ONL673L - Northern Lights
Contents
1. YAOLVYANSO 9019 SSINYVH lt HOLIMS JOMLINOO 3NION3 39nvo N jonvo N lt gt 7 SLH9H 39 9 5 5 TVNOILdO BL S HOLIMS JOHLNOO SISSINSVH QNV NOISN3LX3 HOLIMS SSVdAH NMOGLOHS 33S lt t TENVd TOSINOO HOLIMS SSVdAg NMOQLNHS 1 5 WWNOlldO NO 91 5 TANVd IOYLNOO ONL673L 7 13 34 VOLTAGE REGULATOR F BE JUNCTION BOX 22 68006 t Tot to N 1 2 INDUSTRIAL UNITS ONLY AVR_CONNECTOR YELLOW pO ZEE DARK BROWN 40 ALL INSTALLATION CONDUCTORS TO AWG 14 105 C TYPE MTW MULTISTRAND 600 VAC UNLESS COLOR CODED ALL A D E INSTALLED WIRES ARE TO BE GREY AND MUST BE IDENTIFIED BY NUMBER MARKER AT EACH CONNECTION POINT GROUNDING IS TO BE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE AND ANY APPLICABLE LOCAL CODES MARINE UNITS ALL GROUND CONNECTIONS ARE MADE BY THE CUSTOMER AT THE CUSTOMERS DISCRETION THICK HIDDEN DASHED LINES INDICATE CUSTOMER SUPPLIED AND CONNECTED MAIN OUTPUT CONDUCTORS SIZING DETERMINED PER INSTALLATION MODULE FUSES 1 amp 2 ONLY USED S GSC300 CONTROL PANEL ARE TO BE 1A 250V TYPE ABC 1 AND ARE TO BE MOUNTED IN THE GSC300 PANEL2. 1 1 1 exe L n 1 1 1 FRAME i 1 1 1 ENGINE BLOCK NOTES BIZ l l l SEE NOTE 3 1 ALL INSTALLATION CONDUCTORS TO BE AWG 14 T m l l l l 105 C TYPE MTW MULTISTRAND 600 VAC 2 UNLESS COLOR CODED ALL A D E INSTALLED 10 9 WIRES ARE TO BE GREY AND MUST BE IDENTIFIED BY NUMBER MARKER AT EACH CONNECTION POINT 3 INDUSTRIAL UNITS ONLY GROUNDING IS TO BE IN l l 1 1 ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE xl zl ul AND ANY APPLICABLE LOCAL CODES m 6 MARINE UNITS ALL GROUND CONNECTIONS ARE MADE z BY THE CUSTOMER AT THE CUSTOMERS DISCRETION 1 1 1 1 1 1 1 1 1 1 1 1 1 L1 GND SEE NOTE 3 AC Wiring Diagram Drawing 61030 Wiring diagrams are subject to change without notice ONL673L 7 13 36 Wiring Diagrams 1 REGULATOR CIRCUIT BREAKER 4 P l a kg JUNCTION BOX D GENERATOR V2 ORANGE U2 4 vi A C VOLTAGE GREY CPR2 GENERATOR Res OUTPUT DS 71 2M BREAKER LEADS 22 68006 Y r BLUE AUXILIARY CONTACT gt on OFF OPEN TRIP N O OPEN p_ BROWN TS AVR CONNECTOR q WHITE
3. Prevent Bypass and Accidental Starting Recognize Safety Symbols and Instructions In addition to the information found in this section this operator s manual uses three different signal words to outline potential dangers of a specific nature Do not start engine by shorting across start terminal Engine will T B AN GE DANGER indicates a hazardous situation which if start if normal circuitr x 15 bypassed not avoided will result in death or serious injury creating a hazard by runaway ARNING indicates a hazardous situation which if machiner y ot avoided could result in death or serious injury CAUTION indicates a hazardous situation which Start engine only from operator s station t A UTION if not avoided could result in minor or moderate injury Follow Safety Instructions Carefully read and understand all safety messages in this manual and on your machine s safety 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 ALWAYS STOP ENGINE proper placement of safety signs or clarification on BEFORE FUELING safety issue consult your Northern Lights dealer or MACHINE Always fill factory portable fuel tank outdoors There can be additional safety information contained Never fuel a hot engine Handle Fuel Safely Avoid Flames Diesel is highly flammable and should be
4. Tighten bleed screw 3 Loosen bleed screw Pump hand primer on fuel lift pump until pure fuel no bubbles escapes from bleed screw 4 If the engine does not start after the above bleeding process loosen a fuel line at the injector Crank the engine until fuel escapes then tighten the connection Do each line one at a time 5 After the engine has started check for fuel leaks ONL673L 7 13 20 Servicing Figure 15 Remove return line nuts Figure 19 Reinstall injector Torque to proper tightness ONL673L 7 13 21 Servicing SP11 INJECTOR SERVICE 1 Injectors should be checked every 1000 hours Check should be made by a Northern Lights dealer or local injection repair station CAUTION Escaping diesel fuel under pressure can have sufficient force to penetrate the skin caus ing serious personal injury If injured by escaping diesel fuel see a doctor at once Injector removal a Clean loose dirt from around the injectors and the fuel lines b Relieve high pressure in the fuel lines by loosening the delivery line flare nuts at each injector Figure 12 c Remove delivery lines by disconnecting from injectors and injection pump Figure 13 Remove all lines as an assembly do not remove the clamps Cover the ends of the lines the injector inlets and injection pump outlets to keep dirt out Figure 14 d Remove the return line retaining bolts Figure 15
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6. Lubrication 1 17 DATA SHEETS rz Kel 17 EE 33 1 17 Changing Oil 17 WIRING DIAGRAMS 18 DG Blectfiedl 34 KNEE 18 AC Electrical 120 35 Retightening Cylinder Head Bolts 18 AC Electrical 120 240 36 Valve 40 0 18 AC Electrical 240 37 Fuels 2 0009 19 Proprietary Information This publication is the property of Northern Lights Inc It may not be reproduced in whole or in part without the written permission of Northern Lights Inc Northern Lights Inc All rights reserved Litho U S A Publication number ONL673L 7 13 ONL673L 7 13 1 Introduction Servicing of marine engines and generator sets pres ents unique problems In many cases boats cannot be moved to a repair facility Marine engines cannot be compared to the servicing of automobiles trucks or even farm equipment Failures often occur in remote areas far from competent assistance Marine engines are taxed far more severely than auto or truck engines therefore maintenance schedules must be adhered to more strictly Unit Identification Failures begin with minor problems that are over looked and become amplified w
7. Remove the return line Figure 16 e Unscrew and remove the injectors Figure 17 NOTE Do not use pry bars to remove injectors from cylinder head f After removing the injectors discard the copper sealing washers from the injector hole in the head Figure 18 Cover holes to prevent dirt and debris from entering the cylinders Injector installation a Install a new copper sealing washer in each injector hole Figure 18 b Screw in injector and tighten to 43 or 50 ft Ibs 6 to 7 kgm Figure 19 NOTE Overtightening can damage injector c Install return line using new copper sealing above and below each connection Tighten return line retaining bolts to 22 30 ft Ibs d Install delivery lines Leave loose at injectors for bleeding e Crank the engine to fill lines Tighten lines at injectors Start engine and check for leaks using a piece of paper or cardboard DO NOT use hand to check for leaks SP12 INJECTION PUMP Since operating conditions may vary considerably it is difficult to give a definite interval for checking the injection pump But as a rule pump settings maxi mum speed idle speed and exhaust smoke should be checked after every 2500 hours of operation Service of the fuel injection pump should only be done if checks indicate pump malfunction Black smoke can be an indication of pump malfunction Before servicing the pump check other possible causes a Check cleanliness of air filter
8. USING PANEL MOUNT TYPE FUSE HOLDERS CPR1 REGULATOR CIRCUIT BREAKER dus 4 2 AUXILIARY CONTACT ON CLOSED OFF N TRIP OPEN NOTER 2 1 1 l 1 l P 7 E l l ENGINE BLOCK 22 1 SEE NOTE 3 H l l 0 1 1 E 51 zl lt Fl 8 GND SEE NOTE 3 AC Wiring Diagram Drawing B 6105D Wiring Diagrams GENERATOR OUTPUT LEADS Wiring diagrams are subject to change without notice ONL673L 7 13 35 GENERATOR 120VAC 19 60 HZ Wiring Diagrams 100 120 200 240VAC 12 50 60 HZ JUNCTION BOX 4 A 4 3 GENERATOR GENERATOR BREAKER OUTPUT LEADS REGULATOR 05 71 2 OL TITO 22 68006 AUXILIARY CONTACT F ON BREAK ON N O CLOSED AVR CONNECTOR OUTPUT TERMINAL 4 THICK HIDDEN DASHED LINES INDICATE CUSTOMER SUPPLIED AND CONNECTED MAIN OUTPUT CONDUCTORS SIZING DETERMINED PER INSTALLATION 5 MODULE FUSES 1 amp 2 ONLY USED IN 5 65 300 CONTROL PANEL BE 1A 250V 1 AND ARE TO BE MOUNTED IN THE GSC300 PANEL USING PANEL MOUNT TYPE FUSE HOLDERS BOARD GREEN YELLOW 120 DARK BROWN T v2 sex oso E
