Northern Lights LUGGER M6108 User manual

O6108
For Models: M6108, NL6108, and L6108
OPERATOR’SMANUAL
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.
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4420 14th Avenue N.W.
Seattle, WA 98107
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Copyright ©2001 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.: O6108 08/01

O6108 08/01
1
OPERATOR’S MANUAL
for Models
M6108, NL6108, and L6108
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 O6108 08/01
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.
INTRODUCTION ......................................................2
Models Included ...................................................2
Model Numbers....................................................2
Serial Numbers .....................................................2
WARRANTY ..............................................................3
SAFETY RULES.......................................................3
COMPONENT LOCATIONS
Northern Lights Marine Generator.......................4
Lugger Marine Propulsion Engines......................5
Northern Lights Industrial Generator ...................6
CONTROL PANELS
Northern Lights Generator Sets............................8
Lugger Marine Propulsion Engines......................9
OPERATING PROCEDURES
Before Starting....................................................10
Starting: Generator Sets......................................10
Starting: Propulsion Engines ......................10 - 11
Shutdowns and Alarms.......................................11
Break-in Period...................................................11
SERVICING SCHEDULE CHART...............12 - 13
SERVICING
Lubrication - General..........................................14
Oil Changes ........................................................14
Changing Oil Filter............................................ 15
Air Filter .............................................................15
V-Belts ................................................................15
Valve Clearances.................................................15
Fuels - General....................................................16
Fuel Filters..........................................................16
Bleeding the Fuel System...................................16
Injectors ......................................................16 - 17
Injection Pump....................................................17
Injection Pump Timings..............................18 - 19
Turbocharger.......................................................19
Turbo Boost ........................................................19
Cooling System Requirements ...................20 - 22
Checking Coolant Level.....................................22
Cooling System Flushing....................................22
Heat Exchanger Cleaning (Marine)....................23
Cleaning Gear Oil Coolers..................................23
Zinc Electrodes...................................................23
Raw Water Pump ................................................23
Coolant Filter......................................................23
Gears, PTOs, and Generators..............................23
Electrical System - General........................23 - 24
Glow Plugs..........................................................24
Booster Batteries.................................................24
Battery Care........................................................24
Winterizing / Out-of-Service ..............................24
PROPELLER SIZING CHART..............................25
DATA SHEETS
M6108.................................................................26
L6108..................................................................27
TROUBLESHOOTING
Electrical.............................................................28
Engine.........................................................29 - 32
DC WIRING DIAGRAMS
24 Volt NL Industrial Generator .........................33
24 & 12 Volt NL Marine Generator............34 - 37
24 & 12 Lugger Propulsion Engine............38 - 39
ON-BOARD SPARE PARTS KIT.........................40

O6108 08/01
2
Introduction
Unit Identification
Model Numbers
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 can 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.
MODELS INCLUDED
This manual covers the operating instructions for:
M6108 marine generator sets,
NL6108 industrial generator sets, and
L6108 propulsion engines.
Fill in the model number of your unit in the blank space provided.
This will give you a reference whenever service or maintenance is required:
Model numbers give unit's application, block model, aspiration and RPM:
Lugger turbocharged-aftercooled marine propulsion
engine. Komatsu 6108 block.
Northern Lights turbocharged 1500 or 1800 RPM
marine diesel generator set. Komatsu 6108 block.
M6108QT Northern Lights turbocharged 1200
RPM marine diesel generator set.
Komatsu 6108 block.
Northern Lights turbocharged-after-
cooled 1500 or 1800 RPM industrial
diesel generator set. Komatsu 6108
block.
M6108T
L- Lugger marine propulsion engine Model number of A- Aftercooled (turbo)
M- Northern Lights marine generator set Komatsu engine block D- Naturally aspirat
NL - Northern Lights industrial generator set 6 cylinder, 108 mm bore T- Turbocharged
Q - 1200 RPM
L - M - NL 6108 A, D, T, & Q
L6108A
Serial numbers
Figure 1: Generator set serial number plate.
Your set has three serial numbers : 1an
engine number stamped on the block, 2 a
generator plate, and 3a generator set plate.
Use the serial number on the generator set
plate when ordering parts or in correspon-
dence. The generator set plate is found on the
service side of the generator and resembles
Fig. 1.
NL6108A
Figure 2: Propulsion serial number plate.

