OM673 - Northern Lights
Contents
1. 5 MANUAL 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 2013 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 OM673 07 13 NOR THERN LIGHTS OPERATOR S MANUAL 4 673 6730 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 Models Included ti abeo 2 Model Numbers 2 Serial Numbers eee eene 2 WARRANTY _ 3 SAFETY RULES 3 7 LOCK OUT TAG OUT PROCEDURES 8 COMPONENT LOCATIONS M673 Marine 9 PANELS Northern Lights Generator Sets 10 11 OPERATING PROCEDURES Break in ecce 12 122. l the engine or other driven equipment Wear Protective Clothing 58 CO OM673 07 13 4 Added 6 18 12 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 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 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
3. 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 07 13 Added 6 18 12 Safety Rules Continued components between the high pressure fuel pump material containing asbestos Keep all bystanders and nozzles on engines with high pressure fuel away from any area where asbestos dust may be systems generated ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH Use Proper Lifting Equipment and Techniques PRESSURE FUEL INJECTION SYSTEMS Lifting heavy components incorrectly can cause severe injury or damage to machinery Avoid unbalanced Avoid Hot Exhaust loads Do not use lifting eyes Lift the SB Avoid exposure to and physical generator set using lifting bars inserted contact with hot exhaust through the lifting holes on the skid gases Exhaust parts and streams can reach high Follow all recommended removal and installation temperatures during operation leading to burns or procedures in this and associated Northern Lights other serious injury manuals Cleaning exhaust filters can also lead to exposure to hot exhaust gas and the injury risk associated with Use Proper Tools it Avoid exposure to and physical contact with hot exhaust gases when cleaning exhaust filters A C AUTION During au
4. If you cannot correct problems with these procedures see your Northern Lights dealer OM673 07 13 29 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION S High Oil Consumption Break in period Oil consumption decreases after break in Crankcase oil too light Use proper viscosity oil Oil leaks 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 e 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 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 e See your dealer If you cannot correct problems with these procedures see your Northern Lights dealer OM673 07 13 30 Model RPM kW Rating Frequency Hz GENERAL INFORMATION Northern Lights Marine Data 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 Minimum Through Hull Diameter Raw Water Pump Inle
5. Minimum Suction Line Minimum Return Line Maximum Fuel Pump Head Suction mpi Rated Flywheel HP Specific Fuel Consumption at Maximum Load Approximate Fuel Rate at Maximum Load Northern Lights Marine Data M673L 1500 5 50 45 1 upto 10ft 1 up to 10 ft 1 upto 10ft 1 upto 10 ft 1 upto 10 ft 1 up to 10 ft 20 ft 20 ft 20 ft 20 ft 20 ft 6 1 m 6 1 m 6 1 m 6 1 m 6 1 m 12 V 12 V 12 V 12 V 12 V 200 f min 200 f min 200 f min 166 f min 200 f min 200 f 5 7 m min 5 7 m min 5 7 m min 4 7 5 7 m min 5 7 m min 21 4 f min 17 8 f min 21 4 f min 17 8 f min 23 9 f min 19 9 f min 0 61 m min 0 51 m min 0 61 m min 0 50 m min 0 68 m min 0 57 m min 5 7 in min 5 7 in min 5 7 in min 5 7 in min 5 7 in min 5 7 in min 37 cm min 37 cm min 37 cm min 37 cm min 37 cm min 37 cm min 48 in 48 in H O 48 in H O 48 in H O 48 in 48 in 122 H O 122 H O 122cmH O 122 cm H O 122 122 cm H O 1 5 in OD 1 5 in OD 1 5 in OD 1 5 in OD 1 5 in OD 1 5 in OD 38 mm 38 mm 38 mm 38 mm 38 mm 38 mm 1 25 in NPT 1 25 in NPT 1 25 in NPT 1 25 in NPT 1 25 in NPT 1 25 in NPT 5 16 in 5 16 in 5 16 in 5 16 in 5 16 in 5 16 in 8 mm 8 mm 8 mm 8 mm 8 mm 8 mm 5 16 in 5 16 in 5 16 in 5 16 in 5 16 in 5 16 in 8 mm 8 mm 8 mm 8 mm 8 mm 8 mm 39 in 39
6. 3572 A E 107 4 0SZ 0 q 43035 LOL 3575 3NION3 y _ 1 E lt d x pcm 3 082 H xw ANNOYS ASVO 4 602 l Ova iE 5 3 10 A8 BYNSSIYd 10 aan munoH 2 SLOVINOO 393 VHOSI0 3d HOLIMS AD ee dWal ioi 35 lt 310N 33 TS d cvi 8 gt 5 80902981 9 i AGO us a AVTA 1V3H 34d S 99 Hs 35 AVT3H NM T 3ma8 nr 01297068 B s e L8 0 euas SE oomo PETENS 7349 66 TM WHAO E x o 0 oe i 1391 _ 34 aaa or HOLIMS o 5 ps lt i HOLMS SSVdA8 L909LSS8L dics V 9 NMOGLNHS JOMLNOO 3NI9N3 301911938 07980681 re iu AIL _ YOON MdbNIS Ol au zor gt vo 1 OMV 20 21 S3SSINUVH ONY 1 53101 335 M 1 5 WNOILdJO 81 5 JjNIONJ XOs r SOLVENTS i I JNVd JOYLNOOD OM673 07 13 23 AC Wiring Diagrams n 100 120 200 240VAC 129 50
7. 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 e 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 See your dealer Injection pump out of time See your dealer Engine not at proper temperature Check your thermostats Check water temperature 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 Oil 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
8. 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 BROWN BLUE RED GRAY ORANGE GREEN 120 YELLOW 240 BROWN Figure 29 Control Terminal Board 120 240 Volt Output b Connect U2 and V1 on the output board Figure 30 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 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 0 71 2 1 UJ Figure 27 Control Terminal Board 240 Volt Output b Connect U2 to V1 on the output terminal board Figure 30 Output Terminal Board 120 240 Volt Output Figure 28 OM673 07 13 24 AC Generator 276 amp TF 276D OPERATION 4 Voltage Adjustment In order to ensure a long trouble free life the gen a If there is some voltage but it does not build up erator must be operated properly and the to rated voltage voltage adjustment can be made specified maintenance must be performed using the hand trimmer in the AVR Figure 31 b The normal vo
