OL944D

For Model: L944D

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Northern Lights

4420 14th Avenue N.W.

Seattle, WA 98107

Tel: (206) 789-3880

Fax: (206) 782-5455

Copyright ©2013 Northern Lights, Inc.

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

Northern Lights, Inc.

Printed in U.S.A.

PART NO.: OL944D 11/13

OPERATOR'S MANUAL for Northern Lights

®

L944D Diesel

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 ....................................................4

Model Numbers ..................................................

4

Serial Numbers ...................................................

4

WARRANTY ............................................................5

SAFETY RULES .....................................................5

COMPONENT LOCATIONS

..........................................................

6 - 7

INSTRUMENT PANEL ...........................................8

OPERATING PROCEDURES

Break-in Period ...................................................

9

Before Starting ....................................................

9

Starting .............................................................

10

Operating .........................................................

10

Stopping ...........................................................

10

Alarms .......................................................

10 - 11

Spare Parts ........................................................

11

SERVICING SCHEDULE CHART ............ 12 - 13

SERVICING

Lubrication - General .......................................

14

Checking Oil ....................................................

14

Oil Changes .....................................................

14

Changing Oil Filter ..........................................

15

Air Filter ..........................................................

15

SERVICING (Continued)

V-Belts .............................................................

15

Valve Clearances ..............................................

16

Fuels - General .................................................

17

Fuel Filters .......................................................

17

Bleeding the Fuel System ................................

18

Injector Service ................................................

19

Injection Pump .................................................

20

Cooling System ...............................................

21

Heat Exchanger ................................................

22

Raw Water Pump .............................................

22

Zinc Electrodes ................................................

22

Electrical System - General .............................

23

Booster Batteries ..............................................

23

Battery Care .....................................................

24

Winterizing / Out-of-Service ...........................

24

TROUBLESHOOTING

Electrical ..........................................................

25

Engine ......................................................

26 - 28

SPECIFICATIONS ............................................... 29

WIRING DIAGRAMS

DC Electrical ...........................................

30 - 31

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 OL944D 11/13

OL944D 11/13

3

Revised page 3-2-10

Introduction

The servicing of marine engines and generator sets presents unique problems. In many cases, boats cannot be moved to a repair facility. Marine engines cannot be compared to the servicing of automobiles, trucks, or even farm equipment. Failures often occur in remote areas far from competent assistance. Marine engines are taxed far more severely than auto or truck engines; therefore, maintenance schedules must be adhered to more strictly. Failures begin with minor problems that are overlooked and become amplified when not corrected during routine maintenance.

As operator, it is your obligation to learn about your equipment and its proper maintenance. This is not a comprehensive technical service manual. Nor will it make the reader into an expert mechanic. Its aim is to aid you in maintaining your unit properly.

Unit Identification

MODEL INCLUDED

This manual covers the operating instructions for:

L944D propulsion engine, which use the 944 engine block.

Model Numbers

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

L 944

L - Lugger Propulsion Engine

+

Model number of engine block

Bore Cylinders

94 mm 4

L944D

=

Northern Lights marine diesel generator set with a 944 engine, naturally aspirated.

Serial Numbers

When referencing Northern Lights, Inc. equipment by serial number, please refer only to the number stamped on the Northern Lights

®

or Lugger

®

serial number plate.

OL944D 11/13

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A warranty registration certificate is supplied with your engine. It entitles the original purchaser of our equipment to a warranty covering material or assembly faults. The extent of coverage is described in the Limited

Warranty Statement. We recommend that you study the statement carefully.

Warranty

NOTE: If the warranty is to apply, the servicing instructions outlined in this manual must be followed.

If further information is needed, please contact an authorized dealer or the factory.

Safety Rules

CAUTION: Accident reports show that careless use of engines causes a high percentage of accidents. You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.

• Never leave engine without proper security.

• Turn the coolant tank cap slowly to relieve pressure before removing. Add coolant only when the engine is stopped and cool.

• Mount a fire extinguisher near engine.

• Always disconnect the battery ground strap before making adjustments.

• Operate engines in properly ventilated areas.

• Keep trash and other objects away from engine.

• Escaping fluids under pressure can penetrate your skin. Use a piece of cardboard or wood, not your hands, to search for leaks.

• Avoid wearing loose clothing without a belt when working around engines.

• Do not oil or grease engine while it is running.

• Remove the negative (-) battery terminal cable before servicing electrical components or welding.

• Use caution in handling fuel. Never refuel a hot or running engine. Do not smoke while filling fuel tank or servicing fuel system.

• Keep your hands, feet, hair and clothing away from power-driven parts.

• Check for any loose electrical connections or faulty wiring.

• Engines should be operated only by knowledgeable, qualified personnel.

• Look completely around engine to make sure that everything is clear before starting.

• Do not operate an engine that isn't in proper working order. If an unsafe operating condition is noted, tag the set and control panel so others will also know about the problem.

• Provide first aid kits.

CAUTION: This symbol is used throughout this book to alert you to possible danger areas.

Please take special notice of these sections.

OL944D 11/13

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13

15

14

L944D Component Locations

1 2 3 4 5 6

12

11 10 9 8

7

Figure 2: L944D Service Side

1. Expansion Tank

2. Coolant Fill

3. Rocker Arm Cover

4. Fuel Filter

5. Relay Board Cover

6. Air Filter

7. Transmission Gear

8. Oil Pan

9. Lube Oil Dipstick

10. Oil Filter

11. Fuel Primer Pump

12. Injection Pump

13. Lube Oil Fill

OL944D 11/13

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14. Heat Exchanger Raw Water

Drain and Zinc

15. Thermostat Housing

15 16 13 1 2

L944D Component Locations

17

14

18

19

7 22

Figure 3: L944D Non-Service Side

15. Wet Exhaust Elbow

16. Exhaust Manifold

17. Heat Exchanger

18. Raw Water Pump

21 20 8

19. PTO Housing

20. Belt Guard

25. Oil Pan

21. Alternator

22. Starter

OL944D 11/13

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Instrument Panel

1 2

12

11

10

3

4

9 8 7

Figure 4: Lugger Main Instrument Control Panel

1. TACHOMETER

The tachometer shows the engine speed in revolutions per minute. (RPM). Numbers are multiples of 100.

