation.
NOTE: Before installing a new lter cartridge make sure the
surfaces where the cartridge comes in contact with the
mounting plate are absolutely clean. Dirt can be washed
into the fuel injection system. This may result in severe
damage to the fuel injection pump or nozzles.
d. Install new lter cartridge.
e. Fuel lter cartridge number is: 24-51005
f. Turn on the fuel.

OLP 05/00
SP10. INJECTORS
1. Fuel injectors should be checked by a Lugger-North-
ern Lights dealer or qualied fuel injection
shop every 600 hours.
2. Injector Removal:
You will need the following special tools:
JDE38A—Injection Nozzle Puller
JDE39—Nozzle Bore Cleaning Tool
JD258—Pilot Tool
a. Before removal, carefully remove all dirt from
the cylinder head around fuel injection nozzles.
Clean with compressed air to prevent dirt from
entering the cylinders or valve seats. Plug the
bore in the cylinder head after each fuel injection
nozzle has been removed. Cap fuel line openings
as soon as they are disconnected.
b. Immediately t protective caps over the
nozzle tips and the line connections to avoid
handling damage.
c. Do not bend the fuel delivery lines. When
loosening the fuel pressure lines, hold male union
of nozzle line stationary with a backup wrench.
d. Loosen nuts to remove leak-o lines and T-ttings
and disconnect fuel injection line from nozzle.
NOTE: When all fuel injection nozzles have to be
removed, disconnect leak-o line assembly at fuel
tank, at injection pump, and at each nozzle T-tting.
Lift o complete leak-o line as an assembly.
e. Remove cap screw, clamp and spacer.
f. Pull injection nozzle out of cylinder head with
JDE38A Injection Nozzle Puller.
NOTE: Do not use screwdrivers, pry bars, or similar
tools for this as they might damage the injection nozzle.
3. Clean Injector Bore:
Always turn the tool clockwise through the bore
even when removing from bore, otherwise tool
may become dull.
a. Clean nozzle bore with JDE39 Nozzle Bore
Cleaning Tool. Blow debris from bore with
compressed air and plug the bore to prevent entry
of foreign material.
4. Clean injection nozzles:
a. Remove carbon stop seal (Figure 12-A) and upper
sealing washer (Figure 12-B), using a needle-nose
pliers. Discard seals.
b. Clean exterior of nozzle by soaking in clean
solvent or diesel fuel. Clean tip with brass wire
brush.
Figure 12 Reprinted by permission of Deere & Company, RG6300 Deere & Company, All rights reserved.
NOTE: Do not scrape or disturb the teon coating on
the nozzle body above the carbon stop seal groove.
This coating will become discolored during normal
operation, but this is not harmful. Do not use a motor
driven brush to clean up nozzle body.
Figure 13
5. Install seals on injection nozzle.
NOTE: Each time an injection nozzle is removed
from the cylinder head, replace carbon stop seal (B)
with a new one.
a. Position JD258 (ROS16477) Pilot Tool (Figure
13-C) over nozzle tip. If Pilot Tool (included in
cleaning kit) is not available, use a No. 16189
Nozzle Protector Cap found on every new or
re-placement nozzle.
b. Position a new carbon stop seal (Figure 13-B) on
pilot tool. Use a new seal washer (Figure 13-A) to
help slide the carbon seal into place until it seats
in its groove on nozzle body.
c. Continue to slide upper sealing washer onto
nozzle body until it seats against inlet tting.
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Servicing

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6. Install injection nozzles:
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
prevent proper sealing. Dirt and roughness could
also cause distortion to nozzle when the attaching
screw is tightened, making the valve stick.
c. Install nozzle in cylinder head using a slight
twisting motion as nozzle is seated in bore.
Figure 14: Shows relationship of parts required for installation.
d. Install spacer and cap screw. Do not tighten
capscrew at this stage.
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-o assembly.
h. Bleed air from loose injection line connection.
Tighten connection using two wrenches.
SP13. INJECTION PUMP
1. Since operating conditions may vary considerably,
it is dicult to give a denite service interval. But,
as a rule, the pump settings, maximum speed, idle
speed and exhaust smoke should be checked by your
dealer after every 2400 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 lter.
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 with the proper tools and test devices.
NOTE: All warranties on the engine become null and
void if the injection pump seals are broken by unau-
thorized persons.
DB4 AND DB2 INJECTION PUMPS – REMOVAL
All Stanadyne DB2 and DB4 injection pumps will
have a retained drive shaft (shaft stays in pump when
pump is removed from engine).
