O6140

For Models: L6140A, L6140AL2,

M6140AL, & M6140AL2

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

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

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

Copyright ©2003 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.: O6140 03/03
 O6140
OPERATOR'S MANUAL FOR MODELS L6140A,
L6140AL2, M6140AL, & M6140AL2
Read this operator's manual thoroughly before starting to operate your equipment.
This manual contains information you will need to run and service your new unit.

TABLE OF CONTENTS

Introduction ........................................................2 Servicing (cont.)

Unit Identification Injection Pump Timings ..............................16
Model Designation .........................................2 Turbocharger .................................................17
Serial Numbers ...............................................2 Turbo Boost....................................................17
Warranty ...............................................................3 Cooling System Requirements ........... 18 - 20
Safety Rules .........................................................3 Checking Coolant Level...............................20
Component Locations Flushing the Cooling System ......................20
Lugger Propulsion ..........................................4 Heat Exchanger Cleaning ............................21
Northern Lights Marine Generator Set .......5 Cleaning Gear Oil Coolers ..........................21
Panels Zinc Electrodes..............................................21
Lugger Propulsion Engine ............................6 Raw Water Pump ..........................................21
Series 3 & 4 Generator Sets............................7 Coolant Filter.................................................21
Operating Procedures Gears, PTOs, and Generators ......................21
Before Starting.................................................8 Electrical System - General..........................22
Generator .........................................................8 Booster Batteries ...........................................22
Propulsion Engine .................................... 8 - 9 Battery Care ...................................................22
Shutdown Procedures....................................9 Winterizing - Out-of-Service .......................22
Shutdowns & Alarms .....................................9 Propeller Sizing Chart .....................................23
Break-in Period ...............................................9 Data Sheets
Servicing Schedule Chart .............................10 Lugger ............................................................24
Service Record ................................................11 Northern Lights ............................................25
Servicing Troubleshooting
Lubrication - General ...................................12 Electrical .........................................................26
Oil Changes ...................................................12 Engine.............................................................27
Changing Oil Filter ............................... 12 - 13 DC Wiring Diagrams
Air Filter .........................................................13 12 Volt Lugger Engine .................................28
V-Belts ............................................................13 24 Volt Lugger Engine .................................29
Valve Clearances ...........................................13 24 Volt Standard Marine Gen Set ...............30
Fuels - General ..............................................14 AC Wiring Diagram
Fuel Filters .....................................................14 All Voltages Marine Gen Set .......................31
Bleeding the Fuel System ............................14 Onboard Spare Parts ........................................32
Injectors .................................................. 14 - 15
Injection Pump ................................................15

Proprietary Information
This publication is the property of Alaska Diesel Electric, Inc. It may not be reproduced
in whole or part without the written permission of Alaska Diesel Electric, Inc. ©Alaska Diesel Electric, Inc.
All rights reserved. Litho USA. Publication number O6140 03/03.

O6140 03/03
3
 INTRODUCTION

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

UNIT IDENTIFICATION

MODEL NUMBER
Model numbers give unit's application, block model, aspiration and RPM:

L - M - NL 6140 AL, D, T, & Q

L - Lugger marine propulsion engine Model number of A - Aftercooled (turbo)

M - Northern Lights marine generator set Komatsu engine block AL2 - Aftercooled (turbo-
NL - Northern Lights industrial generator set 6 cylinder, 140 mm bore low profile)
D - Naturally aspirated
T - Turbocharged
QA - 1200 RPM (Aftercooled)

Lugger turbocharged-aftercooled marine propulsion Northern Lights aftercooled-turbocharged 1200

L6140AL2 M6140QA
engine. Komatsu 6140 block. (low profile) RPM marine diesel generator set. Komatsu 6140
block.
Lugger turbocharged-aftercooled marine propulsion
L6140A
engine. Komatsu 6140 block. (high profile) Northern Lights turbocharged-aftercooled 1500 or
NL6140A 1800 RPM industrial diesel generator set.
Northern Lights turbocharged 1500 or 1800 RPM Komatsu 6140 block.
M6140AL2
marine diesel generator set. Komatsu 6140 block.

SERIAL NUMBERS
When referencing Alaska Diesel Electric equipment by serial number, refer only to the number
stamped on the Lugger or Northern Lights serial number plate.

O6140 03/03
4
 WARRANTY

A warranty registration certificate is supplied If the warranty is to apply, the servicing instruc-
with your set. It entitles the original purchaser tions outlined in this manual must be followed.
of this equipment to a warranty covering mate- If further information is needed, please contact
rial or assembly faults. The extent of coverage an authorized dealer or the factory.
is described in the Limited Warranty Statement.
We recommend that you study the statement
carefully.

SAFETY RULES

Accident reports show that careless use • Avoid wearing loose clothing without a belt
of engines cause a high percentage of accidents. when working around engines.
You can avoid accidents by observing these
• Do not oil or grease engine while it is running.
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 fill-
• Never leave engine without proper security.
ing fuel tank or servicing fuel system.
• Turn the coolant tank cap slowly to relieve
• Keep your hands, feet, hair and clothing away
pressure before removing. Add coolant only
from power-driven parts.
when the engine is idling or stopped.
• Check for any loose electrical connections or
• Mount fire extinguisher near engine.
faulty wiring.
• Always disconnect the battery ground strap
• Engines should be operated only by knowl-
before making adjustments.
edgeable, qualified personnel.
• Operate engines in properly ventilated areas.
• Walk completely around engine to make
• Keep trash and other objects away from sure that everything is clear before starting the
engine. engine.
• Escaping fluids under pressure can penetrate • Do not operate an engine that isn't in proper
your skin. Use a piece of cardboard or wood, working order. If an unsafe operating condition
not your hands, to search for leaks. is noted, tag the engine so others will also know
about it.
• Provide first aid kits.

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 COMPONENT LOCATIONS

Lugger Propulsion L6140AL - Low Profile

Figure 1. L6140AL
1. Cooling system vent 9. Injection pump 17. Heat exchanger 26. Jacket water block drain
2. Coolant filter 10. Fuel feed pump & 18. Cooling system fill 27. Gear oil filter
3. Stop solenoid manual priming pump 19. Air cleaner 28. Starter
4. Lube oil fill 11. Lube oil dipstick 20. Crankcase vent outlet 29. Gear oil dipstick
5. DC circuit breaker & relays 12. Raw water pump 21. Aftercooler vent (2) 30. Manifold drain
6. Fuel system bleed plug 13. Expansion tank 23. DC Alternator 31. Cylinder head
7. Fuel filter 15. Zinc (2) 24. Jacket water pump 32. Rocker arm cover
8. Oil filter 16. Gear oil cooler 25. Raw water pump inlet 33. Turbocharger

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 COMPONENT LOCATIONS

M6140AL Northern Lights Marine Generator Set

Figure 2. M6140AL Generator Set

1. Base frame 8. Fuel manifold 16. DC alternator 24. Vibration isolation mounts
2. Coolant filter 9. Lube oil dipstick 17. Turbocharger 25. Expansion tank
3. Fresh water pump 10. Lube oil drain 18. Generator "J" box 26. Coolant system fill
4. Stop solenoid 11. Starter 19. Manifold drain 27. Heat exchanger
5. Lube oil fill 12. Air Cleaner 20. Air vents 28. Rocker arm cover
6. Generator fan 13. Crankcase vent 21. PTO (optional) 29. Cylinder head
7. Fuel feed pump and manual 14. Secondary fuel filter 22. Block drain 30. Raw water pump
priming pump 15. Lube oil filter 23. Fuel injection pump

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 INSTRUMENT PANEL

Lugger Marine Propulsion Engine

1. OIL PRESSURE GAUGE:
8. INSTRUMENT LIGHTING DIMMER :
The oil pressure gauge shows the oil pressure in
the engine lubricating system. If the oil pressure Adjust instrument panel lights. (On some panels
drops BELOW 15 PSI at a speed higher than this is an on/off switch and not a dimmer.)
idling, stop engine immediately and investigate.
9. WARNING LIGHTS:
2. WATER TEMPERATURE GAUGE: a. Light comes on when oil pressure is too low.
This gauge shows the temperature of the cooling b. Light comes on when engine is too hot.
water. If a temperature of over 205o is indicated,
10. ALARM HORN:
stop engine and investigate immediately.
Will sound in case of overheating or low oil
3. TACHOMETER: pressure. Stop engine and investigate.
The tachometer shows the engine speed in Remember horn will sound when key is in "ON"
revolutions per minute (RPM). Numbers are position with engine stopped because there is no
multiples of 100. oil pressure.