2. HOUR METER

Keeps track of the engine running time.

3. D.C. VOLTMETER

When the engine is stopped, the voltmeter shows the condition of the battery. When the engine is running, it indicates the voltage output of the alternator.

4. KEY SWITCH

Turning the key clockwise to the first position will switch on the current. Continue turning the key clockwise to preheat the engine, then again to start the engine. When the engine starts, immediately turn the key back to the first position while the engine is running.

The key must be kept in the “on” or first position

while the engine is running. Turn the key counter clockwise as far as possible to stop the engine.

Note: Optional flybridge panels have engine start switches instead of key switches.

5. COVER

(Stop button not used for this application.)

6 5

6. INSTRUMENT PANEL LIGHTING

The switch turns on the instrument panel lights.

7. OIL PRESSURE FAULT LIGHT

Indicates low oil pressure. Activates in conjunction with alarm horn.

8. ENGINE TEMPERATURE FAULT LIGHT

Indicates engine is over-heating. Activates in conjunction with alarm horn.

9. ALARM HORN

Shut down engine if possible and investigate

immediately.

10. WIRE HARNESS

11. COOLANT TEMPERATURE GAUGE

Water temperature gauge shows the temperature of the engine coolant. If the gauge registers over 200 0 F or drops below 140 0 F, stop the engine and investigate.

12. OIL PRESSURE GAUGE

Shows the oil pressure in the engine lubricating system.

If the pressure drops below 15 PSI at a speed higher than idling, stop the engine immediately.

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BREAK-IN PERIOD

1. The first 100 hours on a new or reconditioned

engine are critical to its life and performance.

2. Constantly check the engine temperature and oil pressure gauges.

3. Oil consumption is greater during break-in as

piston rings take time to seat.

4. Break-In Oil Changes: Change engine oil and

filter at 50 hours. Change oil and filter again at

100 hours (consult Lubricants section for oil

recommendation).

Operating Instructions:

Maintain at least a 75% load on your engine for the first 100 hours. If this is not possible, maintain no less than a 50% load to ensure proper seating of the piston rings. Vary the load to help seat the rings.

Operating Procedures

BEFORE STARTING

1. Check the water level by removing the pressure

cap from the expansion tank. In order to give the cooling water an opportunity to expand, the level should be about 1 in. (2.5 cm) below the filler cap sealing surface when the engine is cold.

CAUTION: Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns.

2. Check the oil level in the crankcase with the dipstick. The oil level must be between high and low marks on the stick. Never allow the level to go below this area. Always add the same viscosity of

oil as is already in the crankcase.

3. Check the fuel tank level and open any fuel valves on the tank and at the secondary fuel filter.

4. Close the sea-cock, check and clean the sea strainer, and reopen the sea-cock.

5. Place the battery switch in the ON position.

NOTE: The battery switch must always be kept ON

while the engine is running. If the switch is

turned OFF while the engine is running,

the battery charging alternator could be

damaged.

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Operating Procedures

STARTING

1. Put the gear control in the neutral position.

2. Move the throttle control to the full speed postion and return back to idle.

3. Turn the key switch to the first position. Check the voltage meter to see the condition of the batteries.

For starting, the voltmeter should not read below 12 volts. (24 volts for 24 volt systems.)

4. Turn the key to the next position; preheat for 5 to 10 seconds. Then turn the key to the starting position and as soon as the engine starts, release the key.

Move the throttle up until the engine is running at approximately 1000 RPM.

5. Do not crank the starter for more than 15 seconds consecutively. If the engine fails to start with the first attempt, be sure that the starter has stopped completely before re-engaging.

Note: Never race a cold engine. Operate at 1000

RPM for a 3 to 5 minute warm-up period.

OPERATING

1. Check the oil pressure as soon as the engine has started. Oil pressure must be above 15 PSI. The engine must never be run if the oil pressure is below

15 PSI.

2. The D.C. voltmeter should read between

13 and 14 volts at 60° F (16° C) ambient temperature.

(26 to 28 volts for 24 volt systems.)

3. The water temperature gauge should not rise above

200° F (94° C). If it does, shut down the engine and investigate the cause of overheating.

4. Do not exceed 800 RPM when shifting marine gear.

Repeated shifts at higher engine speeds can damage the reverse gear.

5. If the proper propeller is used, the engine should reach its appropriate maximum RPM’s at full throttle

(2500 RPM). If the maximum rated RPM’s for your engine application are exceeded at full throttle, then your propeller is too small. If you cannot reach your maximum rated RPM’s at full throttle, etiher your propeller is too large or bottom growth is slowing the boat.

6. To establish Maximum Cruising RPM: Establish th RPM at full throttle and subtract 200-300 RPM.

This will promote engine life and reduce fuel

consumption.

SHUTDOWN

1. Run the engine for a three to five minute cool-down period in neutral at 1000 RPM.

2. Return engine to low idle.

3. Turn the key switch counter clockwise as far as

possible to stop the engine.

4. Close the sea cock and fuel valves and put the

battery switch in OFF position.

Note: Do not turn the battery switch to OFF while the engine is running.

ALARMS

1. Your unit is fitted with a warning system to indicate high water temperature and low oil pressure.

Propulsion engines have warning horns to sound and warn you of a problem.