9. eat holes into clothing and other materials and cause blindness if splashed into eyes To Avoid Hazards Fill batteries only in well ventilated areas Wear appropriate eye protection and rubber gloves e 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 is 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 proc
10. INSTALLATION CONDUCTORS TO BE AWG 14 105 C TYPE MTW MULTISTRAND 600 VAC 2 UNLESS COLOR CODED ALL A D E INSTALLED 10 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 ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE 5 AND ANY APPLICABLE LOCAL CODES lt MARINE UNITS ALL GROUND CONNECTIONS ARE MADE m BY THE CUSTOMER AT THE CUSTOMERS DISCRETION 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 S GSC300 CONTROL PANEL ARE TO BE 1A 250V TYPE ABC 1 AND ARE TO BE MOUNTED IN THE GSC300 PANEL USING PANEL MOUNT TYPE FUSE HOLDERS NOTES i e 4 gt a ee ee ee GND SEE NOTE 3 AC Wiring Diagram Drawing B 6105D Wiring diagrams are subject to change without notice OM673 07 13 36 NORTHERN LIGHTS 4420 14th Ave NW Seattle WA 98107 NOTEN Tel 206 789 3880 1 800 762 0165 Fax 206 782 5455 Northern Lights and Lugger are registered trademarks of Northern Lights Inc www northern lights com 2013 All rights reserved Litho USA
11. NODE 28 30 DATA SHEETS 31 32 WIRING DIAGRAMS DC Electrical 33 AC FEI 34 36 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 OM673 07 13 OM673 07 13 1 Introduction The servicing of marine engines and generator sets Failures begin with minor problems that are presents unique problems In many cases boats overlooked and become amplified when not corrected cannot be moved to repair facility Marine engines during routine maintenance cannot be compared to the servicing of automo biles trucks or even farm equipment Failures often As operator it is your obligation to learn about your occur in remote areas far from competent assistance equipment and its proper maintenance This is not a Marine engines are taxed far more severely than comprehensive technical service manual Nor will it auto or truck engines therefore maintenance make the reader into an expert mechanic Its aim is to schedules must be adhered to more strictly aid you in maintaining your unit properly Unit Identification MODELS INCLUDED This manual covers the operating instructions for M673M M673L and M673D marine generator sets Model Numbers Model numbers give the unit s appli
12. Resistance of A B Figure 33 Brush Location 0 25 ohm at 20 C 68 F c Resistance of U1 V2 c Attach leads to new brush assembly and install it 0 56 ohm at 20 C 68 F with the plastic ears towards the front of the d No load voltage setting generator 242V or 121V at 62 Hz with cold 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 34 OM673 07 13 26 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 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
13. Work 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 fluids and causing serious burns Before opening any pressurized lt cooling system make sure the OM673 6 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
14. 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 OM673 07 13 8 Marine Generator Component Locations Figure 2 M673 Non Service Side Figure 3 M673 Service Side 1 Heat Exchanger End Cap 8 Starter Motor 15 Air Filter Housing 22 Lube Oil Dipstick 2 Coolant Fill 9 DC Regulator 16 Fuel Injector 23 Block Drain 3 Heat Exchanger Expansion 10 Belt Guard 17 Fuel Injection Pump 24 Lube Oil Filter Tank Exhaust Manifold 11 DC Alternator 18 Fuel Lift Pump 25 Secondary Fuel Filter 4 Lube Oil Fill Top 12 DC Circuit Breaker 19 Lube Oil Drain 26 Control Panel Plug In 5 Wet Exhaust Elbow 13 Generator Control Box 20 Sea Water Pump 27 Fuel Inlet and Return 6 Generator End Cover 14 AC Circuit Breaker 21 Lube Oil Fill Side 28 AVR Circuit Breaker 7 Base and Drip Pan OM673 07 13 9 LH PREHEAT amp SHUT GENERATOR GENERATOR DOWN BYPASS START HOURS a Hobbs o oome TOTAL ALLE 3 6 Series 4 Generator Set Control Panel _ Temperature T re Figure 6 C Series 4 Generator Control Panel Control Panels 1 SHUTDOWN BYPASS PREHEAT SWITCH There are three functions built into this switch preheating the engine flashing the generator field and bypassing the engine safety shutdown circuit enabling a start Hold th
15. before starting a cold engine Hold ing the switch on for too long can burn out the glow plugs To start the engine the bypass switch must be held on while moving the engine control switch into the start position As soon as the engine starts release both switches Auto Start Panels 5 7 2 S 7 4 5 7 5 and S 7 6 When the switch is in the auto start position the unit will start upon closure of auxillary contacts Moving the switch to the manual position will start the engine and it will run after the control timers have completed their sequence 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 R