1. Clean the fuel injection pump, lines and area around
the pump with cleaning solvent or a steam cleaner.
IMPORTANT: Never steam clean or pour cold water
on a fuel injection pump while the pump is running
or while it is warm. Doing so may cause seizure of
internal rotating pump parts.
2. Disconnect shuto cable and speed control link-
age or cold start switch, if equipped. Disconnect
electrical connection to shuto solenoid or throttle
positioning solenoid. Tag electrical wires for correct
reassembly.
IMPORTANT: Always use a backup wrench when
loosening or tightening fuel lines at injection pump
so that discharge ttings are not altered which will
prevent internal pump damage.
3. Disconnect fuel return line (Figure 15-A) and fuel
supply line (Figure 15-C).
Figure 15 Reproduced by permission of Deere & Company, c2000. Deere & Company, All rights reserved.
14
Servicing

OLP 05/00
IMPORTANT: Injection pump mounting ange timing
mark (Figure 17-A ) and front plate timing mark
(Figure 17-B) presence and alignment MUST be veri-
ed before removing pumps from engine. DO NOT
reference internal timing marks (on pump cam ring
and governor weight retainer). If timing mark is not
clearly visible on front plate, scribe a visible reference
mark as accurately as possible in-line with mark on
pump ange.
10. Remove three injection pump mounting stud nuts.
Remove injection pump from mounting studs.
11. Plug or cap all openings on injection pump and take
pump to dealer for service
DB4 & DB2 INJECTION PUMP – INSTALLATION
1. Lubricate a new square sealing ring with clean
engine oil. Install ring into groove on front face of
pump mounting ange. Slide injection pump onto
mounting studs while inserting pump shaft into drive
gear.
2. Check pump shaft and index pin for proper
alignment with pump drive gear key slot.
IMPORTANT: Shaft roll pin may be easily damaged
if improperly assembled. Pump drive gear should
not move when initially installing pump index pin into
drive gear key slot.
3. Install injection pump partially onto mounting studs
without engaging pump pilot hub into engine front
plate.
IMPORTANT: DO NOT tighten hex nuts more than
three full turns on mounting studs. Pump drive shaft
index pin may be damaged if pin is not properly
aligned with drive gear key slot and if the nuts are
tightened more than three turns.
4. Install three at washers, lock washers, and hex nuts
onto pump mounting studs. Tighten nuts three turns
only so that pump will not fall o mounting studs.
NOTE: The pump drive gear should begin to move
forward (away from engine front plate) with the pump
when ange is approximately 1/8 in. (3.2mm) away
from engine front plate.
4. Disconnect all fuel delivery (pressure) lines (Figure
15-B) from injection pump using a suitable 17mm
deep-well crowsfoot socket.
5. Remove injection pump drive gear cover. Remove
drive gear retaining nut and washer from end of
pump shaft. Be careful not to let washer fall inside
timing gear cover.
NOTE: The injection pump drive gear ts snugly onto
a tapered drive shaft and indexed by a hollow pin or
Woodru key installed in drive shaft
6. Attach JDG670A Drive Gear Puller (Figure 16-A) to
injection pump drive gear as shown.
NOTE: Replace 6mm Grade 12.9 cap screws (C) as
needed.
7. Evenly tighten the two 6mm, Grade 12.9 screws
(threaded in drive gear) and snugly tighten center
forcing screw (Figure 16-B) against end of pump shaft.
Figure 16. Reproduced by permission of Deere & Company, c.2000. Deere & Company, All rights reserved.
8. Tighten center forcing screw until pump drive gear
is free from tapered shaft. Remove JDG670A puller
(Figure 16-A) and screws from drive gear.
9. Check to make sure that timing marks on back side
of front plate (Figure 17-A) and injection pump ange
(Figure 17-B) are present and properly aligned. This
assures that repaired or replacement pump can be
properly timed to engine when installed.
Figure 17. Reproduced by permission of Deere & Company, c2000. Deere & Company, All rights reserved.
15
Servicing

OLP 05/00
5. Install pump mounting ange ush to engine front
plate with drive gear held ush against front side of
engine front plate.
IMPORTANT: Do not use tightening force of pump
mounting stud nuts to pull pump shaft into drive gear I.D.
6. With the pump shaft index pin properly engaged in the
drive gear key slot, nger tighten mounting stud nuts.