Note: When the engine is not running the horn will sound when the key is in the “on” position because there is no oil pressure.

Do not rely on the alarms to the exclusion of

careful gauge monitoring. Checking the gauges could prevent damage to the unit and dangerous power losses.

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Operating Procedures

ALARMS (continued)

2. If the alarm system is activated:

a. Check the temperature gauge, if the temperature

is above 205 0 F (97 0 C) shut the engine off

immediately.

b. Use the Trouble Shooting Guide on page 25 to

isolate the cause of the overheat.

CAUTION: Do not remove the water fill cap of an overheated engine. Escaping high temperature steam can cause severe burns.

Allow the engine to cool and then remove the cap slowly using protective clothing.

c. Make repairs and restart after the temperature

gauge registers below 200° F (94° C).

d. Watch the temperature gauge regularly and

turn off the unit if the temperature rises above

205° F (96° C). Repeat troubleshooting.

3. If alarm is activated and the temperature gauge shows temperature within normal temperature range:

a. Check the engine crankcase oil level.

b. If the oil level is low, fill with recommended

lubricating oil and restart. Watch the oil pressure

gauge carefully and shut off the engine if it does

not show a normal reading (20-60 PSI) after a

few seconds of operation.

c. If the oil level is normal, DO NOT restart the

engine. Call your Northern Lights or Lugger

dealer for assistance.

SPARE PARTS

1. ADE recommends that you keep the following spare parts on hand for field service. The parts are

available from your local Northern Lights dealer.

Some marine models may already have “On-Board

Kits,” a handy box that contains the most common parts you will need.

a. Primary and secondary fuel filter elements

b. Oil filters

c. Air filter elements

d. Alternator belt

e. Thermostat and gaskets

f. Seawater pump impeller and gaskets

g. Glow plugs

h. Injector and washer

i. Rocker Arm Cover gasket

j. Zinc Anode

k. Relay, SPDT 12 VDC 50 Amp

l. Engine overhaul gasket set

2. If your engine is operating a long distance from a

servicing dealer, add the following:

a. Complete set of injectors

b. Complete set of glow plugs

c. Fuel lift pump

OL944D 11/13

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Servicing Schedule Chart

The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your generator set.

More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’ column.

DAILY:

SP1 Check oil level in engine

SP8 Check primary fuel filter

SP14 Check cooling water level

Check sea strainer

EVERY 250 HOURS:

SP2/3 Change engine oil and filter

SP4 Check air cleaner

SP18 Check zinc electrodes

AFTER FIRST 50 HOURS:

SP2/3 Change engine oil and filter

SP5 Check V-belt tension

SP7 Adjust valves

SP19 Check electrolyte level in batteries

EVERY 50 HOURS:

SP5 Check V-belt tension

SP19 Check electrolyte level in batteries

EVERY 500 HOURS:

SP6 Check valve clearances

SP9 Change primary fuel filter element

SP10 Change secondary fuel filter

SP12 Check injectors

SP15 Check cooling system

SP17 Change impeller

SP20 Check state of charge of batteries

AFTER FIRST 100 HOURS:

SP2/3 Change engine oil and filter

EVERY 2000 HOURS or as needed:

SP13 Check fuel injection pump

SP16 Check and clean heat exchanger

SP24 Inspect starter and alternator

SERVICE

POINT

ENGINE:

SP1 12

SP2 12

SP3 13

SP4 13

SP5 13

SP7 14

Check oil level

Change engine oil 1, 5, 6

Change lube oil filters 1, 5

Check air cleaner 1, 4

Check V-belt tension 1

Check valve clearances 5

50 100 250 500 2000

DAILY Hours Hours Hours Hours Hours

FUEL SYSTEM:

SP8 15

SP9 15

SP10 15

SP11 16

SP12 17

Check primary filter 2

Change primary filter element 1, 3

Change secondary fuel filter 1, 3

Bleed the fuel system 3

Check injectors 1

SP13 18

SP14

SP15

SP16

20

20

21

Check fuel injection pump

COOLING SYSTEM:

Check cooling water level

Check and flush cooling system 7

Check and clean heat exchanger

SP17 21 Change impeller in raw water pump 1, 3

SP18 21 Check zinc electrodes 4

ELECTRICAL SYSTEM:

SP19 23 Check electrolyte level in batteries 1, 4

SP20 23 Check condition of batteries with hydrometer 1

SP24 24 Inspect alternator and starter

OUT OF SERVICE:

SP23 23 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) Whenever necessary.

4) More often if necessary.

5) After first 50 hours.

6) Adjust at first 100 hours.

7) Or every 1 year

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Service

Point

OPERATION

SP5 Check V-belt tension

SP19 Check electrolyte in batteries

SP2 Change engine oil

SP3 Change lubricating oil filters

SP4 Check air cleaner

SP18 Check zinc electrodes

50 HOURS

250 HOURS

SP7 Check valve clearances

SP8 Change primary filter element

SP10 Change secondary fuel filter

SP12 Check injectors

EVERY 500 HOURS

SP15 Check cooling system

SP17 Change impeller in seawater pump

SP20 Check condition of batteries with hydrometer

2000 HOURS or as required

SP13 Check fuel injection pump

SP15 Flush cooling system

SP16 Check and clean heat exchanger

Service Notes:

Service Record

HOURS/ DATE

OL944D 11/13

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Servicing

LUBRICATION - GENERAL

1. Use only clean, high quality lubricants stored in clean containers in a protected area.

2. These lubricants are acceptable: a. API Service CD, CE, and CF-4 single viscosity

oils.

b. API Service CD, CE, and CF-4 multi-viscosity oils.

