OPERATOR`S MANUAL - Northern Lights generatoren
Contents
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3. 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 Q 2 6 appropriate to the job Prolonged exposure to loud noise can cause hearing loss or impairment Wear suitable authorized hearing protection such as earmuffs or plugs to protect against loud noises Operating equipment requires the full attention of the operator Do not use radio or music headphones while operating machinery Practice Safe Maintenance 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 di 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 r
4. Clean and tighten loose battery and harness plug connection Low battery output Check specific gravity of each battery Check electrolyte level of each battery Defective electrical system Repair or replace ground wire Starter Cranks Slowly Low battery output Battery is too small Battery cables are too small Check specific gravity Replace battery if necessary of each battery Check electrolyte level f low fill cells with distilled water of each battery Loose or corroded connections Clean and tighten loose connections Crankcase oil too heavy Fill with oil of appropriate viscosity 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 OM673L3 5 11 21 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 or secondary fuel filter element Dirty or faulty injection nozzles Fuel injected but no ignition Engine Runs Irreg
5. OPERATOR 5 MANUAL A 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 2010 Northern Lights Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Northern Lights Inc Printed in U S A PART NO OM673L3 5 11 NORTHERN LIGHTS OPERATOR S MANUAL for Models M67313 and 673 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 INTRODUCTION 2 SERVICING Models Included 2 Fuels 17 Model NUMDETS 2 i 17 Serial Numbers 2 Bleeding the Fuel 17 15 18 WARRANTY RR RERUMS 3 Injection 19 SAFETY RULES 3 19 Cooling System Flushing 19 COMPONENT LOCATIONS Heat Exchanger 21 M673 Marine 8
6. TVNIWH3L LAdLNO YOLOINNOOD YAY 340 440 er EDV NO LOVLNOD AYVNIXNV IO Oj 90089 22 SUE emm 2 14 5 LINOJ YOLVYANAO ovvor 11538 8 JOVLIOA OV V SOL Ve833N39 LINDYIO YOLVINOSY Tadd OM673L3 5 11 34 eonou 1oe qns TH g 1 2019 d 9 lt lt 1 4 punoJc 5 OC SHOA 21 UNS e eo 766 1 bes weibeig BuuiM 7 66 dois e i isar e L J ox SY purum pams IS 3NION NVd a E 11 y cRNA LMS NMOGLNHS JOMINOO 3NION3 tage L v lt MIN 3dAL 9 38 OL SYOLINGNOD 5 5 F ees INIOd NOILO3NNOO 2 3 LV 3 8 O3LIIN3O 3B ISNN ONY b 339 38 OL SYOLONONOD QITIISNI 3 03002 30709 SSIINN 2 i ber i 0310N Sv Q3013HS 03151 1 1932X3 i 5 2 00 vj 38 Ol S
7. Consult the suppliers for additional safety information Learn how to operate the machine and how to use the controls properly Only trained personnel should operate machines or work on or around them Keep you machine in proper working condition UNAUTHORIZED MODIFICATIONS TO THE MACHINERY MAY IMPAIR ITS FUNCTION AND SAFETY PARAMETERS Prevent Bypass and Accidental Starting Do not start engine by shorting across start terminal Engine will start if normal circuitry is bypassed creating a hazard by runaway machinery Start engine only from operator s station Handle Fuel Safely Avoid Flames Diesel is highly flammable and should be treated with care at all times Do do not refuel while smoking or when near sparks or open flame OM673L3 5 11 3 Revised 5 12 11 Safety Rules ALWAYS STOP ENGINE BEFORE FUELING MACHINE Always fill amp portable fuel tank outdoors 9 Never fuel a hot engine 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
8. M673L3 0 761 Itr 4 2 64 in 67 mm 2 83 in 72 mm CCW 23 5 1 3 2 qts 3 0 Itr Natural 362 Ibs 164 kg 20 25 in 514 5 mm 19 5 in 495 mm 28 5 in 725 mm 0 761 Itr 4 2 64 in 67 mm 2 83 in 72 mm CCW 23 5 1 3 2 qts 3 0 Itr Natural 362 Ibs 164 kg 20 25 in 514 5 mm 19 5 in 495 mm 28 5 in 725 mm 5 gal 2 Itr 0 75 in 19 mm 0 75 in 19 mm 0 75 in 19 mm 250 BTU min 4 2 gal min 15 77 Itr min 39 in 1 m 7 0 gal min 26 Itr min 4 ft 1 2 m 0 75 in NPT 19 1 mm 1 0 in 25 mm OM673L3 5 11 31 0 761 Itr 4 2 64 67 2 83 72 CCW 23 5 1 3 2 qts 3 0 Itr Natural 362 Ibs 164 kg 20 25 in 514 5 mm 19 5 in 495 mm 28 5 in 725 mm 5 gal 2 ltr 0 75 in 19 mm 0 75 in 19 mm 0 75 in 19 mm 350 BTU min 5 0 gal min 18 92 Itr min 39 in 1 m 8 0 gal min 30 Itr min 4 ft 1 2 m 0 75 in NPT 19 1 mm 1 0 in 25 mm M673LD3 0 761 Itr 4 2 64 in 67 mm 2 83 in 72 mm CCW 23 5 1 3 2 qts 3 0 Itr Natural 362 Ibs 164 kg 20 25 in 514 5 mm 19 5 in 495 mm 28 5 in 725 mm 5 gal 2 Itr 0 75 in 19 mm 0 75 in 19 mm 0 75 in 19 mm 250 BTU min 4 2 gal min 15 77 Itr min 39 in 1 m 7 0 gal min 26 Itr min 4 ft 1 2 m 0 75 in NPT
9. 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 2 The pressure valve in the filler cap releases when the pressure is approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it is faulty OM673L3 5 11 Servicing Figure 16 Remove return line nuts Figure 20 Reinstall injector Torque to proper tightness OM673L3 5 11 20 Servicing SP14 COOLING SYSTEM FLUSHING 1 Flush the cooling system every 2500 hours or every 12 months whichever comes first a Remove expansion tank cap and drain engine block b Leave all drains open c Pour clean water into expansion tank until water coming from drains 15 free of discoloration and sediment d Let water drain completely e Close drains and refill with recommended mixture NOTE Open sea cock before running engine 2 Coolant Specifications Use 50 water 50 ethylene glycol antifreeze mix Antifreeze mixture is recommended as a good year round coolant but not methyl alcohol based antifreeze because of its low boiling point Also antifreeze with high silicate should not be used as it could cause silica gelation pr
