Northern Lights OLP LP445 Operator'S Manual Download Page 12

  OLP  05/00

LUBRICATION

Break-in oil

1.  Use one of the following during the first 100 hours 

of operation:

  a.  John Deere Engine Break-In Oil

  b.  API Service CE oil

  c.  ACEA Specification E1

2. 

Do not use

 John Deere PLUS-50 oil or engine oils 

meeting API CG4, API CF4, ACEA E3, or ACEA 

E2 performance levels during the first 100 hours of 

operation of a new or rebuilt engine.  These oils will 

not allow the engine to break-in properly.

Lubrication - General

1.  Use only clean, high quality lubricants stored in 

clean containers in a protected area.

2.  These oils are acceptable after the first 100 hours:

  a.  API Service CC/CD single viscosity oils.

  b.  API Service CD/CG-4/CF-4 multi-viscosity oils.

  c.  ACEA Specification E3/E2 multi-viscosity oils.

3.  Use the proper weight oil for your average operation 

temperature.

4.  Some increase in oil consumption may be expected 

when SAE 5W and SAE 5-20W oils are used. Check 

oil level frequently.

5.  Never put additives or flushing oil in crankcase.

SP1.  CHECK ENGINE OIL LEVEL

1.  Check the oil level in the crankcase, with the oil 

dipstick, daily.

2.  The oil level must be between the “Waffled area” and 

the “oo”. Never allow the level to go below the “oo”. 

3.  Always add the same viscosity of oil as is already in 

the crankcase.

SP2. OIL CHANGES

1.  Using the oil recommended above, change the 

engine oil and filter after the first 50 hours of 

  operation, the first 100 hours and every 200 hours 

thereafter.

Marine Generator Sets:

  a.  Remove plug from outlet in base frame. Screw in 

    owner-supplied drain hose.

  b.  Open valve at oil pan outlet. After oil has been 

    drained into suitable container, close valve, remove 

    drain hose and replace plug in base frame outlet.

  c.  Refill engine with recommended oil.

4.  Engine Lube Oil Capacity:

SP3. CHANGING OIL FILTER

1.  Change the lube oil filter every 200 hours.

2.  Use a filter wrench to remove old filter. Dispose of 

filter in approved manner.

3.  Make sure the gasket from the old filter is removed 

and discarded.

4.  Lubricate the rubber gasket on the new filter and screw 

it on nipple until gasket meet the sealing surface.

5. 

Using hands only, no wrench, tighten filter one-half turn 

farther. Overtightening can do damage to filter housing.

6.  Fill engine with recommended oil. Start engine and 

check for leakage. Stop engine and check oil level. 

Add additional oil if necessary.

SP4. AIR Cleaner

1.  Inspect air cleaner every 100 hours. Replace filter 

every 600 hours, or yearly, whichever comes first.

2.  Clean the rubber tube at the cleaner. Loosen the hose 

clamp and the attaching strip for the cleaner.

3.  Make sure the rubber tube is in good condition and 

that new filter is absolutely clean and installed prop

-

erly.

4.  Start the engine and check for leaks.

 

NOTE:

  Make absolutely sure no impurities enter 

the engine while changing the element. Do not 

run the engine with the air cleaner removed.

 Air 

Single  Multi

 Temperature  Viscosity 

Viscosity

  Above 32°F

 (0°C) 

SAE-30W SAE15-40W

  -10°F to 32°F

  (-23°C to 0°C) 

SAE-10W SAE10-30W

 

  Below -10°F

 (-23°C) 

SAE-5W SAE5-20W

 

445 Series 

14 qts. 

13.2 liters

 

668 Series 

18 qts. 

17.0 liters

10

Servicing

2.  During intermittent cold weather operation, change 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.

Propulsion Engines

 w/Optional Drain Pump:

  a.  Remove dipstick.

  b.  Unscrew dipstick tube and insert the hand pump to

      the bottom of the oil pan.  Drain by pumping.

  c.  Replace dipstick tube and dipstick.

  d   Refill engine with recommended oil.

Summary of Contents for OLP LP445

Page 1: ...OLP For Models LP445 LP455T LP668D and LP668T OPERATOR S MANUAL Marine Generators Marine Diesel Engines Land Based Generators...

Page 2: ...d 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 2000 Northern Lights Inc All rights reserv...

Page 3: ...el System 12 Injector Service 13 14 Injection Pump 14 16 Turbocharger 17 Turbo Boost 17 Cooling System General 17 Engine Coolant Specifications 17 19 Cooling System Flushing 19 Heat Exchanger Cleaning...

Page 4: ...o an expert mechanic Its aim is to aid you in maintaining your unit properly Introduction D T LP Lugger marine propulsion engine Lugger model number 4 Cylinder 4 5 Liters John Deere model number 4 Cyl...

Page 5: ...eck for any loose electrical connections or faulty wiring Engines should be operated only by knowledge able qualified personnel Look completely around engine to make sure that everything is clear befo...

Page 6: ...Lube Oil Fill 7 Lube Oil Dipstick 15 DC Alternator 16 Water Fill 17 Expansion Tank 18 Manifold Drain Cock 19 Starter 20 Block Drain Cock 21 Fuel Injection Pump 8 Lube Oil Drain 9 Lube Oil Filter 10 Se...

Page 7: ...ng the key clockwise to start the engine When the engine starts immediately turn the key back to the first position while the engine is running 5 The key must be kept in the on or first position while...

Page 8: ...ch is turned OFF while the engine is running the battery charging regulator could be ruined 6 Starting 1 Put the gear control in the neutral position 2 Move the throttle control to the full speed posi...