3. Use the proper weight oil for your average operation temperature.

Air Single

Temperature Viscosity

Multi-

Viscosity

Above 32° F SAE 30W SAE 15-40W

(0° C)

-10° to 32° F SAE 10W SAE 10-30W

(-23° to 0° C)

Figure 5: Lube Oils

4. Never put additives or flushing oil in crankcase.

SP1. CHECKING OIL LEVEL

1. While the engine is stopped, check the oil level in the crankcase with the dipstick daily.

The oil level must be between the high and low marks on the stick. Fill with the recommended oil, and fill only to the high mark on the dipstick.

Follow the lubrication recommendations in

Figure 5.

SP2. OIL CHANGES

1. The set is delivered with special break-in oil. Change the engine oil and oil filter after

50 hours of operation. Use Service CC30 weight oil during the first 100 hours.

2. Change the oil and filter again at 100 hours using the oil recommended in the above diagram. After this, change oil and filter every 250 hours.

3. During intermittent cold weather operation, change oil every 100 hours or six weeks, whichever comes first.

4. Change oil at any seasonal change in temperature when a new viscosity of oil is required.

5. Change oil when engine is warm but not

hot.

6. Dispose of waste oil in an approved manner.

7. Never use a flushing oil.

8. Loosen clamp on oil change tube. Remove cap. Drain oil. Replace cap and tube.

9. Refill engine with recommended oil.

10. Engine capacity with new oil filter is:

Model L944D....................2.64 gallons

(10 liters)

OL944D 11/13

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SP3. CHANGING LUBE OIL FILTER

1. Change the lube oil filter every 250 hours.

2. Use a filter wrench to remove old filter. Dispose of

filter in approved manner.

3. Make sure the gasket from the old filter is

removed and discarded. Clean mount face.

4. Spread a thin film of engine oil on the rubber

gasket on the new filter and screw it on nipple

until gasket meets the sealing surface.

5. Using hands only – no wrench – tighten filter

one-half turn farther. Overtightening can do

damage to filter housing.

6. Fill engine with recommended oil. Start engine

and check for leakage. Stop engine, wait 3 minutes,

and check oil level. Add additional oil if necessary.

7. Oil filter part number is:

Model L944D.....................................#24-01201

SP4. AIR CLEANER

1. Visually inspect air cleaner every 250 hours. In

dusty conditions, check more often.

2. Remove the cover on the rear of the air intake

manifold. Remove and inspect the foam element.

If dirty, wash element in soapy water. Rinse and

dry thoroughly before reinstalling.

Note: Make absolutely sure no impurities enter the engine while changing the element, and do not run the engine with the air cleaner removed.

Do not clean the filter with diesel fuel, solvent, or gasoline. Serious engine damage can result.

Servicing

SP5. V-BELTS

1. Check the tension and wear on the V-belt after

every 50 hours.

2. Use your thumb to press on the belt at the

midpoint between the crankshaft and alternator

pulleys. The tension is correct if the belt can be

depressed about .39 to .47 in. (10 - 12 mm) with

22 lbs. (10 kg) force.

OL944D 11/13

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Servicing

SP7. VALVE CLEARANCES

1. Readjust valve clearance after first 50 hours of operation. Check valves every 500 hours thereafter.

2. Check the valves when the engine is cold.

3. Rotate the crankshaft in a clockwise direction, using a turning socket, from the front of the engine to bring the first piston to the top dead center on the

compression stroke. When the mark on the crankshaft pulley aligns with the pointer on the timing gear case stop turning. Make sure the rocker arms of the No. 1 cylinder are loose at TDC. If they are not, rotate the crankshaft one complete turn.

Figure 7: Valve Adjustment

6. Adjust the remaining valves turning the engine 180 0 in the cylinder order of 1-3-4-2.

7. Replace the rocker arm cover.

Figure 6: Timing Mark

4. Measure the valve clearance for No. 1 cylinder, with a feeler gauge.

Standard valve clearances for a cold engine are:

Intake (IN)........................0.0098 in. (0.25 mm)

Exhaust (EX)....................0.0098 in. (0.25 mm)

5. To adjust valve clearance, loosen the lock nut on the adjustment screw. Insert a feeler gauge between the rocker arm and the valve stem cap. Adjust, while measuring the clearance, until the feeler gauge slides with a slight drag. Tighten the lock nut and recheck the clearance ( Figure 7 ).

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Servicing

FUELS - GENERAL

1. Use only clean, high quality fuels of the following specifications, as defined by ASTM designation

D975 for diesel fuels:

a. Use grade No. 2 diesel at ambient temperatures

above freezing 32° F (0° C).

b. Use grade No. 1 at ambient temperatures below

freezing.

c. International fuel specifications:

JIS K2204

ISO-8217-DMA

BS 2869 Part 1 Class A1

BS 2869 Part 2 Class A2

2. Use fuel having less that .2% sulphur of weight (less than 0.05% recommended).

3. The cetane number should be 45 or higher.

4. Particulate contaminate should be 5.0 mg/l (0.00018 oz/U.S. gal) or lower.

5. DO NOT use these unsuitable grades of fuel:

a. Domestic heating oils, all types.

b. Class B engine.

c. Class D domestic fuels.

d. Class E, F, G or H industrial or marine fuels.

e. ASTM-D975-60T No. 4-D and higher number

fuels.

6. Storing fuel:

a. Keep dirt, scale, water, and other foreign matter

out of fuel.

b. Avoid storing fuel for long periods of time.

c. Fill the fuel tank at the end of each day’s

operation. This will reduce condensation.