4. VOLTMETER: 11. START BUTTON:

When the engine is stopped, the voltmeter Will start engine only if key
will indicate the condition of the battery. on main panel is in "ON"
When the engine is running, it shows the position.
alternator voltage output.
12. EXHAUST TEMPERA-
5. HOUR METER: TURE:
The hour meter keeps track of the Maximum temperature:
accumulated length of the engine's operating 975°F (510°C).
time.
6. KEY SWITCH: Figure 5 -
The key must be kept in "ON" position while 13. TURBO BOOST GAUGE. Auxilliary Panel
the engine is running.
14. GEAR PRESSURE GAUGE:
7. STOP BUTTON: See Gear Manual for operating range.
Hold down until engine is completely stopped.

Figure 4 - Flybridge Panel

Figure 3 - Main Panel

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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 heater elements.
2. ENGINE CONTROL SWITCH:
To start the engine, hold switch in start position
until the engine is running. After the engine
starts, release switch and it will return to the
center position. To stop engine, move switch to
stop position and release.
3. OIL PRESSURE GAUGE:
The oil pressure gauge shows the oil pressure in
the engine lubricating system.
4. WATER TEMPERATURE GAUGE:
Figure 6.
Registers temperature of cooling water.
5. HOUR METER:
SERIES 4 GENERATOR CONTROL PANEL 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
Figure 7. (switch #9 above).

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 OPERATING PROCEDURES

BEFORE STARTING above 29 PSI. The DC voltmeter should read

1. Check the water level by removing the pressure between 13 and 14 volts (26-28 volts, 24 volt
cap from the expansion tank. In order to give the systems) at 60oF (16oC) ambient temperature.
Water temperature gauge must be below 205oF
cooling water an opportunity to expand, the level
(96oC). Check AC voltage and frequency meters.
should be about 1 3/4 in. (4-5 cm) below the filler
If gauges deviate from normal levels, shut down
cap sealing surface when the engine is cold. When
the set and investigate.
filling with coolant, all the venting cocks should
2. Let the unit run unloaded for a three to five
be opened to ensure that no air pockets form in
minute warm-up period.
the cooling system. (See Service Point 14, page
3. Do not add full electrical load until the engine has
20)
reached normal operating temperature.
CAUTION: Use protective clothing and open
the filler cap carefully when the engine is warm PROPULSION ENGINE
to prevent burns. Starting
2. Check the oil level in the crankcase with the 1. Put the gear control in the neutral position.
dipstick. The oil level must be in the waffled area 2. Move the throttle control to the full speed position
between the "L" and "H." Never allow the level to and return back to idle.
go below the "L." Always add the same viscosity 3. Turn the key switch to the first position. Check
of oil as is already in the crankcase. (See Service the voltage meter to see the condition of the bat-
Point 1, page 12) teries. For starting, the voltmeter should not read
3. Check the fuel tank level and open any fuel below 12 volts (24 volts for 24 volt systems).
valves. 4. In cold weather, turn the key to the preheat posi-
4. Propulsion Only: Check the oil level in the tion and hold there for 20-30 seconds.
reverse gear. Methods may vary from gear to gear. 5. Turn the key to the starting position and as soon
See your Gear Owner's Manual. as the engine starts, release the key. Move the
5. Close the sea cock, check and clean the strainer throttle up until the engine is running at approxi-
and reopen the sea cock. mately 1000 RPM.
6. Place the battery switch in the ON position. 6. Do not crank the starter for more than 20
NOTE: The battery switch must always be kept seconds consecutively. If the engine fails to start
ON while the engine is running. If the switch with the first attempt, be sure that the starter has
is turned OFF while the engine is running, the stopped completely before re-engaging.
battery charging regulator could be damaged. NOTE: Never race a cold engine. Operate at 1000
GENERATOR RPM for a 3-5 minute warm-up period.
Operating
Starting 1. Check oil pressure as soon as the engine has
1. While holding the Shutdown Bypass-Preheat started. Oil pressure should be above 15 PSI. The
switch in ON position, push the Engine Control engine must never be run if the oil pressure is
switch to START position. As soon as the engine below 15 PSI.
starts, release both switches. Do not crank the 2. Check the voltmeter. It should read 13 to 14 volts
starter for more than 20 seconds. If the engine (26-28 volts, 24 volt systems) at 60oF (16oC).
fails to start the first time be sure the starter has 3. Water temperature should not rise over 205oF
stopped before reengaging. (96oC). If it does, shut down the engine and inves-
2. Cold Weather: Hold Shutdown Bypass-Preheat tigate the cause of overheating.
switch in the ON position for 30 seconds before 4. Do not exceed 800 RPM when shifting marine
starting. This will warm the air heater elements gear. Repeated shifts at higher engine speeds can
and will ease starting. This is not necessary if damage the reverse gear.
engine is warm. A longer preheat time may be 5. Low Idle is 750 RPM. Maximum working engine
required in extremely cold weather. speed is: 2100 RPM for pleasure craft, 2100
Operating RPM for light commercial craft and 1800 RPM
1. Check Gauges Often: Oil pressure must be for continuous duty applications.

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 OPERATING PROCEDURES

6. If the proper propeller is used, the engine should CAUTION: Do not remove the water fill
reach its appropriate maximum speed at full cap of an overheated engine. Escaping high
throttle. If at full throttle the maximum speed is temperature steam can cause severe burns.
exceeded, then the propeller is too small. If c. Allow the engine to cool and then remove
maximum speed cannot be attained, then the the cap slowly using protective clothing.
propeller is too large or bottom growth may be d. Make repairs and restart after the
slowing the boat. (See Prop Chart, page 23.) temperature gauge registers below 180oF
7. To Establish Maximum Cruising RPM: (82oC).
Establish the RPM at full throttle and subtract
200-300 RPM. This will promote engine life and e. Watch the temperature gauge regularly and
reduce fuel consumption. turn off the unit if the temperature rises
above 205oF (96oC). Repeat the
SHUTDOWN PROCEDURES troubleshooting process.
1. Run for three to five minute cool down period. 3. If the warning or shutdown is activated and the
a. Propulsion engines in neutral at 1000 RPM, temperature gauge shows temperature within
then return throttle to low idle. normal temperature range:
b. Generators unloaded. a. Check the engine crankcase oil level.
2. Push STOP button until the engine has completely b. If the oil level is low, fill with recommended
stopped. Turn key switch to OFF position. lubricating oil and restart. Watch the oil
3. Close the sea cock, fuel valves and put the battery pressure gauge carefully and shut off the
switch in OFF position. engine if it does not show a normal reading
NOTE: Do not turn battery switch to OFF while after a few seconds of operation.
engine is running. c. If the oil level is normal, DO NOT restart the
engine. Call your Northern Lights or Lugger
SHUTDOWNS AND ALARMS dealer for assistance.
1. Your unit is fitted with a system to protect it from
high water temperature or low oil pressure. BREAK-IN PERIOD
a. Generator sets have shutdown systems to stop 1. The first 100 hours on a new or reconditioned
the engine. They have no warning horns. engine are critical to its life and performance.
b. Propulsion engines have warning horns 2. Constantly check the engine temperature and oil
to sound and warn you of a problem. pressure gauges.
Remember: when engine is not running the 3. Oil consumption is greater during break-in as
horn will sound when key is in the "ON" piston rings and cylinder liners take time to seat.
position because there is no oil pressure. 4. Break-In Oil Changes: Change engine oil and
Propulsion engines do not have shutdown filter at 50 hours. Change oil and filter again at
systems. 100 hours. (See Gear Owner's Manual for break-
c. Other alarms and shutdowns are available as in oil change procedures. Consult Lubricants
optional equipment. Section for oil recommendation.)
Operating Instructions
NOTE: Do not rely on your warning or shut- 1. Propulsion engines: Never run full speed for
down system to the exclusion of careful gauge more than 5 minutes during the first 50 hours.
monitoring. Watching your gauges can prevent Run engine at 50 to 75% of maximum working
damage to the unit and dangerous power losses. speed for the first 20 hours with as little idling
2. Do the following when your warning or shutdown time as possible. Extended idling can inhibit ring
system is activated. seating, causing cylinder walls to glaze.
a. Check the temperature gauge. If the 2. Generator Sets: Maintain at least a 75% load
temperature is above 205oF (96oC), shut off on your set for the first 100 hours. If this is
the engine immediately. not possible, maintain no less than a 50% load
b Use the Trouble Shooting Guide on page 26- to ensure proper seating of the piston rings. Vary
27 to isolate the cause of the overheat. the load to help seat rings.