7. Push pump drive gear rmly onto shaft taper. Install
washer and retaining nut (Figure 18-A) onto end of
shaft. Tighten retaining nut to 90 lb-ft. (122 N•m) for
DB2, 150 lb-ft. (203 N•m) for DB4.
Figure 18 Reproduced by permission of Deere & Company, c2000. Deere & Company, All rights reserved.
IMPORTANT: Do not overtighten cap screws on pump
cover plate to avoid damage to O-ring.
8. Install access cover plate using a new gasket. Apply
LOCITE 242 (TY9370) to cap screw threads and
tighten to 1.7 lb-ft. (2 N•m).
9. Align timing mark on the pump ange (Figure 19-B)
with timing mark on the cylinder block front plate (A).
Figure 19 Reproduced by permission of Deere & Company, c2000. Deere & Company, All rights reserved.
10. Tighten the three hex nuts securing the pump to the
front plate to 20 foot lbs. (27 N•m).
11. Connect injection pump pressure lines (Figure 20-E).
Beginning with outlet (Figure 21-B) and continue
around the pump head in counterclockwise
direction, attaching lines in same order as engine
ring (1-5-3-6-2-4 on 6-cylinder engines and
1-3-4-2 on 4-cylinder engines).
Figure 20 Reproduced by permission of Deere & Company, c2000. Deere & Company, All rights reserved.
Figure 21 Reproduced by permission of Deere & Company, c2000. Deere & Company, All rights reserved.
12. Tighten fuel delivery (pressure) lines to 20 foot lbs.
(27 N•m), using a suitable 17mm deep-well crows-
foot socket.
IMPORTANT: Always use a backup wrench when
loosening or tightening fuel delivery lines at fuel
injection pump, so that the pump discharge ttings
are not altered. This prevents possible internal pump
damage.
13. Connect fuel supply line (Figure 20-C) and fuel return
line (Figure 20-D).
14. Connect fuel shuto cable and speed control linkage,
if equipped. Install and securely tighten electrical
connections to shuto solenoid and throttle position-
ing solenoid, if equipped. Connect cold start switch,
if equipped.
15. Bleed air from fuel system as outlined on page 19.
Start engine and run for several minutes. Check the
entire system for leaks.
16
Servicing

OLP 05/00
SP12. TURBOCHARGER
1. Check for air leaks every 200 hours. Air leakage
will lower engine output and may cause black
exhaust smoke and soot.
2. Listen along air line while engine is running.
A whistling or hissing sound indicates leakage.
3. Leakage on the pressure side, between turbo and
engine, can be found by applying soapy water to the
air line.
4. Tighten the hose clamps, replace hose or gaskets as
required.
5. Check to see that the lubrication and cooling lines
are tight and without leaks.
SP13. 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 600 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 specications for correct
pressure.
COOLING REQUIREMENTS
1. To meet cooling system protection requirements, the
coolant solution must consist of:
a. Quality water
b. Ethylene glycol concentrate (EGC ) commonly
known as antifreeze.
c. Supplemental coolant additives (SCA's).
2. A coolant solution of ethylene glycol concentrate
(EGC-antifreeze), quality water and supplemental
coolant additives (SCA's) MUST be used YEAR
ROUND to protect against freezing, boil-over, liner
erosion or pitting and to provide a stable, noncorro-
sive environment for cooling system components.
3. Ethylene glycol coolant concentrate (antifreeze)
normally DOES NOT contain the SCA chemical
inhibitors needed to control liner pitting or
erosion, rust, scale, and acidity.
LINER EROSION (PITTING)
1. Cylinder liner walls (Figure 22-A) which are in contact
with engine coolant (Figure 22-B) can be eroded or
pitted unless the proper concentration and type of
SCA's are present in the coolant. Water pump
impellers are also susceptible to pitting.
2. Vapor bubbles (Figure 22-C) are formed when the
piston's impact causes the liner walls to vibrate,
sending pressure waves into the coolant.
3. These tiny vapor bubbles collect on the surface
of metal parts. As the bubbles collapse (pop) a
microscopic piece of metal is eroded from the
metal part. Over a period of time, this pitting may
progress completely through the cylinder liner of a
wet-sleeve, heavy-duty diesel engine. This allows
coolant to enter the combustion chamber. Engine
failure or other serious damage will result.
A- Cylinder Liner Walls B - Engine Coolant C- Vapor Bubbles
Figure 22.