SP8-10. FUEL FILTER

1. Your Lugger engine has a fuel filter installed. We recommend the Northern Lights brand of fuel filters.

a. Check the primary fuel filter daily as

recommended by the filter manufacturer.

b. Change the filter as often as necessary or

every 250 hours.

c. Remove the fuel filter with a filter wrench.

d. Apply a coating of fuel to the o-ring of the new

fuel filter.

e. Tighten the new filter by hand, do not use a filter

wrench for tightening.

f. The filter should be dry.

g. Do not add fuel to the fuel filter before

installation, as this could cause unfiltered fuel to

enter the fuel pump.

h. Bleed the air out of the filter.

The fuel filter part number is:

L944D.........................24-51201

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Servicing

SP11. BLEEDING THE FUEL SYSTEM

CAUTION: Escaping diesel fuel under pressure can penetrate skin causing serious personal injury.

Before disconnecting lines be sure to relieve all pressure. Before applying pressure, be sure all connections are tight and lines, pipes and hoses aren't damaged. Fuel escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks. If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not

administered immediately.

1. Fuel system air bleeding may be needed when:

a. After fuel has been added to a newly installed

engine.

b. A new fuel filter is installed.

c. The engine has run out of fuel.

d. The fuel lines, injection pump, or any other fuel

system component has been removed and

installed.

2. After changing the fuel filter, air only needs to be bled from the fuel filter. To do this:

a. Loosen the air vent plug (#1 on Figure 8) on the fuel

filter by about 1-1/2 turns. (Be sure to cover the

vent with a cloth to prevent fuel from splashing.)

b. Turn the priming pump cap on the fuel feed pump

counterclockwise to unlatch it. Move the priming

pump plunger (#2 on Figure 8) up and down. To

close the pump turn the cap clockwise while

depressing it.

c. Close the air vent plug when no more air bubbles

can be seen in the fuel flowing from the air vent

plug hole.

Figure 8 Fuel Feed Pump

3. To bleed air at the fuel injection pump:

a. Turn the air vent plug (#3 on Figure 8) about 1-1/2 turns to loosen it. (Cover the vent with a cloth to prevent fuel from splashing.)

b. Pump the feed pump cap up and down.

c. When there are no air bubbles to be seen in the fuel flowing from the air vent plug hole, push down the priming pump cap and turn it clockwise to lock it in place.

NOTE:

Do not close the air vent plug before locking the priming pump cap in place, because the internal pressure in the pump will prevent the priming pump cap from returning to the original

position.

4. If the engine does not start after this bleeding

process, loosen a fuel line at the injector while cranking the engine with the starter motor until pure fuel escapes. Then tighten the connections.

Do each line one-at-a-time. After the engine has started, use a piece of cardboard to look for fuel leaks.

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Servicing

SP12. INJECTOR SERVICE

1. Injectors should be checked every 500 hours. This check should be made by a Northern Lights dealer

or local injection repair station.

CAUTION: Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury. If injured by escaping fuel, see a doctor at once.

2. Injector removal:

a. Clean loose dirt from around the injectors and

the fuel lines.

b. Relieve high pressure in the fuel lines by

loosening the delivery line flare nuts at each

injector.

c.

from the injectors and injection pump.

Remove all lines as an assembly; do not remove

the spacers. Cover the ends of the lines, the injector

inlets, and the injection pump outlets to keep dirt out.

d. Remove the return line retaining bolts, washers,

and return line.

e. Loosen the injector retaining nuts at the same

time a little at a time. Remove the injector.

f. Remove the injector seat. Cover the holes to

prevent debris from entering the cylinders.

Note: Do not use pry bars to remove injectors from the cylinder head.

3. Injector repair and cleaning:

a. Take injectors to your Northern Lights dealer

or local injection repair station for testing and

service.

4. Injector installation:

a. Install new injector seal washer seat and

injector. Evenly tighten the injector retaining

nuts to 39.1 to 47.7 ft/lbs (53.0 to 64.7 N•m), or

5.4 to 6.6 kgf•m. Do not overtighten.

b. Reinstall the return line using new sealing

washers. Tighten bolts to 13.0 to 15.9 ft/lbs

(17.7 to 21.6 N•m), or 1.8 to 2.2 kgf•m.

NOTE: Overtightening can damage injectors.

c. Reinstall injection lines. Tighten

flare nuts at injection pump to 19.5 to 23.9

ft/lbs (26.5 to 32.4 N•m), or 2.7 to 3.3 kgf•m.

Leave the lines loose at injectors for bleeding.

d. Bleed the injection lines. Crank the

engine to fill the lines. Tighten flare nuts at

injectors to 15.2 to 18.1 ft/lbs (20.6 to 24.5 N•m),

2.1 to 2.5 kgf•m.

e. Start the engine and check for leaks using a

piece of paper or cardboard. Do not use your

hand to check for leaks.

OL944D 11/13

19

Servicing

SP13. INJECTION PUMP

1. Since operating conditions may vary considerably, it is difficult to give a definite interval for checking the injection pump. But as a rule, pump settings,

maximum speed, idle speed and exhaust smoke should be checked after every 2000 hours of

operation. Service of the fuel injection pump should only be done if checks indicate pump malfunction.

2. Black smoke can be an indication of pump

malfunction. Before servicing the pump, check other possible causes:

a. Check cleanliness of the air filter.

b. Check valve clearances.

c. Clean and check injectors.

3. Any repair which involves disassembly of the

injection pump must be carried out by specially trained mechanics with the proper tools and test equipment.

NOTE: All warranties on the engine become null

and void if the injection pump seals are

broken by unauthorized persons.

4. Injection Pump Removal:

CAUTION: Escaping diesel fuel under pressure can have sufficient force to penetrate the skin, causing serious personal injury. If injured by escaping diesel fuel, see a doctor at once.

a. Clean the injection pump, hoses, and area

around the pump with a cleaning solvent or steam

cleaner.