O6108 08/01
3
Warranty
Safety Rules
CAUTION: Accident reports show that
careless use of engines cause a high per-
centage of accidents. You can avoid
accidents by observing these safety rules.
Study these rules carefully and enforce
them on the job.
• Never leave engine without proper security.
• Turn the coolant tank cap slowly to relieve
pressure before removing. Add coolant only
when the engine is idling or stopped.
• Mount fire extinguisher near engine.
• Always disconnect the baery ground strap
before making adjustments.
• Operate engines in properly ventilated areas.
• Keep trash and other objects away from
engine.
• Escaping fluids under pressure can pen-
etrate your skin. Use a piece of cardboardor
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 run
ning.
• 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 knowl-
edgeable, qualified personnel.
• Walk completely around engine to make
sure that everything is clear before starting
the engine.
• Do not operate an engine that isn't in
proper working order. If an unsafe operating
condition is noted, tag the engine so others
will also know about it.
• Provide first aid kits.
A warranty registration certificate is supplied
with your set. It entitles the original purchaser
of this equipment to a warranty covering mate-
rial or assembly faults. The extent of coverage
is described in the Limited Warranty State-
ment. We recommend that you study the state-
ment carefully.
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 fac-
tory.
CAUTION: This symbol is used throughout
this book to alert you to possible danger areas.
Please take special notice of these sections.

O6108 08/01
4
Marine Generator Set Component Locations
1. Expansion tank
2. Coolant fill
3. Vapor trap valve cover
4. Lube oil fill
5. Heat exchanger
6. Crankcase breather
7. Exhaust manifold
8. Cooling system air vents (3)
2 shown
9. Turbocharger
10. Exhaust manifold drain
(behind hose)
11. Wet exhaust elbow
(optional)
12. Starter
13. Heat exchanger drain
(in rear end cover)
14. Anti-vibration mounts
standard (shown
Hydrolastic mounts
optional)
15. Dipstick
16. Raw Water Pump
17. Raw Water Drain
18. Raw Water Zinc
19. Alternator
20. Air Cleaner
21. Engine Oil Cooler
22. Secondary Fuel Filter
23. Manual Fuel Prime
Pump
24. Fuel Injection Pump
25. Coolant Filter
26. Block Drain
27. Lube Oil Filter
28. Aftercooler
29. P.T.O. with electric clutch
(optional)
30. Lube oil drain
31. Base frame
32. Generator cooling air duct
33. AC generator
Figure 3. M6108A
Generator Set

O6108 08/01
5
Marine Propulsion Engine Component Locations
9. Exhaust Manifold drain
10. Gear Oil Cooler drain
11. Starter
12. Dry Exhaust Elbow
13. Gear Oil Cooler
14. Dipstick
15. Alternator
16. Air Cleaner
1. Expansion Tank
2. Coolant Fill
3. Vapor Trap Valve Cover
4. Lube Oil Fill
5. Crankcase Breather
6. Exhaust Manifold
7. Cooling System air vents (3)
8. Turbocharger
17. Engine Oil Cooler
18. Secondary Fuel Filter
19. Manual Fuel Prime Pump
20. Fuel Injection Pump
21. Coolant Filter
22. Block Drain
23. Lube Oil Filter
24. Aftercooler
25. D.C. Circuit Breaker and
relays
26. Low Water Level Gauge
(Optional)
Figure 4. L6108A2, keel cooled

O6108 08/01
6
Northern Lights Industrial Engine Component Locations
8. Solenoid
9. Fuel Return Line
10. Fuel Inlet Line
11. Oil Filter
(behind Fuel/Water
Separator)
12. Fuel/Water Separator
13. Alternator
14. Dipstick
15. Oil Fill
16. Starter
1. Generator Junction Box
2. Air Cleaner
3. Fuel Filter
4. Corrosion Resister
5. Exhaust Elbow
6. Coolant Fill
7. Thermostat Housing
Figure 5. NL6108

O6108 08/01
7
Notes

O6108 08/01
8
Control Panels - Northern Lights Generator Sets
SERIES 3 GENERATOR CONTROL PANEL 1. SHUTDOWN BYPASS PREHEAT
SWITCH:
Two functions are built into this switch: The
preheating of the engine, and bypassing of
the engine safety shutdown circuit, enabling a
quicker start. Hold switch in up position 10-20
seconds before starting engine, and continue
holding in up position while starting engine.
Holding the switches on too long can burn out
the glow plugs.
2. ENGINE CONTROL SWITCH:
To start the engine, hold switch in start position
until the engine is running. After the engine
starts, release switch and it will return to the
center position. To stop engine, move switch to
stop position and release.
3. OIL PRESSURE GAUGE:
The oil pressure gauge shows the oil pressure in
the engine lubricating system.
4. WATER TEMPERATURE GAUGE:
Registers temperature of cooling water.
5. HOUR METER:
Keeps track of engine running time.
6. D.C. VOLTMETER:
When the engine is stopped, the voltmeter
indicates the condition of the battery. When the
engine is running, the voltmeter indicates the
voltage output of the alternator.
For Series 4 Control Panels Only:
7. A.C. VOLTMETER:
Shows the generator output voltage.
8. FREQUENCY METER (HERTZ):
The frequency meter indicates the frequency of
alternating current: 1200 or 1800 RPM (60 Hz),
1500 RPM (50 Hz).
9. AMMETER SELECTOR SWITCH:
Used to check each phase for load condition. You
must always leave this switch in the "ON" posi-
tion while the unit is running.
10. A.C. AMMETER
Shows the generator load on each phase. The
phase is selected on the Ammeter Selector Switch
(switch #9 above).
Figure 8.
SERIES 4 GENERATOR CONTROL PANEL
Figure 7.