9. filter in approved manner Make sure the gasket from the old filter is removed and discarded Clean mount face Spread a thin film of engine oil on the rubber gasket on the new filter and screw it on nipple until gasket meets the sealing surface Using hands only no wrench tighten filter one half turn farther Overtightening can do damage to filter housing Fill engine with recommended oil Start engine and check for leakage Stop engine wait 3 minutes and check oil level Add additional oil if necessary Oil filter part numbers are 673L 24 08001 ONL673L 7 13 17 Servicing 5 4 AIR CLEANER After every 25 hours of operation take out the ele ment and clean by blowing in compressed air 7 kg cm2 max from inner side In case soot or oil 15 found adhered on element soak for about 15 minutes in detergent solution and after washing several times rinse thoroughly with clean water Then use after allowing to dry naturally When used in dusty places clean earlier than usual Replace with new element once every year Part number is NL673L 408620002 After cleaning shine a light from the element if found to be torn or with pin holes or thin places Replace gasket if damaged Never use any element that is not sufficiently dry NOTE Make absolutely sure no impurities enter the engine while changing the element Do NOT run the engine with the air cleaner removed SP5 V BELTS 1 Check the tens
10. 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 CHECKING OIL LEVEL Check the oil level in the crankcase with the dipstick The oil level must be in the waffled area on the stick Never allow the level to go below this area Follow the lubrication recommendations above Servicing SP2 OIL CHANGES pe m n 9 The set 15 delivered with special break in oil Change the engine oil and oil filter after 50 hours of operation Use Service CC 30 weight oil during the first 100 hours Change the oil and filter again at 100 hours using the oil recommended in the previous diagram After this change oil and filter on industrial units every 250 hours During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes first Change oil at any seasonal change in temperature when a new viscosity of oil is required Change oil when engine is warm Dispose of waste oil in an approved manner Never use a flushing oil Loosen the clamp on the oil change tube Remove cap Drain oil Replace the cap and tube Refill engine with recommended oil 10 Engine capacity with new oil filter is 673L 3 2 quarts 3 0 liters SP3 CHANGING LUBE OIL FILTER Change the lube oil filter every with every oil change Use a filter wrench to remove old filter Dispose of
11. E QQ U1 120 240 24 Ui 02 V2 GREEN AN OUTPUT TERMINAL am BOARD YELLOW i J F 20 T BRUS DARK BROWN 17 102 i i K F BRUS 410 GREEN a GEN FRAME ENG BLOCK SEE NOTE 3 H NOTES 1 ALL INSTALLATION CONDUCTORS TO BE AWG 14 105 C TYPE MTW MULTISTRAND 600 VAC 2 UNLESS COLOR CODED ALL A D E INSTALLED WIRES ARE BE GREY AND MUST BE IDENTIFIED 5 BY NUMBER MARKER AT EACH CONNECTION POINT a ui 3 MARINE GENSETS ARE GROUNDED BY THE CUSTOMER AT CUSTOMERS DISCRETION NDUSTRIAL GENSETS ARE TO BE GROUNDED IN ACCORDANCE WITH THE ATIONAL ELECTRICAL CODE AND ANY APPLICABLE E LOCAL CODES d eB o Z m AC Wiring Diagram Drawing 6104 Wiring diagrams are subject to change without notice ONL673L 7 13 37 NORTHERN LIGHTS 4420 14th Ave NW Seattle WA 98107 NORTE Tel 206 789 3880 1 800 762 0165 Fax 206 782 5455 A Northern Lights and Lugger registered trademarks Northern Lights Inc www northern lights com 2013 rights reserved Litho USA
12. V belt tension Check valve clearances FUEL SYSTEM Check primary filter Racor Change primary filter element Racor Change secondary fuel filter Bleed the fuel system Check injectors Check fuel injection pump COOLING SYSTEM Check cooling water level Check and flush cooling system Check and clean radiator fins ELECTRICAL SYSTEM Check electrolyte level in batteries Check condition of batteries with hydrometer OUT OF SERVICE SP20 Winterizing or out of service Perform all maintenance once a year even if hour level has not been reached 5 After first 50 hours and again after first 100 hours then every Consult manufacturer s maintenance schedule note on chart 250 hours 1 2 3 Whenever necessary 6 Change air cleaner element at 1000 hours 4 More often if necessary ONL673L 7 13 15 Service Record Notes ONL673L 7 13 16 LUBRICATION GENERAL 1 Use only clean high quality lubricants stored in clean containers in a protected area 2 These lubricants are acceptable Service CC CD CE single viscosity oils b API Service CC CD SF multi viscosity oils 3 Use the proper weight oil for your average operation temperature Air Single Multi Temperature Viscosity Viscosity SAE30W SAE 15 40 0 10 to 32 F 23 to 0 C SAE 10W SAE 10 30W Below 10 F 23 C SAE 5W SAE 5 20W Figure 8 Lube Oils
13. and tighten loose battery and harness plug connection Low battery output e Check specific gravity of each battery e Check electrolyte level of each battery Defective electrical system e Repair or replace ground wire Starter Cranks Slowly Low battery output e Battery is too small e Battery cables are too small Check specific gravity e Replace battery 1f necessary of each battery Check electrolyte level f low fill cells with distilled water of each battery Crankcase oil too heavy Fill with oil of appropriate viscosity Loose or corroded connections Clean and tighten loose connections Entire Electrical System Check DC circuit breaker If breaker is tripped reset it Does Not Function Faulty connection Clean and tighten battery and harness plug connections Sulfated or worn out batteries Check specific gravity and electrolyte level of each battery Dead Battery Charge battery If you cannot correct problems with these procedures see your Northern Lights dealer ONL673L 7 13 29 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE Engine Hard to Start Improper starting procedure or Will Not Start No fuel Low battery output Excessive resistance in starting circuit Crankcase oil too heavy Improper type of fuel Water dirt or air in fuel system Clogged primary fuel filter element Clogged secondary fuel filter element Dirty or faulty injection nozzles Engine Runs
14. as earmuffs or plugs to a protect against loud noises CO JH connections or performing fi 4 ex Operating equipment requires the full attention of the operator Do not use radio or music headphones while operating machinery Practice Safe Maintenance CAUTION Understand all service procedures before starting work Keep area clean and dry Never lubricate service or adjust machine while it is in operation Keep hands feet and clothing away from power driven equipment When shutting down an engine disengage all power and operator controls Allow the engine to cool completely before beginning any service Work Securely support any machinery elements that must be raised for service work with support or lifting machinery specifically intended for that purpose Keep all parts in good conditions and properly installed Fix damage immediately Replace any worn or broken parts Remove any build up of grease oil or debris Disconnect battery ground cable before making any adjustments or service work Stay Clear of Rotating Drivelines Entanglement in rotating drivelines can cause serious injury or death Keep shields in place at all times Make sure that rotating shields turn freely in pace with the drivelines Do not wear loose fitting equipment around rotating drivelines Stop the engine and make sure that all moving parts have stopped before making any adjustments Oy any
