Northern Lights LUGGER M6108 Manuel utilisateur

O6108

For Models: M6108, NL6108, and L6108

OPERATOR’SMANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

Diesel engine exhaust and some of its constitu-

ents are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

— CALIFORNIA —

Proposition 65 Warning:

Northern Lights

4420 14th Avenue N.W.

Seattle, WA 98107

Tel: (206) 789-3880

Fax: (206) 782-5455

the Northern Lights logo are trademarks of

Northern Lights, Inc.

Printed in U.S.A.

PART NO.: O6108 08/01

O6108 08/01

OPERATOR’S MANUAL

for Models

M6108, NL6108, and L6108

Proprietary Information

This publication is the property of Northern Lights, Inc.

It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc.

Read this operator's manual thoroughly before starting to operate your equipment.

This manual contains information you will need to run and service your new unit.

INTRODUCTION ......................................................2

Models Included ...................................................2

Model Numbers....................................................2

Serial Numbers .....................................................2

WARRANTY ..............................................................3

SAFETY RULES.......................................................3

COMPONENT LOCATIONS

Northern Lights Marine Generator.......................4

Lugger Marine Propulsion Engines......................5

Northern Lights Industrial Generator ...................6

CONTROL PANELS

Northern Lights Generator Sets............................8

Lugger Marine Propulsion Engines......................9

OPERATING PROCEDURES

Before Starting....................................................10

Starting: Generator Sets......................................10

Starting: Propulsion Engines ......................10 - 11

Shutdowns and Alarms.......................................11

Break-in Period...................................................11

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

SERVICING

Lubrication - General..........................................14

Oil Changes ........................................................14

Changing Oil Filter............................................ 15

Air Filter .............................................................15

V-Belts ................................................................15

Valve Clearances.................................................15

Fuels - General....................................................16

Fuel Filters..........................................................16

Bleeding the Fuel System...................................16

Injectors ......................................................16 - 17

Injection Pump....................................................17

Injection Pump Timings..............................18 - 19

Turbocharger.......................................................19

Turbo Boost ........................................................19

Cooling System Requirements ...................20 - 22

Checking Coolant Level.....................................22

Cooling System Flushing....................................22

Heat Exchanger Cleaning (Marine)....................23

Cleaning Gear Oil Coolers..................................23

Zinc Electrodes...................................................23

Raw Water Pump ................................................23

Coolant Filter......................................................23

Gears, PTOs, and Generators..............................23

Electrical System - General........................23 - 24

Glow Plugs..........................................................24

Booster Batteries.................................................24

Battery Care........................................................24

Winterizing / Out-of-Service ..............................24

PROPELLER SIZING CHART..............................25

DATA SHEETS

M6108.................................................................26

L6108..................................................................27

TROUBLESHOOTING

Electrical.............................................................28

Engine.........................................................29 - 32

DC WIRING DIAGRAMS

24 Volt NL Industrial Generator .........................33

24 & 12 Volt NL Marine Generator............34 - 37

24 & 12 Lugger Propulsion Engine............38 - 39

ON-BOARD SPARE PARTS KIT.........................40

O6108 08/01

Introduction

Unit Identiﬁcation

Model Numbers

Servicing of marine engines and generator sets presents

unique problems. In many cases boats cannot be moved

to a repair facility. Marine engines cannot be compared

to the servicing of automobiles, trucks or even farm

equipment. Failures often occur in remote areas far

from competent assistance. Marine engines are taxed

far more severely than auto or truck engines; therefore,

maintenance schedules must be adhered to more

strictly.

Failures can begin with minor problems that are

overlooked and become ampliﬁed when not corrected

during routine maintenance.

As operator, it is your obligation to learn about your

equipment and its proper maintenance. This is not a

comprehensive technical service manual. Nor will it

make the reader into an expert mechanic. Its aim is to

aid you in maintaining your unit properly.

MODELS INCLUDED

This manual covers the operating instructions for:

M6108 marine generator sets,

NL6108 industrial generator sets, and

L6108 propulsion engines.

Fill in the model number of your unit in the blank space provided.

This will give you a reference whenever service or maintenance is required:

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

Lugger turbocharged-aftercooled marine propulsion

engine. Komatsu 6108 block.

Northern Lights turbocharged 1500 or 1800 RPM

marine diesel generator set. Komatsu 6108 block.

M6108QT Northern Lights turbocharged 1200

RPM marine diesel generator set.

Komatsu 6108 block.

Northern Lights turbocharged-after-

cooled 1500 or 1800 RPM industrial

diesel generator set. Komatsu 6108

block.

M6108T

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

M- Northern Lights marine generator set Komatsu engine block D- Naturally aspirat

NL - Northern Lights industrial generator set 6 cylinder, 108 mm bore T- Turbocharged

Q - 1200 RPM

L - M - NL 6108 A, D, T, & Q

L6108A

Serial numbers

Figure 1: Generator set serial number plate.

Your set has three serial numbers : 1an

engine number stamped on the block, 2 a

generator plate, and 3a generator set plate.

Use the serial number on the generator set

plate when ordering parts or in correspon-

dence. The generator set plate is found on the

service side of the generator and resembles

Fig. 1.

NL6108A

Figure 2: Propulsion serial number plate.

O6108 08/01

Warranty

Safety Rules

CAUTION: Accident reports show that

careless use of engines cause a high per-

centage of accidents. You can avoid

accidents by observing these safety rules.

Study these rules carefully and enforce

them on the job.

• Never leave engine without proper security.

• Turn the coolant tank cap slowly to relieve

pressure before removing. Add coolant only

when the engine is idling or stopped.

• Mount ﬁre extinguisher near engine.

• Always disconnect the baery ground strap

before making adjustments.

• Operate engines in properly ventilated areas.