O6108 08/01
9
Control Panels - Lugger Marine Propulsion Engines
Figure 6 -
Auxilliary
Panel
1. OIL PRESSURE GAUGE:
The oil pressure gauge shows the oil pressure in
the engine lubricating system. If the oil pres-
sure drops BELOW 15 PSI at a speed higher
than idling, stop engine immediately and inves-
tigate.
2. WATER TEMPERATURE GAUGE:
This gauge shows the temperature of the cool-
ing water. If a temperature of over 205ois indi-
cated, stop engine and investigate immediately.
3. TACHOMETER:
The tachometer shows the engine speed in
revolutions per minute (RPM). Numbers are
multiples of 100.
4. VOLTMETER:
When the engine is stopped, the voltmeter
will indicate the condition of the battery.
When the engine is running, it shows the
alternator voltage output.
5. HOUR METER:
The hour meter
keeps track of the
accumulated length
of the engine's oper-
ating time.
6. KEY SWITCH:
The key must be kept
in "ON" position while the engine is running.
7. STOP BUTTON: Hold down until engine has
stopped.
Figure 4 - Main Panel Figure 5 - Flybridge Panel
8. INSTRUMENT LIGHTING DIMMER:
Adjust instrument panel lights. (On some panels
this is an on/off switch and not a dimmer.)
9. WARNING LIGHTS:
a. Light comes on when oil pressure is too low.
b. Light comes on when engine is too hot.
10. ALARM HORN:
Will sound in case of overheating or low oil
pressure. Stop engine and investigate. Remember
horn will sound when key is
in "ON" position with engine
stopped because there is
no oil pressure.
11. START BUTTON:
Will start engine only if key
on main panel is in
"ON" position.
12. EXHAUST
TEMPERATURE:
Maximum temperature:
975°F (510°C).
13. TURBO BOOST GAUGE:
See page 19 for boost range.
14. GEAR PRESSURE GAUGE:
See Gear Manual for operating range.

O6108 08/01
BEFORE STARTING
1. Check the water level by removing the pressure
cap from the expansion tank. In order to give the
cooling water an opportunity to expand, the level
should be about 1 3/4 in. (4-5 cm) below the filler
cap sealing surface when the engine is cold. When
filling with coolant, all the venting cocks should
be opened to ensure that no air pockets form in
the cooling system. (See Service Point 14, page
22)
CAUTION: Use protective clothing and open
the filler cap carefully when the engine is
warm to prevent burns.
2. Check the oil level in the crankcase with the
dipstick. The oil level must be in the waffled area
between the "L" and "H". Never allow the level to
go below the "L". Always add the same viscosity
of oil as is already in the crankcase. (See Service
Point 1, page 14)
3. Check the fuel tank level and open any fuel
valves.
4. Propulsion Only: Check the oil level in the
reverse gear. Methods may vary from gear to gear.
See your Gear Owner's Manual.
5. Close the sea cock, check and clean the strainer
and reopen the sea cock.
6. Place the battery switch in the ON position.
NOTE: The battery switch must always be kept
ON while the engine is running. If the switch
is turned OFF while the engine is running, the
battery charging regulator could be damaged.
GENERATOR
Starting
1. Hold Shutdown Bypass-Preheat switch in the
ON position for 30 seconds before starting. This
will warm the glow plugs and will ease starting.
This is not necessary if engine is warm. Alonger
preheat time may be required in extremely cold
weather.
2. While holding the Shutdown Bypass-Preheat
switch in ON position, push the Engine Control
switch to START position. As soon as the engine
starts, release both switches. Do not crank the
starter for more than 20 seconds. If the engine
fails to start the first time be sure the starter has
stopped before re-engaging.
10
Operating
1. Check Gauges Often: Oil pressure must be
above 29 PSI. The DC voltmeter should read
between 13 and 14 volts (26-28 volts, 24 volt
systems) at 60oF (16oC) ambient temperature.
Water temperature gauge must be below 205oF
(96oC). Check AC voltage and frequency meters.
If gauges deviate from normal levels, shut down
the set and investigate.
2. Let the unit run unloaded for a three to five
minute warm-up period.
3. Do not add full electrical load until the engine has
reached normal operating temperature.
PROPULSION ENGINE
Starting
1. Put the gear control in the neutral position.
2. Move the throttle control to the full speed position
and return back to idle.
3. Turn the key switch to the first position. Check
the voltage meter to see the condition of the bat-
teries. For starting, the voltmeter should not read
below 12 volts (24 volts for 24 volt systems).
4. In cold weather, turn the key to the preheat posi-
tion and hold there for 20-30 seconds.
5. Turn the key to the starting position and as soon
as the engine starts, release the key. Move the
throttle up until the engine is running at approxi-
mately 1000 RPM.
6. Do not crank the starter for more than 20
seconds consecutively. If the engine fails to start
with the first attempt, be sure that the starter has
stopped completely before reengaging.
NOTE: Never race a cold engine. Operate at 1000
RPM for a 3-5 minute warm-up period.
Operating
1. Check oil pressure as soon as the engine has
started. Oil pressure should be above 15 PSI. The
engine must never be run if the oil pressure is
below 15 PSI.
2. Check the voltmeter. It should read 13 to 14 volts
(26-28 volts, 24 volt systems) at 60oF (16oC).
3. Water temperature should not rise over 205oF
(96oC). If it does, shut down the engine and inves-
tigate the cause of overheating.
4. Do not exceed 800 RPM when shifting marine
gear. Repeated shifts at higher engine speeds can
damage the reverse gear.
5. Low Idle is 650 RPM. Maximum working engine
speed is: 2600 RPM for pleasure craft, 2600
RPM for light commercial craft and 2300 RPM
for continuous duty applications.
Operating Procedures