16. cap releases when the pressure is approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it 1s faulty OM673 07 13 19 Servicing Figure 15 Remove return line nuts Figure 19 Reinstall injector Torque to proper tightness OM673 07 13 20 Servicing SP14 COOLING SYSTEM FLUSHING Flush the cooling system every 600 hours or every 12 months whichever comes first Marine sets 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 is 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 Industrial sets a Remove radiator cap and open drain cocks on radiator and engine block b Pour clean water into 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 Coolant Specifications marine and industrial Use 50 water 5096 ethylene glycol antifreeze mix Antifreeze mixture is recommended as a good year round coolant Check hoses and connections and repair any leakage SP15 HEAT EXCHANGER Clean the heat exchanger core onc
17. fuel system is self bleeding However any system may need manual bleeding when a 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 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 Tighten bleed screw Loosen bleed screw Pump hand primer on fuel lift pump until pure fuel no bubbles escapes from bleed screw 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 connec tion Do each line one at a time After the engine has started check for fuel leaks Figure 11 A M673 Fuel System OM673 07 13 18 Servicing SP11 INJECTOR SERVICE 1 Injectors should be checked every 600 hours Check should be made by a Northern Lights dealer or local injection repair station A CAUTION Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury f 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 inject
18. gravity Replace battery if 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 f 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 OM673 07 13 2 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION S Engine Hard to Start Improper starting procedure See starting section of this manual Take or Will Not Start special note of Bypass Switch operation No fuel Check level of fuel in fuel tank Low battery output Check electrolyte level and condition Excessive resistance e Clean and tighten all battery connections in starting circuit Crankcase oil too heavy Use oil of proper viscosity Improper type of fuel Consult fuel supplier and use proper type of fuel for operating condition Water dirt or air in fuel system Drain flush fill and bleed system Clogged primary Clean or replace filter element fuel filter element Clogged secondary Replace filter element fuel fil
19. in 7 7 7 2 8 3 7 0 9 4 Ju 0 497 Ibs hp hr 0 493 Ibs hp hr 0 444 Ibs hp hr 0 444 Ibs hp hr 0 444 Ibs hp hr 0 453 Ibs hp hr 302 g kw hr 300 g kw hr 270 g kw hr 270 g kw hr 270 g kw hr 275 g kw hr 0 53 gal hr 0 50 gal hr 0 54 gal hr 0 43 gal hr 0 59 gal hr 0 49 gal hr 2 05 Itr hr 1 93 Itr hr 2 08 Itr hr 1 66 Itr hr 2 4 Itr hr 1 9 Itr hr OM673 07 13 22 DC Wiring Diagrams e2nou eDueuo d amm V ote ane ZOL aaa l 2019 g amp 032 MS 95 3 45 Lo OG eous d 9 SS3NMVH 5 LUVLS HOLIMS 3415 3NION3 301 T3NVvd len ge e NEA JOMLNOO eed E MUN 3dAL 91 38 OL SYOLONGNOD LNIOd NOLLO3NNOO HOV3 38 LSNW ONY A39 38 OL 3HV SYOLONGNOD Q3TIVISNI Tv 03000 30100 SSFINN Z r 4 ALON SV G31SIML 1d30X3 S I O SOL MUN bL SMV 38 OL SYOLONGNOD NOLVTIVISNI I ES S ZN SALON pri 105 0 yF 3909 L7 4955 NEM NS 2 amp i NE NES AX 3118 C
20. or serious injury CAUTION indicates a hazardous situation which A CA UTION if not avoided could result in minor or moderate injury Follow All 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 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 not refuel while smoking or when n
21. tube Refill engine with recommended oil 10 Engine capacity with new oil filter is 673M D amp L 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 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 673M 24 02001 673L 24 08001 OM673 07 13 15 Servicing SP4 AIR CLEANER 1 Inspect air cleaner every 250 hours In dusty condi tions check more often M673 Inspect the element If it is dirty wash the element in soapy water Rinse and dry thoroughly before re installing 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 Check the tension and wear on the V belt after every 50 hours Use your thumb to press on the belt at the midpoint between the crankshaft and alternator pulleys Th
22. 60 HZ JUNCTION BOX 4 _ GENERATOR REGULATOR DS 71 2M OL To 22 68006 GENERATOR OUTPUT LEADS BREAKER AUXILIARY CONTACT ON BREAKER ON CLOSED OFF N O OP oni 10 AVR_CONNECTOR SUPPLIED AND CONNECTED MAIN OUTPUT CONDUCTORS SIZING DETERMINED PER INSTALLATION 5 MODULE FUSES 1 amp 2 ONLY USED IN S GSC300 CONTROL PANEL ARE BE 1A 250V TYPE 1 AND ARE TO BE MOUNTED IN THE GSC300 PANEL USING PANEL MOUNT TYPE FUSE HOLDERS OUTPUT TERMINAL BOARD YELLOW 20 DARK BROWN BROWN v2 _ 24o 55 ____ 0 i DENM L 1 1 FRAME ENGINE BLOCK NOTES amp EE 1 l SEE NOTE 3 1 ALL INSTALLATION CONDUCTORS TO BE AWG 14 m 1 1 1 1 105 C TYPE MTW MULTISTRAND 600 VAC 1 2 UNLESS COLOR CODED ALL A D E INSTALLED 10 9 1 l 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 1 ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE z 1 AND ANY APPLICABLE LOCAL CODES g m e MARINE UNITS ALL GROUND CONNECTIONS ARE MADE z 74 BY THE CUSTOMER AT THE CUSTOMERS DISCRETION 1 4 THICK HIDDEN DASHED LINES INDICATE CUSTOMER 1 1 et et et L1 GND SEE NOTE 3 2 AC Wiring Diagram Drawing B 6103G Wi