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 SERVICING SCHEDULE CHART
The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your unit. More
detailed coverage of each Service Point (SP) is listed on the page noted in the 'page' column.
DAILY: EVERY 250 HOURS (Continued)
SP1 Check oil level in engine SP8 Change primary fuel filter element
SP7 Check primary fuel filter SP12 Check turbocharger air, oil and cooling lines for leakage
SP14 Check cooling water level SP18 Check zinc electrodes. HE engines only
SP21 Check oil level in reverse gear FIRST 500 HOURS
FIRST 50 HOURS: SP20 Change coolant filter
SP2 Change engine oil EVERY 500 HOURS (or yearly):
SP3 Change lube oil filter SP20 Change coolant filter
EVERY 50 HOURS (or weekly): EVERY 750 HOURS (or yearly):
SP5 Check V-belt tension
SP24 Check electrolyte in batteries SP4 Replace air filter
SP6 Check valve clearances
FIRST 100 HOURS: SP9 Change secondary fuel filter
SP2 Change oil SP10 Check injectors
SP3 Change lube oil filter SP13 Check turbocharger boost pressure
SP6 Check valve clearances SP15 Check and flush cooling system
FIRST 250 HOURS: SP19 Change impeller in sea water pump
SP20 Change coolant filter SP25 Check condition of batteries with hydrometer
EVERY 250 HOURS (or every 6 months): EVERY 2400 HOURS:
SP2 Change engine oil SP11 Check fuel injection pump
SP3 Change lube oil filter SP16 Check and clean heat exchanger
SP4 Check air filter SP17 Check and clean gear oil cooler

SERVICE 50 250 500 750 2400

POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours
ENGINE:
SP1 12 Check oil level •
SP2 12 Change engine oil 1) 4) •
SP3 12&13 Change lube oil filter 1) 4) •
SP4 13 Replace air filter 1) 3)   • 
SP5 13 Check V-Belt tension 1) 4) •
SP6 13 Check valve clearances 1) 5)  •
FUEL SYSTEM:
SP7 14 Check primary filter (Racor) 2) 3) •
SP8 14 Change primary filter element 2) 3)  •
SP9 14 Change secondary filter 1) 3)  •
SP10 14&15 Check injectors 1) 3)  •
SP11 15 Check fuel injection pump  •
TURBOCHARGER:
SP12 17 Check air lines, oil and cooling water lines for leakage 1) 3) •
SP13 17 Check boost pressure  •
COOLING SYSTEM
SP14 18&20 Check cooling water level •
SP15 20&21 Check and flush cooling system 1)  •
SP16 21 Check and clean heat exchanger 1) •
SP17 21 Check and clean gear oil cooler 1)  •
SP18 21 Check zinc electrodes-HE engines only 1) 3) •
SP19 21 Change impeller in seawater pump 1) 3)     •
SP20 21 Change coolant filter 1) 3)  •
DRIVEN EQUIPMENT:
SP21 21 Check oil level in reverse gear •
SP22 21 Change oil in reverse gear 2)
SP23 21 Clutch and PTO service 2)
ELECTRICAL SYSTEM:
SP24 22 Check electrolyte level in batteries 1) 3)  •
SP25 22 Check condition of batteries with hydrometer 1) 4)  •
OUT OF SERVICE:
SP26 22 Winterizing or out-of-service 3)
3) When necessary.
1) Perform all maintenance once a year even if hour level has not been reached.
4) Change at first 50 and first 100 hours.
2) Consult manufacturer's maintenance schedule, note on chart.
5) Adjust at first 100 hours.

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 SERVICE RECORD

Service
Point OPERATION HOURS/DATE
50 HOURS (or weekly)

SP5 Check V-belt tension

SP25 Check electrolyte in batteries

250 HOURS (or every 6 months)

SP2 Change engine oil

SP3 Change lubricating oil filter

SP4 Check air cleaner

SP8 Change primary fuel filter element

SP12 Check turbocharger air, oil & cooling lines for leakage

SP18 Check zinc electrodes - HE engines only

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 pressure

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

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 SERVICING

LUBRICATION - GENERAL b. Use a wrench to turn the selector valve to

1. Use only clean, high quality lubricants drain the engine or gear. Use marks on the
stored in clean containers in a protected area. valve stem as a guide. (See below).
2. These lubricants are acceptable: c. Turn pump handle in clockwise direction
a. API Service CC/CD single viscosity oils. and pump oil into a suitable container.
b. API Service CC/CD/SF multi-viscosity oils. When the engine is empty, switch the valve
and drain the gear oil.
3. Use the proper weight oil for your average
d. Close valve. Refill engine and gear with
operation temperature.
recommended oils.
Air Single Multi- NOTE: Make sure the valve is in the closed
Temperature Viscosity Viscosity position before starting engine. If it is left
Above 320F SAE-30W SAE 15-40W
-10 to 320F SAE-10W SAE 10-30W open it is possible for crankcase oil to be
(-23 to 00C) pumped into the reverse gear and out of
Below -100F SAE-5W SAE 5-20W the gear dipstick and breather. This can
(-230C)
ruin the engine.
4. Some increase in oil consumption may be
expected when SAE 5W and SAE 5-20W oils
are used. Check oil level frequently.
5. Never put additives or flushing oil in crank-
case.
6. Propulsion Engines: See Gear Owner's Manual
for gear lubrication recommendations.
SP1. CHECK OIL LEVEL
1. Check oil in the crankcase daily with the dip- Hand pump selector valve
stick. The oil level must be in the waffled area
between the “L” and “H.” Never allow the 7. Marine Generator Sets:
level to go below the “L.” a. Remove plug from outlet in base frame.
2. Always add the same viscosity of oil as is Screw in owner-supplied drain hose.
already in the crankcase. (See above recom- b. Open valve at oil pan outlet. After oil has
mendations.) been drained into suitable container, close
valve, remove drain hose and replace plug
SP2. OIL CHANGES in base frame outlet.
1. Using the oil recommended in the above dia- c. Refill engine with recommended oil.
gram, change the engine oil and filter after the
first 50 hours of operation, the first 100 hours 8. Engine capacity with new oil filter is 10 gallons
of operation, and every 250 hours thereafter. (38 liters).
2. During intermittent cold weather operation, SP3. CHANGING OIL FILTER
change oil every 100 hours or six weeks,
whichever comes first. 1. Change the lube oil filter after the first 50 hours
3. Change oil at any seasonal change in tempera- of operation, after the first 100 hours of
ture when a new viscosity of oil is required. operation and every 250 hours thereafter.
4. Change oil when engine is warm. 2. Use a filter wrench to remove old filter.
5. Dispose of waste oil in an approved manner. Dispose of filter in approved manner.
6. Propulsion Engines with Optional Drain Pump: 3. Make sure the gasket from the old filter is
a. Your engine is fitted with a hand pump that removed and discarded.
drains the engine crankcase and marine 4. Lubricate the rubber gasket on the new filter
gear. and screw it on nipple until gasket meets the
sealing surface.

O6140 03/03
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 SERVICING

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.
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. Figure 8.
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 Figure 9.
every 50 hours.
2. Use your thumb to press on the belt at the Hold top of crosshead lightly and tighten
midpoint between the crankshaft and alternator adjustment screw until it contacts valve stem, then
pulleys. The tension is correct if the belts can be tighten 20° more. Then loosen nut (see Fig. 10-
depressed about 3/8 in. (10mm). 1) on valve adjustment screw (Fig. 10-2), insert
3. Belts that operate in pairs should both be feeler gauge between crosshead (Fig. 10-3) and
replaced in pairs, even if only one of them needs rocker arm (Fig. 10-4) and adjust the
to be replaced. clearance with the adjustment screw until the
thickness gauge slides with a slight drag. After the
SP6. VALVE CLEARANCES
clearance is properly adjusted, tighten the lock nut
1. Check the valve clearances after the first 100 to secure the adjustment screw using 47 to 54 foot
hours, and every 750 hours thereafter. lbs. of torque (7 to 7.5 kgm).
2. Turn off battery switch. 7. Valves should be set cold with the following
3. Remove valve covers which are held by three clearances:
bolts. a. Intake Valves - .017 in (.43mm)
4. Use a breaker bar, with a 19mm or 3/4" socket,
b. Exhaust Valves - .031 in (.80mm)
on the pulley that powers the alternator to rotate
the crankshaft in a clockwise direction. Align the 8. Rotate the engine one full revolution. Adjust
mark on the vibration damper with the pointer valves marked “O” to above clearances.
according to data plate specifications. In this
position No. 1 cylinder is at top dead center of
the compression stroke, and No. 6 cylinder's
intake valves will start to move. (see figure 8.)
5. Adjust the valve clearance for valves marked
with an "X" in Fig. 9.
6. To adjust the valve clearance, first adjust the
crosshead. Loosen the crosshead lock nut (Fig.
10-5), then the adjustment screw (Fig. 10-6).

Figure 10.

