OPERATOR`S MANUAL
Contents
1. 02 MOTI3A ZA 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 mia Wiring Diagrams savan Z ad NzZ 12 Sd 30193339 901911534 z339 32 1 0 V YOLVYINAD NOLLONNAL i ey OM673L2 7 13 35 DC Wiring Diagrams o a eae 2019 9 BumeIq 090 9 da punog SHOA 21 K a 66 ARD 9015 Pa E A A e SSINAYH SS3NUVH 1 1 IS 3NIDN NVd E Ti 107 NOTTS NMOGLNHS fe TOYNLNOD 3NI9NI MLN 91 OMY 38 OL SYOLINGNOD 9 5 F 22 INIOd NOILOSNNOD 2 3 Lv XIAYVN YSBWNN AJ 0 0 LSNW ONY I x 339 38 OL SYOLONONOD 0311 15 3 TY 03002 50709 SSIINN 2 a 4 0310 SV ONY Q3073IHS 0316101 1832 3 i AER P oa i ONVHLSILIAN 5 90 MIW 3dAL OMY OL SYOLINANOD NOLWTIVLSNI TIV a 7772 1 i t z T 5 33073 S 24 _ SS 1 l 7 aNd 252. Ka 5 Tn lt 2 4900 QNNOYD 35 2 1754 08 0 lt I vv 4 2 36 2 dN3L 3NIDN3 A amp 7 oe _ 324 A gt 512 HOLMS gt Nid a re 1 X3LVM i mr Ie 3SV2 _ v B aeee 310N 335 159 i 2349 5 5 TWNOILdO 9 HOLIMS wT 35155355 10 1 21 m 2 CO lt 08 98 GB lt LW3H 34d T 2 Lh ONNOYND 35 2 if 008 J 28 Ja 1 0 40 4 7 lt 4 HOLYOIGNI m im 4a faos ETO gg gf SINH MOTD WE ay 4 NA 1 5 0 7 HOLIMS lt lt lt 0113 190915681 K 08 60 035 lt 51 HOLIS OGLNHS 1031409 301911935 ERTE 50 E MOLON LVS NON OL KE XVN 318 2 SISSINYVH ONY 5 1 335 i 1 1918 1 5 IWNOILdO 30 8 5 NONI
3. 202 22 0 22 CF 22 COMPONENT LOCATIONS Raw Water Pump 22 M673 Marine 9 Generator 225 22 Electrical System 22 PANELS Glow PGS 23 Northern Lights Generator 10 11 Booster S aspiran 23 Battery Cai a 23 OPERATING PROCEDURES Winterizing 1 23 Breakin CO ie 12 Betore Starte 12 GENERATOR TF 276D SUATUIG 12 AS a crn csc aera 24 Operating 9 0 12 25 12 il 26 Shutdowns and Alarms 4122 13 WAIHI 26 27 13 SERVICING SCHEDULE CHART _ 14 15 28 SERVICING PECAN 29 31 Lubrication 16 Checking 16 DATA SHEET Changes cccccecsecsseecsesssesssesseesstesssesstesseessees 16 32 Changing Oil Filtet 16 E EEE 17 WIRING DIAGRAMS EN 17 4
4. engine has been shut off Do not remove a filler cap unless it is cool enough to comfortably grip with bare hands Slowly loosen cap to relieve pressure before opening fully Avoid High Pressure Fluids Relieve pressure prior to disconnecting pressurized lines Escaping fluid under pressure can penetrate the skin causing serious injury Always relieve pressure before disconnecting hydraulic or other pressurized lines Tighten all connections firmly before re applying pressure If searching for leaks use a piece of cardboard Always protect your hands and other body parts from high pressure fluids If an accident occurs see a doctor immediately Any high pressure spray injected into the skin must be removed within a few hours to prevent the risk of gangrene or other infection Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns and bodily injury Pressurized lines can rupture when heat goes beyond the immediate flame area Do not weld solder or use a torch or open flame near pressurized lines or other flammable fluids Do Not Open 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 OM673L2 7 13 6 Added 6 19 12 Safety Rules Contin
5. 4 6 m aGHSIONLXA 381 WNOLdO SINISVN 3 0 J wows i a ae 7 vie oO oO 55 34065344 10 XILINI F i titi _ a 754 5 5 1 0 LOL lt 1041409 __ 5 3 710 A gt 1 3105 F Wve 133 lt 21 1 l I 2 our lt 1909165819 011193 i Ar a WOLNE 66 034 134 0 lt lt amp 0 4 66 8 g 0 1 i Vor 01 01 os WOW 01 HILIMS _ her ay lt 21 SSVdAg LA T 101405 JINNI I 113413 SUVS wS lt lt 2016 2 3 13 OL 1 i 52553 72 ONV 1 SALON 335 1 5 wNOUdO YO B1 S ok gt NOISNLX3 e 4 IOYLNOOD OM673L2 7 13 37 NORTHERN LIGHTS 4420 14th Ave NW Seattle WA 98107 Tel 206 789 3880 1 800 762 0165 Fax 206 782 5455 Northern Lights and Lugger are registered trademarks of Alaska Diesel Electric Inc www northern lights com 2013 Allrights reserved Litho USA
6. 0 71 2 Figure 28 Control Terminal Board 240 Volt Output b Connect U2 to V1 on the output terminal board Figure 29 Figure 31 Output Terminal Board 120 240 Volt Output OM673L2 7 13 25 Generator TF 276D OPERATION 4 Voltage Adjustment In order to ensure a long trouble free life the gen erator must be operated properly and the specified maintenance must be performed OPERATING ENVIRONMENT Always keep electrical equipment clean Moisture salt dust and 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 above items the following are required 1 Periodically check all bolts and nuts for proper torque This is especially true for coupling bolts 2 Be to keep the generator area clean and dry a Dust an