23. 7 mm 2 83 in 72 mm CCW 24 1 3 4 qts 3 2 Itr Natural 350 165 159 kg 20 25 in 513 mm 17 2 437 mm 27 1 in 688 mm Heat Rejection to Jacket Water Fresh Water Pump Capacity Maximum Seawater Pump Suction Head Seawater Pump Capacity Keel Cooler Turbo Tube Length Keel Cooler Head Diameter Keel Cooler Water Hose I D Discharge and Suction 350 BTU min 250 BTU min 600 BTU min 5 0 gal min 4 2 gal min 5 0 gal min 18 92 Itr min 15 77 Itr min 18 92 Itr min 39 in 39 in 39 in 1 m 1 m 1 m 8 0 gal min 7 0 gal min 9 0 gal min 30 Itr min 26 Itr min 34 Itr min 4 ft 4 ft 4 ft 1 2 m 1 2 m 1 2 m 0 75 in NPT 0 75 in NPT 0 75 in NPT 19 1 mm 19 1 mm 19 1 mm 1 0 in 1 0 in 1 0 in 25 mm 25 mm 25 mm OM673 07 13 ad 600 BTU min 4 1 gal min 15 77 Itr min 39 in 1 m 7 5 gal min 28 4 Itr min 4 ft 1 2 m 0 75 in NPT 19 1 mm 1 0 in 25 mm 420 BTU min 5 0 gal min 8 0 gal min 30 Itr min 4 ft 1 2 m 0 75 in NPT 19 1 mm 1 0 in 25 mm Model RPM kW Rating Frequency Hz ELECTRICAL Minimum Battery Capacity Amp hr Battery Cable Size Instrument Harness Length Standard Starting Voltage Negative Ground AIR Generator Cooling Air Flow min Air Consumption Minimum Engine Room Vent Maximum Exhaust Back Pressure Wet Exhaust Elbow OD Dry Exhaust Elbow ID MAXIMUM INTERMITTENT
24. Er A 12 OS UN 12 Stopping goss var aacecacaupactneccercncsanaressecennvasnecsinevaenses 12 Shutdowns Alarms 13 Spare PariS 13 SERVICING SCHEDULE CHART 14 SERVICING Lubrication General eene 15 15 15 Changing Oil Filter sccacossandesancssanssanseaxencentanseaoss 15 16 NP RR 16 Valve 1 16 SERVICING coNTINUED Fuels Getieral ade 17 17 Bleeding the Fuel System 18 Injector coenae otio dicen 19 21 Injection PW 19 Cooling System 1 19 Cooling System preis 20 21 Raw Water aS PRI 21 OP DEOS 21 Electrical System General 21 Glow PIOS 22 Booster 22 Battery C die eet er er 22 Winterizing 1 22 AC GENERATOR TF 276M TF 276D Bre e A E 23 Connec ONS 24 25 Maintenance 25 26 TROUBLESHOOTING BIG 27 FAVS TING
25. PM 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 OM673 07 13 11 Operating Procedures 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 is greater during break in as piston 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 for oil recom mendation 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 1 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 the waffled area on the stick Never allow the level to go below this area Always add the same viscosity of oil as is already in th
26. age 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 the alternator or regulator 7 AD C circuit breaker protects your control panel and wiring harness It 1 located in the side of the generator junction box OM673 07 13 2d Servicing GLOW PLUGS SP 17 18 BATTERY CARE 1 Each cylinder is supplied with a glow plug which 1 Check electrolyte level every 50 hours or once per serves to heat the combustion chamber for starting month Add distilled water to manufacturer s 2 check the glow plugs loosen the current recommended level carrying flat wire between the plus poles of the 2 Batteries cables and cable terminals should glow plugs Figure 20 Connect a D C test bulb be checked and cleaned every 100 hours between the plus pole of the battery and the Clean corrosion with a water and baking soda solu plus pole of the glow plug If the bulb lights up tion Flush with clean water Tighten terminals and the glow plug is functioning properly grease them to inhibit corrosion 3 Check all glow plugs and replace any faulty ones 3 Check the battery condition with a hydrometer every 600 hours SP19 WINTERIZING OUT OF SERVICE 1 Drain fresh water and seawater cooling systems completely Remember to shut off seacocks before opening drain cocks if the ve
27. cation block model aspiration and RPM M 673 M Northern Lights marine generator set M673M _ Northern Lights marine diesel generator set with a 673 engine TF 276M generator end and an automatic voltage regulator Model number of engine block Bore Cylinders 67 mm 3 M673L Northern Lights marine diesel generator set with a 673 engine TF 276D generator end and an automatic voltage regulator M673D Northern Lights marine diesel generator set with a 673 engine TF 276D generator end and an automatic voltage regulator Serial Number Your set has three serial numbers 1 an engine number stamped on the block 2 a generator number and 3 a generator set number NORTHERN LIGHTS Generator Set Data Set Serial Set Model Use the serial number on the generator set data plate when ordering parts in correspondence The generator set data plate is found on Model No 4 Serial No the service side of the generator and resembles the drawing in Figure 1 KW INSUL KVA AMB C RPM 2 HERTZ eae PHASE 5 C RISE RULE AMPS CE Northern Lights Inc WA USA www northern lights com Figure 1 Generator set serial number data plate OM673 07 13 2 Revised 7 10 13 Warranty A warranty registration certificate is supplied with your set It entitles the original purchaser of
28. e tension is correct if the belt can be depressed about 3 16 in 5 mm TORQUING CYLINDER HEAD BOLTS E Tighten bolts when the engine 15 cold Loosen the nuts and remove rocker arm cover Remove fuel injectors and related tubes Tighten head bolts with a torque wrench in the order shown in the figure below Tighten bolts evenly in 2 or 3 passes ending at the specified torque in final pass a Torque 26 29 ft Ibs 3 5 4 0 kg m Re install rocker arm shaft and adjust valves Torque nuts to 7 9 ft Ibs 1 0 1 3 kg m Re install injectors and tubes and rocker cover Torque injectors to 43 51 ft Ibs 6 7 kg m Use new injector sealing washers Figure 9 673M Head Torque Sequence Valve Adjustment Screw d Rocker Arm 0 008 0 200 Figure 10 Valve Adjustment SP6 VALVE CLEARANCES Re adjust valve clearance after first 50 hours of operation and every 1000 hours thereafter Valve adjustments should be done after the cylinder head bolts have been re tightened Engine should be cold and NOT running 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 Loosen the lock nut and ad