10. 19 1 mm 1 0 in 25 mm eDueuo Ogo 19 310N 335 ZH 09 06 CIN UNO OV SHOA 07 00 0c L 00L Hum oy SYSCIOH 3504 LNNOW TANVd SNISn TANVd 00959 JHL NI GSLNNOW 38 OL 38V L 98V AOSZ VL 38 OL I3NVd TONLNOO l 00 9 9 NI 435 AINO SASNA FINGOW 76 NOLLVTIVISNI Yad Q3NIWH313Q SNIZIS SYOLONGNOD LAdLNO Q3193NNOO Q3llddns YSWOLSND 31VOIQNI SINI 5 N3GGIH MOIHL l lo lo SYSWOLSND LV YSWOLSND 3HL 3QVW 38V SNOLLOANNOO GNNOYS SUNN 3NISVIN m 54402 WOOT 318 2 3909 71951919313 39NVQ3OOD2V 38 OL SNIGNNOYD AINO SLINN IWINLSNGNI aay 3LIHA LNIOd NOLLO3NNOO HOV4 LV Y3MXYW YSEWNN A8 38 ISAW 9 38 OL 53 93905 30709 SS3INn OVA 009 GNVYLSILINN MLW 3dAL 5 501 38 OL SYOLONGNOD NOLVTIVISNI 1 SALON o 310N 33S 42018 3NION3 3ANVMJ N39 S 31ON 33S IJN Z4N m p oo ee m pio io io eee adio dio eee eee eee e
11. Motor ed 24 Lube Oil Fill Side Tank Exhaust Manifold 11 DC Regulator 1 Pater 25 Block Drain 4 Lube Oil Fill Top 12 DC Alternator n E aped 26 Lube Oil Dipstick 5 Wet Exhaust Elbow 13 Belt Guard 2 E ee ump 27 Lube Oil Filter 6 Generator Junction Box 14 AVR Circuit Breaker er e es 28 Fuel Inlet and Return 7 Control Panel Plug In 15 AC Circuit Breaker Water rump 29 Coolant Recovery Tank OM673L3 5 11 8 Revised 5 12 11 Marine Generator Component Locations Figure 2 M673L3 Non Service Side with 2010 or later baseframe Figure 3 M673L3 Service Side with 2010 or later baseframe 28 27 ee es 1 Heat Exchanger End Cap 8 Generator End Cover 2 Coolant Fill Pressure 9 Vibration Mount 16 DC Circuit Breaker 23 Lube Oil Drain 3 Heat Exchanger Expansion 10 Starter Motor 17 Air Filter Housing 24 Lube Oil Fill Side Tank Exhaust Manifold 11 DC Regulator ie 25 Block Drain 4 Lube Oil Fill Top 12 DC Alternator OF 26 Lube Oil Dipstick 5 Wet Exhaust Elbow 13 Belt Guard Fuel Injection Pump 27 Lube Oil Filter 6 Generator Junction Box 14 AVR Circuit Breaker 21 Fuel Lift Pump 28 Fuel Inlet and Return 7 Control Panel Plug In 15 AC Circuit Breaker 22 Sea Water Pump 29 Coolant Recovery Tank 67313 5 11 9 Updated 6 24 10 Control Panels PREMEAT GENERATOR 1 SHUTDOWN BYPASS PREHEAT SWITCH SHUTOOWN CAUT
12. Remove Paint Before Welding or Heating Hazardous fumes can be generated when paint is heated by welding soldering or using a torch To avoid potentially toxic fumes and dust remove paint before heating Remove paint a minimum of 100 mm 4 in from the area that will be affected by heat If paint cannot be removed wear an approved respirator If 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 Work only in areas that are well ventilated Dispose of paint and solvent properly Service Cooling System Safely Opening a pressurized cooling system release explosive ds 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 18 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 T
13. amounts of water or milk without exceeding 2 liters 2 quarts 3 Get medical attention immediately WARNING 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 techniques 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 OM673L3 5 11 Revised 5 12 11 Safety Rules Continued Contact your Northern Lights dealer or Northern Lights factory for MSDS s used on Northern Lights products Work in Well Ventilated Areas 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
14. the first attempt Operating Instructions be sure that it has stopped completely before re Maintain at least a 75 load on your generator engaging set for the first 100 hours Vary the load will help NOTE Excessive cranking of the starter on Marine seat the rings sets equipped with a water lift muffler can cause engine damage If the engine does not start after three BEFORE STARTING 10 second cranks remove the impeller from the raw water pump This will prevent the muffler from filling Check the water level by removing the pressure with water and backfilling the exhaust line and engine cap from the expansion tank or radiator In order to Once the engine starts shut it off immediately and re give the cooling water an opportunity to expand the install the impeller Re start the engine and check the level should be about 1 in 2 5 cm below the filler exhaust overboard outlet for gushes of water cap sealing surface when the engine is cold If using an overflow bottle the manifold should be full to OPERATING cap and the bottle should have coolant in it Units with Series 3 and Series 4 Control Panels check CAUTION Use protective clothing and open gauges often Oil pressure must be above 15 PSI The the filler cap carefully when the engine is warm D C voltmeter should read between 11 and 15 volts at to prevent burns 80 F 25 C ambient temperature The coolant tempera ture gauge must be between 167 F and 194 F 75 C to 2 Check t
15. to exposure to hot exhaust gas and the injury risk associated with it Avoid exposure 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 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 15 usually found in a resin 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 15 not available apply a mist of oil or water on the 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
16. 206 789 3880 1 800 762 0165 Fax 206 782 5455 Northern Lights Lugger are registered trademarks of Northern Lights Inc www northern lights com 2010 rights reserved Litho USA
17. 5W SAE 5 20W Never use a flushing oil Loosen the clamp on the oil change tube Remove cap Drain oil Replace the cap and tube 9 Refill engine with recommended oil eo Figure 9 Lube Oils 10 Engine capacity with new oil filter 1s 4 Some increase in oil consumption may be expected M673L3 amp LD3 3 3 quarts 3 1 liters when SAE 5W and SAE 5 20W oils are used Check oil level frequently SP3 CHANGING LUBE OIL FILTER 5 Never put additives or flushing oil in crankcase 1 Change the lube oil filter every with every oil SP1 CHECKING OIL LEVEL change 2 Use a filter wrench to remove old filter Dispose of 1 Check the oil level in the crankcase with the dip filter in approved manner stick The oil level must be in the waffled area 3 Make sure the gasket from the old filter is removed on the stick Never allow the level to go below this and discarded Clean mount face area Follow the lubrication recommendations above 4 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 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 wait 3 minutes and check oil level Add additional oil if necessary 7 filter part numbers are M673L3 amp LD3 24 08001 OM673L3 5 11 15 Upd