15. leads ORANGE GREEN 120 YELLOW 240 BROWN AVR CIRCUIT BREAKER Figure 34 Breaker Locations 9 Parts See Parts Book for complete list a Bearing Part 22 68305 b Brush assembly Part 22 68304 10 Test Specifications See Wiring Diagram s a Resistance of J K 16 6 ohm at 20 C 68 F b Resistance of A B 0 25 ohm at 20 C 68 F c Resistance of U1 V2 Figure 33 Brush Location 0 56 ohm at 20 C 68 F c Attach leads to new brush assembly and install it d No load voltage setting with the plastic ears towards the front of the 242V or 121V at 62 Hz with cold generator generator NOTE Be sure to connect wire J to terminal J and connect wire K to terminal K 6 Generator Protection To protect the generator and AVR from unbalanced loads and over loads two 20 amp breakers are placed in the output circuit and one 3 amp breaker 15 placed in the AVR sensing circuit Figure 34 ONL673L 7 13 28 Troubleshooting DC ELECTRICAL SYSTEM PROBLEM POSSIBLE CAUSE RECOMMENDATION S Battery Will Not Charge Loose or corroded connections e Clean and tighten battery connections Sulfated or worn out batteries e Check specific gravity of each battery e Check electrolyte level of each battery Loose or defective alternator belt Adjust belt tension e Replace belt Starter Inoperative Check DC circuit breaker f the breaker is tripped reset it Loose or corroded connections e Clean
16. other type of service to the engine or other driven equipment p ONL673L 7 13 Revised 6 19 12 Install all Safety Guards Direct contact with rotating fans belts pulley and drives can cause serious injury Keep all guards in place at all times during engine operation Wear close fitting clothes Stop the engine and be sure all fans belts pulleys and drives are stopped before making adjustments connections or cleaning near fans and their components Do not allow anything on your person to dangle into or come in contact with a moving fan belt pulley or drive Fans can act as vacuums and pull materials up from below so avoid that area as well while in service Safe Battery Handling Prevent Battery Explosions Battery gas 15 highly flammable Battery explosions can cause severe injury or death To help prevent battery explosions keep sparks lighted matches and open flame away from the top of battery When checking battery electrolyte level use a flashlight Never check battery charge by contacting the posts with a metal object Use a volt meter or hydrometer Frozen batteries may explode if charged Never charge a battery that has not been allowed to warm to at least 16 609 Always remove grounded battery clamp first and replace ground clamp last Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin eat holes into clothing and other materials and
17. plugs NOTE Three position Engine Control switches must be in the RUN position during preheating Preheat switch must be held in ON position during starting ENGINE CONTROL SWITCH To start the engine hold this switch in the START position until the engine is running NOTE Excessive cranking of marine sets equipped with water lift muffler systems can cause engine damage See page 6 After the engine starts release the switch and it will return to RUN position To stop the engine hold the switch in the STOP position NOTE The rocker switch is used on Series 1 panels only and has a light that glows when the set is running HOUR METER Keeps track of engine running time OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system WATER TEMPERATURE GAUGE Registers the temperature of the cooling water D C VOLTMETER OR AMMETER When the engine is stopped the voltmeter indicates the condition of the battery When the engine is running the voltmeter indicates the voltage output of the alternator For Series 4 Control Panels Only A C VOLTMETER Shows the generator output voltage FREQUENCY METER Hertz The frequency meter indicates engine speed 1200 or 1800 RPM 60 Hz or 1500 RPM 50 Hz AMMETER SELECTOR SWITCH Used to check each phase for load condition NOTE Always leave this switch in the ON position while the unit is running A C AMMETER Shows the generator load on each phas
18. the alternator or regulator 7 AD C circuit breaker protects your control panel and wiring harness It is located in the side of the generator junction box ONL673L 7 13 25 Servicing GLOW PLUGS 1 Each cylinder is supplied with a glow plug which serves to heat the combustion chamber for starting To check the glow plugs loosen the current carrying flat wire between the plus poles of the glow plugs Figure 20 Connect a D C test bulb between the plus pole of the battery and the plus pole of the glow plug If the bulb lights up the glow plug 15 functioning properly 3 Check all glow plugs and replace any faulty ones Figure 20 Glow plugs BOOSTER BATTERIES CAUTION Battery gas can explode Keep all flames and sparks away from batteries 1 Before changing or using booster batteries check bat tery electrolyte level Add distilled water if necessary 2 Booster and main batteries must have the same volt age rating 3 First connect positive terminal of booster bat to positive terminal of main battery Then connect negative terminal of booster battery to ground on the engine block see Figure 21 4 Remove booster battery after starting engine 5 Sealed batteries See manufacturer charging and booster instructions Figure 21 Battery connections Battery SP 18 19 BATTERY CARE Check electrolyte level every 50 hours or once per month Add distilled
19. Below normal engine temperature or Stalls Frequently Clogged primary fuel filter element Clogged secondary fuel filter element Water or dirt in the fuel system Dirty or faulty injection nozzles Air in fuel system Improper type of fuel Lack of Engine Power Intake air restriction Clogged primary fuel filter element Clogged secondary fuel filter element Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles ONL673L 7 13 30 RECOMMENDATION S See starting section of this manual Take special note of Bypass Switch operation Check level of fuel in fuel tank Check electrolyte level and condition Clean and tighten all battery connections Use oil of proper viscosity Consult fuel supplier and use proper type of fuel for operating condition Drain flush fill and bleed system Clean or replace filter element Replace filter element Have your dealer check injection nozzles Remove and check thermostat Clean or replace filter element Replace secondary filter element Drain flush fill and bleed system Have your dealer check injection nozzles nspect clamps and hoses on suction side of fuel pump for air leak Consult fuel supplier and use proper type of fuel for operating condition Service air cleaner Clean or replace filter element Replace filter ele
20. DUCTION 2 Model 00 7 2 Serial 2 SERVICING CONTINUED Fuel Filters ossscesecaxceenataaesteeceseaosstenedeosieeusancedionads 19 WARRANTY 3 Bleeding the Fuel System 20 SAFETY RULES 3 7 Injection 22 LOCK OUT TAG OUT PROCEDURES 8 Cooling System General 22 Cooling System BEIUSDIBS us coser hamis 23 COMPONENT LOCATIONS Clean 23 NL 673 Industrial Generator 10 Electrical Systent e General 23 GIO e S scout 24 PANELS Booster 00 0 24 Northern Lights Generator Sets 11 12 Battery in msi 24 OPERATING PROCEDURES Winterizing Out of Service 24 Break in Period 13 AC GENERATOR TF 276D 13 25 13 Connections 26 13 13 27 0 ste eee MuIi _ cM UBS te cease oo oa ce 14 27 28 Spare 14 TROUBLESHOOTING SERVICING SCHEDULE CHART 15 1 29 IE DT 30 32 SERVICING
21. Generator excitation is provided by residual magnetism and electrical output voltage is controlled by the automatic voltage regulator AVR located in the control box Figure 24 Item 2 Generator GENERATOR Figure 23 1 Stator Core Stator Coil End Cover Brush Ball Bearing Slip Ring Frame Coupling Plate Field Coil Field Core 11 Shaft 12 Ventilation Cover 9 n OQ t N a WY nO Rh CONTROL BOX Figure 24 Control Terminal Block 2 Automatic Voltage Regulator AVR 3 2 Volt DC Circuit Breaker 4 AC Circuit Breaker 5 AVR Circuit Breaker 6 Output Terminal Board 5 9 BLUE BED GRAY ORANGE 120 YELLOW 240 BROWN Figure 24 Control Box Components ONL673L 7 13 25 2760 CONNECTIONS 120 Volt Output a 120 volt output can be selected by connecting the terminals of the control terminal board to 120 Figure 25 also see page 29 V2 AVR DS 71 2M 1 WHITE BROWN BLUE RED GRAY ORANGE Figure 28 Output Terminal Board 240 Volt Output G