NOTE: Never steam clean or pour cold water

on an injection pump while the engine is

running or the pump is warm.

b. Remove the injection lines from the

pump and injectors. Remove all lines as an

assembly. Do not remove the spacers. Cover the

ends of the lines, the injector inlets, and the

injection pump outlets to keep dirt out of the

injectors, lines, and pump.

c. Align timing marks on timing gear by engaging

c. (cont.)

the turning socket (part #5830973100) with the

crankshaft pulley nut and turn it clockwise (when

viewed at the front of the engine). Stop where

the “O” mark on the outside of the crankshaft

pulley is aligned with the pointer on the timing

gear case. To check Top Dead Center of the No.

1 cylinder, move the rocker arms of the inlet and

exhaust valves up and down, checking that the push

rods do not push up the rocker arms of the valves.

This is Top Dead Center of the No. 1 piston. If

the pushrods do push up the rocker arms, rotate

the crankshaft one more turn.

d. Remove the pump support bracket on rear of

pump.

e. Remove the 4 mounting nuts.

f. Take the pump to your Northern Lights dealer or

an injection pump repair station for testing and

service.

Figure 9: Timing Marks

5. Injection Pump Installation:

a. Install the fuel injection pump after having

aligned its gear alignment mark with that of

the idler gear alignment mark as shown in

Figure 9 above. When the alignment marks

of the timing gears align as in the diagram

above, the No. 1 piston is top dead center in

the compression stroke.

Install the injection pump to the side of the

engine first then put in the end bolts, and

then the tube with its bolts, and then the side

bracket.

c. Torque mounting bolts to 13.0 - 18.1 ft/lbs

(17.7 to 24.5 N•m), 1.8 to 2.5 kgf•m.

OL944D 11/13

20

COOLING SYSTEM - GENERAL

NOTE: Be sure to close the sea-cock before working

on the engine cooling system.

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

WATER QUALITY

1. Distilled, deionized, soft water is preferred for use in cooling systems. Bottled distilled water from a food store or water supplier is recommended. Tap water often has a high mineral content. Tap water should

NEVER be put in a cooling system unless 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

Maximum Chlorides

Maximum Sulfates

Maximum Dissolved Solids

Maximum Total Hardness

Parts Grains per Million per Gallon

40

100

340

170

2.5

5.9

20.0

10.0

PH Level 5.5 to 9.0

3. If chlorides, sulfates or total dissolved solids are higher than the above given specification, the water must be distilled, demineralized, or

deionized before it is used in a cooling system.

4. If total hardness is higher than 170 ppm and all other parameters are within the given

specifications, the water must be softened before it is used to make coolant solution.

SP14. CHECK THE COOLANT LEVEL

1. Check the coolant level each day before starting the engine.

Check the water level by removing the pressure

cap from the expansion tank. In order to give the revised 11-8-13

Servicing

cooling water an opportunity to expand, the level

should be about 1 in. (2.5 cm) below the filler cap

sealing surface when the engine is cold.

b. Soft water with about a pH about 6.5 to 8.5

combined with an antifreeze in a 30% to 50%

(maximum) solution should be used. 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.

c. The antifreeze should not contain amine, silicate,

or borate.

d. Test kits are available through your Northern

Lights or Lugger dealer to check the coolant

condition. Part numbers are 20-00005 for a 4

pack and 20-00010 for a 50 pack.

SP15. COOLING SYSTEM FLUSHING

1. Flush the cooling system every 2000 hours or every

12 months, whichever comes first.

2. Remove fill cap and open drains on engine block.

The engine block drain is on the service side of the engine above the dipstick, next to the flywheel

housing.

3. Pour clean water into the engine until water coming from engine is clear of discoloration. Close drains and refill the engine with recommended coolant mixture.

4. Use 50% water / 50% (maximum) ethylene glycol antifreeze mix. Antifreeze mixture is recommended as a good year-round coolant.

5. Coolant capacity is approximately 3 gal. (11.4 liters).

6. Check hoses and connections and repair any

leakage.

7. Start the engine and check for leaks. Run the engine for five minutes, then shut it down. Let engine cool, and then check the coolant level in the engine. Add

coolant as needed.

NOTE: Be sure to open the sea-cock after working

on the engine cooling system and starting the

engine.

OL944D 11/13

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Servicing

SP16. HEAT EXCHANGER

1. Clean the heat exchanger core once a year or after

2000 hours of operation.

2. Drain the expansion tank and heat exchanger.

3. Remove the heat exchanger end covers.

4. Clean the inside of the exchanger core tubes using

a metal rod. Flush, inspect, and clean again if

necessary.

5. Reassemble the heat exchanger. Fill the cooling system. Start the engine and check for leaks.

SP17. RAW WATER PUMP

1. Change the raw water pump impeller every 500 hours, or as needed.

2. Remove the pump cover. Pry out the impeller using needle-nose pliers or two screwdrivers. Be sure to remove all pieces of the failed impeller.

NOTE: Place some kind of protection under the

screwdrivers in order to not damage the

pump housing.

3. Clean the inside of the housing.

4. Press in the new impeller and place the sealing plug in the outer end of the impeller center if this has not already been done.

NOTE: Make sure that there is always an extra

impeller and cover gasket in reserve on

board.

SP18. ZINC ANODES

1. A zinc anode is installed in the heat exchanger

cooling system to protect the engine from

electrolysis. Check it faithfully every 250 hours. If you are in warm saltwater, or where electrolysis is a known problem, check it more often.

2. Remove the zinc holder from the bottom of the exchanger. This will drain raw water from the exchanger.

3. Scrape or wire brush the zinc anode clean. If more than 50% of the anode is corroded away, replace it with a new zinc. The anode screws out of the holder.