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 SERVICING

FUELS - GENERAL BLEEDING THE FUEL SYSTEM

1. Use only clean, high quality fuels of the follow- CAUTION: Escaping diesel fuel under
ing specifications, as defined by ASTM pressure can penetrate the skin, causing
designation D975 for diesel fuels: serious personal injury. Before disconnecting
a. Use grade No. 2 diesel at ambient tempera- lines be sure to relieve all pressure. Before
tures above freezing 32oF (0oC). applying pressure to the system be sure all
b. Use grade No. 1 at ambient temperatures connections are tight and the lines, pipes and
below freezing and for all temperatures at an hoses are not damaged. Fuel escaping from
altitude of above 5,500 ft. (1500 meters). a very small hole can be almost invisible. Use
2. Use fuel having less than 1% sulphur (preferably a piece of cardboard or wood, rather than the
less than 0.5%). hands, to search for suspected leaks. If injured
3. The cetane number should be a minimum of 45. by escaping fuel, see a doctor at once.
4. DO NOT use these unsuitable grades of fuel:
Serious infection or reaction can develop if
a. Domestic heating oils, all types.
proper medical treatment is not administered
b. Class B engine. immediately.
c. Class D domestic fuels.
d. Class E, F, G or H industrial or marine fuels. 1. Whenever the fuel system has been opened for
e. ASTM-D975-60T No. 4-D and higher service, (lines disconnected, filter changed, etc.)
number fuels. it should be bled.
2. To bleed the fuel system, loosen the vent plug
5. Storing fuel:
in the top of the fuel filter housing. Unscrew the
a. Keep dirt, scale, water and other foreign
hand primer knurled knob on the injection pump
matter out of fuel.
and loosen until it can be pulled up by hand (see
b. Avoid storing fuel for long periods of time. Fig. 11,10). Operate the hand primer up and
c. Fill the fuel tank at the end of each day's down until most of the air bubbles are expelled
operation. This will reduce condensation. and clear fuel escapes the vent plug. Push hand
primer down and tighten. Tighten the vent plug.
SP7-9. FUEL FILTERS 3. If the engine will not start, it may be necessary
1. Your engine or generator set should have a to loosen the fuel pipes at the injectors. With the
primary fuel filter installed. We recommend the throttle on full, crank the engine over with the
Racor brand of fuel filter - water separators. starter until fuel without air flows from the loose
a. Check the primary fuel filter daily as fuel pipe connections. Tighten the connections.
recommended by the filter manufacturer.
SP10. INJECTORS
Empty the collection bowl as necessary.
1. Fuel injectors should be checked by a Lugger-
b. Change the element every 250 hours or when
Northern Lights dealer or qualified fuel injection
necessary.
shop after every 750 hours.
c. If the bowl fills with water, change the pri- 2. Injector Removal:
mary and secondary element immediately. a. Thoroughly clean the area around injection
2. Change secondary fuel filter every 750 hours. pump, fuel line connecting nuts and rocker
a. Remove the filter cartridge by turning it arm housing cover.
counterclockwise with a filter wrench. Fill b. Remove rocker arm housing cover.
the new cartridge with fuel and install it
c. Remove fuel line nuts on fuel inlet connec-
after applying engine oil to gasket surface.
tor and injection pump. Remove fuel line
Screw on until the gasket surface comes into
clamps. Pull fuel lines loose.
contact with sealing surface of filter base.
Then, tighten it two-thirds of a turn by hand. d. Remove fuel inlet connector. (Note: loosen
lock nut first, and then screw out connector.
Connector should be replaced.)

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 SERVICING

e. Remove injector hold down bolts. NOTE: All warranties on the engine become null
f. Using injector hold down and bolt, screw and void if the injection pump seals are broken
bolt into top of injector and lift out. by unauthorized persons.
4. Injection Pump Removal:
3. Clean Injector Bore:
a. Clean injection pump, hoses and area around
Injector seat in cylinder head can be cleaned
the pump with cleaning solvent or a steam
by wrapping a clean, lint-free rag around the
cleaner.
tapered end of a wooden rod and wiping the bore
and seat. Hardened carbon can be removed from NOTE: Never steam clean or pour cold water
the seat by using a tapered wire brush to break on an injection pump while the engine is
carbon free. Then clean the bore with rag and running or the pump is warm.
rod. b. Remove line clamps (see Fig. 11-1) and fuel
4. Have injectors tested and rebuilt if necessary. Or, injection lines (Fig. 11-2).
take them to a Lugger-Northern Lights dealer c. Remove feed lines (Fig. 11-3) and lubrica-
and use them as core exchange for rebuilt injec- tion tubes (Fig. 11-4 & 11-5) and return line
tors. (Fig. 11-6).
5. Injector Installation:
d. Remove coupling bolts (Fig. 13-2) between
a. Install new o-ring in groove on injector.
the coupler (13-3) and the flange (Fig. 13-4)
b. Install new copper seat on end of injector. on the pump drive.
c. Insert injector aligning fuel inlet hole with e. Remove the four mounting bolts (Fig. 11-
fuel inlet connecting hole in rocker housing. 7) which hold the injection pump on the
d. Install new fuel inlet connector. bracket.
e. Install injector hold down, ballwasher and 6. Injection Pump Installation:
bolt. Torque to 48 ft. lbs. (6.75 kgm). a. Position pump on bracket. Positioning
f. Torque inlet connector to 27 ft. lbs. (3.8 sleeves on two of the bolt holes help align
kgm) and lock nut to 29 ft. lbs. (4.0 kgm). the pump.
g. Install injector lines. Torque fuel line nuts to b. Tighten four mounting bolts (see Fig. 11-7)
17-18 ft. lbs. (2.3-2.5 kgm). to 49-54 foot lbs (6.75-7.50 kgm).
h. Bleed the fuel system, start the engine and c. Reinstall coupling (Fig. 13-2) bolts, but do
check the system for leaks using a piece of not tighten them until pump is timed as per
cardboard. next section.
d. Reinstall feed lines (Fig. 11-3) and lubrica-
SP11. INJECTION PUMP tion oil lines (Fig. 11-4 & 11-5) using new
1. The pump settings, maximum speed, idle speed gasket washers on both sides of banjo bolts.
and exhaust smoke should be checked after • Torque nuts for line (Fig. 11-5):
every 2400 hours of operation. Service of the 18-31 foot lbs. (2.5-3 kgm)
fuel injection pump should only be done if • Torque nuts for line (Fig. 11-4):
checks indicate pump malfunction.
11-14 foot lbs. (1.5-2 kgm)
2. Low power and no smoke can indicate a fuel
injection pump malfunction. Check for full e. Reinstall fuel injection lines (Fig. 11-2) and
throttle, proper solenoid adjustment and air filter line clamps (Fig. 11-1). Fuel delivery line
cleanliness before replacing pump. Black smoke sleeve nuts (Fig. 11-8) torque to 16-18 foot
occasionally may indicate an injection pump lbs. (2.4-2.5 kgm).
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.

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 SERVICING

TIMING INJECTION PUMP

1. The Match Mark Alignment Method:
This is used when the injection pump is installed
on the original engine and the pump has NOT
been repaired.
a. Turn the crankshaft by hand in clockwise
direction to bring the number one cylinder
to top dead center of the compression stroke.
The compression stroke can be determined
by removing the number one cylinder valve
cover and turning the engine until all valves
are closed.
b Rotate crankshaft in counter-clockwise Figure 12. Pointer and Crankshaft Damper
direction 30-40o (1/8 turn) to remove gear
lash. d. Confirm that the stamped line "a" on the
c. Align the injection timing stamp line (27o injection pump is aligned with the stamped
±1o BTDC, 24o on 600HP Luggers) on No. line "b" on the coupling (see Fig. 13-1).
1 cylinder on the crankshaft damper with e. If the stamped lines are out of alignment,
the pointer by slowly rotating the crankshaft loosen nuts (Fig.13-2) and align the stamped
in the clockwise direction (see Fig. 12). On lines by shifting the coupling (see Fig. 13-3)
IMO certified engines, refer to the data plate and re-tightening the nuts to 43-46 foot lbs.
on the block for proper timing data. torque (5.8-6.2 kgm).

Figure 11. Injection Pump Servicing Points

1. Injection line clamps 4. Lubrication line (inlet) 7. Pump mounting bolts 10. Hand priming pump
2. Fuel injection line 5. Lubrication line (outlet) 8. No. 1 delivery line 11. Air vent point.
3. Fuel feed line 6. Fuel return line 9. Throttle

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 SERVICING

j. Tighten two nuts (see Fig. 13-2). Now re-

check the injection timing to see it is properly
adjusted by repeating steps e through g.
k. If line "b" on coupling does not align with the
line "a" on the pump, re-stamp coupling with
new line.
l. Reassemble the delivery valve and reinstall
fuel lines (see Fig. 11-2) and clamps (Fig. 11-1).
m. Bleed fuel system.

