This document is an Operator's Manual for Northern Lights Lugger OLP series marine diesel engines, specifically models LP445, LP455T, LP668D, and LP668T. These engines are designed for marine generator and propulsion applications.
Function Description:
The Northern Lights Lugger OLP series engines are primarily used as marine generators and marine diesel engines for propulsion. They are designed to provide reliable power in demanding marine environments. The manual covers the operation, maintenance, and troubleshooting of these engines, ensuring safe and efficient use.
Important Technical Specifications:
The manual provides detailed specifications for each model:
-
LP445D:
- Output: 85 kW @ 2500 rpm (63 kW @ 2500 rpm) Medium Duty Rating, 55 kW @ 2400 rpm (41 kW @ 2400 rpm) Continuous Duty Rating.
- Maximum Flywheel Torque: 223 ft lbs @ 1200 rpm.
- Fuel Consumption (approximate): 0.8 US gph (2.9 lph) @ 1500 rpm high output, 1.7 US gph (6.2 lph) @ 1800 rpm high output, 2.4 US gph (9.2 lph) @ 2000 rpm high output, 3.1 US gph (11.7 lph) @ 2200 rpm high output, 3.5 US gph (17.0 lph) @ 2500 rpm high output.
- Cylinders: 4 Inline.
- Displacement CID (ltr): 276 (4.5).
- Operation Cycle: 4.
- Aspiration: Natural.
- Bore: 4.19 in (106 mm).
- Stroke: 5.0 in (127 mm).
- Approximate Weight WITHOUT Gear: 1070 lbs (485 kg).
- Keel Cooled: Yes.
- Heat Exchanger: 1100 lbs (499 kg).
- Cooling (General): Circulating pump flow 54 US gal @ 2500 rpm (204 l @ 2500 rpm).
- Heat rejection to jacket water: 2563 BTU-min.
- Cooling (Heat Exchanger): Raw water intake & discharge dia. 1.25 inch NPT. Raw water pump flow @ RPM 31 gpm @ 2500 rpm (117 lpm @ 2500 rpm). Max. raw water pump suc. head in 15 ft (4.5 m). Max. raw water temp. at inlet 85°F (30°C). Fresh water system capacity 5 US gal (18.9 ltr).
- Cooling (Keel Cooled): Water hose inside diameter 2-3/8 in (60 mm). Head tube diameter 1-1/2 in (38 mm). Head tube length 12 ft (3.6 m). One inch main round tube length 14 ft (4.4 m). Skin cooler 12 sq ft (1.1 m²). Aluminum 20 sq ft (1.8 m²). Steel 42 sq ft (3.9 m²).
- Electrical: Minimum battery capacity - 12V 640 CCA. Battery cable size up to 10 ft run 0. Standard harness length 20 ft (6 m).
- Air: Engine air consumption 166 cfm @ 2500 rpm (4.7 m³/min @ 2500 rpm). Minimum engine room vent area 48 sq ft (4.5 m²). Exhaust gas flow 771 cfm @ 2500 rpm (13.8 m³/min @ 2500 rpm). Exhaust gas temperature at rpm 923°F @ 2500 rpm (495°C @ 2500 rpm). Maximum exhaust back pressure 48 in (1219 mm) H₂O.
- Dry: 3 in (75 mm). Wet: 4 in (100 mm).
- Fuel and Oil: Min. fuel suction and return line 3/8 in (9 mm). Maximum fuel pump head 14 US lbs (13.2 ltr). Crankcase oil capacity 14 US lbs (13.2 ltr).
- Gear, PTO, Engine Angle: Engine rotation (facing flywheel) Counter-Clockwise. Flywheel housing size SAE #4. Front PTO size (optional) SAE #5. Max. intermittent operating angle Front down 15°. Rear down 0°.
-
LP455T:
- Output: 120 kW @ 2500 rpm (89 kW @ 2400 rpm) Medium Duty Rating, 80 kW @ 2400 rpm (78 kW @ 2200 rpm) Continuous Duty Rating.
- Maximum Flywheel Torque: 339 ft lbs @ 1500 rpm.
