ONL2-2
For Models: NL1064D, NL1064T1, NL1064T2,
NL1064H1, NL1066T, NL1066H1,
NL1066H2, and NL1066H3
OPERATOR’S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators
Page 1: ...ONL2 2 For Models NL1064D NL1064T1 NL1064T2 NL1064H1 NL1066T NL1066H1 NL1066H2 and NL1066H3 OPERATOR S MANUAL Marine Generators Marine Diesel Engines Land Based Generators...
Page 2: ...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 Copyright 2013 Northern Lights Inc All rights reserve...
Page 3: ...l 16 Checking Oil 16 Oil Changes 16 Changing Oil Filter 16 Air Filter 16 Belt Tension 17 Valve Clearances 18 Fuels General 19 Crankshaft Vibration Damper 6 Cyl 20 Fuel Filters 19 20 Proprietary Inform...
Page 4: ...h a mechanically controlled fuel system NL 1064 or 1066 Northern Lights turbocharged industrial generator set with a John Deere Powertech Tier II 4045 engine block with a mechanically controlled fuel...
Page 5: ...afety signs Keep signs in good and clean condition Replace missing or damaged signs Be sure new equipment components and repair parts include the current safety signs For replacement signs proper plac...
Page 6: ...ving parts have stopped before making any adjustments connections or performing any other type of service to the engine or other driven equipment Prevent accidental discharge of starting fluids by sto...
Page 7: ...olyte is poisonous and strong enough to burn skin eat holes into clothing and other materials and cause blindness if splashed into eyes To Avoid Hazards Fill batteries only in well ventilated areas We...
Page 8: ...ilated Dispose of paint and solvent properly Service Cooling System Safely Opening a pressurized cooling system can release explosive fluids and causing serious burns Before opening any pressurized co...
Page 9: ...source components between the high pressure fuel pump and nozzles on engines with high pressure fuel systems ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH PRESSURE FUEL INJECTION SYSTEMS...
Page 10: ...er or other material cannot be achieved at the local supply valve shut off valves further back in the system and re check the bleed off point until complete shut off is achieved Affix a DO NOT OPERATE...
Page 11: ...ONL2 2 7 13 9 Notes...
Page 12: ...hroud 7 Alternator 8 Vibration Mount 9 Lube Oil Filter 10 Fuel Manifold 11 Lube Oil Dipstick 12 Starter 13 Fuel Filter 14 Turbocharger 15 Exhaust Manifold 16 Electronic Control Unit Component Location...
Page 13: ...ator Shroud Figure 3 4 NL1066T Electronically Controlled Fuel System 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 2 17 18 8 Alternator 9 Vibration Mount 10 Lube Oil Filter 11 Low Oil Level Gauge optional 12...
Page 14: ...l 9 Alternator 10 Oil Filter 11 Dipstick 12 Low Oil Level Gauge optional 13 Fuel Filter Water Separator optional 14 Fuel Filter 15 Fuel Manifold 16 Secondary Fuel Filter Component Locations Figures 5...
Page 15: ...t the engine hold this switch in the START position until the engine is running After the engine starts release the switch and it will return to RUN position To stop the engine hold the switch in the...
Page 16: ...perature is above 205 F 97 C shut off the engine immediately Operating Procedures BEFORE STARTING 1 Check the water level by removing the pressure cap from the expansion tank In order to give the cool...
Page 17: ...th minimal idling to help seat engine components properly 3 Constantly check the engine temperature and oil pressure gauges 4 Oil consumption is greater during break in as piston rings and cylinder li...
Page 18: ...k and clean radiator SP23 Test thermostats SP31 Adjust variable speed droop Mechanical Engines Only 1 Change the oil and filter before the first 100 hours of operation during engine break in 2 Perform...
Page 19: ...tion SP9 Change primary fuel filter element SP10 Change secondary fuel filter SP11 Check injectors SP13 Check turbocharger air oil cooling lines for leakage SP14 Check turbocharger boost pressure SP16...