O6108 08/01
CAUTION: Do not remove the water fill cap
of an overheated engine. Escaping high
temperature steam can cause severe burns.
c. Allow the engine to cool and then remove
the cap slowly using protective clothing.
d. Make repairs and restart after the tempera-
ture gauge registers below 180oF (82oC).
e. Watch the temperature gauge regularly and
turn off the unit if the temperature rises
above 205oF (96oC). Repeat the troubleshoot-
ing process.
3. If the warning or shutdown is activated and the
temperature gauge shows temperature within
normal temperature range:
a. Check the engine crankcase oil level.
b. If the oil level is low, fill with recommended
lubricating oil and restart. Watch the oil pres-
sure gauge carefully and shut off the engine
if it does not show a normal reading after a
few seconds of operation.
c. If the oil level is normal, DO NOT restart the
engine. Call your Northern Lights or Lugger
dealer for assistance.
BREAK-IN PERIOD
1. The first 100 hours on a new or reconditioned
engine are critical to its life and performance.
2. Constantly check the engine temperature and oil
pressure gauges.
3. Oil consumption is greater during break-in as
piston rings and cylinder liners take time to seat.
4. Break-In Oil Changes: Change engine oil and
filter at 50 hours. Change oil and filter again at
100 hours. (See Gear Owner's Manual for break-
in oil change procedures. Consult Lubricants
Section for oil recommendation.)
Operating Instructions
1. Propulsion engines: Never run full speed for
more than 5 minutes during the first 50 hours.
Run engine at 50 to 75% of maximum working
speed for the first 20 hours with as little idling
time as possible. Extended idling can inhibit ring
seating, causing cylinder walls to glaze.
2. Generator Sets: Maintain at least a 75% load
on your set for the first 100 hours. If this is
not possible, maintain no less than a 50% load
to ensure proper seating of the piston rings. Vary
the load to help seat rings.
6. If the proper propeller is used, the engine should
reach its appropriate maximum speed at full
throttle. If at full throttle the maximum speed
is exceeded, then the propeller is too small. If
maximum speed cannot be attained, then the
propeller is too large or bottom growth may be
slowing the boat. (See Prop Chart, page 25.)
7. To Establish Maximum Cruising RPM: Estab-
lish the RPM at full throttle and subtract 200-300
RPM. This will promote engine life and reduce
fuel consumption.
SHUTDOWN PROCEDURES
1. Run for three to five minute cool down period.
a. Propulsion engines in neutral at 1000 RPM,
then return throttle to low idle.
b. Generators unloaded.
2. Push STOP button until the engine has stopped.
Turn key switch to OFF position.
3. Close the sea cock, fuel valves and put the bat-
tery switch in OFF position.
NOTE: Do not turn battery switch to OFF while
engine is running.
SHUTDOWNS AND ALARMS
1. Your unit is fitted with a system to protect it
from high water temperature or low oil pressure.
a. Generator sets have shutdown systems to
stop the engine. They have no warning
horns.
b. Propulsion engines have warning horns to
sound and warn you of a problem. Remem-
ber: when engine is not running the horn
will sound when key is in the "ON" position
because there is no oil pressure. Propulsion
engines do not have shutdown systems.
c. Other alarms and shutdowns are available as
optional equipment.
NOTE: Do not rely on your warning or shut-
down 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 shut-
down system is activated.
a. Check the temperature gauge. If the tem-
perature is above 205oF (96o), shut off the
engine immediately.
b. Use the Trouble Shooting Guide on page 28
to isolate the cause of the overheat.
11
Operating Procedures