- Fuel Consumption (approximate): 1.9 US gph (7.2 lph) @ 1500 rpm high output, 2.5 US gph (9.4 lph) @ 1800 rpm high output, 3.5 US gph (13.2 lph) @ 2000 rpm high output, 4.6 US gph (17.4 lph) @ 2200 rpm high output, 6.9 US gph (26.1 lph) @ 2500 rpm high output.
- Cylinders: 4 Inline.
- Displacement CID (ltr): 276 (4.5).
- Operation Cycle: 4.
- Aspiration: Turbocharged.
- Bore: 4.19 in (106 mm).
- Stroke: 5.0 in (127 mm).
- Approximate Weight WITHOUT Gear: 1160 lbs (526 kg).
- Keel Cooled: Yes.
- Heat Exchanger: 1190 lbs (540 kg).
- Cooling (General): Circulating pump flow 54 US gal @ 2500 rpm (204 l @ 2500 rpm).
- Heat rejection to jacket water: 3630 BTU-min.
- Cooling (Heat Exchanger): Raw water intake & discharge dia. 1.25 inch NPT. Raw water pump flow @ RPM 31 gpm @ 2500 rpm (117 lpm @ 2500 rpm). Max. raw water pump suc. head in 15 ft (4.5 m). Max. raw water temp. at inlet 85°F (30°C). Fresh water system capacity 5 US gal (18.9 ltr).
- Cooling (Keel Cooled): Water hose inside diameter 2-3/8 in (60 mm). Head tube diameter 1-1/2 in (38 mm). Head tube length 12 ft (3.6 m). One inch main round tube length 14 ft (4.4 m). Skin cooler 20 sq ft (1.8 m²). Aluminum 65 sq ft (6.0 m²). Steel 65 sq ft (6.0 m²).
- Electrical: Minimum battery capacity - 12V 640 CCA. Battery cable size up to 10 ft run 0. Standard harness length 20 ft (6 m).
- Air: Engine air consumption 321 cfm @ 2500 rpm (9.1 m³/min @ 2500 rpm). Minimum engine room vent area 65 sq ft (6.0 m²). Exhaust gas flow 771 cfm @ 2500 rpm (21.8 m³/min @ 2500 rpm). Exhaust gas temperature at rpm 729°F @ 2500 rpm (392°C @ 2500 rpm). Maximum exhaust back pressure 30 in (750 mm) H₂O.
- Dry: 3 in (75 mm). Wet: 4 in (100 mm).
- Fuel and Oil: Min. fuel suction and return line 3/8 in (9 mm). Maximum fuel pump head 19 US lbs (13.2 ltr). Crankcase oil capacity 19 US lbs (13.2 ltr).
- Gear, PTO, Engine Angle: Engine rotation (facing flywheel) Counter-Clockwise. Flywheel housing size SAE #4. Front PTO size (optional) SAE #5. Max. intermittent operating angle Front down 15°. Rear down 0°.
-
LP668D:
- Output: 130 kW @ 2500 rpm (96 kW @ 2400 rpm) Medium Duty Rating, 87 kW @ 2400 rpm (67 kW @ 2400 rpm) Continuous Duty Rating.
- Maximum Flywheel Torque: 340 ft lbs @ 1500 rpm.
- Fuel Consumption (approximate): 1.9 US gph (6.4 lph) @ 1500 rpm high output, 3.0 US gph (11.4 lph) @ 1800 rpm high output, 4.0 US gph (15.1 lph) @ 2000 rpm high output, 5.3 US gph (20.1 lph) @ 2200 rpm high output, 6.9 US gph (26.1 lph) @ 2500 rpm high output.
- Cylinders: 6 Inline.
- Displacement CID (ltr): 414 (6.78).
- Operation Cycle: 4.
- Aspiration: Natural.
- Bore: 4.19 in (106 mm).
- Stroke: 5.0 in (127 mm).
- Approximate Weight WITHOUT Gear: 1450 lbs (660 kg).
- Keel Cooled: Yes.
- Heat Exchanger: 1490 lbs (675 kg).
- Cooling (General): Circulating pump flow 61 US gal @ 2500 rpm (230 l @ 2500 rpm).
- Heat rejection to jacket water: 4672 BTU-min.