29. e a year or after 2400 hours of operation Drain expansion tank and heat exchanger Remove heat exchanger end covers and remove core Clean the inside of exchanger core tubes using a metal rod Flush inspect and clean again if neces Sary Reassemble Fill the cooling system start the engine and check for leaks SP16 RAW WATER PUMP 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 a 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 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 and DC volt
30. e crankcase 3 Check the fuel tank level and open any fuel valves 4 Marine Sets close the sea cock check and clean the sea strainer and reopen the sea cock 5 Marine Sets place the battery switch in the ON posi tion NOTE The battery switch must always be kept ON while the engine is running If the switch is turned OFF while the engine is running the bat tery charging regulator could be ruined STARTING FOR S 1 S 1B S 3 AND S 4 SEE PAGE 6 FOR S 7 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 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 NOTE Excessive cranking of the starter on Marine sets equipped with a water lift muffler can cause engine damage If the engine does not start after three 20 second cranks remove the impeller from the raw water pump This will prevent the muffler from filling with water and backfilling the exhaust line and engine Once the engine starts shut it off immedi ately and re install the impeller Re start the engine and check the exhaust overboard outlet fo
31. e switch in the ON position for approxi mately 10 to 20 seconds before starting a cold engine Holding the switch ON for too long can burn out the glow 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 2 ENGINE CONTROL SWITCH To start the engine hold this switch in the START posi tion 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 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 3 HOUR METER Keeps track of engine running time 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 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 7 VOLTMETER Shows the generator output voltage 8 FREQUENCY METER Hertz The frequency meter indicates engine speed 1200 or 1800 RPM 60 Hz or 1500 RPM 50 Hz 9 AMMETER SELECTOR SWITCH Used
32. ear sparks or open flame ALWAYS STOP ENGINE BEFORE FUELING MACHINE Always fill portable fuel tank outdoors Never fuel a hot engine OM673 07 13 d Added 6 18 12 Safety Rules Prevent accidental discharge of starting fluids by Operating equipment requires the full attention of storing all cans in a cool safe place away from sparks operator Do not use radio or music headphones or open flame Store with cap securely on container while operating machinery Never incinerate or puncture a fuel container Prevent fires by keeping machine clean of accumulated Practice Safe Maintenance trash grease and debris Always clean any spilled fuel as swiftly as possible Do not store oily rags which can ignite and burn spontaneously CAUTION ge Understand all service procedures Be prepared if a fire starts Keep a first aid kit and fire before starting work Keep area clean and dry extinguisher handy Keep emergency contact numbers Never lubricate service or adjust machine while it is for fire department doctors ambulance and hospital in operation near the telephone Keep hands feet and clothing away from power driven equipment When shutting down an engine Service Machines Safely disengage all power and operator controls Allow the engine to cool completely before beginning any A ANGER service work Do not wear a necktie scarf necklace rings or other jewelry or any loose clothing w
33. edures and emergency response techniques OM673 07 13 5 Added 6 18 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 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 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
34. eed 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 E 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 removed Ensure that all personnel
35. el system SP18 Check condition of batteries with a hydrometer 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 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 heat exchanger Change impeller in raw water pump Inspect condition of exhaust elbow 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 OM673 07 13 14 Servicing SP2 OIL CHANGES LUBRICATION GENERAL 1 Use only clean high quality lubricants stored in clean containers in a protected area 2 These lubricants are acceptable a API Service CC CD CE single viscosity oils b API Service CC CD SF multi viscosit
36. ers Air filter industrial units only Alternator belt Thermostat and gaskets Raw water pump impeller amp gaskets marine only Glow plug Injector and washer mmr If your set is operating a long distance from servic ing 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 OM673 07 13 13 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 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 SP16 Change impeller 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 fu