7. Do not pour waste onto the ground down a drain or into any water source OM673L2 7 13 7 Added 6 19 12 Lock 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 e Removing or bypassing a guard or other safety device e Placing any part of your body in a position where you could be caught by moving machinery e Cleaning or oiling machinery when in operation e Adjusting circuits chillers pumps air handlers valves circuit breakers or fans while in operation e Working on piping or high pressure systems Lock Out Tag Out Instructions Electrical Equipment Be sure the equipment s ON OFF switch is in the OFF position and is unplugged from any electrical source before attempting to perform any type of work on the equipment Obtain an electrical plug cap cover with a lockset Secure the plug terminal end using the electrical plug lockout cap Lock the cap and retain the key If the equipment is directly wired into an electrical box with a shut off switc
8. CAUTION The cooling water in the engine A 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 Check the coolant level each day before starting the engine Check the water level by removing the pres sure cap from the expansion tank or radiator In order to give the cooling water an opportunity to expand the level should be about 1 in 2 5 cm below the filler cap sealing surface when the engine is cold The pressure valve in the filler cap releases when the pressure 1s approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it is faulty OM673L2 7 13 Servicing Figure 16 Remove return line nuts Figure 20 Reinstall injector Torque to proper tightness OM673L2 7 13 21 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 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 2 Coolant Specifications Us
9. OPERATOR 5 MANUAL 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 2012 Alaska Diesel Electric Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Alaska Diesel Electric Inc Printed in U S A PART NO OM673L2 07 13 NORTHERN LIGHTS OPERATOR S MANUAL for Models M6731L2 M673LD2 M67313 and M673LD3 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 2 SERVICING conTINUED Model CES reei 2 18 Seral NUMDELS 2 18 Bleeding the Fuel 19 WARRANTY 3 Injector 20 21 SAFETY RULES 3 7 ee ee 21 Cooling System 21 LOCK OUT TAG OUT PROCEDURES 8 Cooling System
10. lt ID xog ER NOISN31X3 OM673L2 7 13 36 DC Wiring Diagrams o yaya 728 8 a SHOA 21 oe teal i b 2 0 Gad SS3NYVH 53 ia Kae 3015 3NION3 3015 TINY NMOGLNHS 1051405 3NIDN3 ae a ei MLN 91 38 OL SYOLININOD ANOJ 531435 L i ri N LNIOd NOILO3NNOD 9 3 LV Y3xYVN AG 0 38 ISNW ONY 4 A349 38 OL IBV 550191009 0311 15 1 7307 03002 20102 6631 0 72 ERR a 0310 SY ONY 03013 5 03151 1 1032 3 ONVYISILINN 2 501 SMV 38 OL SYOLONONOD NOLVTIVLSNI 11 t 1 4 5310 7 71 l pee lt 4 3062 01 _ 77 7 i WONI NF ______ 5 3 Figana 1 P P E i lt 2 ue A 305220 19 lt 17 WF ______ q andi ANON E SLAVIN 1 4 0 i 0 lt pe 1 3
11. NOD 5 1 YOLVYANAD ZH 09 04 l 6 004 061 001 owe Tadd 53002 1 201 4009 1 21 12313 JONVQYOOOV NI GaGNNOYD OL SLASN3D 0435 5 3 16 LV 15 5 GAGNNONS 38 OL JYV SLASNAD 1 HOVA LV AG LSNW 4349 38 OL SAYIM G3TIVLSNI 71 03002 5531 Z OVA 009 41 MLW 72 601 vk OMY OL SYOLONGNOD NOIWVTIVISN 11 SALON ALON 335 INVYS YOLVYINIO 2018 foe 5 90089 22 YOLV INDIAN FOVLIOA 727 NOILONAF OM673L2 7 13 33 o 37019 Buimeiq OV SHOA 07 00 lt d N weibeig oy 01 1 S3009 1 201 3198 21199 3009 719515313 TWNOILLVN JHL 302 04092 GSGNNOYD 38 OL 5135 39 IWINLSNONI NOILJY SIQ SY3NOLSND LV YSWOLSND 3 1 AG ASGNNOYS 5135 39 HOVA YASWNN AB 0313114301 38 ISAW 38 OL 38 SSAYIM 0311 15 Tv 03002 530705 5531 Z ALON 335
12. turn off the unit if the temperature rises above 205 F 96 C Repeat troubleshooting If shutdown is activated and the temperature gauge shows temperature within normal temperature range a Check the engine crankcase oil level b If the oil level is low fill with recommended lubricating oil and restart Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading 20 60 PSI after a few seconds of operation c If the oil level is normal DO NOT restart the engine Call your dealer for assistance SPARE PARTS 1 Northern Lights recommends that you keep the following spare parts on hand for field service The parts are available from your local Northern Lights dealer 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 filters Air filter Alternator belt Thermostat and gaskets 22 Raw water pump impeller amp gaskets Glow plug Injector and washer 9 If your set is operating a long distance from servicing dealer add the following a Complete set of injectors b Copper washers for injector change c Complete set of glow plugs d Fuel lift pump OM673L2 7 13 13 Servicing Schedule Chart The Servicing Schedule Chart below shows the service schedule required for proper maintenan