18. 8304 held in position by two screws Figure 34 10 Test Specifications See Wiring Diagram s Remove the screws and unplug leads 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 Resistance of U1 V2 0 56 ohm at 20 C 68 F d No load voltage setting 242V or 121V at 62 Hz with cold generator Figure 34 Brush Location c Attach leads to new brush assembly and install it with the plastic ears towards the front of the generator NOTE Be sure to connect wire J to terminal J and connect wire K to terminal K 8 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 is placed in the AVR sensing circuit Figure 35 DC CIRCUIT BREAKER 222221 DO F po ZZZZ Circuit Breaker AVR CIRCUIT BREAKER Figure 35 Breaker Locations OM673L3 5 11 26 page updated 6 22 10 Troubleshooting DC ELECTRICAL SYSTEM PROBLEM POSSIBLE CAUSE RECOMMENDATION S Battery Will Not Charge Loose or corroded connections Clean and tighten battery connections Sulfated or worn out batteries Check specific gravity of each battery Check electrolyte level of each battery Loose or defective alternator belt Adjust belt tension Replace belt Starter Inoperative Check DC circuit breaker f the breaker is tripped reset it Loose or corroded connections
19. 9 Raw Water 21 Generator NGS eitis 21 PANELS Electrical System General 21 Northern Lights Generator Sets 10 Gia 22 Booster 22 OPERATING PROCEDURES Battery de 22 Break in 11 Winterizing Out of Service 22 11 11 2760 Operating 11 GE STA 23 11 Connections 24 Shutdowns and 1 12 25 Spare 12 25 26 SERVICING SCHEDULE CHART 13 TROUBLESHOOTING SERVICING neinni an 27 15 28 30 Checking Oilasini 15 DANTES UM 15 DATA SHEET Changing Oil Filter 15 31 NER EDS 16 RR RE E 16 WIRING DIAGRAMS Valve 1 2 16 AC Electrical 32 34 DC Electrical sre 35 36 Proprietary Information This publication is the property of Northern Lights Inc It may not be reproduced in whole or in part without
20. ION Ovewrenhing ence x x BYPASS This switch serves two functions 1 Preheats glowplugs before beginning the starting process Press switch for 10 20 seconds OTE before attempting start up epee 2 Bypasses the safety shutdown feature during the starting process Keep switch engaged while starting engine and for 2 to 3 seconds afterwards allowing oil pressure to build beyond shutdown setpoint 2 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 7 After the engine starts release the switch and it will return to RUN position To stop the engine press the switch to the STOP position NOTE The rocker switch is used on Series I panels only and has a light that glows when the set is running 3 HOUR METER Keeps track of engine running time QUARTZ 4 OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system 5 WATER TEMPERATURE GAUGE Registers the temperature of the cooling water 6 D C VOLTMETER When the engine is running the voltmeter indicates the voltage output of the alternator For Series 4 Control Panels Only 7 A C VOLTMETER Shows the generator output voltage Series 4 8 FREQUENCY METER Hertz Generator Set MER Control Panel The frequency meter indicates engine sp
21. SS3NAVH ONY S3LON 335 po j S TWNOILdO 8 5 jNION3 j pq X087 YOLVaSs 0 0 TANVd TONLNOD OM673L3 5 11 35 DC Wiring Diagrams eonou m oe ee ATA 7777777777 I 8 Duiweiq Au Pe TOR EP Y SHOA 21 80 mobs uic nana webera MN CN N V p Tes Io L J LUVLS H LIMS 14 553 SS3NHVH 47 g HDRINDTEI SSVdAH 3015 3NION3 3015 V HOLMS NMOGLNHS 1051409 3NION3 a MLN 91 OMY 38 01 SYOLINGNOD ANOJ 5314365 76 1NIOd HOV3 LV H3XHVM AG 38 ISN i lt l e 1349 38 OL SYOLONGNOD 0311 15 1 3 0 Tiv 03002 30102 SSIINN 72 Mec A Sv ONY 030131 5 03151 1 1939 3 NL I ONVULSILINN 9501 38 OL SYOLONGNOD NOLVTYVISNI 1 i 1 4 SALON Lee ie t z 7777 lt 3 39nv9 SL 7 4 9131 NONI X m TTT ii dana c c 4000 1738 77771 81 JIIHM 8i lt I NO t d em 4 1 HOLNS
22. YOLINGNOD NOLVTIVISNI 1 2777 amp B TwWL Ll 310N VEN CUP M 5092 0 1 39nvo S I dW3l N l UT HAN doe ELEN PEN Lll 0 QNNOYD 35v2 08 0 M 1 21 3onvo 74 z lt 34nSS34H 539439 pm A E c Ke 1 T J GNNOYD 4 02 WS d 08 0 gt gt gt E 3 907 39495 i S340 AB O 3unSS3Nd 10 17 annos 7 7 ANO duse x e V M Cl sen Por ias ET dq 3 i ze O ONNOYD 3592 _ lt i a i 310N 335 Q 1359 nd v S S wNOILaO aa Pare HOLIMS gt Ne 3unsS3d 4 i ee __ wwe X18 0 lt Es Q 4 NV 1 oi T ONNOYD 35 2 inia 3 XR mer 3078 71 0129706811 i 8 o YOLVNYSI TV or __ lt z SINA MOTD 18 4 g 18 oe F 934 1340 x gt a 5 ee S 190916681 bi Ko OGLNHS 312018 3NI9N3 IB 3045 H2v3 Li G iaa YOLOW 5318415 Or 9 31 Zi lt lt lt ll S1BVD 9 V 20 21 S3
23. aised 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 connections or performing any other type of service to the engine or other driven equipment OM673L3 5 11 Revised 5 12 11 Safety Rules Continued 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 Ah 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 s
24. alves with the adjustment screw Figure 3 16 in 5 mm 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 Valve Adjustment Screw 6 Replace the rocker arm cover Tighten cover nuts to _ Rocker Arm 5 8 ft lbs 0 8 2 3 kg m 0 008 i 0 200 mm co Figure 10 Valve Adjustment Cylinder No 1 2 3 Valve Arrangement Int Exh Int Exh Int Exh When No 1 cylinder is at Top Dead Center in the QO QO QO Figure 11 Timing Mark stroke With the crankshaft turned 360 in normal direction from above Valve Arrangement OM673L3 5 11 16 Servicing FUELS GENERAL 1 Use only clean high quality fuels of the following specifications as defined by ASTM designation D975 for diesel fuels a Use Grade No 2 diesel at ambient temperatures above freezing 32 F 0 b Use Grade No 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 DONOT 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 industr
