OL1276 For Models: L1276A and L1276A2 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 ©2010 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.: L1276 03/10 Revised page 3-2-10 OPERATOR'S MANUAL #OL1276 for Model L1276A and L1276A2 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 Cooling System Flushing ................................. 15 Models Included .................................................2 Heat Exchanger Cleaning ................................ 15 Model Numbers ..................................................2 Zinc Electrodes ........................................ 15 - 16 Serial Numbers ...................................................2 Raw Water Pump ............................................. 16 Electrical System - General ............................. 16 WARRANTY ............................................................3 Welding and ECU Precautions ........................ 16 Booster Batteries .............................................. 17 SAFETY RULES .....................................................3 Battery Care ..................................................... 17 COMPONENT LOCATIONS Winterizing / Out-of-Service ........................... 17 L1276A ...............................................................4 TROUBLESHOOTING OPERATING PROCEDURES Engine ...................................................... 18 - 19 Before Starting ....................................................6 Shutdown Procedures ...................................6 - 7 DIAGNOSTIC TROUBLE CODES ............ 20 - 21 Break-In Period ...................................................7 DATA SHEETS SERVICING SCHEDULE CHART .......................8 Unit Specifi cations ........................................... 22 SERVICE RECORD ................................................9 ON-BOARD SPARE PARTS .............................. 23 SERVICING Lubrication - General ....................................... 10 WIRING DIAGRAMS ................................... 25 - 28 Checking Oil .................................................... 10 Oil Changes ..................................................... 10 Changing Oil Filter .......................................... 10 Air Filter .......................................................... 10 Valve Clearances ...............................................11 Fuels - General ..................................................11 Crankshaft Damper ...........................................11 Fuel Filters ....................................................... 12 Bleeding the Fuel System ................................ 12 Turbocharger .................................................... 13 Turbo Boost ..................................................... 13 Cooling System - General ................................ 14 Engine Coolant Specifi cations ................. 14 - 15 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 OL1276 03/10 OL1276 03/10 3 Revised page 3-2-10 Introduction Servicing of marine engines presents unique problems. Failures begin with minor problems that are overlooked In many cases boats cannot be moved to a repair and become amplifi ed when not corrected during facility. Marine engines cannot be compared to the routine maintenance. servicing of automobiles, trucks or even farm equipment. Failures often occur in remote areas far As operator, it is your obligation to learn about your from competent assistance. Marine engines are taxed equipment and its proper maintenance. This is not a far more severely than auto or truck engines; comprehensive technical service manual. Nor will it therefore, maintenance schedules must be adhered to make the reader into an expert mechanic. Its aim is to more strictly. aid you in maintaining your unit properly. Model Numbers Model numbers give the unit's application, block model, and aspiration: L 1276 A, 2 L - Lugger propulsion engine + Model number + A - After cooled 6 Cylinder 127 mm bore 2 - Tier II ® L1276A2 Lugger turbocharged propulsion engine with a = John Deere engine block, aftercooled, Tier II. 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. OL1276 03/10 4 Warranty A warranty registration certifi cate is supplied followed. If further information is needed, please with your set. The extent of coverage is described contact an authorized dealer or the factory.. in the Limited Warranty Statement. We recommend that you study the statement carefully. NOTE: If the warranty is to apply, the servicing instructions outlined in this manual must be 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. • Use caution in handling fuel. Never refuel a hot • Turn the coolant tank cap slowly to relieve pres- or running engine. Do not smoke while fi lling sure before removing. Add coolant only when fuel tank or servicing fuel system. the engine is stopped and cool. • Keep your hands, feet, hair and clothing away from power-driven parts. • Mount a fi re extinguisher near engine. • Check for any loose electrical connections or • Always disconnect the battery ground strap faulty wiring. before making adjustments. • Engines should be operated only by knowledge- • Operate engines in properly ventilated areas. able, qualifi ed personnel. • Keep trash and other objects away from engine. • Look completely around engine to make sure • Escaping fl uids under pressure can penetrate that everything is clear before starting. your skin. Use a piece of cardboard or wood, • Do not operate an engine that isn't in proper work- not your hands, to search for leaks. ing order. If an unsafe operating condition is noted, • Avoid wearing loose clothing when working tag the set and control panel so others will also around engines. know about the problem. • Do not oil or grease engine while it is running. • Provide fi rst aid kits. CALIFORNIA Proposition 65 Warning: CAUTION: This symbol is used throughout Diesel engine exhaust and some of its constitu- this book to alert you to possible danger areas. ents are known to the State of California to cause Please take special notice of these sections. cancer, birth defects, and other reproductive harm. OL1276 03/10 5 L1276A Component Locations Figure 1: L1276A 1. Expansion Tank 8. Starter 15. Rocker Arm Cover 2. Heat Exchanger 9. Electronic Control Unit 16. Thermostat Housing 3. Gear Oil Cooler 10. Salt Water Inlet Elbow 17. DC Alternator 4. Water Fill 11. Lube Oil Drain 18. Lube Oil Filter 5. Heat Exchanger Zinc (2) 12. Raw Water Pump 19. Dipstick 6. Crankcase Vent 13. Lube Oil Fill 20. Oil Cooler 7. Air Cleaner 14. Turbocharger 21. Secondary Fuel Filter OL1276 03/10 6 Notes OL1276 03/10 7 Operating Procedures BEFORE STARTING Operating 1. Check the water level by removing the pressure 1. Check oil pressure as soon as the engine has started. cap from the expansion tank. In order to give the Oil pressure should be above 15 PSI. The engine cooling water room to expand, the level should be must never be run if the oil pressure is below 15 PSI. about 1 3/4 in. (4-5 cm) below the fi ller cap sealing 2. Check the voltmeter. It should read 13 to 14 volts surface when the engine is cold. When fi lling with (26-28 volts, 24 volt systems) at 600F (160C). coolant, the venting cock on top of the turbocharger 3. Water temperature should not rise over 2000F (940C). should be opened to ensure that no air pockets form If it does, shut down the engine and investigate the in the cooling system (see Service Point #14). cause of overheating. 4. Do not exceed 800 RPM when shifting marine gear. CAUTION: Use protective clothing and open Repeated shifts at higher engine speeds can damage the fi ller cap carefully when the engine is warm to prevent burns. the reverse gear. 5. Low idle is 650 RPM. Maximum working engine 2. Check the oil level in the crankcase with the dipstick. speed is: 2100 RPM for High Output, 1900 RPM for The oil level should be between the “waffl ed area” Medium Duty, and 1800 RPM for Continuous Duty. and the “Add”. Never allow the level to go below 6. If the proper propeller is used, the engine should the “Add”. Do not fi ll above the crosshatch pattern. reach its appropriate maximum RPMs at full throttle. Oil levels within the crosshatch are considered in the If the maximum rated RPMs for your engine applica- acceptable operating range. Always add the same tion is exceeded at full throttle, then your propeller is viscosity of oil as is already