Northern Lights Lugger Engine

⚠ Engine should be cold and NOT running.

Tools: Feeler gauge, Wrench

1. Adjust valve clearance after first 50 hours and every 600 hours thereafter.
2. Do adjustment after cylinder head bolts have been retightened; engine cold and NOT running.
3. Turn engine by hand until inlet valve starts to open and exhaust valve starts to close; turn one more full turn.
4. Loosen lock nut and adjust clearance between rocker arm and valve guide to 0.008 in. (0.2 mm).
5. Repeat for each cylinder; replace rocker arm cover and tighten cover nuts to 5 - 8 ft/lbs.

⚠ Do NOT run the engine with the air cleaner removed.

1. Inspect air cleaner every 200 hours; check more often in dusty conditions.
2. Marine: if dirty, wash element in soapy water; rinse and dry thoroughly before reinstalling.
3. Marine: replace element if necessary.
4. Industrial: element cannot be cleaned; replace when necessary.
5. Make sure no impurities enter engine while changing element.

⚠ Battery gas can explode; keep flames and sparks away from batteries.

Tools: Hydrometer

1. Check electrolyte level every 50 hours or once per month; add distilled water to manufacturer's recommended level.
2. Check and clean batteries, cables, and terminals every 100 hours.
3. Clean corrosion with water and baking soda solution; flush with clean water.
4. Tighten terminals and grease them to inhibit corrosion.
5. Check battery condition with a hydrometer every 600 hours.

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

⚠ Use cardboard or wood, not hands, to search for suspected leaks.

Tools: Wrench

1. Loosen bleed bolt A on top of the filter.
2. Pump hand primer B on fuel lift pump until pure fuel without bubbles escapes from bleed bolt A; tighten A.
3. Loosen bleed screw C; pump hand primer B until pure fuel escapes; tighten C.
4. If engine does not start, loosen a fuel line at the injector while cranking until pure fuel escapes; tighten connection.
5. After engine starts, use cardboard to look for fuel leaks.

⚠ Overtightening can damage the filter housing.

Tools: Filter wrench

1. Use a filter wrench to remove old filter; discard in approved manner.
2. Remove and discard old filter gasket; clean mount face.
3. Spread thin film of engine oil on new filter gasket.
4. Screw filter on until gasket meets sealing surface.
5. Tighten one-half turn farther by hand only.
6. Fill engine with recommended oil; start and check for leakage.
7. Stop engine, wait 3 minutes, and check oil level; add oil if necessary.

⚠ Allow engine to cool before working on cooling system.

⚠ Open filler cap carefully using protective clothing when engine is warm.

1. Flush cooling system every 600 hours or every 12 months, whichever comes first.
2. Marine: remove expansion tank cap and drain engine block.
3. Marine: open block drain cock and remove hose from bottom of heat exchanger tank.
4. Marine: flush with clean water until drains are free of discoloration and sediment; drain completely and refill with recommended mixture.
5. Industrial: remove radiator cap and open drain cocks on radiator and engine block.
6. Industrial: flush until water is clear; drain completely and refill with recommended coolant mixture; clean radiator fins.
7. Check hoses and connections and repair any leakage.

⚠ Never use flushing oil or additives in crankcase.

⚠ Dispose of waste oil in an approved manner.

Tools: Oil drain container

1. Change engine oil and oil filter after first 50 hours; use Service CC 30 weight oil during first 100 hours.
2. Change oil and filter again at 100 hours; thereafter change every 200 hours.
3. Warm engine, loosen clamp on oil change tube, remove cap, and drain oil.
4. Replace cap and tube; refill with recommended oil for the season.

⚠ Do not overtighten.

Tools: Filter wrench

1. Remove spin-on filter by turning counterclockwise with a filter wrench.
2. Fill new cartridge with fuel and apply engine oil to gasket surface.
3. Screw on until gasket surface contacts sealing surface of filter base.
4. Tighten two-thirds of a turn by hand; do not overtighten.

⚠ Place protection under screwdrivers so pump housing is not damaged.

⚠ Keep an extra impeller and cover gasket in reserve on board.

Tools: Needle-nose pliers or two screwdrivers

1. Change seawater pump impeller every 600 hours or as needed.
2. Remove pump end cover.
3. Pry out impeller using needle-nose pliers or two screwdrivers.
4. Remove all pieces of failed impeller and clean inside of housing.
5. Press in new impeller and place sealing washers in outer end of impeller center.
6. Replace cover using a new gasket.

Tools: Torque wrench

1. Tighten bolts when the engine is cold.
2. Loosen nuts and remove rocker arm cover.
3. Tighten head bolts with a torque wrench in the order shown.
4. Tighten evenly in 2 or 3 passes, ending at specified torque in final pass.

⚠ Store set in a dry, protected place; if stored outside, protect with a cover.

1. Marine: drain fresh water and seawater cooling systems completely; shut off seacocks before opening drain cocks.
2. Marine: drain water supply lines and wet exhaust line; loosen seawater pump cover and drain pump.
3. Industrial: drain and flush radiator and cooling system; leave dry or refill with antifreeze-water mixture.
4. Industrial: fill fuel tank or add biocide; seal air cleaner inlet, exhaust opening, crankcase breather pipe, and fuel tank vent.
5. Marine and industrial: change crankcase oil and filter; loosen alternator belt.
6. Disconnect and clean battery; remove to warm storage if possible.
7. Clean outside of unit; paint scratched or chipped surfaces; apply corrosion preventative to exposed metal.

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

⚠ The battery switch must always be kept ON while the engine is running.

1. Check coolant level about 1 in. (2.5 cm) below filler cap sealing surface when cold.
2. Check crankcase oil with dipstick; level must be in waffled area.
3. Check fuel tank level and open any fuel valves.
4. Marine: close sea-cock; clean sea strainer; reopen sea-cock.
5. Marine: place battery switch in ON position and keep it ON while running.