25. ase with correct oil Replace filter e Oil consumption decreases after break in Use proper viscosity oil Check for leaks in lines around gaskets and drain plug e Service air cleaner e Have dealer check back pressure Use correct fuel for temperature e See your dealer e See your dealer Use correct fuel for temperature Warm up engine to normal operating temperature Remove and check thermostat e See your dealer If you cannot correct problems with these procedures see your Northern Lights dealer OM673L3 5 11 30 Model RPM kW Rating Frequency Hz GENERAL INFORMATION Cylinders Displacement Cycle Bore Stroke Rotation facing flywheel Compression Ratio Crankcase Capacity w Oil Filter Aspiration Dry Weight Complete Unit Height Width Length COOLING SYSTEM Approximate Cooling System Capacity 5 gal 2 Itr Minimum Through Hull Diameter 0 75 in 19 mm Raw Water Pump Inlet Hose I D 0 75 in 19 mm Minimum Seawater Discharge 0 75 in 19 mm Heat Rejection to Jacket Water 350 BTU min Fresh Water Pump Capacity 5 0 gal min 18 92 Itr min Maximum Seawater Pump Suction Head 39 in 1 Seawater Pump Capacity 8 0 gal min 30 Itr min Keel Cooler Turbo Tube Length 4 ft 1 2 m Keel Cooler Head Diameter 0 75 in NPT 19 1 mm Keel Cooler Water Hose I D Discharge and Suction 1 0 in 25 mm revised 4 12 10 Northern Lights Marine Data
26. ated 6 23 10 Servicing SP4 AIR CLEANER SP6 VALVE CLEARANCES 1 Inspect air cleaner every 250 hours In dusty 1 Adjust valve clearance every 1000 hours conditions check more often 2 Valve adjustments should be done if the cylinder 2 Inspect the element If it is dirty wash the element in head bolts have been re tightened Engine should be soapy water Rinse and dry thoroughly before cold and NOT running re installing Replace if necessary Part number is 3 To bring the No 1 cylinder to top dead center in the M673L3 amp LD3 24 28003 compression stroke align the timing mark the top mark of the crank pulley with that of the timing gear NOTE Make absolutely sure no impurities enter case Remove the rocker arm cover and turn the the engine while changing the element Do NOT crankshaft foward and backward If the inlet and run the engine with the air cleaner removed exhaust valves of the No 1 cylinder do not move it is in top dead center position When the valves SP5 V BELTS move or rock turn the crankshaft one full turn and align the top mark of the crank pulley with the top Check the tension and wear on the V belt daily mark of the timing gear case 2 Use your thumb to press on the belt at the midpoint 4 Loosen the lock nut and adjust the clearance between between the crankshaft and alternator pulleys The the rocker arm and valve guide of both the intake tension is correct if the belt can be depressed about and exhaust v
27. e 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 cardboard 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 administered immediately Figure 12 M673 Fuel System The fuel system is self bleeding However any system may need manual bleeding when a Anew 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 Loosen bleed screw Figure 12 on top of the filter Pump hand primer B on fuel lift pump until pure fuel no bubbles escapes from bleed screw Tighten bleed screw Loosen bleed screw Pump hand primer on fuel lift pump until pure fuel no bubbles escapes from bleed screw OM673L3 5 11 18 If the engine does not start after the above bleeding process loosen a fuel line at the injector Crank the engine until pure fuel escapes then tighten the connection Do each line one at a time After the engine has started check for fuel leaks using a piece of cardboard Servicing SP11 INJECTOR SERVICE Injectors should be checked every 1000 hours or more often as necessary Check should be made by a North
28. e temperature gauge shows temperature within normal temperature range a This shutdown could have happened because of a too high exhaust temperature This could have been caused by a damaged impeller or a partially blocked sea water strainer Check the sea water Strainer first If it is clear then check the condition of the sea water impeller b Check the engine crankcase oil level c 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 d If the oil level is normal DO NOT restart the engine Call your dealer for assistance OM673L3 5 11 12 page updated 6 22 10 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 SP21 Inspect condition of exhaust elbow SP13 Check cooling water level Check sea strainer EVERY 1000 HOURS SP17 Check electrolyte 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 SP16 C
29. e terminals of the control terminal board to 120 Figure 26 v2 AVR DS 71 2M Figure 29 Output Terminal Board 240 Volt Output 3 120 240 Volt Output a Connect the control terminal board for 240 volts Figure 30 v2 240 BROWN Figure 26 Control Terminal Board 120 Volt Output AVR DS 71 2M WHITE 1 b Connect U1 to U2 and V1 to V2 on the output terminal board Figure 27 Connect 120 volt output leads to terminals U1 and V2 U1 GREEN 120 YELLOW 240 BROWN Figure 30 Control Terminal Board 120 240 Volt Output b Connect U2 and V1 on the output board Figure 31 Connect output leads to U1 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 2 240 Volt Output a 240 volt output can be selected by connecting possible between two 120 volt circuits the terminals of the control terminal board to 240 Figure 28 Figure 27 Output Terminal Board 120 Volt Output AVR DS 71 2M 240 BROWN Figure 28 Voltage Selector Terminal 240 Volt Output b Connect U2 to V1 on the output terminal board Figure 29 Figure 31 Output Terminal Board 120 240 Volt Output OM673L3 5 11 24 Generator TF 276D 4 Voltage Adjustment In order
30. ealer optional equipment Some marine models already have On Board Kits NOTE Do not rely on your warning to the a handy box that contains the most common parts exclusion of careful gauge monitoring Watching you will need your gauges can prevent damage to the unit and 2 Allowners should have the following dangerous power losses a Primary and secondary fuel filter elements 2 Dothe following when your warning or shutdown b Oil filters system is activated c Air filter a Engage the preheat switch to check the d Alternator belt temperature gauge e Thermostat and gaskets b If above 205 96 use the Trouble Shoot f Raw water pump impeller amp gaskets ing Guide on page 25 to isolate the cause of the g Glow plug overheat h Injector and washer 3 If your set is operating a long distance from a CAUTION Do not remove the water fill servicing dealer add the following of an overheated engine Escaping high a Complete set of injectors temperature steam can cause severe burns b Copper washers for injector change Allow the engine to cool and then remove the c Complete set of glow plugs d cap Slowly using protective clothing Fuel lift pump c Make repairs Restart your generator set after the temperature gauge registers below 200 F 94 d Watch the temperature gauge regularly and turn off the unit if the temperature rises above 205 F 96 C Repeat troubleshooting 3 If shutdown is activated and th