O6108 08/01
SERVICE 50 250 500 750 2400
POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours
ENGINE:
SP1 10&14 Check oil level •
SP2 14 Change engine oil 1) 4) •
SP3 15 Change lube oil filter 1) 4) •
SP4 15 Replace air filter 1) 3) •
SP5 15 Check V-Belt tension 1) 4) •
SP6 15 Check valve clearances 1) 5) •
FUEL SYSTEM:
SP7 16 Check primary filter (Racor) 2) 3) •
SP8 16 Change primary filter element 2) 3) •
SP9 16 Change secondary filter 1) 3) •
SP10 16&17 Check injectors 1) 3) •
SP11 17–19 Check fuel injection pump •
TURBOCHARGER:
SP12 19 Check air lines, oil and cooling water lines for leakage 1) 3) •
SP13 19 Check boost pressure •
COOLING SYSTEM
SP14 10&22 Check cooling water level •
SP15 22 Check and flush cooling system 1) •
SP16 23 Check and clean heat exchanger 1) •
SP17 23 Check and clean gear oil cooler 1) •
SP18 23 Check zinc electrodes-HE engines only 1) 3) •
SP19 23 Change impeller in seawater pump 1) 3) •
SP20 23 Change coolant filter 1) 3) •
DRIVEN EQUIPMENT:
SP21 10&23 Check oil level in reverse gear •
SP22 23 Change oil in reverse gear 2)
SP23 23 Clutch and PTO service 2)
ELECTRICAL SYSTEM:
SP24 24 Check electrolyte level in batteries 1) 3) •
SP25 24 Check condition of batteries with hydrometer 1) 4) •
OUT OF SERVICE:
SP26 24 Winterizing or out-of-service 3)
1) Perform all maintenance once a year even if hour level has not been reached.
2) Consult manufacturer's maintenance schedule, note on chart.
3) When necessary.
4) Change at first 50 and first 100 hours.
5) Adjust at first 100 hours.
12
DAILY:
SP1 Check oil level in engine
SP7 Check primary fuel filter
SP14 Check cooling water level
SP21 Check oil level in reverse gear
FIRST 50 HOURS:
SP2 Change engine oil
SP3 Change lube oil filter
EVERY 50 HOURS (or weekly):
SP5 Check V-belt tension
SP24 Check electrolyte in batteries
FIRST 100 HOURS:
SP2 Change oil
SP3 Change lube oil filter
SP6 Check valve clearances
FIRST 250 HOURS:
SP20 Change coolant filter
EVERY 250 HOURS (or every 6 months):
SP2 Change engine oil
SP3 Change lube oil filter
SP4 Check air filter
EVERY 250 HOURS (Continued)
SP8 Change primary fuel filter element
SP12 Check turbocharger air, oil and cooling lines for leakage
SP18 Check zinc electrodes. HE engines only
FIRST 500 HOURS
SP20 Change coolant filter
EVERY 500 HOURS (or yearly):
SP20 Change coolant filter
EVERY 750 HOURS (or yearly):
SP4 Replace air filter
SP6 Check valve clearances
SP9 Change secondary fuel filter
SP10 Check injectors
SP13 Check turbocharger boost pressure
SP15 Check and flush cooling system
SP19 Change impeller in sea water pump
SP25 Check condition of batteries with hydrometer
EVERY 2400 HOURS:
SP11 Check fuel injection pump
SP16 Check and clean heat exchanger
SP17 Check and clean gear oil cooler
The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your unit. More
detailed coverage of each Service Point (SP) is listed on the page noted in the 'page' column.
Servicing Schedule Chart

O6108 08/01
Service
Point
OPERATION HOURS/DATE
50 HOURS (or weekly)
SP5 Check V-belt tension
SP25 Check electrolyte in batteries
250 HOURS (or every 6 months)
SP2 Change engine oil
SP3 Change lubricating oil filter
SP4 Check air cleaner
SP8 Change primary fuel filter element
SP12 Check turbocharger air, oil & cooling lines for leakage
SP18 Check zinc electrodes - HE engines only
500 HOURS (or annually)
SP20 Change cooling system filter
750 HOURS (or annually)
SP4 Replace air cleaner
SP6 Check valve clearances
SP9 Change secondary fuel filter
SP10 Check injectors
SP13 Check turbocharger boost pessure
SP15 Check and flush cooling system
SP19 Change impeller in sea water pump
SP25 Check state of charge of batteries
2400 HOURS
SP11 Check fuel injection pump
SP16 Check and clean heat exchanger
SP17 Check and clean gear oil cooler
13
Service Record