4. Reinstall the zinc holders. Be sure the threads are clean for good metal-to-metal contact. Do not use thread sealant.

5. Start the engine and check for leaks.

OL944D 11/13

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Servicing

ELECTRICAL SYSTEM - GENERAL

1. Never switch the battery switch off or break the circuit between the alternator and the batteries while the engine is running. Alternator damage can result.

2. Do not reverse the polarity of the battery cables when installing the battery.

3. When welding on the unit, disconnect the regulator and battery. Isolate the leads.

4. Disconnect the battery cables when servicing the DC alternator.

5. Never test with a screwdriver, etc... against any terminal to see if it emits sparks.

BOOSTER BATTERIES

CAUTION: Battery gas can explode. Keep all flames and sparks away from batteries.

1. Before changing or using booster batteries, check the battery electrolyte level. Add distilled water if necessary.

2. Booster and main batteries must have the same

voltage rating.

3. First, connect the positive (+) terminal of the booster battery to the positive (+) terminal of the main

battery. Then, connect the negative (–) terminal of the booster battery to ground on the engine block

( Figure 10 ).

4. Remove the booster battery after starting the engine.

5. Sealed Batteries:

See the manufacturer's charging and booster

instructions.

OL944D 11/13

23

Figure 10: Booster Battery Connections

Servicing

SP19-20. BATTERY CARE

1. Check the electrolyte level every 50 hours, or once a month. Add distilled water to the manufacturer's recommended level.

2. Batteries, cables, and cable terminals should be checked and cleaned every 100 hours. Clean

corrosion with a water and baking soda solution.

Flush with clean water. Tighten terminals and grease them to inhibit future corrosion.

3. Check the battery condition with a hydrometer every

500 hours.

SP23. WINTERIZING / OUT-OF-SERVICE

NOTE: Remember to close the sea-cock before

opening drain cocks.

For engines not going to be used for more than 3 months:

1. Change the crankcase oil and filter. Fill with rust preventative oil, and make a mixture of rust

preventative oil and fuel 1:1 and fill the fuel tank with the mixture. Start the engine and operate it with no load for 5 to 10 minutes. Stop the engine, spray rust preventative agent into intake pipe. Drain the rust preventative oil and fuel.

2. Drain fresh water and seawater cooling systems

completely. Flush fresh water systems and refill with the proper antifreeze mixture.

3. Drain the water supply lines and wet exhaust line.

Cover the intake and exhaust ports with adhesive fabric tape.

4. Loosen the seawater pump cover and drain the pump.

5. Loosen the alternator belt.

6. Cover the terminals and openings of the starter and alternator with adhesive fabric tape. Cover the starter and alternator with

polyethylene sheets and put desiccant inside covering.

7. Disconnect and clean the battery. Remove the battery to a cool dry storage place, if possible.

8. Clean the outside of the unit. Paint any scratched or chipped surfaces. Put corrosion preventative on all exposed metal surfaces.

9. Cover the engine.

OL944D 11/13

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Troubleshooting

DC ELECTRICAL SYSTEM

PROBLEM

Battery Will Not Charge

Starter Inoperative

Starter Cranks Slowly

POSSIBLE CAUSE

Loose or corroded connections

RECOMMENDATION(S)

• Clean and tighten battery connections.

Sulfated or worn out batteries • Check specific gravity of each battery.

• Check electrolyte level of each battery.

Loose or defective alternator belt • Adjust belt tension.

• Replace belt.

Check DC circuit breaker

Loose or corroded connections

Low battery condition

Defective electrical system ground wire:

Low battery condition

Check specific gravity of each battery

Check electrolyte level of each battery

Crankcase oil too heavy

Loose or corroded connections

• If the breaker is tripped, reset it.

• Clean and tighten loose battery and

harness plug connection.

• Check specific gravity of each battery.

• Check electrolyte level of each battery.

• Repair or replace.

• Battery is too small.

• Battery cables are too small.

• Replace battery if necessary.

• If low, fill cells with distilled water.

Entire Electrical System

Does Not Function

Check DC circuit breaker

Faulty connection

Sulfated or worn out batteries

• Fill with oil of appropriate viscosity.

• Clean and tighten loose connections.

• If breaker is tripped, reset it.

• Clean and tighten battery and harness

plug connections.

• Check specific gravity and electrolyte

level of each battery.

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

OL944D 11/13

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Troubleshooting

ENGINE

PROBLEM POSSIBLE CAUSE

Engine Hard to Start Improper starting procedure

or Will Not Start

No fuel

RECOMMENDATION(S)

• See starting section of this manual.

Low battery condition

Excessive resistance in starting circuit

Crankcase oil too heavy

• Check level of fuel in fuel tank.

• Check electrolyte level and condition.

• Clean and tighten all battery connections.

Improper type of fuel

• Use oil of proper viscosity.

• Consult fuel supplier and use proper type

of fuel for operating condition.

Water, dirt or air in fuel system • Drain, flush, fill and bleed system.

Clogged primary fuel filter element

• Clean or replace filter element.

Clogged secondary fuel filter element

• Replace filter element.

Dirty or faulty injection nozzles • Have your dealer check injection nozzles.

OL944D 11/13

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PROBLEM

Lack of Engine Power

(continued)

Engine Overheats

Engine Knocks

Troubleshooting

ENGINE

POSSIBLE CAUSE

Low compression pressure

(worn piston rings, etc...)

Engine overloaded

Low coolant level

Keel cooling tubes have been painted

Cooling system needs flushing

Defective thermostat

Defective temperature gauge

Water pump impeller worn or broken

RECOMMENDATION(S)

• Consult dealer.

• Check propeller size or pitch.

• Fill tank to proper level.

• Check hoses for loose connections

and leaks.

• Remove paint from tubes.

