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Northern Lights OLP LP445 Operator's Manual

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OLP
For Models: LP445, LP455T, LP668D and LP668T
OPERATOR'S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators

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Summary of Contents for Northern Lights OLP LP445

  • Page 1 For Models: LP445, LP455T, LP668D and LP668T OPERATOR’S MANUAL Marine Generators | Marine Diesel Engines | Land-Based Generators...
  • Page 2 4420 14th Avenue N.W. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455 Copyright ©2000 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.: OLP 05/00...

  • Page 3: Table Of Contents

    OPERATOR'S MANUAL #OLP for Models LP445D, LP445T, LP668D, and LP668T 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 Turbo Boost .............

  • Page 4: Introduction

    John Deere Powertech 4045 engine block. engine block. Serial Numbers When referencing Alaska Diesel Electric equipment by serial number, please refer only to the number stamped on the Northern Lights or Lugger serial number plate. ® ®...

  • Page 5: Warranty

    Warranty A warranty registration certificate is supplied NOTE: If the warranty is to apply, the servicing with your set. It entitles the original purchaser of instructions outlined in this manual must be our equipment to a warranty covering material followed. If further information is needed, please or assembly faults.

  • Page 6: Component Locations

    Lugger Component Locations Figure 1: LP668D1 HE with gear (note: components of LP445 are in a similar location). 1. Heat Exchanger 8. Lube Oil Drain 15. DC Alternator 22. Heat Exchanger 2. Heat Exchanger Zinc (2) 9. Lube Oil Filter 16.

  • Page 7: Lugger Control Panel

    Lugger Control Panel Figure 2: Lugger Instrument Control Panel The key must be kept in the on or first position while 1. OIL PRESSURE GAUGE the engine is running. The oil pressure gauge shows the oil pressure in Turn the key counterclockwise as far as possible to the engine lubricating system.

  • Page 8: Operating Procedures

    Operating Procedures Starting BEFORE STARTING 1. Put the gear control in the neutral position. 1. Check the water level by removing the pressure 2. Move the throttle control to the full speed position cap from the expansion tank. In order to give the and return back to idle.

  • Page 9: Idle Speeds

    If the oil level is normal, DO NOT restart the engine. Call your Northern Lights or Lugger Shutdown dealer for assistance. 1. Run engine three to five minutes in neutral at 1000 RPM, for cool down period.

  • Page 10: Servicing Schedule Chart

    Servicing Schedule Chart The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your marine engine or generator set. More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’ column. DAILY: SP18 Check zinc electrodes Check oil level in engine...

  • Page 11: Service Record

    Service Record Service OPERATION HOURS/DATE Point 50 HOURS SP23 Check electrolyte in batteries 200 HOURS Change engine oil Change lubricating oil filters Check air cleaner Change primary fuel filter element SP12 Check turbocharger air, oil & cooling lines for leakage SP18 Check zinc electrodes 600 HOURS...

  • Page 12: Servicing

    Servicing LUBRICATION 2. During intermittent cold weather operation, change oil Break-in oil every 100 hours or six weeks, whichever comes first. 1. Use one of the following during the first 100 hours 3. Change oil at any seasonal change in temperature when of operation: a new viscosity of oil is required.

  • Page 13: Valve Clearances

    Servicing SP6. VALVE CLEARANCES 6-CYLINDER ENGINES: The following special tools will be needed: NOTE: Firing order is 1 - 5 - 3 - 6 - 2 - 4 JDE 820 or JDE 83 Flywheel Turning Tool. JDE 81-4 Timing Pin. 1.

  • Page 14: Fuel Filters

    Servicing NOTE: Before installing a new filter cartridge make sure the 5. Storing fuel: surfaces where the cartridge comes in contact with the a. Keep dirt, scale, water and other foreign matter mounting plate are absolutely clean. Dirt can be washed out of fuel.

  • Page 15: Injector Service

    Servicing SP10. INJECTORS b. Clean exterior of nozzle by soaking in clean 1. Fuel injectors should be checked by a Lugger-North- solvent or diesel fuel. Clean tip with brass wire ern Lights dealer or qualified fuel injection brush. shop every 600 hours. 2.
  • Page 16 Servicing 6. Install injection nozzles: 2. Black smoke can be an indication of pump malfunctions. Before servicing pump, check the NOTE: Before installing injection nozzles, make sure other possible causes. nozzles are clean and free from oil or grease. Do not a.

  • Page 17: Injection Pump

    Servicing IMPORTANT: Injection pump mounting flange timing 4. Disconnect all fuel delivery (pressure) lines (Figure mark (Figure 17-A ) and front plate timing mark from injection pump using a suitable 17mm 15-B) (Figure 17-B) presence and alignment MUST be veri- deep-well crowsfoot socket.
  • Page 18 Servicing 5. Install pump mounting flange flush to engine front plate with drive gear held flush against front side of engine front plate. IMPORTANT: Do not use tightening force of pump mounting stud nuts to pull pump shaft into drive gear I.D. 6.