37. everage containers that may mislead containing asbestos When servicing wear an someone into drinking from them approved respirator A special vacuum cleaner is recommended to clean asbestos If this vacuum is Do not pour waste onto the ground down a drain or not available apply a mist of oil or water on the into any water source OM673 07 13 7 Added 6 18 12 Lock Out Tag 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 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 Electrical Equipment Be sure the equipments ON OFF switch is in the OFF position and is unplugged from any electrical source before attempting to perform any type o
38. f 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 back in the system and re check the bl
39. gnetism 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 2 Stator Coil 3 End Cover 4 Brush 5 Ball Bearing 6 Slip Ring 7 Frame 8 Coupling Plate 9 Field Coil 2 10 Field Core 11 Shaft 3 12 Ventilation Cover CONTROL BOX Figure 24 o 1 Control Terminal Board 2 Automatic Voltage Regulator AVR 5 3 12 Volt DC Circuit Breaker 4 AC Circuit Breaker 6 5 AVR Circuit Breaker 6 Output Terminal Board 2 7 45 mU m L e rere EL rr e ee eee A 5 2 9 9 120 YELLOW RE 240 BROWN Figure 24 Control Box Components OM673 07 13 29 AC Generator 276 amp TF 276D CONNECTIONS 1 120 Volt Output a 120 volt output can be selected by connecting the terminals of the control terminal board to 120 Figure 25 V2 AVR DS 71 2M Figure 28 Output Terminal Board 240 Volt Output 3 120 240 Volt Output a Connect the control terminal board for 240 volts Figure 29 v2 120 YELLOW 240 BROWN Figure 25 Control Terminal Board 120 Volt Output AVR DS 71 2M 1 WHITE
40. hen working near moving parts Tie long hair behind your head If any of these Keep all parts in good conditions and properly items get caught in moving machinery severe injury or installed Fix damage immediately Replace any death could result worn or broken parts Remove any build up of grease oil or debris Securely support any machinery elements that must be raised for service work with support or lifting machinery specifically intended for that purpose Check for any loose electrical connections or faulty wiring Disconnect battery ground cable before making any adjustments or service work Look completely around engine to make sure that everything is clear before starting Stay Clear of Rotating Drivelines Entanglement in rotating drivelines can cause serious injury or death Keep shields in place at all times To prevent catching anything in moving machinery Make sure that rotating shields turn freely in pace always wear close fitting clothes and safety equipment with the drivelines appropriate to the job Prolonged exposure to loud noise can cause hearing Do not wear loose fitting equipment around rotating loss or impairment gs drivelines Stop the engine and make sure that all Wear suitable authorized T A moving parts have stopped hearing protection such Y3 before making any adjustments as earmuffs or plugs to connections or performing protect against loud noises any other type of service to
41. ivated a Check the temperature gauge If above 205 F 96 C shut off the engine immediately b Use the Trouble Shooting Guide on page 25 to isolate the cause of the overheat CAUTION Do 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 Marine set after the temperature gauge registers below 200 F 94 C d Watch the temperature gauge regularly and turn off the unit if the temperature rises above 205 F 96 C on Marine units 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 1s 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 ADE recommends that you keep the following spare parts on hand for field service The parts are available from your local Northern Lights dealer Some marine models already have On Board Kits a handy box that contains the most common parts you will need All owners should have the following a Primary and secondary fuel filter elements Oil filt
42. just 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 Repeat steps 3 and 4 for each cylinder Each set of valves must be adjusted individually Replace the rocker arm cover Tighten cover nuts to 7 2 8 7 ft Ibs 1 0 1 2 kg m OM673 07 13 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 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 J 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 instal
43. led 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 200 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 numbers are 11224 52020 Found on all M673M D amp L units OM673 07 13 17 Servicing SP10 BLEEDING THE FUEL SYSTEM A 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 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 medi cal treatment isn t administered immediately The
44. ltage setting at no load is 121 volts OPERATING ENVIRONMENT at 62 Hertz or 242 volts at 62 Hertz 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 HAND TRIMMER MAINTENANCE Figure 31 Hand Trimmer Location on AVR Proper and effective maintenance is required to ensure trouble free operation In addition to the 5 Check the ball bearing in the generator end above items the following are required a Listen for unusual noise 1 Periodically check all bolts and nuts for proper b Abnormal temperature rise can be noted by torque This is especially true for coupling bolts discoloration 2 sure to keep the generator area clean and dry c If the bearing is failing it must be replaced a Dust and foreign material may reduce the flow of d Generator bearing should be replaced by your cooling air reducing heat dissipation and causing Northern Lights dealer at 10 000 hours the generator to overheat 6 Check the brushes b If electrically conductive debris accumulates on a The carbon brushes gradually wear with use so the windings or if moisture or salt water are they must be inspected periodically and replaced absorbed into