31. ee eee eee o o ee L Wiring Diagrams 5 H 90089 22 50 31 INdLNo HS ovvor YOLV 1 934 8 9 YOLVYANAD SN L3 lo o E 7 ZH 09 05 L OVAOVC OO0C 041 001 Tadd OM673L3 5 11 32 eonou 37019 OV SHOA 092 002 GND 9 oy Iz Im z E 3009 14201 z jl8vOllddv ANY 3002 121419313 TVNOILVN na JHL 30 04022 NI G3ONNOYD 38 OL S 13 39 WINLSNGNI NOIL3HOSIQ SY3INOLSND 1Y YAWOLSND AG SI3SN39 3NINVW E NOIL23NNOO HOV3 LV H3 iBVW 38 LSNW 43X9 38 OL 33 SJXIM Q3TWISNI SOV 03009 0709 SSIINN Z i 310N 33S OVA 009 ONVYLSILINW MIN 2 801 X90078 ON3 38 OL SYOLONGNOD NOILVTIVISNI 11 1 3Wv33 N39 SJ LON Oif i E IN 5 A E EN M ee e Q3vog Z Tuna naino RYT pen 1 9 5 ON 200 0350195 121NO 90089 22 AN ETE WNZ 11 59 1 dl 2vvOE MOIV3H3N39 YOLVINOSY 8 JOVLION YOLVYINIO
32. eed 1800 RPM 60 Hz or 1500 RPM 50 Hz 9 AMMETER SELECTOR SWITCH Used to check each phase for load condition NOTE Always leave this switch in the ON position And Prnt eh ed while the unit is running 10 A C AMMETER Shows the generator load on each phase The phase is selected with the Ammeter Selector switch Item 9 Figure 6 Series 4 Generator Control Panel OM673L3 5 11 10 Updated 6 23 10 Operating Procedures BREAK IN PERIOD The first 100 hours on a new or reconditioned engine are critical to its life and performance Constantly check the engine temperature and oil pressure gauges sets with Series 3 or 4 panels STARTING 1 11 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 Oil consumption is greater during break in as 2 While holding the Shutdown Bypass Preheat switch piston rings take time to seat in the ON position push the Engine Control switch to Break In Oil Changes Change engine oil and the START position filter at 50 hours Change oil and filter again at 3 As soon as the engine starts release the start switch 100 hours then at every 250 hours consult Then hold the bypass for 2 3 more seconds Do not Lubricants section for oil recommendation crank the starter for more than 10 seconds consecu tively If the engine fails to start with
33. ern Lights dealer or local injection repair station CAUTION Escaping diesel fuel under pressure A can have sufficient force to penetrate the skin causing serious personal injury 1 injured by escaping diesel fuel see a doctor at once 2 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 13 c Remove delivery lines by disconnecting from injectors and injection pump Figure 14 Remove all lines as an assembly do not remove the clamp Cover the ends of the lines the injector inlets and injection pump outlets to keep dirt out Figure 15 d Remove the return line retaining bolts Figure 16 Remove the return line Figure 17 e Unscrew and remove the injectors Figure 18 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 19 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 19 b Screw in injector and tighten to 43 or 50 ft Ibs 6 to 7 kgm Figure 20 NOTE Overtightening can damage injector c Install return line using new copper sealing below each connection Tighten return line retaining bolts to 22 30 ft Ibs d Install deli
34. ers D Series designation 67 mm 3 3 Tier M673LD3 Northern Lights marine diesel generator set with a 673 engine long stroke TF 276D generator end Tier 5 kW Serial Number Your set has three serial numbers 1 an engine number stamped NORTHERN LIGHTS on the block 2 a generator plate and 3 a generator set plate Use the serial number on the generator set plate when ordering parts Serial No or in correspondence The generator set plate 15 found on the service Model 34 side of the generator and resembles the drawing in Figure 1 Northern Lights 22 Red Note an additional label with the set serial number is placed on the upper front corner of the generator junction box Figure 1 Generator set serial number plate OM673L3 5 11 2 Revised 5 12 11 Warranty A warranty registration certificate is supplied with your set It entitles the original purchaser of our equipment to a warranty covering material or assembly faults The extent of coverage is described in the Limited Warranty Statement We recommend that you study the statement carefully NOTE If the warranty is to apply the servicing instructions outlined in this manual must be followed If further information is needed please contact an authorized dealer or the factory Safety Rules CAUTION Accident reports show that careless use of engines causes a high percentage of accidents You can avoid acciden
35. ery Booster Battery OM673L3 5 11 22 page updated 6 22 10 AC Generator TF 276D GENERAL 1 Generator Set includes the engine the generator Control and the control or J box Figure 23 2 The generator and the control or J box produce the electrical power 3 Generator excitation is provided by activation of the pre heat circuit and electrical output voltage is controlled by the automatic voltage regulator AVR located in the control box Figure 25 Item 2 Generator GENERATOR Figure 24 1 Stator Core Stator Coil End Cover Brush Ball Bearing Slip Ring Frame Coupling Plate Field Coil Field Core 11 Shaft 12 Ventilation Cover Se ae dex 29 D e e 2 NY 7 Or ee amp C 8 9 S F CONTROL BOX Figure 25 1 Voltage Selector Terminal 2 Automatic Voltage Regulator AVR 3 12 Volt DC Circuit Breaker 4 AC Circuit Breaker 5 AVR Circuit Breaker 6 Output Terminal Board E gt 5 8 C Figure 24 Generator Components Figure 25 Control Box Components OM673L3 5 11 23 Generator TF 276D CONNECTIONS 1 120 Volt Output a 120 volt output can be selected by connecting th