O6108 08/01
LUBRICATION - GENERAL
1. Use only clean, high quality lubricants
stored in clean containers in a protected area.
2. These lubricants are acceptable:
a. API Service CC/CD single viscosity oils.
b. API Service CC/CD/SF multi-viscosity oils.
3. Use the proper weight oil for your average
operation temperature.
4. Some increase in oil consumption may be
expected when SAE 5W and SAE 5-20W oils
are used. Check oil level frequently.
5. Never put additives or flushing oil in crank-
case.
6. Propulsion Engines: See Gear Owner's Manual
for gear lubrication recommendations.
SP1. OIL LEVEL
1. Check engine oil level daily with the dip-
stick. The oil level must be in the waffled area
between the “L” and “H”. Never allow the
level to go below the “L”.
2. Always add the same viscosity of oil as is
already in the crankcase. (See above recom-
mendations.)
SP2. OIL CHANGES
1. Using the oil recommended in the above dia-
gram, change the engine oil and filter after the
first 50 hours of operation, the first 100 hours
of operation, and every 250 hours thereafter.
2. During intermittent cold weather operation,
change oil every 100 hours or six weeks,
whichever comes first.
3. Change oil at any seasonal change in tempera-
ture when a new viscosity of oil is required.
4. Change oil when engine is warm.
5. Dispose of waste oil in an approved manner.
6. Propulsion Engines with Optional Drain Pump:
a. Your engine is fitted with a hand pump that
drains the engine crankcase and marine
gear.
b. Use a wrench to turn the selector valve to
drain the engine or gear. Use marks on the
valve stem as a guide. (See Fig. 9).
c. Turn pump handle in clockwise direction
and pump oil into a suitable container.
When the engine is empty, switch the valve
and drain the gear oil.
d. Close valve. Refill engine and gear with
recommended oils.
NOTE: Make sure the valve is in the closed
position before starting engine. If it is left
open it is possible for crankcase oil to be
pumped into the reverse gear and out of
the gear dipstick and breather. This can
ruin the engine.
Figure 9. Hand Pump Selector Valve
7. Marine Generator Sets:
a. Remove plug from outlet in base frame.
Screw in owner-supplied drain hose.
b. Open valve at oil pan outlet. After oil has
been drained into suitable container, close
valve, remove drain hose and replace plug
in base frame outlet.
c. Refill engine with recommended oil.
8. Engine capacity with new oil filter is 6.2 gal-
lons (23.5 liters).
SP3. CHANGING OIL FILTER
1. Change the lube oil filter after the first 50 hours
of operation, after the first 100 hours of opera-
tion and every 250 hours thereafter.
2. Use a filter wrench to remove old filter. Dis-
pose of filter in approved manner.
3. Make sure the gasket from the old filter is
removed and discarded.
4. Lubricate the rubber gasket on the new filter
and screw it on nipple until gasket meets the
sealing surface.
5. Using hands only, no wrench, tighten filter
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 and check
oil level. Add additional oil if necessary.
14
Servicing
Air Single Multi-
Temperature Viscosity Viscosity
Above 320F SAE-30W SAE 15-40W
-10 to 320F SAE-10W SAE 10-30W
(-23 to 00C)
Below -100F SAE-5W SAE 5-20W
(-230C)

O6108 08/01
SP4. AIR FILTER
1. Inspect air cleaner every 250 hours, replace
the filter every 750 hours, or yearly, whichever
comes first.
2. After replacing element and cover, start engine
and check for air leaks.
NOTE: Make absolutely sure no impurities enter
the engine while changing the element. Do not
run the engine with the air cleaner removed.
SP5. V-BELTS
1. Check the tension and wear on the V-belts after
every 50 hours.
2. Use your thumb to press on the belt at the
midpoint between the crankshaft and alternator
pulleys. The tension is correct if the belts can be
depressed about 1/2" (14-17 mm) with 13 lb. (6 kg)
pressure.
3. Belts that operate in pairs should both be replaced
in pairs, even if only one of them needs to be
replaced.
SP6. VALVE CLEARANCES
1. Check the valve clearances after the first
100 hours, and every 750 hours thereafter.
2. Shut off fuel supply. Turn off battery switch.
3. Remove the valve cover. Use a breaker bar with a
27 mm socket to rotate the crankshaft in a clock-
wise direction. Align the “1.6 TOP” mark on the
vibration damper with the pointer. In this posi-
tion No. 1 cylinder is at top dead center of the
compression stroke, and No. 6 cylinder's intake
valves will start to move. (See Fig. 10).
Figure 10.
15
4. Adjust the valve clearance for valves marked with
an “X” in Fig. 11.
5. Rotate the crankshaft in clockwise direction one
complete revolution until “1.6 TOP” is again at
the pointer and adjust the valve clearance for the
valves marked with an “O” in Fig. 11.
Cylinder No. 1 2 3 4 5 6
Intake Valve X X O X O O
Exhaust Valve X O X O X O
Figure 11.
6. To adjust the valve clearance, loosen nut on
adjustment screw, insert feeler gauge between
the valve stem and rocker arm, and adjust the
clearance with the adjustment screw until the
thickness gauge slides with a slight drag. After the
clearance is properly adjusted, tighten the lock nut
to secure the adjustment screw using 29 to 36 foot
lbs. of torque (4-5 kgm).
7. Valves should be set cold with the following
clearances:
a. Intake Valves .013 in. (.33 mm).
b. Exhaust Valves .026 in. (.66 mm).
8. Rotate the engine one full revolution and adjust
valves with “O” to above clearances.
NOTE: The firing order is 1-5-3-6-2-4.
FUELS - GENERAL
1. Use only clean, high quality fuels of the following
specifications, as defined by ASTM designation
D975 for diesel fuels:
a. Use grade No. 2 diesel at ambient tempera-
tures above freezing 32oF (0oC).
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.
Servicing
Front