  • Page 19: Turbocharger

    Servicing SP12. TURBOCHARGER 2. Vapor bubbles are formed when the (Figure 22-C) 1. Check for air leaks every 200 hours. Air leakage piston's impact causes the liner walls to vibrate, will lower engine output and may cause black sending pressure waves into the coolant. exhaust smoke and soot.
  • Page 20 Run the engine for 2 hours and retest -37°C +109°C the coolant. Continue process until SCA concentration Optimum -34°F +226°F meets recommended levels. 3. SCA is available from your Northern Lights dealer in -24°C +106°C Minimum the following sizes. -12°F +222°F Pint - Part Number....20-00002 -52°C...

  • Page 21: Cooling System Flushing

    If applicable, open the cooling system amount of EGC (antifreeze). air vent on top of turbocharger. 3. Test kits are available through your Northern Lights 4. Open the drains on the exhaust manifold and engine or Lugger Dealer.

  • Page 22: Zinc Electrodes

    Servicing SP18. ZINC ANODES SP20, 21. DRIVEN EQUIPMENT 1. Zincs are installed in the cooling system to protect Gears and PTO's your engine from electrolysis. Check them faithfully 1. Manufacturer's service recommendations vary. See every 200 hours. If you are in warm salt water or your Owner's Manual for service information.

  • Page 23: Booster Batteries

    Servicing BOOSTER BATTERIES SP27. WINTERIZING, OUT-OF-SERVICE 1. Drain seawater cooling systems completely. CAUTION: Battery Gas Can Explode. Keep all Remember to shut off sea cocks before opening flames and sparks away from batteries. drain cocks. 2. Drain seawater supply lines and wet exhaust line. 1.

  • Page 24: Troubleshooting

    Troubleshooting If you cannot correct problems with these procedures, see your Lugger or Northern Lights dealer. DC ELECTRICAL SYSTEM ENGINE Battery Will Not Charge Engine Hard to Start or Will Not Start Loose or corroded connections: Improper starting procedure: • See starting section of this manual. Take •...
  • Page 25 Troubleshooting If you cannot correct problems with these procedures, see your Lugger or Northern Lights dealer. Lack of Engine Power (continued) • See your dealer. Improper type of fuel: High Fuel Consumption (continued) • Consult fuel supplier and use proper type of Injection pump out of time: fuel for operating conditions.

  • Page 26: Lugger Performance Specifications

    Specifications PERFORMANCE AND SPECIFICATIONS Model Number LP445D LP445T LP668D LP668T Performance High Output Rating 85 FWHP @ 2500 rpm 135 FWHP @ 2500 rpm 130 FWHP @ 2400 rpm 174 FWHP @ 2400 rpm (63 kW @ 2500 rpm) (100 kW @ 2500 rpm) (96 kW @ 2400 rpm) (130 kW @ 2400 rpm) Medium Duty Rating...

  • Page 27: Lugger Installation Data

    Specifications INSTALLATION DATA Model Number LP445D LP445T LP668D LP668T Cooling (General) Freshwater circulating pump flow 54 US gal @ 2500 rpm 54 US gal @ 2500 rpm 61 US gal @ 2400 rpm 61 US gal @ 2400 rpm (204 ltr @ 2500 rpm) (204 ltr @ 2500 rpm) (229 ltr @ 2400 rpm) (229 ltr @ 2400 rpm0...

  • Page 28: Heat Exchanger Diagram

    Heat Exchanger Description and Part Numbers Heat Exchanger, 20-19501 10. Hex nut, 14-00322 Gasket, 11-11043 11. Hose, 18-62520 O-ring, 16-19502 12. Hose clamp, 19-01028 Capscrew, 12-00312 13. Tube, 27-11035 Capscrew, 12-00354 14. Plug, 21-00530 Lock washer, 15-00302 15. O-ring, 16-14804 Heat Exchanger Kit Stud, 13-00335 16.

  • Page 29: Wiring Diagrams

    Wiring Diagrams OLP 05/00...
  • Page 30 Wiring Diagrams OLP 05/00...
  • Page 31 Wiring Diagrams OLP 05/00...
  • Page 32 Wiring Diagrams OLP 05/00...

  • Page 33: On-Board Spare Parts

    On Board 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”...
  • Page 34 Notes OLP 05/00...
  • Page 36 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 © 2000 All rights reserved. Litho USA.

This manual is also suitable for:

Olp lp455tOlp lp668dOlp lp668t

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