13. 4 4000400 01 33 35 17 DC Electrical 4 4 4 0 4490440 4 36 37 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 OM673L2 7 13 OM673L2 7 13 1 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 M673L2 M673L3 M673LD2 and M673LD3 marine generator sets Model Numbers Model numbers give the unit s application block model a
14. 7 Control Panels STATUS INDICATORS 9 SYSTEM READY nea aH 3 EMERGENCY STOP hich encime Low on pressure ENGINE OVERSPEED overcean vice encime reme ow on LOW ENGINE TEMP ow vet eves gt NOT IN AUTO START 3 LOW BATTERY WOLTS CHARGE FAULT MANUAL START LAMP TEST ALARM RESET OFF A RESET 5 1 7 Figure 8 Control Panels Series 7 1 through Series 7 6 Generator Standard 5 7 3 thru 5 7 6 Standard 5 7 6 Standard 5 7 6 Standard 5 7 3 thru 5 7 6 Standard 5 7 3 thru S 7 6 Standard S 7 4 thru S 7 6 Standard 5 7 4 thru 5 7 6 Standard 5 7 3 thru 5 7 6 Standard S 7 3 thru S 7 6 Standard S 7 5 amp S 7 6 Standard 5 7 5 amp 5 7 6 Standard 5 7 5 amp 5 7 6 Standard 5 7 6 Standard 5 7 6 a Status Indicators for Series 7 3 through Series 7 6 Generator Control Panels 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 before starting a cold engine Holding 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 S 7 2 S 7
15. Injection nozzles dirty Injection pump out of time Engine overloaded Engine not at proper temperature Thermostats not working properly Temperature gauge not working properly e Adjust nozzle holder alignment e Check cylinder bore wear e Fill tank or radiator to proper level Check hoses for loose connections and leaks e Fan belt slipping Remove paint from tubes e Flush cooling system e Remove and check thermostat e Check water temperature with thermometer and replace gauge if necessary e Check impeller and replace if necessary e Call your dealer e Call your dealer e Check your thermostats e Check water temperature to see if temperature gauge is working properly See Engine Overheating section Use correct fuel for temperature e Service air cleaner e See your dealer e See your dealer e See your dealer Check load usage e Check your thermostats e Check water temperature with thermometer and replace gauge if necessary Check thermostats e Check water temperature with thermometer If you cannot correct problems with these procedures see your Northern Lights dealer OM673L2 7 13 30 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 oil pump Improper type o
16. a time After the engine has started check for fuel leaks using a piece of cardboard OM673L2 7 13 19 Servicing SP11 INJECTOR SERVICE Injectors should be checked every 1000 hours or more often as necessary Check should be made by a Northern 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 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 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
17. b Screw in injector and tighten to 43 or 50 6 to 7 kgm Figure 20 NOTE Overtightening can damage injector c Installreturn 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 Start engine and check for leaks using a piece of paper or cardboard DO NOT use hand to check for leaks SP12 INJECTION PUMP Since operating conditions may vary considerably it is difficult to give a definite interval for checking the injection pump But as a rule pump settings 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 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 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
18. contact an authorized dealer or the factory 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 CAUTION 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 or serious injury CAUTION indicates a hazardous situation which 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 dama
19. 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 1 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 valves 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 e 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 j Figure 10 Valve Adjustment Figure 11 Timing Mark OM673L2 7 13 17 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