O6108 08/01
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.
SP7-9. FUEL FILTERS
1. Your engine or generator set should have a
primary fuel filter installed. We recommend the
Racor brand of fuel filter - water separators.
a. Check the primary fuel filter daily as recom-
mended by the filter manufacturer. Empty
the collection bowl as necessary.
b. Change the element every 250 hours or when
necessary.
c. If the bowl fills with water, change the pri-
mary and secondary element immediately.
2. Change secondary fuel filter every 750 hours.
a. Remove the filter cartridge by turning it
counterclockwise with a filter wrench. Fill
the new cartridge with fuel and install it
after applying engine oil to gasket surface.
Screw on until the gasket surface comes into
contact with sealing surface of filter base.
Then, tighten it two-thirds of a turn by hand.
BLEEDING THE FUEL SYSTEM
CAUTION: Escaping diesel fuel under pres-
sure can penetrate the skin, causing serious
personal injury. Before disconnecting lines
be sure to relieve all pressure. Before apply-
ing pressure to the system be sure all con-
nections are tight and the lines, pipes and
hoses are not damaged. Fuel escaping from
a very small hole can be almost invisible. Use
a piece of cardboard or wood, rather than
the hands, to search for suspected leaks. If
injured by escaping fuel, see a doctor at once.
Serious infection or reaction can develop if
proper medical treatment is not administered
immediately.
1. Whenever the fuel system has been opened for
service, (lines disconnected, filter changed, etc.)
it should be bled.
2. To bleed the fuel system, loosen the vent plug
in the top of the fuel filter housing. Unscrew the
16
hand primer knurled knob on the injection pump
and loosen until it can be pulled up by hand (see
Fig. 12,6).
Operate the hand primer up and down until most
of the air bubbles are expelled and clear fuel
escapes the vent plug. Push hand primer down and
tighten. Tighten the vent plug.
3. If the engine will not start, it may be necessary
to loosen the fuel pipes at the injectors. With the
throttle on full, crank the engine over with the
starter until fuel without air flows from the loose
fuel pipe connections. Tighten the connections.
SP10. INJECTORS
1. Fuel injectors should be checked by a Lugger-
Northern Lights dealer or qualified fuel injection
shop after every 750 hours.
2. Injector Removal:
a. Thoroughly clean the area around injection
pump and injectors, including all pipe and line
connections. Use compressed air if available.
b. Remove fuel line connecting nuts from injec-
tion pump and injectors. Remove fuel line
clamps below the intake manifold.
c. Put fuel lines aside. It is not necessary to
remove the pipes entirely.
d. Remove the return lines from the injectors.
e. Remove hold down bolts, holders and injec-
tors.
3. Clean Injector Bore:
Injector seat in cylinder head can be cleaned by
wrapping a clean, lint-free rag around the tapered
end of a wooden rod and wiping the bore and seat.
Hardened carbon can be removed from the seat by
using a tapered wire brush to break carbon free.
Then clean the bore with rag and rod.
4. Have injectors tested and rebuilt if necessary. Or,
take them to a Lugger-Northern Lights dealer and
use them as core exchange for rebuilt injectors.
5. Injector Installation:
a. Insert injector into bore. Install holders and
torque to 29-36 foot lbs. (4-5 kgm).
b. Install injector fuel return line. Torque banjo
bolts to 8-11 foot lbs. (1.0-1.5 kgm).
c. Install injector lines. Torque fuel line nuts to
14.5-18footlbs.(2-2.5kgm).Onthepumpside,
torque nuts 18-25 foot lb. (2.5-3.5 kgm).
d. Bleed the fuel system, start the engine
and check the system for leaks using a piece of
cardboard.
Servicing