SP12. TURBOCHARGER
Figure 13. Pointer and Crankshaft Damper 1. Check for air leaks every 250 hours. Air leakage
will lower engine output and may cause black
2. Delivery Valve Method: exhaust smoke and soot.
Use delivery valve method when a repaired or 2. Listen along air line while engine is running. A
replaced injection pump is installed. whistling or hissing sound indicates leakage.
a. Disconnect fuel injection line from the No. 3. Leakage on the pressure side, between turbo and
1 cylinder delivery valve on the injection engine, can be found by applying soapy water to
pump (see Fig. 11-8). the air line.
b. Remove delivery valve holder. Remove 4. Tighten the hose clamps, replace hose or gaskets
spring and delivery valve and put valve as required.
holder back in injection pump. 5. Check to see that the lubrication and cooling lines
are tight and without leaks.
c. Place the throttle (Fig. 11-9) in the full fuel
(forward) position. SP13. TURBO BOOST
d. Slowly rotate the crankshaft in a clockwise 1. This check measures the amount of air the turbo
direction while operating the priming pump is pushing into the engine. It should be done by an
(Fig. 11-10). This is best done by two people. authorized dealer every 750 hours.
e. Stop rotating and pumping when fuel stops 2. Your engine can have a boost gauge permanently
flowing out of the delivery valve holder (Fig. installed so you can monitor the turbo's output
11-8). from the control panel. (See page 6).
f. If the injection timing stamp line on the
crankshaft damper is aligned with the
pointer, according to data plate specifica-
tions, it is correct. (see Fig. 12).
g. To adjust timing, rotate the crankshaft 30o-
40o (1/8 turn) in counter-clockwise direc-
tion from No. 1 cylinder top dead center to
remove gear lash.
h. Align the injection timing line on the damper
with the pointer by slowly rotating the
crankshaft in the clockwise direction.
i. Loosen two nuts (see Fig. 13-2) on the cou-
pling. Rotate the coupling (Fig.13-3) on the
pump side little by little while operating the
priming pump (see Fig. 11-10) until no fuel
flows out of the delivery valve holder (Fig.
11-8).

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 SERVICING

COOLING REQUIREMENTS LINER EROSION (PITTING)

1. To meet cooling system protection requirements, 1. Cylinder liner walls (A) which are in contact
the coolant solution must consist of: with engine coolant (B) can be eroded or pitted
a. Quality water unless the proper concentration and type of
b. Ethylene glycol concentrate (EGC ) com- SCA's are present in the coolant. Water pump
monly known as antifreeze. impellers are also susceptible to pitting.
2. Vapor bubbles (C) are formed when the piston's
c. Supplemental coolant additives (SCA's).
impact causes the liner walls to vibrate, sending
2. A coolant solution of ethylene glycol concentrate pressure waves into the coolant.
(EGC-antifreeze), quality water and supplemen- 3. These tiny vapor bubbles collect on the surface
tal coolant additives (SCA's) MUST be used of metal parts. As the bubbles collapse (pop) a
YEAR ROUND to protect against freezing, microscopic piece of metal is eroded from the
boil-over, liner erosion or pitting and to provide metal part. Over a period of time, this pitting
a stable, noncorrosive environment for cooling may progress completely through the cylinder
system components. liner of a wet-sleeve, heavy-duty diesel engine.
3. Ethylene glycol coolant concentrate (anti- This allows coolant to enter the combustion
freeze) normally DOES NOT contain the SCA chamber. Engine failure or other serious damage
chemical inhibitors needed to control liner will result.
pitting or erosion, rust, scale, and acidity. 4. Unprotected engines with low quality water as
4. Your engine is equipped with a spin-on coolant coolant can have liner failure in as few as 500
filter conditioner element which provides the hours.
SCA's to protect your cylinder liners. 5. The SCA's released by the filter will significantly
5. The coolant filter conditioner element performs reduce erosion and pitting. The chemicals in the
two functions at once: additives reduce the quantity of vapor bubbles. It
• The outer paper element filters out rust, scale also forms a protective film on the metal engine
or dirt particles in the coolant. parts which act as a barrier against collapsing
• The inner element releases chemicals into vapor bubbles.
the coolant to maintain a proper acid/alkaline
balance, inhibit corrosion and suppress erosion WATER QUALITY
pitting which is discussed below. 1. Distilled, deionized, soft water is preferred for
use in cooling systems. Bottled distilled water
from a food store or water supplier is recom-
mended. Tap water often has a high mineral
content. Tap water should NEVER be put in
a cooling system unless first tested by a water
quality laboratory. Do not use water made by
the reverse osmosis method unless it has been
PH neutralized.
2. Here are acceptable water quality specifications
Contaminates Parts Per Grains Per
Million Gallon
Maximum Chlorides 40 2.5
Maximum Sulfates 100 5.9
A - Cylinder Liner Walls Max. Dissolved Solids 340 20
B - Engine Coolant Max. Total Hardness 170 10
PH Level 5.5 to 9.0
C - Vapor Bubbles

3. If chlorides, sulfates or total dissolved solids are

higher than the above given specification, the
water must be distilled, demineralized, or de-
ionized before it is used in a cooling system.

O6140 03/03
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 SERVICING

4. If total hardness is higher than 170 ppm and all seals on cylinder liners which are in contact with
other parameters are within the given specifica- coolant.
tions, the water must be softened before it is
used to make coolant solution. DO NOT use an EGC containing sealer or
stop-leak additives.
ETHYLENE GLYCOL CONCENTRATE -
EGC (ANTIFREEZE) DO NOT use EGC containing more than 0.1%
1. Ethylene glycol coolant concentrate is com- anhydrous metasilicate. This type of concen-
monly mixed with water to produce an engine trate, which is intended for use in aluminum
coolant with a low freeze point and high boiling engines, may cause a gel-like deposit to form
point. that reduces heat transfer and coolant flow.
2. A low silicate form of ethylene glycol coolant is Check container label or consult with supplier.
recommended for all diesel engines.
3. Use an ethylene glycol coolant concentrate meet-
SUPPLEMENTAL COOLANT ADDITIVE
ing ASTM D 4985P, SAEJ1941, General Motors (SCA)
Performance Specification GM1899M, or CAUTION: Supplemental coolant
formulated to GM6038M. additive contains alkali. Avoid contact with
4. This product is concentrated and should be eyes. Avoid contact with skin. Do not take
mixed to the following specification. internally. In case of contact, immediately
Distilled EGC % Freezing Boiling wash skin with soap and water. For eyes, flush
Water % Antifreeze Point Point with large amounts of water for at least 15
Optimum 50% 50% -370C +1090C
minutes. Call a physician. KEEP OUT OF
-340F +2260F REACH OF CHILDREN. Follow all
Minimum 60% 40% -240C +1060C warnings on the container.
-120F +2220F 1. Your engine is equipped with a spin-on coolant
Maximum 40% 60% -520C +1110C filter conditioner element which provides the
-620F +2320F
SCA's to protect your cylinder liners. The inner
element releases chemicals into the coolant to
5. If additional coolant solution needs to be added maintain a proper acid/alkaline balance, inhibit
to the engine due to leaks or loss, the glycol corrosion and suppress erosion pitting.
concentration should be checked with a 2. Important: All engines.
hydrometer to assure that the desired freeze point ALWAYS change the coolant conditioner-filter
is maintained. element according to the service chart in this
manual.
CAUTION: EGC (Antifreeze) is flammable. 3. Important: Radiator and heat exchanger cooled
Keep it away from any open flame. Avoid engines.
contact with eyes. Avoid contact with skin. Do Additional SCA's should NOT be added to the
not take internally. In case of contact, mixture of EGC/H20 on initial fill up of engines
immediately wash skin with soap and water. with a coolant conditioner-filter. A high SCA
For eyes, flush with large amounts of water for concentration will result and can cause silicate-
at least 15 minutes. Call a physician. KEEP dropout. When this happens, a gel-type deposit
OUT OF REACH OF CHILDREN. Follow is created in the cooling system which retards
all warnings on the container. heat transfer and coolant flow.
4. Important: Engines with Keel Cooling.
6. IMPORTANT The SCA in the spin-on filter may not be able
DO NOT use methyl alcohol or methoxy pro- to treat the large volume of coolant in a vessel's
panol base EGC. These concentrates are not keel cooling system. The operator must use a
compatible with chemicals used in supplemental test kit strip to determine the amount of addi-
coolant additives. Damage can occur to rubber tional SCA's that need to be added to the cooling
system.