- Cooling (Heat Exchanger): Raw water intake & discharge dia. 1.25 inch NPT. Raw water pump flow @ RPM 30 gpm @ 2400 rpm (114 lpm @ 2400 rpm). Max. raw water pump suc. head in 15 ft (4.5 m). Max. raw water temp. at inlet 85°F (30°C). Fresh water system capacity 6 US gal (22 ltr).
- Cooling (Keel Cooled): Water hose inside diameter 2-3/8 in (60 mm). Head tube diameter 1-1/2 in (38 mm). Head tube length 12 ft (3.6 m). One inch main round tube length 14 ft (4.4 m). Skin cooler 19.5 sq ft (1.8 m²). Aluminum 65 sq ft (6.0 m²). Steel 87 sq ft (8.1 m²).
- Electrical: Minimum battery capacity - 12V 800 CCA. Battery cable size up to 10 ft run 0. Standard harness length 20 ft (6 m).
- Air: Engine air consumption 220 cfm @ 2400 rpm (6.2 m³/min @ 2500 rpm). Minimum engine room vent area 65 sq ft (6.0 m²). Exhaust gas flow 843 cfm @ 2400 rpm (18.2 m³/min @ 2400 rpm). Exhaust gas temperature at rpm 923°F @ 2400 rpm (495°C @ 2400 rpm). Maximum exhaust back pressure 48 in (1219 mm) H₂O.
- Dry: 3 in (75 mm). Wet: 4 in (100 mm).
- Fuel and Oil: Min. fuel suction and return line 3/8 in (9 mm). Maximum fuel pump head 19 US lbs (17 ltr). Crankcase oil capacity 19 US lbs (17 ltr).
- Gear, PTO, Engine Angle: Engine rotation (facing flywheel) Counter-Clockwise. Flywheel housing size SAE #4. Front PTO size (optional) SAE #5. Max. intermittent operating angle Front down 15°. Rear down 0°.
-
LP668T:
- Output: 174 kW @ 2500 rpm (129 kW @ 2400 rpm) Medium Duty Rating, 103 kW @ 2200 rpm (76 kW @ 2200 rpm) Continuous Duty Rating.
- Maximum Flywheel Torque: 507 ft lbs @ 1800 rpm.
- Fuel Consumption (approximate): 2.4 US gph (9.1 lph) @ 1500 rpm high output, 3.4 US gph (14.3 lph) @ 1800 rpm high output, 5.1 US gph (19.3 lph) @ 2000 rpm high output, 6.8 US gph (25.8 lph) @ 2200 rpm high output, 9.2 US gph (34.7 lph) @ 2500 rpm high output.
- Cylinders: 6 Inline.
- Displacement CID (ltr): 414 (6.78).
- Operation Cycle: 4.
- Aspiration: Turbocharged.
- Bore: 4.19 in (106 mm).
- Stroke: 5.0 in (127 mm).
- Approximate Weight WITHOUT Gear: 1475 lbs (670 kg).
- Keel Cooled: Yes.
- Heat Exchanger: 1515 lbs (685 kg).
- Cooling (General): Circulating pump flow 61 US gal @ 2500 rpm (230 l @ 2500 rpm).
- Heat rejection to jacket water: 4672 BTU-min.
- Cooling (Heat Exchanger): Raw water intake & discharge dia. 1.25 inch NPT. Raw water pump flow @ RPM 30 gpm @ 2400 rpm (114 lpm @ 2400 rpm). Max. raw water pump suc. head in 15 ft (4.5 m). Max. raw water temp. at inlet 85°F (30°C). Fresh water system capacity 6 US gal (22 ltr).
- Cooling (Keel Cooled): Water hose inside diameter 2-3/8 in (60 mm). Head tube diameter 1-1/2 in (38 mm). Head tube length 12 ft (3.6 m). One inch main round tube length 14 ft (4.4 m). Skin cooler 26 sq ft (2.4 m²). Aluminum 65 sq ft (6.0 m²). Steel 87 sq ft (8.1 m²).
- Electrical: Minimum battery capacity - 12V 800 CCA. Battery cable size up to 10 ft run 0. Standard harness length 20 ft (6 m).