36. hange impeller in raw water pump SP6 Adjust valves EVERY 2500 HOURS AFTER FIRST 100 HOURS SP12 Check fuel injection pump SP2 3 Change engine oil and filter SP14 Check and flush cooling system SP15 Check and clean heat exchanger EVERY 250 HOURS SP2 3 Change engine oil and filter SP4 Check air cleaner SP10 Bleed the fuel system SP18 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 change element 1000 hrs 1 4 Check 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 16 Check cooling water level 17 Check and flush cooling system 17 Check and clean heat exchanger 17 Change impeller in raw water pump Inspect condition of exhaust elbow ELECTRICAL SYSTEM SP17 18 Check electrolyte level in batteries SP18 18 Check condition of batteries with hydrometer IPIE SP20 18 W interizing or out of service 3 Perform all maintenance once a year even if hour level has not been reached Consult manufacturer s maintenance schedule note on chart 6 Clean injection nozzles every 1500 hours 7 For EPA emission standards fuel nozzle needs to be cleaned e
37. he oil level in the crankcase with the 90 Check the voltage and frequency meters dipstick The oil level must be in the waffled area on Series 4 panel If the gauges deviate from normal the stick Never allow the level to go below this area levels shut down the generator set and investigate Always add the same viscosity of oil as is already in 2 Letthe unit run unloaded for a 3 5 minute warm up the crankcase period Check the fuel tank level and open any fuel valves 3 Add electrical load Close the sea cock check and clean the sea strainer and reopen the sea cock STOPPING Place the battery switch in the ON position NOTE The battery switch must always be kept 1 Remove electrical load from the generator set ON while the engine is running If the switch is 2 Run the engine for a 3 to 5 minute cool down period turned OFF while the engine is running the 3 Move the Engine Control switch to the STOP battery charging regulator could be ruined position momentarily 4 Shut off the seacock fuel valve and battery switch OM673L3 5 11 page updated 8 27 09 Operating Procedures SHUTDOWNS AND ALARMS SPARE PARTS 1 Generator sets have shutdown systems to stop the 1 Northern Lights recommends that you keep the engine in the event of high water temperature or low following spare parts on hand for field service The oil pressure parts are available from your local Northern Lights a Other alarms and shutdowns are available as d
38. ial or marine fuels ASTM D975 60T No 4 D and higher number fuels 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 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 500 hours c If the bowl fills with water change the primary and secondary element immediately Change secondary fuel filter every 500 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 engine 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 number is M673L3 amp LD3 24 52020 OM673L3 5 11 17 1 Updated 6 23 10 Servicing 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 sur
39. ighten 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 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 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 OM673L3 5 11 Revised 5 12 11 Safety Rules Continued 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
40. ion Uneven compression cylinders Service air cleaner Clean or replace primary filter element replace secondary filter element 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 ENGINE PROBLEM Lack of Engine Power continued Engine Overheats Engine Knocks High Fuel Consumption Below Normal Engine Temperature page updated 6 22 10 Troubleshooting POSSIBLE CAUSE RECOMMENDATION S Cylinder compression pressure low Adjust valve clearance Low coolant level or cooling system defective Keel cooling tubes have been painted Cooling system needs flushing Defective thermostat Defective temperature gauge Water pump impeller worn broken Insufficient Injection pump out of time Below normal engine temperature Engine overheating Improper type of fuel Clogged or dirty air cleaner Improper valve clearance Injection nozzles dirty Injection pump out of time Engine overloaded Engine not at proper temperature Thermostats not working properly Temperature gauge not working properly Adjust nozzle holder alignment Fill tank or radiator to proper level Check hoses for loose connections and leaks Fan belt slipping Remove paint from tubes e F
41. lush cooling system e Remove and check thermostat Check water temperature with thermometer and replace gauge if necessary Check impeller and replace if necessary Call your dealer Call your dealer Check your thermostats Check water temperature to see if temperature gauge is working properly See Engine Overheating section Use correct fuel for temperature Service air cleaner e See your dealer e See your dealer e See your dealer Check load usage Check your thermostats Check water temperature with thermometer and replace gauge if necessary e Check thermostats Check water temperature with thermometer If you cannot correct problems with these procedures see your Northern Lights dealer OM673L3 5 11 29 ENGINE PROBLEM Low Oil Pressure High Oil Consumption Engine Emits Black or Gray Exhaust Smoke Engine Emits White Smoke Troubleshooting POSSIBLE CAUSE Low oil level Clogged filter and strainer or worn bearings and pump Improper type of oil Partially plugged oil filter Break in period Crankcase oil too light Oil leaks Clogged or dirty air cleaner Defective muffler back pressure too high Improper fuel Injection nozzles dirty Engine out of time Improper fuel Cold engine Defective thermostat Engine out of time RECOMMENDATION S e Fill crankcase to proper level Repair or replace Drain and fill crankc
42. o avoid that area as well while in Service Safe Battery Handling Prevent Battery Explosions Battery gas is 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 C 60 F 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 cause blindness if splashed into eyes 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