• Flush cooling system.

• Remove and check thermostat.

• Check water temperature with thermometer

and replace gauge if necessary.

• Check the impeller and replace if necessary.

Insufficient oil

Injection pump out of time

• Call your dealer.

• Call your dealer.

Below normal engine temperature • Check your thermostats.

• Check water temperature to see if

temperature gauge is working properly.

Faulty fuel injector

Engine overheating

• Call your dealer.

• See “Engine Overheating” section.

High Fuel Consumption Improper type of fuel

Clogged or dirty air cleaner

Engine overloaded

Improper valve clearance

Injection nozzles dirty

Injection pump out of time

• Use correct fuel for temperature.

• Service air cleaner.

• Reduce the electrical load.

• See your dealer.

• See your dealer.

• See your dealer.

Engine not at proper temperature • Check your thermostats.

• Check water temperature with thermometer

and replace gauge if necessary.

Below Normal

Engine Temperature

Thermostats not working properly • Check thermostats.

Temperature gauge not working properly

• Check water temperature with thermometer.

Low Oil Pressure Low oil level

Improper type of oil

Partially plugged oil filter

• Fill crankcase to proper level.

• Drain and fill crankcase with correct oil.

• Replace filter.

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

OL944D 11/13

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Troubleshooting

PROBLEM

High Oil Consumption

Engine Emits Black or Gray Exhaust Smoke

ENGINE

POSSIBLE CAUSE

Break-in period

Crankcase oil too light

Oil leaks

Crankcase over full

Clogged or dirty air cleaner

Defective muffler

Improper fuel

Fuel pump faulty

Injection nozzles dirty

Engine overloaded

Injection nozzles dirty

Injection pump faulty

Engine out of time

Incorrect valve clearance

Engine Emits

White Smoke

RECOMMENDATION(S)

• Oil consumption decreases after break in.

• Use proper viscosity oil.

• Check for leaks in lines around gaskets

and drain plug.

• Remove excess oil.

• Service air cleaner.

• Have dealer check back pressure.

(back pressure too high)

• Use correct fuel for temperature.

• See your dealer.

• See your dealer.

• Reduce the electrical load.

• See your dealer.

• Consult your dealer.

• See your dealer.

• Consult your dealer.

Improper fuel

Cold engine

Defective thermostat

Engine out of time

• Use correct fuel for temperature.

• Warm up engine to normal operating

temperature.

• Remove and check thermostat.

• See your dealer.

Low Compression Pressure

Low engine oil viscosity

• See your dealer.

• Use proper viscosity of oil to ambient

temperature.

Excessive amount of engine oil • Maintain correct oil level.

Fuel injection nozzles faulty

(uneven injection)

• See your dealer.

OL944D 11/13

28

Added 5-27-09, updated 6-10-09

Specifications

Hp/ RPM

65 Hp

2500 RPM

General Information

Engine Type

Cylinders

Displacement

Cycles 4

Bore x Stroke

Rotation (Facing Flywheel)

Crankcase Capacity including Oil Filter

Rated Crankshaft kW 2

Weight w/Heat Exchanger without gear

Weight Keel cooled without gear

Length

Width

Height

Inline 4

203 in 3 (3.33 liters)

3.7 x 4.72 in (94 x 120 mm) counter-clockwise

Aspiration Natural

Flywheel Housing Size

Optional PTO Size

Rated Crankshaft Hp 1

11 qts (10 liter)

SAE 4

SAE B- Pad

65 Hp @ 2500 RPM

48.5 kW @ 2500 RPM

620 lbs. (281 kg)

600 lbs. (272 kg)

40.1 in (1018 mm)

24.9 in (682 mm)

29.0 in (737 mm)

Cooling System

Approx. Coolant Cap.

Minimum Sea Water Discharge Dia.

Heat Rejection to Jacket Coolant

Coolant Pump Flow

Seawater Pump Flow

Maximum Seawater Pump Suction Head

Keel Cooler TurboTube Length

Keel Cooler Head Diameter

Keel Cooler Water Hose ID

D.C. Electrical

Minimum Battery Capacity

Battery Cable Size

Voltage, Standard Ground

3 gal (11 liter)

3/4 in (20 mm)

2588 BTU/min

16 gpm (61 lpm)

16 gpm (61 lpm)

39 in (990 mm)

19 feet (0.48 M)

1.25 in (31.75 mm)

1.5 in (38 mm)

200 Amp Hour - 640 CCA

“00”

12 Volt

Air Intake and Exhaust

Air Consumption

Maximum Exhaust Backpressure

Wet Exhaust Elbow ID

Exhaust Gas Flow Volume

Fuel System

Minimum Suction Line

Minimum Return Line

Maximum Fuel Pump Suction Head

132 cfm (3.74 M

3 in (76 mm)

360 cfm (10.19 M

.375 in (10 mm)

.375 in (10 mm)

39 in (990 mm)

Maximum Engine Operating Angle

Continuous Operation

(More than 2 minutes requires use of a remote expansion tank)

Front Down

0°

Intermittent Operation (Sustained up to two minutes) 0° - 35°

3

27 in (686 mm) H

/m)

2

O

3 /m)

Rear Down

0° - 10°

0° - 35°

1. Based on SAE J816b.

2. Based on EN ISO 8665: 2006.

OL944D 11/13

29

OL944D 11/13

30

DC Wiring Diagram

olt Standard Ground Drawing C-6359

OL944D 11/13

31

DC Wiring Diagram

olt Standard Ground Drawing C-6360

4420 14th Ave. NW., Seattle WA 98107

Tel: (206) 789-3880 • 1-800-762-0165 • www.northern-lights.com

Northern Lights and Lugger are registered trademarks of Northern Lights, Inc.

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