O6140 03/03
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 SERVICING

SCA'S CONTINUED 2. The pressure valve in the filler cap releases when
If additional SCA's are needed, prepare a mix- the pressure is approximately 7 PSI (0.5 bar).
ture of 50% quality water and 50%EGC (anti- Use a cap pressure tester to check cap if you
freeze). Add liquid SCA at a rate of 3%, by suspect it is faulty.
volume. 4. The makeup coolant, added to compensate for
Example: 30 mL of SCA per liter of H2O/EGC loss or leaks, must meet engine coolant
mixture. (1.0 fl oz of SCA per qt of H2O/EGC). requirements outlined in previous section.
Add the resulting mixture to the cooling system
in quart increments. Run the engine for 2 hours SP15. FLUSHING THE COOLING SYSTEM
and retest the coolant. Continue process until CAUTION: The cooling water in the engine
SCA concentration meets recommended levels. reaches extremely high temperatures. You
5. SCA is available from your Northern Lights/ must use extreme caution when working on
Lugger dealer in the following sizes. hot engines to avoid burns. Allow the engine
Pint - Part Number...............20-00002 to cool before working on the cooling system.
1/2 gallon - Part Number.....20-00003
Open the filler cap carefully, using protective
6. DO NOT use any coolant system additives con-
clothing when the engine is warm.
taining soluble oil.
COOLANT TESTING IMPORTANT
1. Coolant test kits are available to allow on-site Be sure to close the sea cock before working on the
evaluation of the coolant condition. engine cooling system.
2. The kits use small strips of paper which are 1. Flush the cooling system and check for leaks and
dipped into the coolant. The paper changes color blockage every 750 hours, or yearly.
and indicates the SCA concentration. It also 2. The engine must be stopped and cold. Remove
indicates the amount of EGC (antifreeze). the filler cap with caution. Open cooling system
3. Test kits are available through your Northern air vents on top of the turocharger, at the
Lights or Lugger Dealer. front and rear of the aftercooler and for heat
4 Pack - Part Number.......................20-00005 exchanged units on top of heat exchanger. (see
Fig. 1)
3. Drain the jacket (fresh) water circuit of the
SP14. CHECKING COOLANT LEVEL. cooling system.
CAUTION: The cooling water in the engine HE = heat exchanger cooled units
reaches extremely high temperatures. You KC = keel cooled units
must use extreme caution when working on a. Exhaust manifold: Drain is under manifold
near rear of engine for both HE & KC.
hot engines to avoid burns. Allow the engine
to cool before working on the cooling system. b. Engine block: Drains are on the water pump
Open the filler cap carefully, using protective outlet and turbo coolant line (see Fig. 1).
clothing when the engine is warm. c. Gear oil cooler: Bottom of right gear oil
1. Check the coolant level each day before starting cooler elbow (propulsion engines only).
the engine. Check the coolant level by remov- d. Remote expansion tank: Remove hose from
ing the pressure cap from the expansion tank. bottom of tank.
In order to give the coolant an opportunity to 4. To drain the raw water circuit of HE engine,
expand, the level should be about 1 3/4 in. (4-5 open the drain in the starboard end cap of the
cm) below the filler cap sealing surface when heat exchanger (see Fig. 1).
the engine is cold. When filling with coolant, the 5. With drains open, pour clean water into the filler
venting cock on top of the turbocharger should cap. When the water from each drain is clear
be opened to ensure that no air pockets form in and free from discoloration and sediment, close
the cooling system. that drain. When all drains are closed, flushing
is complete.

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 SERVICING

FLUSHING THE COOLING SYSTEM (cont.) SP19. RAW WATER PUMP

6. Re-drain the engine and refill the jacket (fresh) 1. Heat exchanger cooled engines only. Change
water circuit with coolant mixture as described the the sea water pump impeller every year, or as
in previous section. needed.
7. Close cooling system air vent. 2. Remove the pump end cover. Pry out the
8. Open sea cock. impeller with the help of two screwdrivers. Be
9. Start engine. Monitor temperature gauge care- sure you remove all pieces of a failed impeller.
fully and check cooling system for leaks. NOTE: Place some kind of protection under the
SP16. HEAT EXCHANGER CLEANING screwdrivers in order not to damage the
housing.
1. Clean the heat exchanger core once a year or 3. Clean the inside of the housing.
after 2400 hours of operation. 4. Press in the new impeller and place the sealing
2. Drain expansion tank and heat exchanger. washers in the outer end of the impeller center if
3. Remove heat exchanger covers. this has not already been done.
4. Clean the inside of exchanger core tubes using a 5. Replace the cover using a new gasket.
metal rod. NOTE: Make sure that there is always an extra
5. Re-assemble using new gaskets. Fill the cooling impeller and cover gasket in reserve on board.
system, start the engine and check for leaks.
SP20. COOLANT FILTER
SP17. CLEANING GEAR OIL COOLERS
1. Change coolant filter after the first 250 hours, the
For propulsion engines only: first 500 hours and every 500 hours thereafter.
1. Drain fresh water cooling circuit. 2. Shut off both valves on filter body.
2. Remove end covers of gear oil cooler. 3. Use filter wrench to remove filter.
3. Wash the core in diesel fuel and blow it dry with 4. Make sure old gasket is removed.
compressed air. Clean the end covers of the core 5. Lubricate new filter gasket and screw on new
with a steel brush and use a metal rod to clean filter until gasket meets housing.
inside of tubes. 6. Hand tighten two-thirds of a turn more.
4. Re-assemble using new gaskets. Fill the cooling 7. Open valves on filter body.
system, start the engine and check for leaks. 8. Start the engine and check for leaks.
SP18. ZINC ELECTRODES 9. Stop engine and check water level in expansion
tank.
1. Zincs are installed in the heat exchanger cooling
system to protect your engine from electrolysis. SP21,22,23. GEARS, PTOS AND
Check them faithfully every 250 hours. If you GENERATORS
are in warm salt water or where electrolysis is a
1. Manufacturer's service recommendations vary.
known problem, check them more often. Keel
See your Owner's Manual for service informa-
cooled engines do not have zincs.
tion. If you do not have a manual, see your local
2. Heat exchanger cooled engines: Drain the raw
dealer for the equipment in question.
water from heat exchanger (Fig's. 1&4,13), then
NOTE: Some PTO and marine gears have rigid
drain the expansion tank (Fig's 1&4,1). Remove
lubrication requirements. Follow service
zinc holders (Fig's 1&4,18) from back end of heat
recommendations closely.
exchanger and raw water pipe elbow.
2. If you have a Northern Lights generator set, the
3. Scrape or steel brush the zinc electrode clean.
maintenance and operation recommendations
If more than 50% of the electrode is corroded
for the generator end are in a separate Owner's
away, replace it with a new one. The electrode
Manual. If you do not have one of these
screws out of the holder.
manuals, contact your local Northern Lights
4. Re-install the zinc holders. Be sure the threads
dealer.
are clean for good metal-to-metal contact.
5. Refill cooling system, start engine, check for
leaks.

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 SERVICING

ELECTRICAL SYSTEM - GENERAL SP24,25. BATTERY CARE

1. Never switch battery switch off or break the 1. Check electrolyte level every 50 hours or
circuit between the alternator and batteries while weekly. Add distilled water to manufacturer's
the engine is running. Regulator damage can recommended level.
result. 2. Batteries, cables and cable terminals should be
2. Do NOT reverse the polarity of battery cables checked and cleaned every 100 hours. Clean
when installing the battery. corrosion with a water and baking soda solution.
3. When welding on the unit, disconnect the regula- Flush with clean water. Tighten terminals and
tor and battery. Isolate the leads. grease them to inhibit corrosion.
4. Disconnect battery cables when servicing the DC 3. Check the battery condition with a hydrometer
alternator. every 750 hours or yearly.
5. Never test with a screwdriver, etc., against any
terminal to see if it emits sparks. SP26. WINTERIZING, OUT-OF-SERVICE
6. Do not polarize the alternator or regulator. MARINE
7. A DC circuit breaker protects your control panel 1. Drain seawater cooling systems completely.
and wiring harness (see Fig. 1,5 for location). Remember to shut off sea cocks before opening
drain cocks.
BOOSTER BATTERIES 2. Drain seawater supply lines and wet exhaust
CAUTION: Battery Gas Can Explode. Keep all line.
flames and sparks away from batteries. 3. Loosen the seawater pump cover and drain
pump.
1. Before changing or using booster batteries, 4. Check freshwater antifreeze mixture. If refilling,
check battery electrolyte level. Add distilled run the engine up to operating temperature to
water if necessary. circulate the antifreeze.
2. Booster and main batteries must have the same 5. Fill fuel tank and add biocide as per manufactur-
voltage rating. er's instructions.
3. First, connect positive (+) terminal of booster 6. Seal air cleaner inlet, exhaust opening, crankcase
battery to positive (+) terminal of main battery. breather pipe and fuel tank vent with plastic bags
Then, connect negative (-) terminal of booster and tape.
battery to ground on the engine block (see Fig. 7. Change the crankcase oil and filter.
14). 8. Loosen drive belts.
9. Disconnect and clean battery. Remove to warm
storage place if possible.
10. Clean outside of unit. Paint any scratched or
chipped surfaces. Put corrosion preventative on
all exposed metal surfaces.

Figure 14. Booster Battery Connections.