22. High Pressure Fuel System Many Northern Lights engines use high pressure fuel injection High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt any repair of fuel lines sensors or other ONL673L 7 13 6 Added 6 19 12 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 Avoid Hot Exhaust Avoid exposure to and physical contact with hot exhaust gases Exhaust parts and streams can reach high temperatures during operation leading to burns or other serious injury Cleaning exhaust filters can also lead to exposure to hot exhaust gas and the injury risk associated with it Avoid exposure to and physical contact with hot exhaust gases when cleaning exhaust filters During auto or manual stationary exhaust filter cleaning operations the engine will run at elevated temperatures for an extended period of time Exhaust parts and streams can reach high temperatures during operation leading to burns or other serious injury Avoid Harmful Asbestos Dust Inhaling asbestos fibers may cause 32 lung cancer Avoid breathing any dust that may be generated when handling components containing asbestos fibers including some gaskets The asbestos used in these components is usually found in a r
23. REEN 120 YELLOW 240 BROWN 3 120 240 Volt Output a Connect the control terminal board for 240 volts Figure 25 Control Terminal Board 120 Volt Output Figure 29 also see page 30 b Connect U1 to U2 and to V2 on the output terminal board Figure 26 Connect 120 volt output leads to terminals U1 and V2 AVR DS 71 2M Figure 29 Control Terminal Board 120 240 Volt Output b Connect U2 and V1 on the output board Figure 30 Connect output leads to U2 and V2 and neutral lead to V1 or U2 240 volt output is available from the leads connected to U1 and V2 The 120 volt load should be divided as equally as possible between two 120 volt circuits Figure 26 Output Terminal Board 120 Volt Output 2 240 Volt Output a 240 volt output can be selected by connecting the terminals of the control terminal board to 240 Figure 27 V2 WHITE AVR DS 71 2M RED ORANGE GREEN 120 YELLOW 240 BROWN GRAY Figure 27 Control Terminal Board 240 Volt Output b Connect U2 to V1 on the output terminal board Figure 28 also see page 31 Figure 30 Output Terminal Board 120 240 Volt Output ONL673L 7 13 26 OPERATION In order to ensure a long trouble free life the gen erator must be operated properly and the specified maintenance must be performed OPERATING ENVIRONMEN
24. T Always keep electrical equipment clean Moisture salt dust and oil will damage the generator The operating environment must be kept as clean and moisture free as possible VENTILATION Good ventilation is important for proper genera tor operation When installing the generator set be sure the ambient temperature does not exceed 40 104 F during operation MAINTENANCE Proper and effective maintenance 15 required to ensure trouble free operation In addition to the above items the following are required Periodically check all bolts and nuts for proper torque This is especially true for coupling bolts 2 Besure to keep the generator area clean and dry a Dust and foreign material may reduce the flow of cooling air reducing heat dissipation and causing the generator to overheat b If electrically conductive debris accumulates on the windings or if moisture or salt water are absorbed into the windings the windings may short or ground reducing voltage output c Wiping is the only effective method for removing dust and foreign materials Use a clean lint free piece of cloth 3 generator has not been operated for an extended period of time check the insulation resis tance of each stator coil and the rotor Disconnect the AVR from the generator when per forming this test 2760 4 Voltage Adjustment a b If there is some voltage but it does not build
25. W Rating Frequency Hz kW OUTPUT 60 Hz 1800 RPM 120 240 Volt Amperage 120 Volt Amperage Phase Optional Phase kW OUTPUT 50 Hz 1500 RPM 110 220 Volt Amperage 110 Volt Amperage Phase Optional Phase ENGINE Lugger Model Diesel Cylinders Displacement Bore Stroke Horsepower 1800 RPM Approximate Fuel Rate Rated Speed with Full Load DIMENSIONAL DATA Exhaust Outlet Fuel Inlet and Return Hose Height Width Length Approximate Dry Weight Notes 1 Based on 1 0 unity power factor Deratings 3 per 1000 ft over 500 ft above sea level 1 for every 10 over 85 F L673L 3 46 4 in 0 761 Itr 2 64 in 67 mm 2 83 in 72 mm 9 9 0 59 gal hr 2 4 Itr hr 1 50 in 38 mm 0 25 in 6 mm 26 38 in 670 mm 15 35 in 390 mm 33 in 834 mm 377 lbs 171 kg NL673L 1500 L673L 3 46 4 in 0 761 Itr 2 64 in 67 mm 2 83 in 72 mm 8 5 0 49 gal hr 1 9 Itr hr 1 50 in 38 mm 0 25 in 6 mm 26 38 in 670 mm 15 35 in 390 mm 33 in 834 mm 377 lbs 171 kg ONL673L 7 13 33 Northern Lights Industrial Data _ yvig 0 AB SLOVINOD 3OMSVHOSIQ 384 uJHSIPONILX3 TVNOILdO cg0gazcel 4 2019 9 Buimeiq 350
26. b Check valve clearances c Clean and check injectors Any repair which involves disassembly of the injec tion pump must be carried out by specially trained mechanics with the proper tools and test equipment NOTE All warranties on the engine become null and void if the injection pump seals are broken by unauthorized persons COOLING SYSTEM GENERAL CAUTION The cooling water 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 system Open the filler cap carefully using protective clothing when the engine is warm SP13 CHECK THE COOLANT LEVEL 1 Check the coolant level each day before starting the engine Check the water level by removing the pres sure cap from the expansion tank or radiator In order to give the cooling water an opportunity to expand the level should be about 1 in 2 5 cm below the filler cap sealing surface when the engine is cold The pressure valve in the filler cap releases when the pressure is approximately 12 8 PSI 0 91 bar Use a cap pressure tester to check cap if you suspect it is faulty ONL673L 7 13 22 SP14 COOLING SYSTEM FLUSHING Flush the cooling system every 2500 hours or every 12 months whichever comes first 2 Cooling System Flushing a Remove radiator cap and open drain cocks on radiator and engine block b Pour clean water int
27. back in the system and re check the bleed off point until complete shut off is achieved Affix a DO NOT OPERATE tag to each valve handle that requires shut off Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment Lock Out Tag Out Instructions Air Hose Connected Pneumatic Equipment Equipment connected to the compressed air system through an air hose with a detachable fitting must be shutdown and unplugged Excess air must be bled prior to removing the air hose prior to any maintenance or repair activities Affix a DO NOT OPERATE tag to the air hose near the detachable fitting Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment Check that the equipment cannot be operated by activating the ON switch Stored Energy Immediately after applying Lock Out or Tag Out devices ensure that all potentially hazardous stored or residual energy is relieved disconnected restrained and otherwise rendered safe Verification of Isolation CAUTION Verify the machinery or equipment is actually isolated and de energized prior to beginning work on a machine or on equipment that has been locked out Restarting Procedures CAUTION Follow the procedures below prior to restoring energy Ensure that all machinery or equipment is properly reassembled Inspect the machinery or equipment to verify non essential items have been
28. cause blindness if splashed into eyes Safety Rules Continued To Avoid Hazards e Fill batteries only in well ventilated areas Wear appropriate eye protection and rubber gloves Never use air pressure to clean batteries Wear appropriate ventilation equipment to avoid inhaling fumes when adding electrolyte Do not spill or drip electrolyte Use correct jump start procedure if required If acid is spilled on skin or in eyes 1 Flush skin with water 2 Apply baking soda or lime to help neutralize acid 3 Flush eyes with water for 15 30 minutes 4 Get medical attention immediately If acid 1s swallowed 1 DO NOT induce vomiting 2 Drink large amounts of water or milk without exceeding 2 liters 2 quarts 3 Get medical attention immediately Battery posts terminals and related accessories can contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injury Among the potentially hazardous chemicals that may be used with Northern Lights products are lubricants coolants paints and adhesives All potentially hazardous chemicals come with a Material Data Safety Sheet MSDS The MSDS provides specific details on chemical products including physical hazards safety procedures and emergency response tech