45. nd 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 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 NOTE Marine sets 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 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
46. or 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 clamp 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 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 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 Startengine and check forleaks 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 a
47. our equipment to a warranty covering material or assembly faults The extent of coverage is 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 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 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 uses three different signal words to outline potential dangers of a specific nature T D ANGE DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death
48. r gushes of water OPERATING 1 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 F 25 C ambient temperature The water temperature gauge on Marine sets must be below 200 F 94 C on Industrial units 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 investigate 2 Let the unit run unloaded for a 3 5 minute warm up period 3 Add electrical load STOPPING 1 Remove electrical load from the generator set Run the engine for a 3 to 5 minute cool down period Move the Engine Control switch to the STOP posi tion momentarily Marine Sets shut off the seacock fuel valve and battery switch OM673 07 13 Operating Procedures SHUTDOWNS AND ALARMS d A 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 exclu sion of careful gauge monitoring Watching your gauges can prevent damage to the unit and danger ous power losses Do the following when your warning or shutdown system is act
49. ring diagrams are subject to change without notice OM673 07 13 34 AC Wiring Diagrams 1 SAAC REGULATOR CIRCUIT 1 JUNCTION BOX 3 GENERATOR 4 REGULATOR GENERATOR Ds 71 2M 22 68006 a O zu 1 Pit AVR CONNECTOR 1 1 2 E mew 200 240VAC 1 50 60 HZ GEN FRAME ENG BLOCK SEE NOTE 3 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 TO BE GREY AND MUST BE IDENTIFIED BY NUMBER MARKER AT EACH CONNECTION POINT 3 MARINE GENSETS ARE GROUNDED BY THE CUSTOMER AT CUSTOMERS DISCRETION INDUSTRIAL GENSETS ARE TO BE GROUNDED IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE AND ANY APPLICABLE LOCAL CODES BLACK GREEN WHITE SEE NOTE 3 A 1 Lo AC Wiring Diagram Drawing B 6104E Wiring diagrams are subject to change without notice OM673 07 13 35 AC Wiring Diagrams CPRI REGULATOR JUNCTION BOX pars REGULATOR GENERATOR CPR2 LEADS A C VOLTAGE B 74 F BREAKER E E12 F H ____ OFF OPEN oni _ 10 GREEN 1 YELLOW 209 H v2 ________ GEN FRAME 120VAC 19 60 HZ ENGINE BLOCK SEE NOTE 3 4 MF1 SEE NOTE 5 ALL
50. ssel is in the water 2 Drain water supply lines and wet exhaust line 3 Loosen the seawater pump cover and drain pump Figure 20 Glow plugs 4 Change the crankcase oil and filter 5 Loosen the alternator belt BOOSTER BATTERIES 6 Disconnect and clean battery Remove to warm storage place if possible A CAUTION Battery gas can explode 7 Clean outside of unit Paint any scratched or Keep all flames and sparks away from batteries chipped surfaces Put corrosion preventative on all exposed metal surfaces 1 Before changing or using booster batteries check bat 8 Fill the fuel tank or add biocide as per tery electrolyte level Add distilled water if necessary manufacturer s instructions 2 Booster and main batteries must have the same volt age rating 3 First connect positive terminal of booster bat tery 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 OM673 07 13 22 GENERAL 1 AC Generator TF 276KM amp TF 276D Control Box A Generator Set includes the engine the generator and the control or J box Figure 22 2 The generator and the control or J box produce the electrical power 3 Generator excitation is provided by residual ma
51. t Hose I D Minimum Seawater Discharge 41 1 in 0 676 Itr 4 2 64 in 67 mm 2 52 in 64 mm CCW 24 1 3 0 qts 2 8 Itr Natural 352 Ibs 160 kg 19 6 in 498 mm 17 2 in 437 mm 26 9 in 683 mm 5 gal 2 Itr 0 75 in 19 mm 0 75 in 19 mm 0 75 in 19 mm 41 1 in 0 676 Itr 4 2 64 in 67 mm 2 52 in 64 mm CCW 24 1 3 0 qts 2 8 Itr Natural 352 Ibs 160 kg 19 6 in 498 mm 17 2 in 437 mm 26 9 in 683 mm 5 gal 2 Itr 0 75 in 19 mm 0 75 in 19 mm 0 75 in 19 mm 41 1 in 0 676 Itr 4 2 64 in 67 mm 2 52 in 64 mm CCW 24 1 3 0 qts 2 8 Itr Natural 355 Ibs 161 kg 19 46 in 496 mm 17 2 in 437 mm 27 1 in 688 mm 5 gal 2 Itr 0 75 in 19 mm 0 75 in 19 mm 0 75 in 19 mm 41 1 in 0 676 Itr 4 2 64 in 67 mm 2 52 in 64 mm CCW 24 1 3 0 qts 2 8 Itr Natural 355 Ibs 161 kg 19 46 in 496 mm 17 2 437 mm 27 1 in 688 mm 5 gal 2 0 75 in 19 mm 0 75 in 19 mm 0 75 in 19 mm 46 4 in 0 761 Itr 4 2 64 in 67 mm 2 83 in 72 mm CCW 24 1 3 4 qts 3 2 Itr Natural 350 165 159 kg 20 25 in 513 mm 17 2 in 437 mm 27 1 in 688 mm 5 gal 2 Itr 0 75 in 19 mm 0 75 in 19 mm 0 75 in 19 mm 46 4 in 0 761 Itr 4 2 64 in 6