4. Remove booster battery after starting engine.

5. Sealed batteries: see manufacturer charging and
booster instruction.

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 THREE BLADED PROPELLER SIZING CHART

Use this chart to find aproximate propeller sizes for boats 1)Find the boat speed your boat builder expects from
with single engine using a three blade propeller and gears an engine of this horsepower in the left column.
with a 3% loss factor. 2)Locate the gear ratio desired on the top line.
NOTE: Prop size is influenced by many factors (hull 3)Find where two columns intersect for an approxi-
design, load, boat use). It is impossible to make an mate propeller size. See the column bottom for
absolute recommendation. For more accurate shaft RPM and shaft diameter.
recommendations, contact your dealer. Example: 700 HP rating; 20 knot boat with 2:1 gear
needs a 35 x 32 three blade propeller.

High Output Rating: 700 flywheel HP, 675 SHP at 2100 RPM
Speed Gear Ratios and Propellers
Knots 1:1 1.5:1 1.75:1 2:1 2.5:1 3:1 3.5:1
11 - 13 – – – 35x24 40x26 44x28 48x32
13 - 15 – – 32x20 35x26 40x28 44x32 48x38
15 - 17 – 28x20 32x22 35x28 40x32 44x36 48x44
17 - 19 23x15 28x22 32x24 35x30 40x34 44x40 48x48
19 - 21 23x16 28x24 32x26 35x32 40x38 44x44 48x52
21 - 23 23x17 28x25 32x28 35x34 40x42 44x48 –
23 - 25 23x19 28x28 32x30 35x38 – – –
25 - 27 23x20 28x30 32x32 35x40 – – –
27 - 29 23x22 28x32 32x35 35x42 – – –
29 - 31 23x24 28x34 32x38 35x44 – – –
Sft. rpm 2100 1400 1200 1050 840 700 600
Sft. dia. in 1.75 2 2 2.5 3 3.5 4

Medium Duty Rating: 600 flywheel HP, 579 SHP at 2100 RPM
Speed Gear Ratios and Propellers
Knots 1.5:1 1.75:1 2:1 2.5:1 3:1 3.5:1 4:1
9 - 11 – – 34x22 39x24 43x26 48x30 52x34
11 - 13 – – 34x24 39x26 43x28 48x32 52x36
13 - 15 – 32x20 34x26 39x28 43x32 48x38 52x42
15 - 17 28x20 32x22 34x28 39x30 43x36 48x44 52x48
17 - 19 28x22 32x24 34x30 39x34 43x40 48x48 –
19 - 21 28x24 32x26 34x32 39x38 43x44 48x52 –
21 - 23 – 32x28 34x34 39x42 43x43 – –
Sft. rpm 1400 1200 1050 840 700 600 525
Sft. dia. in 2 2 2.5 3 3.5 4 4.5

Continuous Duty Rating: 500 flywheel HP, 482 SHP at 1800 RPM
Speed Gear Ratio and Propellers
Knots 2.5:1 3:1 3.5:1 4:1 4.5:1 5:1 6:1
5-7 – – 50x18 54x20 58x22 61x25 68x30
7-9 40x20 46x22 50x27 54x28 58x30 61x34 68x40
9 - 11 40x24 46x28 50x31 54x34 58x38 61x42 68x50
11 - 13 40x28 46x32 50x35 54x40 58x45 – –
13 - 15 40x30 46x36 50x39 54x46 58x53 – –
Sft. rpm 720 600 514 450 400 360 300
Sft. dia. in 3.5 4 4.5 4.5 5 6 6

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25
 LUGGER DATA

Displacement ....................................930 in3 (15.24 liters) DC Electrical

Bore x Stroke .........5.51 in (140 mm) x 6.49 in (165mm) Voltage ........................... 24 volt standard, 12 volt optional
High Output......................................... 700HP/2100RPM Minimum battery capacity ......... 2 x 225 amp hrs/1150 cca
Medium Duty....................................... 600HP/2100RPM Battery cable size ................................. "00" up to 10 ft run
Continuous Duty ................................. 500HP/1800RPM Standard instrument harness length ...................20 ft (6 m)
Approximate dry weight: Air Intake and Exhaust
Keel cooled, less gear ......................3362 lbs (1526 kg) Engine air consumption at rated speed
Heat exchanger cooling, less gear ....3505 lbs (1591 kg) High Output.......................... 1500 f3/min (42.5 m3/min)
Cooling (General) Medium Duty ...................... 1250 f3/min (35.4 m3/min)
Freshwater circulating flow at rated speed Continuous Duty .................. 1045 f3/min (29.6 m3/min)
High Output .............................. 158 US gpm (600 lpm) Minimum engine room intake vent area
Medium Duty ............................ 119 US gpm (450 lpm) High Output ........................................ 400 in2 (0.26 m2)
Continuous Duty ....................... 106 US gpm (400 lpm) Medium Duty ...................................... 335 in2 (0.22 m2)
Heat rejection to jacket water Continuous Duty ................................280 in2 (0.18 m2)
High Output.........................................16,066 BTU/min Exhaust gas flow at rated speed
Medium Duty ......................................13,776 BTU/min High Output......................... 3380 f3/min (95.7 m3 /min)
Continuous Duty ................................. 11,180 BTU/min Medium Duty ....................... 2900 f3/min (82.1 m3/min)
Cooling (Heat Exchanger) Continuous Duty .................. 2740 f3/min (77.6 m3/min)
Raw-water intake diameter ............................ 3 in (75 mm) Maximum exhaust gas temperature at rated speed
Raw-water discharge diameter ....................... 3 in (75 mm) High Output............................................ 875°F (472°C)
Raw-water pump flow at rated speed Medium Duty ......................................... 800°F (430°C)
High output.................................. 82 US gpm (310 lpm) Continuous Duty .................................... 750°F (402°C)
Medium Duty .............................. 82 US gpm (310 lpm) Maximum exhaust back pressure ....... 30 in (760 mm) H2O
Continuous Duty ......................... 69 US gpm (265 lpm) Suggested dry exhaust I.D.
Raw-water pump maximum suction head......... 39 in (1 m) 500 & 600 hp: 6 inch. 700 hp: 8 in.
Maximum raw-water temperature at inlet... 100° F (37° C) Suggested wet exhaust I.D.
Freshwater system capacity-engine only 10 US gal (38 ltr) 500 & 600 hp: 8 inch. 700 hp: 10 in.
Cooling (Keel Cooled)* Fuel and Oil
Water hose inside diameter ....................... 2.87 in (73 mm) Minimum fuel line:
Keel cooler head diameter .................................2.5 in NPT Suction (return) ...................1/2 "-12 mm (3/8"-10 mm)
Turbo tube length, High Output ................... 110 ft (34 m) Maximum fuel pump head ................................ 39 in (1 m)
Medium Duty ..............................................84 ft (26 m) Crankcase oil capacity ............................ 40 US qts (38 ltr)
Continuous Duty .........................................70 ft (22 m) Gear, PTO, Engine Angle
Skin cooler-aluminum, High Output........120 ft2 (11.2 m2) Engine rotation (facing flywheel)
Medium Duty ..........................................90 ft2 (8.4 m2) Counter-clockwise
Continuous Duty ......................................80 ft2 (7.4 m2) Flywheel housing size
Skin cooler-steel, High Output.................360 ft2 (33.5 m2) SAE #1 14" (SAE 0, 18" optional)
Medium Duty .......................................300 ft2 (27.9 m2) Front PTO size (optional)
Continuous Duty ..................................250 ft2 (23.2 m2) SAE #4 10", SAE #3 11.5"
Max. operating angle:
Any direction 35° for less than 2 minutes
Max. installed operating angle
10° rear down, 0° front down
*Note:
Based on 70° F (21°C) seawater temperature and minimum boat speed of 8 knots at full rpm. Return water 120-165°F (50-75°C).

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 NORTHERN LIGHTS MARINE SPECIFICATIONS

Model Number M6140AL

AC Output1
1800 RPM, 60 Hz 330 kW
1500 RPM, 50 Hz 280 kW
Phase (Optional Phase) 3
RPM/ Hz Available in 1800 RPM/60 Hz and 1500 RPM/ 50 Hz
Voltages 60 Hz 120/208, 120/240, 127/220, 139/240, 220/380, 240/416, 254/440 and 277/480
Voltages 50 Hz 110/190, 110/220, 115/230, 120/208, 127/220, 220/380, 240/416

Engine
Aspiration Turbo/AC
Cylinders Inline 6
Displacement cu. in. (l) 930 (15.24)
Bore in (mm) 5.51 (140)
Stroke in (mm) 6.49 (165)

Specific Fuel Rate(3)lb/bhp/hr 0.331

Fuel Rate-Full Load(4)gal/hr(lph 23.1 (87.4)
Fuel Rate-1/2 Load(4)gal/hr(lph) 12.0 (45.4)

Model Number M6140QA

1
AC Output
1200 RPM, 60 Hz 200 kW
50 Hz ––
Phase (Optional Phase) 3
Voltages 60 Hz 120/208, 120/240, 127/220, 139/240, 220/380, 240/416, 254/440 and 277/480

Engine
Aspiration Turbo/AC
Cylinders Inline 6
Displacement cu. in. (l) 930(15.24)
Bore in (mm) 5.51 (140)
Stroke in (mm) 6.49 (165)

Specific Fuel Rate(3)lb/bhp/hr 0.350

Fuel Rate-Full Load(4)gal/hr(lph) 14.8 (56)
Fuel Rate-1/2 Load(4)gal/hr(lph) 7.7 (29.14)

1. Prime kW rating. 1 kW equals 1000 watts. 0.8 power factor.

2. Net flywheel hp rating for fully equipped engine at RPM under SAE J816b.
3. Based on prime HP rating at rated (1800 or 1200) RPM.
4. Based on prime kW rating at rated (1800 or 1200) RPM. Fuel rate may vary depending on operating conditions.