29. crank the starter for more than 20 seconds consecutively If the engine fails to start with the first attempt be sure that it has stopped completely before re engaging OPERATING Units with Series 3 Series 4 and Series 7 Control Panels check gauges often Oil pressure must be above 15 PSI The D C voltmeter should read between 11 and 15 volts at 80 25 ambient temperature The water temperature gauge must be below 225 F 107 C Check the A C voltage and frequency meters Series 4 and 6 panels If the gauges deviate from normal levels shut down the generator set and investi gate 2 Letthe unit run unloaded for a 3 5 minute warm up period 3 Add electrical load STOPPING Remove electrical load from the generator set 2 Run the engine for a3 to 5 minute cool down period Move the Engine Control switch to the STOP position momentarily ONL673L 7 13 13 Operating Procedures SHUTDOWNS AND ALARMS 1 Your unit may be fitted with a warning horn to protect it from high water temperature or low oil pressure a Generator sets have shutdown systems to stop the engine They have no warning horns b Other alarms and shutdowns are available as optional equipment NOTE Do not rely on your warning to the exclusion of careful gauge monitoring Watching your gauges can prevent damage to the unit and dangerous power losses Do the following when your warning or shutdown system is a
30. ctivated a Check the temperature gauge If above 230 F 110 C shut off the engine immediately b Use the Trouble Shooting Guide on page 23 to isolate the cause of the overheat CAUTION not remove the water fill cap of an overheated engine Escaping high temperature steam can cause severe burns Allow the engine to cool and then remove the cap slowly using protective clothing c Make repairs Restart your set after the temperature registers below 225 F 107 C d Watch the temperature gauge regularly and turn off the unit if the temperature rises above 230 F 110 C on Industrial sets Repeat troubleshooting If shutdown is activated and the temperature gauge shows temperature within normal temperature range a Check the engine crankcase oil level b If the oil level is low fill with recommended lubricating oil and restart Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading 20 60 PSI after a few seconds of operation c If the oil level is normal DO NOT restart the engine Call your dealer for assistance SPARE PARTS 1 Northern Lights recommends that you keep the following spare parts on hand for field service The parts are available from your local Northern Lights dealer 2 All owners should have the following Primary and secondary fuel filter elements Oil filters Air filter industrial units only Alternator belt Thermostat an
31. d gaskets Glow plug Injector and washer 3 If your set is operating a long distance from a servicing dealer add the following a Complete set of injectors b Copper washers for injector change c Complete set of glow plugs d Fuel lift pump ONL673L 7 13 14 Servicing Schedule Chart The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your generator set More detailed coverage of each Service Point SP is listed on the page noted in the page column DAILY EVERY 500 HOURS SP1 Check oil level in engine SP8 Change primary fuel filter element SP5 Check V belt tension SP9 Change secondary fuel filter SP7 Check primary fuel filter SP13 Check coolant level EVERY 1000 HOURS SP18 Check electrolyte level in batteries SP4 Change air cleaner element SP6 Check valve clearances AFTER FIRST 50 HOURS SP11 Check injectors SP2 3 Change engine oil and filter SP6 Adjust valves EVERY 2500 HOURS SP12 Check fuel injection pump AFTER FIRST 100 HOURS SP14 Check and flush cooling system SP2 3 Change engine oil and filter EVERY 250 HOURS SP2 3 Change engine oil and filter 5 4 Check air cleaner SP10 Bleed the fuel system SP16 Check and clean radiator fins SP19 Check state of charge of batteries SERVICE 250 500 1000 POINT OPERATION DAILY Hours Hours Hours ENGINE Check oil level Change engine oil Change lube oil filters Check air cleaner Check
32. e The phase is selected with the Ammeter Selector switch Item 9 Industrial Control Panels o fa A LA Nw TIU mmm OM d gt 9 5 NW Figure 7 A Series 7 1 through Series 7 6 Generator DELE ELI Agor OFF 5 rn MANUAL START Control Panels STATUS INDICATORS as Standard S 7 3 thru S 7 6 Standard 5 7 6 Standard S 7 6 Standard S 7 3 thru S 7 6 Standard S 7 3 thru S 7 6 Standard S 7 4 thru S 7 6 Standard 5 7 4 thru 5 7 6 Standard 5 7 3 thru S 7 6 Standard S 7 3 thru S 7 6 Standard S 7 5 amp S 7 6 Standard 5 7 5 amp S 7 6 Standard S 7 5 amp S 7 6 Standard S 7 6 Standard S 7 6 system eaor emencency stor Low on pressure Q encime Hich encime a LOW ENGINE TEMP row ve uve E NOT IN AUTO START LOW BATTERY WOLTS CHARGE FAULI E m a g 9 LAMP TEST o ALARM RESET o RESET ii 1 L 1 7 Figure 7 B Status Indicators for Series 7 3 through Series 7 6 Generator Control Panels ONL673L 7 13 11 12 ENGINE CONTROL SWITCH Manual Start S 7 1 through S 7 6 Move the switch in the MANUAL position and the engine will start and run Auto Start Panels S 7 1 through S 7 6 When the switch is placed in
33. esel fuels a Use grade No 2 diesel at ambient temperatures above freezing 32 0 b Use grade no 1 at ambient temperatures below freezing and for all temperatures at an altitude of above 5 500 ft 1500 meters 2 Use fuel having less than 1 sulphur preferably less than 0 5 3 The cetane number should be a minimum of 45 4 DO NOT use these unsuitable grades of fuel a Domestic heating oils all types Class B engine Class D domestic fuels Class E F G or H industrial or marine fuels ASTM D975 60T No 4 D and higher number fuels CO C 5 Storing fuel a Keep dirt scale water and other foreign matter out of fuel b Avoid storing fuel for long periods of time c Hill the fuel tank at the end of each day s operation This will reduce condensation Servicing SP7 9 FUEL FILTERS 1 Your generator set should have a primary fuel filter installed We recommend the Racor brand of fuel filter water separators a Check the primary fuel filter daily as recommended by the filter manufacturer Empty the collection bowl as necessary b Change the element as often as necessary or every 250 hours c If the bowl fills with water change the primary and secondary element immediately Change secondary fuel filter every 250 hours a Remove the spin on filter by turning it counterclockwise with a filter wrench Fill the new cartridge with fuel and install it after applying e
34. esin or otherwise sealed Normal handling of these components is not dangerous as long as airborne dust containing asbestos is not generated Avoid creating dust Never use compressed air for cleaning Avoid brushing or grinding materials containing asbestos When servicing wear an approved respirator A special vacuum cleaner is recommended to clean asbestos If this vacuum is not available apply a mist of oil or water on the Safety Rules Continued material containing asbestos Keep all bystanders away from any area where asbestos dust may be generated Use Proper Lifting Equipment and Techniques Lifting heavy components incorrectly can cause severe injury or damage to machinery Avoid unbalanced loads Do not use lifting eyes Lift the generator set using lifting bars inserted through the lifting holes on the skid Follow all recommended removal and installation procedures in this and associated Northern Lights manuals Use Proper Tools CAUTION Makeshift tools and procedures can create safety hazards Always use appropriate tools for the job Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware always use the correct sized tools Do not use US measurement tools on metric fasteners or vice versa Use only service parts that meet Northern Lights specifications Dispose of Waste Properly CAUTION Disposing of waste improperly can threaten the env