4. Unprotected engines with low quality water as cool-
ant can have liner failure in as few as 500 hours.
WATER QUALITY
1. Distilled, deionized, soft water is preferred for use in
cooling systems. Bottled distilled water from a food
store or water supplier is recommended. Tap water
often has a high mineral content. Tap water should
NEVER be put in a cooling system unless rst tested
by a water quality laboratory. Do not use water
made by the reverse osmosis method unless it has
been PH neutralized.
2. Here are acceptable water quality specications:
Parts Grains
Contaminates per Million per Gallon
Maximum Chlorides 40 2.5
Maximum Sulfates 100 5.9
Maximum Dissolved Solids 340 20.0
Maximum Total Hardness 170 10.0
PH Level 5.5 to 9.0
17
Servicing

OLP 05/00
3. If chlorides, sulfates or total dissolved solids are
higher than the above given specication, the water
must be distilled, demineralized, or deionized before
it is used in a cooling system.
4. If total hardness is higher than 170 ppm and all other
parameters are within the given specications, the
water must be softened before it is used to make
coolant solution.
EGC: ETHYLENE GLYCOL CONCENTRATE
(ANTIFREEZE)
CAUTION: EGC (Antifreeze) is ammable.
Keep it away from any open ame. Avoid contact
with eyes. Avoid contact with skin. Do not take inter-
nally. In case of contact, immediately wash skin with
soap and water. For eyes, ush with large amounts
of water for at least 15 minutes. Call a physician.
KEEP OUT OF REACH OF CHILDREN. Follow all
warnings on the container.
1. Ethylene glycol coolant concentrate is commonly
mixed with water to produce an engine coolant with
a low freeze point and high boiling point.
2. A low silicate form of ethylene glycol coolant is
recommended for all diesel engines.
3. Use an ethylene glycol coolant concentrate
meeting ASTM D 4985P, SAEJ1941, General
Motors Performance Specication GM1899M,
or formulated to GM6038M.
4. This product is concentrated and should be mixed
to the following specication.
5. If additional coolant solution needs to be added
to the engine due to leaks or loss, the glycol
concentration should be checked with a hydrometer
to assure that the desired freeze point is maintained.
IMPORTANT
1. DO NOT use methyl alcohol or methoxy propanol
base EGC. These concentrates are not compatible with
chemicals used in supplemental coolant additives.
Damage can occur to rubber seals on cylinder liners
which are in contact with coolant.
2. DO NOT use an EGC containing sealer or stop-leak
additives.
3. DO NOT use EGC containing more than 0.1% anhy-
drous metasilicate. This type of concentrate, which is
intended for use in aluminum engines, may cause a
gel-like deposit to form that reduces heat transfer and
coolant ow. Check container label or consult with
supplier.
SUPPLEMENTAL COOLANT ADDITIVE (SCA)
CAUTION: Supplemental coolant additive con-
tains alkali. Avoid contact with eyes. Avoid contact
with skin. Do not take internally. In case of contact
immediately wash skin with soap and water. For
eyes, ush with large amounts of water for at least
15 minutes. Call a physician. KEEP OUT OF REACH
OF CHILDREN. Follow all warnings on the container.
1. Important heat exchanger cooled engines
Additional SCA's should NOT be added to the mixture
of EGC/H20 on initial ll up of engines with a coolant
conditioner-lter. A high SCA concentration will result
and can cause silicate-dropout. When this happens, a
gel-type deposit is created in the cooling system which
retards heat transfer and coolant ow.
2. If additional SCA's are needed, prepare a mixture
of 50% quality water and 50%EGC (antifreeze).
Add liquid SCA at a rate of 3%, by volume.
Example: 30 mL of SCA per liter of H2O/EGC
mixture (1.0  oz of SCA per qt of H2O/EGC).
Add the resulting mixture to the cooling system in
quart increments. Run the engine for 2 hours and retest
the coolant. Continue process until SCA concentration
meets recommended levels.
3. SCA is available from your Northern Lights dealer in
the following sizes.
Pint - Part Number...............20-00002
1/2 gallon - Part Number.....20-00003
4. DO NOT use any coolant system additives
containing soluble oil.
Distilled EGC % Freeze Boiling
Water % Antifreeze Point Point
Optimum 50% 50% -37°C +109°C
-34°F +226°F
Minimum 60% 40% -24°C +106°C
-12°F +222°F
Maximum 40% 60% -52°C +111°C
-62°F +232°F
18
Servicing