43. oblems 3 Check hoses and connections and repair any leakage SP15 HEAT EXCHANGER 1 Clean the heat exchanger core once a year or after 2500 hours of operation 2 Drain expansion tank and heat exchanger 3 Remove heat exchanger end covers and remove core 4 Clean the inside of exchanger core tubes using a metal rod Flush inspect and clean again if necessary 5 Reassemble Fill the cooling system start the engine and check for leaks SP16 RAW WATER PUMP 1 Change the seawater pump impeller every 1000 hours or as needed 2 Remove the pump end cover Pry out the impeller using needle nose pliers or two screwdrivers Be sure you remove all pieces of failed impeller NOTE Place some kind of protection under the screwdrivers in order not to damage the pump housing 3 Clean the inside of the housing 4 Press in the new impeller and place the sealing washers in the outer end of the impeller center if this has not already been done 5 Replace the cover using new gasket or o ring NOTE Make sure that there is always an extra impeller and cover gasket in reserve on board GENERATOR ENDS The maintenance and operation recommendations for the generator end are located on pages 19 22 under the heading AC Generator 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
44. reverse the polarity of battery cables when installing the battery 3 When welding on the unit disconnect the AC and 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 terminal to see if it emits sparks 6 Do not polarize 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 OM673L3 5 11 Servicing GLOW PLUGS SP 17 18 BATTERY CARE 1 Each cylinder is supplied with a glow plug which 1 Check electrolyte level daily Add distilled water to serves to heat the combustion chamber for starting manufacturer s recommended level 2 To check the glow plugs loosen the current 2 Batteries cables and cable terminals should carrying flat wire between the plus poles of the be checked and cleaned every 100 hours glow plugs Figure 21 Connect a D C test bulb Clean corrosion with a water and baking soda between the plus pole of the battery and the solution Flush with clean water Tighten terminals plus pole of the glow plug If the bulb lights up and grease them to inhibit corrosion the glow plug is functioning properly 3 Check the battery condition with a hydrometer every 3 Check all glow plugs and replace any faulty ones 250 hours SP19 WINTERIZING OUT OF SERVICE 1 Drain fresh water and seawater cooling s
45. set MS 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 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 Disposing of waste improperly can threaten the environment 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 OM673L3 5 11 Revised 5 12 11 Marine Generator Component Locations Figure 2 M673L3 Non Service Side with 2009 base frame Figure 3 M673L3 Service Side with 2009 base frame e 27 1 Heat Exchanger End 8 Generator End Cover MM 2 Coolant Fill Pressure Cap 9 Vibration Mount c 2 2 23 Lube Oil Drain 3 Heat Exchanger Expansion 10 Starter
46. t c Wiping 15 the only effective method for removing dust and foreign materials Use a clean lint free piece of cloth 3 If the generator has not been operated for an extended period of time check the insulation resistance of each stator coil and the rotor Disconnect the AVR from the generator when performing this test Check the ball bearing in the generator end a Listen for unusual noise b Abnormal temperature rise can be noted by discoloration c If the bearing 15 failing it must be replaced d Generator bearing should be replaced by your Northern Lights dealer at 10 000 hours Check the brushes a The carbon brushes gradually wear with use so they must be inspected periodically and replaced as necessary b If the brushes are excessively worn as to expose the pigtail Figure 33 sparking will occur at the surface of the slip ring causing surface damage Therefore periodic inspection of the brushes 15 important c Normally the brushes will have to be replaced with a new brush assembly within 3 000 hours PIGTAIL Figure 33 Brush Pigtail OM673L3 5 11 25 page updated 6 22 10 AC Generator TF 276D 7 Replacing Brushes 9 Parts See Parts Book for complete list a Shut down the generator Remove four screws a Bearing and end cover of the generator Part 22 68305 b Brush assembly is black plastic with two wires b Brush assembly leading to it It is located at ten o clock and 15 Part 22 6
47. the written permission of Northern Lights Inc Northern Lights Inc All rights reserved Litho U S A Publication number OM673L3 05 11 OM673L3 5 11 1 revised 4 9 10 Introduction Servicing of marine engines and generator sets Failures begin with minor problems that are presents unique problems In many cases boats cannot overlooked and become amplified when not be moved to a repair facility Marine engines cannot corrected during routine maintenance be compared to the servicing of automobiles trucks or even farm equipment Failures often occur in remote As operator it is your obligation to learn about your areas far from competent assistance Marine engines equipment and its proper maintenance This is not a are taxed far more severely than auto or truck engines comprehensive technical service manual Nor will it therefore maintenance schedules must be adhered to make the reader into an expert mechanic Its aim 15 more strictly to aid you in maintaining your unit properly Unit Identification MODELS INCLUDED This manual covers the operating instructions for M673L3 M673LD3 marine generator sets Model Numbers Model numbers give the unit s application block model aspiration and RPM 673 L D 3 M Northern Lights marine generator set M673L3 Northern Lights marine diesel generator set with a 673 engine long stroke TF 276D generator end Tier Ill Model number of engine block L Long Stroke Bore Cylind