52. ter element Dirty or faulty injection nozzles Have your dealer check injection nozzles Engine Runs Irregularly Below normal engine temperature Remove and check thermostat or Stalls Frequently Clogged primary Clean or replace filter element fuel filter element Clogged secondary Replace secondary filter element fuel filter element Water or dirt in the fuel system e Drain flush fill and bleed system Dirty or faulty injection nozzles Have your dealer check injection nozzles Air in fuel system nspect clamps and hoses on suction side of fuel pump for air leak Improper type of fuel Consult fuel supplier and use proper type of fuel for operating condition Lack of Engine Power Intake air restriction Service air cleaner Clogged primary Clean or replace filter element fuel filter element Clogged secondary Replace filter element fuel filter element Improper type of fuel Consult fuel supplier and use proper type of fuel for operating conditions Overheated engine See Engine Overheats in next category Below normal engine temperature Remove and check thermostat Improper valve clearance Reset valves Best done by dealer Dirty or faulty injection nozzles Replace injectors Best done by dealer See your local dealer OM673 07 13 28 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION S Engine Overheats Low coolant level e Fill tank or radiator to proper level
53. the windings the windings may as necessary short or ground reducing voltage output b If the brushes are excessively worn as to expose c Wiping is the only effective method for removing the pigtail Figure 32 sparking will occur at the dust and foreign materials Use a clean lint free surface of the slip ring causing surface damage piece of cloth Therefore periodic inspection of the brushes is 3 If the generator has not been operated for an important extended period of time check the insulation resis c Normally the brushes will have to be replaced tance of each stator coil and the rotor with a new brush assembly within 3 000 hours Disconnect the AVR from the generator when per forming this test PIGTAIL Figure 32 Brush Pigtail OM673 07 13 25 AC Generator 276 amp TF 276D 7 Replacing Brushes a Shut down the generator Remove four screws WHITE AVR and end cover of the generator 25712 b Brush assembly is white plastic with two wires BLUE RED fo leading to it It is located at ten o clock and is EE Ne held in position by two screws Figure 33 ORANGE GREEN Remove the screws and unplug leads 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
54. to check each phase for load condition NOTE Always leave this switch in the ON position 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 OM673 07 13 10 Control Panels NULPM Ble IG _ ATEA Figure 7 A Series 7 1 through Series 7 6 Generator Control Panels STATUS INDICATORS gt ENGINE RUNNING Standard 5 7 6 Standard 5 7 6 SYSTEM READY EI EMERGENCY STOP hich Low on pressure E ENGINE OVERSPEED 3 OVERCRANK b HIGH ENGINE TEMP E J LOW ENGINE TEMP LOW FUEL LEVEL NOT IN AUTO START LOW BATTERY WOLTS Standard S 7 6 EU CHARGE FAULT Standard 5 7 6 3 6 p UAL START OFF A RESET ue AUTO START A LAMP TEST o ALARM RESET D Figure 7 B Status Indicators for Series 7 3 through Series 7 6 Generator Control Panels Standard 5 7 3 thru 5 7 6 Standard S 7 3 thru 5 7 6 Standard S 7 3 thru 5 7 6 Standard S 7 4 thru S 7 6 Standard S 7 4 thru 5 7 6 Standard S 7 3 thru S 7 6 Standard S 7 3 thru 5 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 10 11 12 SHUTDOWN BYPASS SWITCH Manual Start Panels S 7 0 and S 7 3 Hold the switch in the on position for approximately 10 to 20 seconds
55. to or manual stationary exhaust filter Makeshift tools and procedures cleaning operations engine will run at can create safety hazards elevated temperatures for an extended period of Always use appropriate tools for time Exhaust parts and streams can reach high the job temperatures during operation leading to burns or other serious injury Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware always use the correct sized tools Avoid Harmful Asbestos Dust 4 Do not use US measurement tools on metric fasteners or vice versa Use only service parts that meet Northern Lights specifications Inhaling asbestos fibers may cause lung cancer Avoid breathing any dust that may be generated when handling components containing asbestos fibers including some A CAUTION gaskets Disposing of waste improperly can threaten the Dispose of Waste Properly The asbestos used in these components is usually environment and lead to unsafe working conditions found in a resin or otherwise sealed Normal Potentially harmful waste used in Northern Lights handling of these components is not dangerous equipment can include oil fuel coolant filters and as long as airborne dust containing asbestos is not batteries generated Avoid creating dust Never use compressed air for Use leakproof containers to drain fluid Do not cleaning Avoid brushing or grinding materials use food or b
56. y oils 3 Use the proper weight oil for your average operation temperature Air Single Multi Temperature Viscosity Viscosity SAE30W SAE 15 40W 0 C 10 to 32 F g 23 to 0 C SAE 10W SAE 10 30W Below 10 F 23 C SAE 5W SAE 5 20W Figure 8 Lube Oils 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 1 Check the oil level in the crankcase with the dip stick 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 pe n 9 The set is 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 marine 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
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