35. fore attempting to perform any type of work on the equipment Obtain an electrical plug cap cover with a lockset Secure the plug terminal end using the electrical plug lockout cap Lock the cap and retain the key If the equipment is directly wired into an electrical box with a shut off switch obtain a lock pad and or the appropriate colored tags and place the lock and tag through the shut off lever Retain the key until the repair is completed and the machine is safe to start Be certain the shut off lever is in the OFF position before restarting NEVER give a lock out key to unauthorized personnel If the equipment is directly wired into an electrical box without a shut off switch and lock out capability then a circuit breaker lock out will be required Obtain a circuit lock and tag set Install the lock onto the circuit breaker box Ensure the unit ON OFF switch is in the OFF position before restarting Lock Out Tag Out Instructions Pneumatic and Hydraulic Equipment For servicing pneumatic and hydraulic equipment the following additional procedures must be implemented following completion of lock out tag out procedures for the unit to be serviced Shut off air water or supply valves at the equipment to be serviced Check the local bleed off point for completed release of pressurized air water or oil If shutting off of air water or other material cannot be achieved at the local supply valve shut off valves further
36. hen not corrected during routine maintenance As operator it is your obligation to learn about your equipment and its proper maintenance This is not a comprehensive technical service manual Nor will it make the reader into an expert mechanic Its aim is to aid you in maintaining your unit properly MODELS INCLUDED This manual covers the operating instructions for NL673L industrial generator sets Model Numbers Model numbers give the unit s application block model aspiration and RPM NL NL Northern Lights industrial generator set Dus an automatic voltage regulator and a radiator Serial Numbers 673 Model number of engine block Bore Cylinders 67 mm 3 Northern Lights industrial diesel generator set with an 673 engine TF 276D generator end NORTHERN LIGHTS Serial No Model No Northern Lights 4420 14th Ave NW Seattle WA 98107 Figure 1 Generator set serial number plate Your set has three serial numbers engine number stamped on the block 2 generator plate and 3 a generator set plate Use the serial number on the generator set plate when ordering parts or in correspondence The generator set plate is found on the service side of the generator and resembles the drawing in Figure 1 ONL673L 7 13 Revised 7 10 13 Warranty A warranty registration certificate is supplied NOTE If the warranty is to apply the servicing with your set It entitle
37. i OPERATOR 5 MANUAL ULTRA LOW SULFUR FUEL ONLY RE529956 As of January 2011 U S EPA regulations require the application of a permanently applied label near the fuel tank fill port for diesel driven equipment This label is to state ULTRA LOW SULFUR FUEL ONLY Northern Lights is providing this label for application to the fuel inlet of the fuel supply tank for each engine or generator set This is to be applied by the installer of the engine or gen set or by the manufacturer of the equipment that the engine or gen set is installed in The location of the label must be in clear site of personnel that refill the supply tank CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constitu ents are known to the State of California to cause cancer birth defects and other reproductive harm Northern Lights 4420 14th Avenue N W Seattle WA 98107 Tel 206 789 3880 Fax 206 782 5455 Copyright 92013 Northern Lights Inc All rights reserved Northern and the Northern Lights logo are trademarks of Northern Lights Inc Printed in U S A PART NO ONL673L 7 13 NORTHERN LIGHTS OPERATOR S MANUAL for Model NL673L 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 INTRO
38. ion and wear on the V belt daily 2 Use your thumb to press on the belt at the midpoint between the crankshaft and alternator pulleys The tension is correct if the belt can be depressed about 3 16 in 5 mm cu Valve Adjustment Screw Rocker Arm AS 08 in 00 mm NO Figure 10 Valve Adjustment SP6 VALVE CLEARANCES 1 Readjust valve clearance after first 50 hours of operation and every 1000 hours thereafter 2 Valve adjustments should be done after the cylinder head bolts have been re tightened Engine should be cold and NOT running 3 Watch the valves while turning the engine over by hand Turn until the 1 cylinder inlet valve starts to open and the exhaust valve starts to close the valves are rocking Then turn the crankshaft one more full turn and adjust the clearance on both valves for this cylinder 4 Loosen the lock nut and adjust the clearance between the rocker arm and valve stem of both the intake and exhaust valves with the adjustment screw Figure 10 Clearance on both intake and exhaust valves should be 0 008 in 0 2 mm 5 Repeat steps 3 and 4 for each cylinder Each set of valves must be adjusted individually 6 Replace the rocker arm cover Tighten cover nuts to 7 2 8 7 ft lbs 1 0 1 2 kg m ONL673L 7 13 18 FUELS GENERAL 1 Useonly clean high quality fuels of the following specifications as defined by ASTM designation 0975 for di
39. ironment and lead to unsafe working conditions Potentially harmful waste used in Northern Lights equipment can include oil fuel coolant filters and batteries Use leakproof containers to drain fluid Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source ONL673L 7 13 7 Added 6 19 12 Lock Out Out Procedures Scope During maintenance repairs or retooling of a Northern Lights generator set simply turning the machine off or unplugging it while it is being worked on does not give enough protection to others who are not performing the maintenance or repair Many serious accidents happen when someone thought the machine was turned off or all of its energy was safely blocked or released General Policy CAUTION To avoid dangerous or hazardous situations refrain from any of the following e Removing or bypassing a guard or other safety device Placing any part of your body in a position where you could be caught by moving machinery Cleaning or oiling machinery when in operation Adjusting circuits chillers pumps air handlers valves circuit breakers or fans while in operation Working on piping or high pressure systems Lock Out Tag Out Instructions Equipmen Be sure the equipments ON OFF switch is in the OFF position and is unplugged from any electrical source be
40. ment Consult fuel supplier and use proper type of fuel for operating conditions See Engine Overheats in next category Remove and check thermostat Reset valves Best done by dealer Replace injectors Best done by dealer See your local dealer Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION Ey Engine Overheats Low coolant level Fill tank or radiator to proper level Check hoses for loose connections and leaks Keel cooling tubes have been Remove paint from tubes painted marine Cooling system needs flushing Flush cooling system Defective thermostat Remove and check thermostat Defective temperature gauge Check water temperature with thermometer and replace gauge if necessary Water pump impeller worn broken Check impeller and replace if necessary Engine Knocks Insufficient oil Call your dealer Injection pump out of time Call your dealer Below normal engine temperature Check your thermostats Check water temperature to see if temperature gauge is working properly Engine overheating See Engine Overheating section High Fuel Consumption Improper type of fuel Use correct fuel for temperature Clogged or dirty air cleaner Service air cleaner Improper valve clearance See your dealer Injection nozzles dirty e See your dealer Injection pump out of time e See your dealer Engine not at proper temperature Check your thermostats Check water te