48. to ensure a long trouble free life the generator must be operated properly and the specified maintenance must be performed OPERATING ENVIRONMENT 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 C 104 F during operation a If there is some voltage but it does not build up to rated voltage voltage adjustment can be made using the hand trimmer in the AVR Figure 32 b The normal voltage setting at no load is 121 volts at 62 Hertz or 242 volts at 62 Hertz HAND TRIMMER MAINTENANCE Figure 32 Hand Trimmer Location on AVR Proper and effective maintenance is required to ensure trouble free operation In addition to the Bi 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 6 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 outpu
49. ts by observing these safety rules Study these rules carefully and enforce them on the job IMPORTANT SAFETY INSTRUCTIONS Electromagnetic equipment including generator sets and their accessories can cause bodily harm and life threatening injuries when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL PRIOR TO THE INSTALLATION OF ANY GENERATOR SET OR ACCESSORY KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE Recognize Safety Symbols and Instructions In addition to the information found in this section this operator s manual will use the CAUTION warning to outline potential dangers of a specific nature CAUTION indicates the presence of a potential hazard that can or will cause severe or minor property damage personal injury or death 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 proper placement of safety signs or clarification on any safety issue consult your Northern Lights dealer or the factory There can be additional safety information contained on parts and components from outside suppliers that is not reproduced in this manual
50. ularly Below normal engine temperature or Stalls Frequently Clogged primary secondary fuel filter element replace secondary filter element Water or dirt in the fuel system Dirty or faulty injection nozzles Air in fuel system Improper type of fuel Low idle not stable Lack of Engine Power Intake air restriction Clogged primary or secondary fuel filter element Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles OM673L3 5 11 28 RECOMMENDATION S e 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 primary filter element replace secondary filter element Have your dealer check injection nozzles Glow plug malfunction njection timing not correct Low cylinder compression pressure e Remove and check thermostat Clean or replace primary 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 condit
51. very 1500 hours the fuel nozzle and fuel pump need to be cleaned adjusted or repaired every 3000 hours and the quality guarantee for these parts is 1500 hours or 2 years More often if necessary 1 2 3 Whenever necessary 4 5 After first 50 hours then at 100 hours then every 250 hours OM673L3 5 11 13 Service Record Notes OM673L3 5 11 14 Servicing LUBRICATION GENERAL SP2 OIL CHANGES 1 Use only clean high quality lubricants stored in 1 The set is delivered with special break in oil clean containers in a protected area Change the engine oil and oil filter after 50 hours 2 These lubricants are acceptable of operation Use Service CC 30 weight oil during a API Service CC CD CE single viscosity oils the first 100 hours b API Service CC CD SF multi viscosity oils 2 Change the oil and filter again at 100 hours using the 3 Use the proper weight oil for your average operation oil recommended in Figure 9 After this change oil temperature and filter every 250 hours 3 During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes Air Single Multi Temperature Viscosity pem first 4 Change oil at any seasonal change in temperature SAE 30W 15 40W when a new viscosity of oil 1s required Change oil when engine 15 warm Dispose of waste oil in an approved manner 10 to 32 F 23 to 0 SAE 10W SAE 10 30W Below 10 23 SAE
52. very lines Leave loose at injectors for bleeding e Crank the engine to fill lines Tighten lines at injectors Startengine 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 maximum speed idle speed and exhaust smoke should be checked after every 2400 hours of operation Service of the fuel injection pump should only be done if checks indicate pump malfunction 2 Black smoke can be an indication of pump malfunction Before servicing the pump check other possible causes a Check cleanliness of air filter b Check valve clearances c Clean and check injectors 3 Any repair which involves disassembly of the injection 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 NOTE Be sure to close the sea cock before working on the engine cooling system CAUTION 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 system Open the filler cap carefully using protective clothing
53. ystems completely Remember to shut off seacocks before opening drain cocks if the vessel is in the water 2 Drain water supply lines and wet exhaust line 3 Loosen the seawater pump cover and drain pump 4 Fill the fuel tank or add biocide as per Figure 21 Glow plugs manufacturer s instructions 5 Seal the air cleaner inlet exhaust opening crankcase BOOSTER BATTERIES breather pipe and fuel tank vent with plastic bags and tape A CAUTION Battery gas can explode 6 Store the set in a dry protected place If unit must Keep all flames and sparks away from batteries be stored outside be sure it is well protected with a cover 1 Before changing or using booster batteries check 7 Change the crankcase oil and filter battery electrolyte level Add distilled water if necessary 8 Loosen the alternator belt 2 Booster and main batteries must have the same 9 Disconnect and clean battery Remove to warm voltage rating storage place if possible 3 First connect positive terminal of booster battery 10 Clean outside of unit Paint any scratched or to positive terminal of main battery Then connect chipped surfaces Put corrosion preventative on negative terminal of booster battery to ground on all exposed metal surfaces the engine block see Figure 22 4 Remove booster battery after starting engine 5 Sealed batteries See manufacturer charging and booster instructions Figure 22 Battery connections Batt
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