Page 20: ...oil every 100 hours or six weeks whichever comes first 3 Change oil at any seasonal change in temperature when a new viscosity of oil is required a Remove plug from outlet in base frame Screw in owner...
Page 21: ...ed by permission of Deere Company c2005 Deere Company All rights reserved RG10556 Figure 9 A Belt Tension Gauge B Capscrew C Capscrew Note If an automatic spring tensioner is used a belt tension gauge...
Page 22: ...ke Valve 0 014 0 36 mm Exhaust Valve 0 018 in 0 46 mm 5 If the valves need adjusting loosen the jam nut A on Figure 12 on the rocker arm adjusting screw Turn the adjusting screw until you feel a sligh...
Page 23: ...n 6 Biodiesel Biodiesel involves the transesterification of vegetable oils or animal fats Mainly in the U S soybean methyl ester is used SME but in Europe mainly rapeseed canola methyl ester is made R...
Page 24: ...Figure 17 B counter clockwise until the filter cartridge Figure 17 C slides out NOTE Before installing a new filter cartridge make sure the surfaces where the cartridge comes in contact with the moun...
Page 25: ...leaning Tool JD258 Pilot Tool a Before removal carefully remove all dirt from the cylinder head around fuel injection nozzles Clean with compressed air to prevent dirt from entering the cylinders or v...
Page 26: ...ug if installed previously from nozzle bore in cylinder head and blow out bore with compressed air b Make sure that the sealing surface of the cylinder head on which the seal washer will be resting is...
Page 27: ...A and fuel supply line Figure 21 C Figure 21 Reproduced by permission of Deere Company c 2005 Deere Company All rights reserved RG5659 Servicing 4 Disconnect all fuel delivery pressure lines Figure 21...
Page 28: ...s onto pump mounting studs Tighten nuts three turns only so that pump will not fall off mounting studs NOTE The pump drive gear should begin to move forward away from engine front plate with the pump...
Page 29: ...de between turbo and engine can be found by applying soapy water to the air line 4 Tighten the hose clamps replace hose or gaskets as required 5 Check to see that the lubrication and cooling lines are...
Page 30: ...ds 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 p...
Page 31: ...ing sizes Pint Part Number 20 00002 1 2 gallon Part Number 20 00003 4 DO NOT use any coolant system additives containing soluble oil COOLANT TESTING 1 Coolant test kits are available to allow on site...
Page 32: ...battery switch off or break the circuit between the alternator and batteries while the engine is running Regulator damage can result 2 DO NOT reverse the polarity of battery cables when installing the...
Page 33: ...engine is to be stored for a year or longer 3 Crank the engine a few times with a starter with out starting the engine 4 Remove and clean batteries 5 All engine openings should be sealed with plastic...
Page 34: ...dealer Injection pump not getting fuel or air in fuel system Check fuel flow at supply pump or bleed fuel system DC ELECTRICAL SYSTEM Battery Will Not Charge Loose or corroded connections Clean and ti...
Page 35: ...tly Below normal engine temperature Remove and check thermostat Clogged primary fuel filter element Clean or replace filter element Clogged secondary fuel filter element Replace secondary filter eleme...
Page 36: ...nkcase to proper level Improper type of oil Drain and fill crankcase with correct oil Partially plugged oil filter Replace filter High Oil Consumption Break in period Oil consumption decreases after b...
Page 37: ...ONL2 2 7 13 35 AC Wiring Diagram A C Wiring All voltages with a SX460 Voltage Regulator Drawing B 5703C...
Page 38: ...ONL2 2 7 13 36 DC Wiring Diagram D C Wiring 12 Volt Standard Ground for NL1064D Drawing C 5775...
Page 39: ...ONL2 2 7 13 37 DC Wiring Diagram D C Wiring 24 Volt Standard Ground for NL1064D Drawing C 5776...
Page 40: ...ONL2 2 7 13 38 Notes...
Page 41: ...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 2013 All rights reserved Litho USA...