41. mperature with thermometer and replace gauge if necessary Below Normal Thermostats not working properly Check thermostats Engine Temperature Temperature gauge Check water temperature with thermometer not working properly Low Pressure Low oil level Fill crankcase to proper level Improper type of oil Drain and fill crankcase with correct oil Partially plugged oil filter Replace filter If you cannot correct problems with these procedures see your Northern Lights dealer ONL673L 7 13 3 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION S High Oil Consumption Break in period e Oil consumption decreases after break in Crankcase oil too light e Use proper viscosity oil Oil leaks e Check for leaks in lines around gaskets and drain plug Engine Emits Black Clogged or dirty air cleaner Service air cleaner or Gray Exhaust Smoke Defective muffler Have dealer check back pressure back pressure too high Improper fuel Use correct fuel for temperature Injection nozzles dirty e See your dealer Engine out of time e See your dealer Engine Emits Improper fuel Use correct fuel for temperature White Smoke Cold engine Warm up engine to normal operating temperature Defective thermostat Remove and check thermostat Engine out of time See your dealer If you cannot correct problems with these procedures see your Northern Lights dealer ONL673L 7 13 22 Model RPM k
42. ngine oil to gasket surface Screw on until the gasket surface comes into contact with sealing surface of filter base Then tighten it two thirds of a turn by hand Do not overtighten b Fuel filter part numbers are 360720020 24 52020 1 Found on older NL673 units Found on newer NL673 amp NL673L units ONL673L 7 13 19 SP10 BLEEDING THE FUEL SYSTEM CAUTION Escaping diesel fuel under pressure can penetrate skin causing serious personal injury Before disconnecting lines be sure to relieve all pressure Before applying pressure be sure all connections are tight and lines pipes and hoses aren t damaged Fuel escaping from a very small hole can be almost invisible Use a piece of card board or wood rather than hands to search for suspected leaks If injured by escaping fuel see a doctor at once Serious infection or reaction can develop if proper medical treatment isn t adminis tered immediately Figure 11 B NL673L Fuel System EI 2 1 The fuel system 15 self bleeding However any system may need manual bleeding when a new fuel filter is installed b The engine has run out of fuel c The fuel lines injection pump or any other fuel system component has been removed and installed 2 Loosen bleed screw Figure 11 on top of the filter Pump hand primer B on fuel lift pump until pure fuel no bubbles escapes from bleed screw
43. niques ONL673L 7 13 5 Added 6 19 12 Safety Rules Continued Read and understand the MSDS for each chemical before you start any job that includes it Follow the procedures and use appropriate equipment exactly as recommended Contact your Northern Lights dealer or Northern Lights factory for MSDS s used on Northern Lights products Work in Well Ventilated Areas CAUTION Exhaust fumes from engines contain carbon monoxide and can cause sickness or death Work in well ventilated areas to avoid prolonged exposure to engine fumes If it is necessary to run an engine in an enclosed area route the exhaust fumes out of the area with an approved leak proof exhaust pipe extension Remove Paint Before Welding or Heating Hazardous fumes can be generated when paint is heated by welding soldering or using a torch To avoid 55 potentially toxic fumes and dust remove paint before heating 2 Remove paint a minimum of 100 mm 4 in from the area that will be affected by heat f paint cannot be removed wear an approved respirator f you sand or grind paint use an approved respirator f you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers from the area Allow at least 15 minutes for fumes to disperse before welding or heating Do not use a chlorinated solvent in an area where welding Will occur W
44. o radiator until water coming from radiator is clear of discoloration c Close the radiator drain and continue flushing until water from engine drain is clear d Open all drain cocks and drain completely e Close drain cock and refill with recommended coolant mixture f Clean fins on radiator 3 Coolant Specifications marine and industrial Use 50 water 50 ethylene glycol antifreeze mix Antifreeze mixture is recommended as a good year round coolant 4 Check hoses and connections and repair any leakage SP16 CLEAN RADIATOR 1 Remove debris from radiator fins daily 2 In very dusty applications clean the radiator with compressed air or steam cleaner every 100 hours Clean in the reverse direction of the airflow GENERATOR ENDS The maintenance and operation recommendations for the generator end are located on pages 19 22 under the heading Generator Servicing ELECTRICAL SYSTEM GENERAL 1 Never switch 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 battery 3 When welding on the unit disconnect the AC amp DC voltage regulator and battery Isolate the leads 4 Disconnect the battery cables when servicing the D C alternator 5 Never test with a screwdriver etc against any ter minal to see if it emits sparks 6 Do not polarize
45. ork only in areas that are well ventilated Dispose of paint and solvent properly Service Cooling System Safely Opening a pressurized cooling system can release explosive gt fluids and causing serious burns Before opening any pressurized cooling system make sure the engine has been shut off Do not remove a filler cap unless it is cool enough to comfortably grip with bare hands Slowly loosen cap to relieve pressure before opening fully Avoid High Pressure Fluids Relieve pressure prior to disconnecting pressurized lines Escaping fluid under pressure can penetrate the skin causing serious injury Always relieve pressure before disconnecting hydraulic or other pressurized lines Tighten all connections firmly before re applying pressure If searching for leaks use a piece of cardboard Always protect your hands and other body parts from high pressure fluids If an accident occurs see a doctor immediately Any high pressure spray injected into the skin must be removed within a few hours to prevent the risk of gangrene or other infection Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns and bodily injury Pressurized lines can rupture when heat goes beyond the immediate flame area Do not weld solder or use a torch or open flame near pressurized lines or other flammable fluids Do Not Open
46. removed e Ensure that all personnel are safely outside danger zones Notify personnel that lock out tag out devices have been removed and energy will be reapplied Only authorized personnel may remove lock out tag out devices or notices ONL673L 7 13 8 ONL673L 7 13 9 Industrial Generator Component Locations Figure 4 NL673L Non Service Side Figure 5 NL673L Service Side o Alternator Muffler Exhaust Outlet Starter DC Regulator Generator Control Box AC Circuit Breaker 7 Air Filter 13 Fuel Lift Pump 8 DC Circuit Breaker 14 Block Water Drain 9 Bleed Screw 15 Lube Oil Dipstick 10 Fuel Injector 16 Lube Oil Filter 11 Coolant Fill 17 Lube Oil Drain 12 Fuel Injection Pump 18 Secondary Fuel Filter ONL673L 7 13 10 19 Fuel Inlet and Return 20 AVR Circuit Breaker 21 Control Panel 9 PREHEAT amp SHUT GENERATOR GENERATOR DOWN BYPASS START HOURS Hobbs o o ome TOTAL HOURS Series 4 Generator Set Control Panel _ amp Figure 6 C Series 4 Generator Control Panel 7 ONL673L 7 13 11 Control Panels SHUTDOWN BYPASS PREHEAT SWITCH There are two functions built into this switch preheating the engine and bypassing the engine safety shutdown circuit enabling a start Hold the switch in the ON position for approximately 10 to 20 seconds before starting a cold engine Holding the switch ON for too long can burn out the glow