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 TROUBLESHOOTING
If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer.
ELECTRICAL Improper type of fuel:
• Consult fuel supplier and use proper type of fuel for
Battery will not charge operating condition.
Loose or corroded connections: Water, dirt or air in fuel system:
• Clean and tighten battery connections. • Drain, flush, fill and bleed system.
Sulfated or worn out batteries: Clogged primary fuel filter element:
• Check specific gravity of each battery. • Clean or replace filter element.
• Check electrolyte level of each battery. Clogged secondary fuel filter element:
Loose or defective alternator belt: • Replace filter element.
• Adjust belt tension. Dirty or faulty injection nozzles:
• Replace belt. • Have your dealer check injection nozzles.
• Defective alternator
Fuel pump primer lever left on upward end of
 Starter inoperative stroke.
Check DC circuit breaker.
Engine runs irregularly or stalls frequently
Loose or corroded connections:
Below normal engine temperature:
• Clean and tighten loose battery and harness plug connec-
• Remove and check thermostat.
tion.
Clogged primary fuel filter element:
Low battery output:
• Clean or replace filter element.
• Check specific gravity of each battery.
• Check electrolyte level of each battery. Clogged secondary fuel filter element:
• Replace secondary filter element.
Defective electrical system ground wire:
• Repair or replace. Water or dirt in the fuel system.
Starter cranks slowly Dirty or faulty injection nozzles:
• Have your dealer check injection nozzles.
Low battery output:
• Batteries too small. Air in fuel system:
• Battery cables too small. • Inspect clamps and hoses on suction side of fuel pump
for air leak.
Check specific gravity of each battery.
Improper type of fuel:
Check electrolyte level of each battery.
• Consult fuel supplier and use proper type of fuel for
Crankcase oil too heavy. operating condition.
Loose or corroded connections: Lack of engine power
• Clean and tighten loose connections. Engine overloaded:
Entire electrical system does not function • Reduce load.
Check DC circuit breaker. Intake air restriction:
Faulty connection: • Service air cleaner.
• Clean and tighten battery and harness plug connections. Clogged primary fuel filter element:
Sulfated or worn out batteries: • Clean or replace filter element.
• Check specific gravity and electrolyte level of each bat- Clogged secondary fuel filter element:
tery.
• Replace filter element.
ENGINE Improper type of fuel:
• Consult fuel supplier and use proper type of fuel for
Engine hard to start or will not start operating conditions.
Improper starting procedure. Overheated engine:
No fuel. • See "Engine Overheats" in next category.
Low battery output: Below normal engine temperature:
• Check electrolyte level and specific gravity of battery. • Remove and check thermostat.
Excessive resistance in starting circuit: Improper valve clearance:
• Clean and tighten all connections on batteries. • See your local dealer.
Crankcase oil too heavy: Dirty or faulty injection nozzles:
• Use oil of proper viscosity. • See your local dealer.

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 TROUBLESHOOTING (CONT.)
If you cannot correct problems with these procedures see your Lugger or Northern Lights dealer.
Lack of engine power (cont.) Improper valve clearance:
Injection pump out of time: • See your dealer.
• See your local dealer. Injection nozzles dirty:
Improper propeller: • See your dealer.
• Consult your dealer and prop chart. Injection pump out of time:
Grass, etc. on bottom of boat: • See your dealer.
• Clean hull. Engine not at proper temperature
Turbocharger malfunction: • Check your thermostats.
• Stop the engine. • Check water temp. with thermometer to see if tempera-
• Remove the air cleaner. ture gauge is working properly.
• Make sure the compressor wheel is stationary and then Below normal engine temperature
rotate it with your hand to see whether it is stiff to rotate. Thermostats not working properly:
• First rotate the wheel under light pressure, then by lightly • Check thermostats.
pulling axially. If the wheel is stiff to rotate, blades are Temperature gauge not working properly:
damaged or blades hit housing, the turbocharger should • Check water temperature with thermometer.
be replaced as soon as possible.
Low oil pressure
 Engine overheats Low oil level.
Engine overloaded:
Improper type of oil:
• Reduce load (generator sets).
• Drain and fill crankcase with correct oil.
• Check propeller size (propulsion).
Partially plugged oil filter:
Low coolant level:
• Replace filter.
• Fill tank to proper level.
• Check hoses for loose connections and leaks.
High oil consumption
Break-in period.
Keel cooling tubes have been painted.
Crankcase oil too light:
Cooling system needs flushing.
• Use proper viscosity oil.
Defective thermostat:
Oil leaks:
• Remove and check thermostat.
• Check for leaks in lines around gaskets and drain plug.
Defective temperature gauge/sender:
Engine overheats:
• Check water temperature with thermometer and replace
gauge or sender if necessary. • See "Engine Overheats".
Water pump impeller worn/broken (HE Engine). Engine emits black or gray exhaust smoke
Engine knocks Clogged or dirty air cleaner:
Insufficient oil: • Service air cleaner.
• Check dipstick Defective muffler (back pressure too high).
• Call your dealer. Improper fuel.
Injection pump out of time: Engine overloaded:
• Call your dealer. • Reduce load.
Below normal engine temperature: • Check propeller size.
• Check your thermostats. Injection nozzles dirty:
• Check water temperature to see if temperature gauge is • See your dealer.
working properly. Engine out of time:
Engine overheating: • See your dealer.
• See "Engine Overheating" section. Engine emits white smoke
High fuel consumption Improper fuel.
Improper type of fuel. Cold engine:
Clogged or dirty air cleaner: • Warm up engine to normal operating temperature.
• Service air cleaner. Defective thermostat:
Engine overloaded: • Remove and check thermostat.
• Reduce load. Engine out of time:
• Check proper propeller size. • See your dealer.
• Grass, etc. on bottom of boat.

O6140 03/03
29
30
O6140 03/03
DC Wiring Diagram C-5298B
L6140AL 12 Volt Standard Ground
31
O6140 03/03
DC Wiring Diagram C-5228A
L6140AL 24 Volt Standard Ground
32
O6140 03/03
DC Wiring Diagram C-5299
M6140AL 24 Volt Standard Ground
33
O6140 03/03
AC Wiring Diagram B-7429H
M6140 with Voltage Regulator
AVC63-12, all voltages
 ONBOARD SPARE PARTS

Safety at sea depends on careful preparation, product knowledge, and

having the right tools and parts. Below is a list of parts Alaska Diesel
Electric, Inc. recommends you carry onboard at all times.
Onboard Parts Kits are available from your dealer. "Standard" Kits are
suitable for inland and offshore cruising. "World Class" Kits are for
world cruising and trans-ocean cruising.
We consider these minimum quantities. Your vessel's operating condi-
tions may require more of a given part. Consult your dealer.
Standard World
Item Description Quantity Class

1 Lube Oil Filter 4 4

2 Air Filter Element 1 1
3 Fuel Filter 2 2
 
4 Water Filter 2 2
5 Injector 0 6
6 O-Ring 0 6
7 O-Ring 0 12
8 Gasket 0 6
9 Impeller and Gasket  2 2
10 Thermostat 2 2
11 Thermostat Ring 2 2
12 Relay 0 2
13 Valve Cover Gasket 6 6
14 Alternator Drive Belt 1 2
15 Zinc  6 12
16 Drive Belt - Raw Water Pump  0 2
17 Fuel Washer Kit 1 1
18 Raw Water Pump  0 1
19 Workshop Manual 0 1
20 Gasket Kit Top 0 1
21 Gasket Kit Bottom 0 1
 Note: Heat exchanger cooled engines only.
 Note: Double this quantity if engine is keel cooled.

O6140 03/03
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 4420 14th Ave. NW., Seattle WA 98107
Tel: (206) 789-3880 • 1-800-762-0165 • Fax: (206) 782-5455
Northern Lights and Lugger are registered trademarks of Northern Lights, Inc.
www.northern-lights.com © 2003 All rights reserved. Litho USA.