O6108 08/01
b. Reinstall bracket between the engine block
and rear of pump. Leave pump mounting nut
(see Fig. 12,8) loose until pump is timed.
c. Reinstall feed lines (see Fig. 12,7) and
torque banjo bolts to 18.0 ft. lbs. (2.5 kg).
Reinstall lubrication oil line (see Fig. 12,1)
and torque banjo bolt to 9.0 ft. lbs. (1.25 kg)
Install new sealing washers on both sides of
banjo bolts.
d. Reinstall fuel injection lines (see Fig. 12,2)
and line clamp (Fig. 12,1). Torque fuel line
sleeve nuts at injection pump to 18-25 ft. lbs.
(2.5-3.5 kg). Torque fuel line sleeve nuts at
the injectors to 14.5-18 ft. lbs. (2.0-2.5 kg).
TIMING INJECTION PUMP
1. The Match Mark Alignment Method:
Note: This is used when the injection pump is
being reinstalled on the original engine and the
pump has NOT been repaired.
a. When the stamped line on the injection
pump is aligned with the stamped line on the
drive case, the pump is correctly timed (see
Fig. 14).
2. Delivery Valve Method:
Use delivery valve method when a repaired or
replaced injection pump is being installed.
a. Disconnect fuel injection line from the No.
1 cylinder delivery valve on the injection
pump (12,4).
b. Remove delivery valve holder. Remove
spring and delivery valve and put valve
holder back in injection pump.
c. Place the throttle (12,9) in the full fuel (for-
ward) position.
d. Use a breaker bar with the appropriate
socket to rotate the crankshaft in a clockwise
direction while operating the priming pump
(12,6). This is best done by two people.
e. Stop rotating and pumping when fuel stops
flowing out of the delivery valve holder
(12,4).
17
SP11. INJECTION PUMP
1. The pump settings, maximum speed, idle speed
and exhaust smoke should be checked after
every 2400 hours of operation. Service of the
fuel injection pump should only be done if
checks indicate pump malfunction.
2. Low power and no smoke can indicate a fuel
injection pump malfunction. Check for full
throttle, proper solenoid adjustment and air filter
cleanliness before replacing pump. Black smoke
occasionally may indicate an injection pump
problem.
3. Any repair which involves disassembly of the
injection pump must be carried out by trained
mechanics with the proper tools and test devices.
NOTE: All warranties on the engine become null
and void if the injection pump seals are broken
by unauthorized persons.
4. Injection Pump Removal:
a. Clean injection pump, hoses and area around
the pump with cleaning solvent or a steam
cleaner.
NOTE: Never steam clean or pour cold water
on an injection pump while the engine is
running or the pump is warm.
b. Remove line clamps (see Fig. 12,3) & fuel
injection lines (Fig. 12,2).
c. Remove feed lines (see Fig. 12,7), lubri-
cation tube (Fig. 12,1) and return line
(Fig. 12,5).
d. Remove pump mounting nut (see Fig. 12,8)
and mounting bracket at rear of pump.
e. Remove four nuts (see Fig. 12,10) between
the drive case and the flange on the pump
drive. It will be necessary to use a socket
wrench, a universal joint and an extension to
loosen the two bolts on the back side of the
pump.
f. Remove pump from drive case.
6. Injection Pump Installation:
a. Line up pump to drive case. The spline lacks
a tooth, so match male and female to this
position. Reinstall the four nuts (see Fig.
12,10) holding the pump to the drive case
but do not tighten until pump is timed. (See
Injection Pump Timing, Pg. 18.)
Servicing

O6108 08/01
Figure 12 Injection Pump Servicing Points
1. Lube line
2. Fuel injection line 3. Injection line clamp 4. No. 1 delivery line 5. Fuel return line
6. Hand priming pump
7. Fuel feed lines
8. Pump mounting nut
9. Throttle
10. Pump flange mounting nuts (also
two on back of pump)
18
Servicing
TIMING INJECTION PUMP
1. The Match Mark Alignment Method:
Note: This is used when the injection pump is being
reinstalled on the original engine and the pump has
NOT been repaired.
a. When the stamped line on the injection pump is
aligned with the stamped line on the drive case,
the pump is correctly timed (see Fig. 14).
2. Delivery Valve Method:
Use delivery valve method when a repaired or
replaced injection pump is being installed.
a. Disconnect fuel injection line from the No. 1 cyl-
inder delivery valve on the injection pump (12,4).
b. Remove delivery valve holder. Remove spring and
delivery valve and put valve holder back in injec-
tion pump.
c. Place the throttle (12,9) in the full fuel (forward)
position.
d. Use a breaker bar with the appropriate socket
to rotate the crankshaft in a clockwise direc-
tion while operating the priming pump (12,6).
This is best done by two people.
e. Stop rotating and pumping when fuel stops
flowing out of the delivery valve holder
(12,4).
f. The pointer (Fig. 13) should align with the
timing specification found in the Technical
manual or on the data plate on the engine.
1) If the injection timing line has passed the
pointer, the timing is retarded.
2) If the injection timing line has not
reached the pointer, the timing is
advanced.
g. To adjust timing, rotate the crankshaft 30°-
40°(1/8 turn) in counterclockwise direction
from "1.6 TOP" mark to remove gear lash.