- Air: Engine air consumption 436 cfm @ 2400 rpm (12.3 m³/min @ 2200 rpm). Minimum engine room vent area 127 sq ft (11.8 m²). Exhaust gas flow 843 cfm @ 2400 rpm (24.0 m³/min @ 2400 rpm). Exhaust gas temperature at rpm 973°F @ 2400 rpm (523°C @ 2400 rpm). Maximum exhaust back pressure 30 in (750 mm) H₂O.
- Dry: 3 in (75 mm). Wet: 4 in (100 mm).
- Fuel and Oil: Min. fuel suction and return line 3/8 in (9 mm). Maximum fuel pump head 19 US lbs (17 ltr). Crankcase oil capacity 19 US lbs (17 ltr).
- Gear, PTO, Engine Angle: Engine rotation (facing flywheel) Counter-Clockwise. Flywheel housing size SAE #4. Front PTO size (optional) SAE #5. Max. intermittent operating angle Front down 15°. Rear down 0°.
Usage Features:
- Safety First: The manual emphasizes safety with a dedicated "Safety Rules" section, including warnings about diesel engine exhaust (California Proposition 65) and general operating precautions. It advises users to wear appropriate safety gear, keep the engine area clean, and avoid contact with hot surfaces or moving parts.
- Pre-start Checks: Before starting, users are instructed to check the water level in the expansion tank, oil level in the crankcase, fuel level, and ensure all seacocks are open. The battery switch must be ON.
- Starting Procedure: The engine should be started in neutral position. The throttle control should be moved to full speed position and returned to idle. The key switch is used to turn the engine over, and the voltmeter should read above 12 volts. The starter should not be cranked for more than 15 seconds consecutively.
- Shutdown Procedure: For normal shutdown, the engine should run for five minutes at 1000 RPM, then return to idle, turn the key switch counterclockwise to stop, and close the seacock and fuel valves.
- Instrumentation: The control panel includes an oil pressure gauge, tachometer, hour meter, DC voltmeter, key switch, stop button, instrument panel lighting, oil pressure fault light, engine temperature fault light, alarm horn, and coolant temperature gauge. These instruments provide critical information for monitoring engine health and operation.
- Cold Engine Operation: The manual advises against racing a cold engine and recommends operating at 1000 RPM for 3 to 5 minutes to warm up.
- Propeller Recommendations: For LP445, LP455T, LP668D, and LP668T, the manual provides propeller recommendations based on RPM and gear ratio, emphasizing the importance of selecting the correct propeller for optimal performance and to avoid overloading the engine.
Maintenance Features:
- Servicing Schedule: A detailed servicing schedule is provided, outlining daily, 50-hour, 200-hour, 600-hour, 1200-hour, and 2400-hour maintenance tasks. These include checking oil levels, changing engine oil and filters, checking air cleaner, inspecting fuel system components, checking turbocharger, cooling system, electrical system, and winterizing procedures.
- Lubrication: Specific recommendations for lubricating oil are provided, including API Service CE oil and John Deere PLUS-50 oil or engine oils meeting API CG4, API CD, ACEA E1, or ACEA E2 performance levels. The manual also specifies oil viscosity based on air temperature.
- Fuel System Maintenance: Instructions for checking and changing fuel filters, bleeding the fuel system, and injector service are included. The manual highlights the importance of using clean, high-quality fuels that meet ASTM specifications.
- Cooling System Maintenance: Procedures for checking coolant level, flushing the cooling system, and maintaining the heat exchanger are detailed. It specifies the use of ethylene glycol concentrate (antifreeze) and supplemental coolant additives (SCA) to prevent corrosion and cavitation.
- Air System Maintenance: Instructions for checking and cleaning the air cleaner element are provided.
- Electrical System Maintenance: Guidance on checking battery electrolyte levels, cleaning battery terminals, and ensuring proper battery connections is included.
- Winterizing/Out-of-Service: Steps for preparing the engine for storage, including draining seawater cooling systems, adding antifreeze, and preserving fuel and exhaust lines, are outlined.
- Troubleshooting Guide: A comprehensive troubleshooting section helps users diagnose and resolve common issues related to the DC electrical system, engine starting, engine running, lack of engine power, engine overheats, engine knocks, high fuel consumption, and engine emits black or gray exhaust smoke.
- On-Board Spare Parts: A list of recommended spare parts is provided, categorized by "Standard" and "World Class," to ensure essential components are readily available for maintenance and repairs.
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