Page 9: ...Low idle is 700 RPM Maximum working engine speed is 2500 RPM for pleasure craft 2400 RPM for light commercial craft 2200 RPM for continuous duty applications LP668 Low idle is 700 RPM Maximum working...

Page 10: ...P16 Check and clean heat exchanger SP17 Check and clean gear oil cooler 1 Perform all maintenance once a year even if hour level has not been reached 2 Consult manufacturer s maintenance schedule note...

Page 11: ...nes for leakage SP18 Check zinc electrodes 600 HOURS SP4 Replace air cleaner SP5 Check belt condition SP9 Change secondary fuel filter SP10 Check injectors SP13 Check turbocharger boost pressure SP15...

Page 12: ...n base frame outlet c Refill engine with recommended oil 4 Engine Lube Oil Capacity SP3 CHANGING OIL FILTER 1 Change the lube oil filter every 200 hours 2 Use a filter wrench to remove old filter Disp...

Page 13: ...s and No 1 and No 2 intake valves Rotate flywheel 360 Lock No 4 piston at TDC compression stroke C Adjust valve clearance on No 2 and No 4 exhaust valves and No 3 and No 4 intake valves 6 CYLINDER ENG...

Page 14: ...y 1 Whenever the fuel system has been opened for service lines disconnected filter changed etc it will be necessary to bleed air from the system a To bleed the fuel system loosen the bleed plug Figure...

Page 15: ...might damage the injection nozzle 3 Clean Injector Bore Always turn the tool clockwise through the bore even when removing from bore otherwise tool may become dull a Clean nozzle bore with JDE39 Nozz...

Page 16: ...jection pump should only be done if checks indicate pump malfunction 2 Black smoke can be an indication of pump malfunctions Before servicing pump check the other possible causes a Check cleanliness o...

Page 17: ...4 Install three flat washers lock washers and hex nuts 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 mo...

Page 18: ...securing the pump to the front plate to 20 foot lbs 27 N m 11 Connect injection pump pressure lines Figure 20 E Beginning with outlet Figure 21 B and continue around the pump head in counterclockwise...

Page 19: ...l liner pitting or erosion rust scale and acidity LINER EROSION PITTING 1 Cylinder liner walls Figure 22 A which are in contact with engine coolant Figure 22 B can be eroded or pitted unless the prope...

Page 20: ...contact with coolant 2 DO NOT use an EGC containing sealer or stop leak additives 3 DO NOT use EGC containing more than 0 1 anhy drous metasilicate This type of concentrate which is intended for use...

Page 21: ...The cooling water in the engine reaches extremely high temperatures You must use extreme caution when working on hot engines to avoid burns Allow the engine to cool before working on the cooling syste...

Page 22: ...ll pieces of a failed impeller 3 Clean the inside of the housing 4 Press in the new impeller and place the sealing washer in the outer end of the impeller center if this has not already been done 5 Re...

Page 23: ...and booster instructions SP16 17 BATTERY CARE LEAD ACID TYPE BATTERIES 1 Check electrolyte level every 50 hours or once per month Add distilled water to manufacturer s recommended level 2 Batteries ca...

Page 24: ...onsult fuel supplier and use proper type of fuel for operating condition a Lack of Engine Power Intake air restriction Service air cleaner Clogged primary fuel filter element Clean or replace filter e...

Page 25: ...erature Defective thermostat Remove and check thermostat Engine out of time See your dealer 23 a Lack of Engine Power continued Improper type of fuel Consult fuel supplier and use proper type of fuel...

Page 26: ...276 4 5 276 4 5 414 6 78 414 6 78 Operating Cycle 4 4 4 4 Aspiration Natural Turbocharged Natural Turbocharged Bore 4 19 in 106 mm 4 19 in 106 mm 4 19 in 106 mm 419 in 106 mm Stroke 5 0 in 127 mm 5 0...

Page 27: ...n water on keel cooling 70 to 130 F Electrical Minimum battery capacity 12V 640 CCA 640 CCA 800 CCA 800 CCA Battery cable size up to 10 ft run 0 0 0 0 Standard harness length 20 ft 6 m 20 ft 6 m 20 ft...

Page 28: ...18 62520 3 O ring 16 19502 12 Hose clamp 19 01028 4 Capscrew 12 00312 13 Tube 27 11035 5 Capscrew 12 00354 14 Plug 21 00530 6 Lock washer 15 00302 15 O ring 16 14804 7 Stud 13 00335 16 Capscrew 12 00...

Page 29: ...OLP 05 00 27 Wiring Diagrams DC Engine Wiring Diagram 12 Volt Lugger LP668 Drawing C 4363B...

Page 30: ...OLP 05 00 28 DC Engine Wiring Diagram 12 Volt Lugger LP445 Drawing C 4364A Wiring Diagrams...

Page 31: ...OLP 05 00 Wiring Diagrams 29 DC Engine Wiring Diagram 24 Volt Lugger LP668 Drawing C 4370A...

Page 32: ...OLP 05 00 Wiring Diagrams 30 DC Engine Wiring Diagram 24 Volt Lugger LP445 Drawing C 4371...

Page 33: ...1 17 Fuel Washer Kit Std 1 w c 1 18 Glow Plug 0 6 Heat exchanger cooled engines only Safety at sea depends on careful preparation product knowledge and having the right tools and parts Below is a list...

Page 34: ...OLP 05 00 32 Notes...

Page 35: ......

Page 36: ...ern lights com 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 2000 All rights reserved L...

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