• Keep trash and other objects away from

engine.

• Escaping ﬂuids under pressure can pen-

etrate your skin. Use a piece of cardboardor

wood, not your hands, to search for leaks.

• Avoid wearing loose clothing without a belt

when working around engines.

• Do not oil or grease engine while it is run

ning.

• Use caution in handling fuel. Never refuel

a hot or running engine. Do not smoke

while ﬁlling fuel tank or servicing fuel

system.

• Keep your hands, feet, hair and clothing

away from power-driven parts.

• Check for any loose electrical connections

or faulty wiring.

• Engines should be operated only by knowl-

edgeable, qualiﬁed personnel.

• Walk completely around engine to make

sure that everything is clear before starting

the engine.

• Do not operate an engine that isn't in

proper working order. If an unsafe operating

condition is noted, tag the engine so others

will also know about it.

• Provide ﬁrst aid kits.

A warranty registration certiﬁcate is supplied

with your set. It entitles the original purchaser

of this equipment to a warranty covering mate-

rial or assembly faults. The extent of coverage

is described in the Limited Warranty State-

ment. We recommend that you study the state-

ment carefully.

If the warranty is to apply, the servicing

instructions outlined in this manual must be

followed. If further information is needed,

please contact an authorized dealer or the fac-

tory.

CAUTION: This symbol is used throughout

this book to alert you to possible danger areas.

Please take special notice of these sections.

O6108 08/01

Marine Generator Set Component Locations

1. Expansion tank

2. Coolant ﬁll

3. Vapor trap valve cover

4. Lube oil ﬁll

5. Heat exchanger

6. Crankcase breather

7. Exhaust manifold

8. Cooling system air vents (3)

2 shown

9. Turbocharger

10. Exhaust manifold drain

(behind hose)

11. Wet exhaust elbow

(optional)

12. Starter

13. Heat exchanger drain

(in rear end cover)

14. Anti-vibration mounts

standard (shown

Hydrolastic mounts

optional)

15. Dipstick

16. Raw Water Pump

17. Raw Water Drain

18. Raw Water Zinc

19. Alternator

20. Air Cleaner

21. Engine Oil Cooler

22. Secondary Fuel Filter

23. Manual Fuel Prime

Pump

24. Fuel Injection Pump

25. Coolant Filter

26. Block Drain

27. Lube Oil Filter

28. Aftercooler

29. P.T.O. with electric clutch

(optional)

30. Lube oil drain

31. Base frame

32. Generator cooling air duct

33. AC generator

Figure 3. M6108A

Generator Set

O6108 08/01

Marine Propulsion Engine Component Locations

9. Exhaust Manifold drain

10. Gear Oil Cooler drain

11. Starter

12. Dry Exhaust Elbow

13. Gear Oil Cooler

14. Dipstick

15. Alternator

16. Air Cleaner

1. Expansion Tank

2. Coolant Fill

3. Vapor Trap Valve Cover

4. Lube Oil Fill

5. Crankcase Breather

6. Exhaust Manifold

7. Cooling System air vents (3)

8. Turbocharger

17. Engine Oil Cooler

18. Secondary Fuel Filter

19. Manual Fuel Prime Pump

20. Fuel Injection Pump

21. Coolant Filter

22. Block Drain

23. Lube Oil Filter

24. Aftercooler

25. D.C. Circuit Breaker and

relays

26. Low Water Level Gauge

(Optional)

Figure 4. L6108A2, keel cooled

O6108 08/01

Northern Lights Industrial Engine Component Locations

8. Solenoid

9. Fuel Return Line

10. Fuel Inlet Line

11. Oil Filter

(behind Fuel/Water

Separator)

12. Fuel/Water Separator

13. Alternator

14. Dipstick

15. Oil Fill

16. Starter

1. Generator Junction Box

2. Air Cleaner

3. Fuel Filter

4. Corrosion Resister

5. Exhaust Elbow

6. Coolant Fill

7. Thermostat Housing

Figure 5. NL6108

O6108 08/01

Notes

O6108 08/01

Control Panels - Northern Lights Generator Sets

SERIES 3 GENERATOR CONTROL PANEL 1. SHUTDOWN BYPASS PREHEAT

SWITCH:

Two functions are built into this switch: The

preheating of the engine, and bypassing of

the engine safety shutdown circuit, enabling a

quicker start. Hold switch in up position 10-20

seconds before starting engine, and continue

holding in up position while starting engine.

Holding the switches on too long can burn out

the glow plugs.

2. ENGINE CONTROL SWITCH:

To start the engine, hold switch in start position

until the engine is running. After the engine

starts, release switch and it will return to the

center position. To stop engine, move switch to

stop position and release.

3. OIL PRESSURE GAUGE:

The oil pressure gauge shows the oil pressure in

the engine lubricating system.

4. WATER TEMPERATURE GAUGE:

Registers temperature of cooling water.

5. HOUR METER:

Keeps track of engine running time.

6. D.C. VOLTMETER:

When the engine is stopped, the voltmeter

indicates the condition of the battery. When the

engine is running, the voltmeter indicates the

voltage output of the alternator.

For Series 4 Control Panels Only:

7. A.C. VOLTMETER:

Shows the generator output voltage.

8. FREQUENCY METER (HERTZ):

The frequency meter indicates the frequency of

alternating current: 1200 or 1800 RPM (60 Hz),

1500 RPM (50 Hz).

9. AMMETER SELECTOR SWITCH:

Used to check each phase for load condition. You

must always leave this switch in the "ON" posi-

tion while the unit is running.

10. A.C. AMMETER

Shows the generator load on each phase. The

phase is selected on the Ammeter Selector Switch

(switch #9 above).

Figure 8.

SERIES 4 GENERATOR CONTROL PANEL

Figure 7.

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