47. s 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 The extent of coverage is contact an authorized dealer or the factory described in the Limited Warranty Statement We recommend that you study the statement carefully Safety Rules A NOTICE Accident reports show that careless use of engines causes a high percentage of accidents You can avoid accidents by observing these safety rules Study these rules carefully and enforce them on the job IMPORTANT SAFETY INSTRUCTIONS on parts and components from outside suppliers Electromagnetic equipment including generator sets that is not reproduced in this manual Consult the and their accessories can cause bodily harm and suppliers for additional safety information life threatening injuries when improperly installed operated or maintained To prevent accidents be aware Learn how to operate the machine and how to use of potential dangers and act safely the controls properly Only trained personnel should operate machines or work on or around them READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL Keep you machine in proper working condition PRIOR TO THE INSTALLATION UNAUTHORIZED MODIFICATIONS TO THE OF ANY GENERATOR SET OR MACHINERY MAY IMPAIR ITS FUNCTION ACCESSORY KEEP THESE AND SAFETY PARAMETERS INSTRUCTIONS FOR FUTURE REFERENCE
48. the AUTO START position the unit will automatically start if an ATS is connected OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system HOUR METER Keeps track of engine running time ENGINE TEMPERATURE GAUGE Registers the temperature of the coolant D C VOLTMETER When the engine is running the voltmeter indicates the voltage output of the alternator STATUS INDICATOR PANEL Engine monitoring alarms and lamps for monitoring engine functions ALARM LAMP TEST AND RESET BUTTON Press UP to test the indicator lights and press DOWN to reset the alarm A C VOLTAGE ADJUSTMENT RHEOSTAT Voltage has been set at the factory and should only be adjusted by factory trained personnel AMMETER SELECTOR SWITCH Used to check each phase for load condition NOTE Always leave this switch in the ON position while the unit is running FREQUENCY METER HERTZ The frequency meter indicates alternator current fre quency 60 Hz 1200 or 1800 RPM or 50 Hz 1500 RPM A C VOLTMETER Shows the generator output voltage A C AMMETER Shows the generator load on each phase The phase is selected with the Ammeter Selector switch Item 9 BREAK IN PERIOD 1 The first 100 hours on a new or reconditioned engine are critical to its life and performance 2 Constantly check the engine temperature and oil pressure gauges sets with Series 3 or 4 panels 3 Oil consumption 15 greater during break in as pis
49. ton rings take time to seat 4 Break In Oil Changes Change engine oil and filter at 50 hours Change oil and filter again at 100 hours consult Lubricants section p 11 for oil recommendation Operating Instructions Maintain at least a 75 load on your generator set for the first 100 hours Vary the load will help seat the rings BEFORE STARTING Check the water level by removing the pressure cap from the expansion tank or radiator In order to give the cooling water an opportunity to expand the level should be about 1 in 2 5 cm below the filler cap sealing surface when the engine 15 cold CAUTION Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns 2 Check the oil level in the crankcase with the dip stick The oil level must be in area on the stick Never allow the level to go below this area Always add the same viscosity of oil as 15 already in the crankcase 3 Check the fuel tank level and open any fuel valves Operating Procedures STARTING FOR S 1 S 1B S3 AND S4 SEE PAGE 6 FOR S7 Hold the Shutdown Bypass Preheat switch in the ON position for 10 to 20 seconds before starting a cold engine Holding the switch too long can burn out the glow plugs While holding the Shutdown Bypass Preheat switch in the ON position push the Engine Control switch to the START position As soon as the engine starts release both switches Do not
50. treated with care at all times Do not refuel while smoking or when near sparks or open flame S ONL673L 7 13 3 Revised 6 19 12 Safety Rules Prevent accidental discharge of starting fluids by storing all cans in a cool safe place away from sparks or open flame Store with cap securely on container Never incinerate or puncture a fuel container Prevent fires by keeping machine clean of accumulated trash grease and debris Always clean any spilled fuel as swiftly as possible Do not store oily rags which can ignite and burn spontaneously Be prepared if a fire starts Keep a first aid kit and fire extinguisher handy Keep emergency contact numbers for fire department doctors ambulance and hospital near the telephone Service Machines Safely Do not wear a necktie scarf necklace rings or other jewelry or any loose clothing when working near moving parts Tie long hair behind your head If any of these items get caught in moving machinery severe injury or death could result Check for any loose electrical connections or faulty wiring Look completely around engine to make sure that everything is clear before starting Wear Protective Clothing To prevent catching anything in moving machinery always wear close fitting clothes and safety equipment appropriate to the job Prolonged exposure to loud noise can cause hearing loss or impairment Wear suitable authorized ED hearing protection such
51. up to rated voltage voltage adjustment can be made using the hand trimmer in the AVR Figure 31 The normal voltage setting at no load is 121 volts at 62 Hertz or 242 volts at 62 Hertz HAND TRIMMER Figure 31 Hand Trimmer Location on AVR 5 Check the ball bearing in the generator end a b le Listen for unusual noise Abnormal temperature rise can be noted by discoloration If the bearing 1s failing it must be replaced Generator bearing should be replaced by your Northern Lights dealer at 10 000 hours 6 Check the brushes a The carbon brushes gradually wear with use so they must be inspected periodically and replaced as necessary If the brushes are excessively worn as to expose the pigtail Figure 32 sparking will occur at the surface of the slip ring causing surface damage Therefore periodic inspection of the brushes is important Normally the brushes will have to be replaced with a new brush assembly within 3 000 hours PIGTAIL Figure 32 Brush Pigtail ONL673L 7 13 21 2760 7 Replacing Brushes WHITE AVR a Shut down the generator Remove four screws 05 71 2 BROWN BLUE and end cover of the generator Circuit b Brush assembly is white plastic with two wires Hg GRAY Breaker leading to it It is located at ten o clock and is held in position by two screws Figure 33 Remove the screws and unplug
52. water to manufacturer s recom mended level Batteries cables and cable terminals should be checked and cleaned every 100 hours Clean corrosion with a water and baking soda solu tion Flush with clean water Tighten terminals and grease them to inhibit corrosion Check the battery condition with a hydrometer every 600 hours SP20 WINTERIZING OUT OF SERVICE Industrial sets a Drain and flush the radiator and cooling system Leave dry or refill with antifreeze water mixture If refilling start the engine and run to circulate the antifreeze b Seal the air cleaner inlet exhaust opening crankcase breather pipe and fuel tank vent with plastic bags and tape Store the set in a dry protected place If unit must be stored outside be sure it is well protected with cover d Change the crankcase oil and filter e Loosen the alternator belt f Disconnect and clean battery Remove to warm storage place if possible g Clean outside of unit Paint any scratched or chipped surfaces Put corrosion preventative on all exposed metal surfaces h Hill the fuel tank or add biocide as per manufacturer s instructions ONL673L 7 13 24 Hevised 6 19 12 2760 GENERAL 1 A Generator Set includes the engine the generator Control Box and the control or J box Figure 22 2 generator and the control or J box produce the electrical power 3
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