20. out batteries Loose or defective alternator belt Check DC circuit breaker Loose or corroded connections Low battery output Defective electrical system ground wire Low battery output Check specific gravity of each battery Check electrolyte level of each battery Crankcase too heavy Loose or corroded connections Check DC circuit breaker Does Not Function Faulty connection Sulfated or worn out batteries Dead Battery RECOMMENDATION S e Clean and tighten battery connections e Check specific gravity of each battery e Check electrolyte level of each battery e Adjust belt tension e Replace belt If the breaker is tripped reset it e Clean and tighten loose battery and harness plug connection e Check specific gravity of each battery e Check electrolyte level of each battery e Repair or replace e Battery is too small e Battery cables are too small e Replace battery if necessary If low fill cells with distilled water e Fill with oil of appropriate viscosity e Clean and tighten loose connections If breaker is tripped reset it e Clean and tighten battery and harness plug connections e Check specific gravity and electrolyte level of each battery e Charge battery If you cannot correct problems with these procedures see your Northern Lights dealer OM673L2 7 13 28 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE Engine Hard to Start Imprope
21. terminal of booster battery to ground on chipped surfaces Put corrosion preventative on the engine block see Figure 22 all exposed metal surfaces 4 Remove booster battery after starting engine 5 Sealed batteries See manufacturer charging and booster instructions Figure 22 Battery connections Battery Booster Battery OM673L2 7 13 23 revised 6 19 12 Generator TF 276D GENERAL 1 Generator Set includes the engine the generator and the control or J box Figure 23 2 generator and the control or J box produce the electrical power 3 Generator excitation is provided by residual magnetism and electrical output voltage is controlled by the automatic voltage regulator AVR located in the control box Figure 25 Item 2 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 eS aS SS 9 CONTROL BOX Figure 25 1 Control Terminal Board 2 Automatic Voltage Regulator AVR 3 12 Volt DC Circuit Breaker 4 AC Circuit Breaker 5 AVR Circuit Breaker 6 Output Terminal Board Control Generator D 2 A Ly TY ik x 7 Sz
22. 4 S 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 1 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 frequency 60 Hz 1200 or 1800 RPM or 50 Hz 1500 RPM A C VOLTMETER Shows the generator output voltage A C AMMETER Shows the generator load on each phase The phase is selected with the Ammeter Selector switch Item 9 OM673L2 7 13 11 Operating Procedures BREAK IN PERIOD The first 100 hours on a new or
23. 6D 7 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 white plastic with two wires b Brush assembly leading to it 15 located at ten o clock and is Part 22 68304 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 c 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 Circuit Breaker AVR CIRCUIT BREAKER Figure 35 Breaker Locations OM673L2 7 13 Troubleshooting DC ELECTRICAL SYSTEM PROBLEM Battery Will Not Charge Starter Inoperative Starter Cranks Slowly Entire Electrical System POSSIBLE CAUSE Loose or corroded connections Sulfated or worn
24. OM673L2 7 13 18 1 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 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 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 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
25. ON Understand all service procedures before starting work Keep area clean and dry Never lubricate service or adjust machine while it is in operation Keep hands feet and clothing away from power driven equipment When shutting down an engine disengage all power and operator controls Allow the engine to cool completely before beginning any service work Securely support any machinery elements that must be raised for service work with support or lifting machinery specifically intended for that purpose Keep all parts in good conditions and properly installed Fix damage immediately Replace any worn or broken parts Remove any build up of grease oil or debris Disconnect battery ground cable before making any adjustments or service work Stay Clear of Rotating Drivelines Entanglement in rotating drivelines can cause serious injury or death Keep shields in place at all times Make sure that rotating shields turn freely in pace with the drivelines Do not wear loose fitting equipment around rotating drivelines Stop the engine and make sure that all moving parts have stopped before making any adjustments any other type of service to the engine or other driven equipment OM673L2 7 13 4 Added 6 19 12 Safety Rules Continued Install all Safety Guards To Avoid Hazards Fill batteries only in well ventilated areas e Wear appropriate eye protection and rubber g
26. OVA 009 GNVYLSILINN MLN 72 00 ONS 38 OL SYOLONGNOD NOILVTIVISNI 11 1 ve 5310 335 3LIHM 3359 IVAMOVG OO0C ZH 09 09 l 90089 22 Pa G gt 79 5 1 42 14 54 YOLVYINIAD YOLVINDSY JOVLION 727 YOLVYINIO OM673L2 7 13 34 o 96019 OW SHOA Oct BLON 33S BION 33S Hum oy NOLLVTIVLSNI 93 1 9 1715 N SYOLONGNOD LNdLNO 0931934409 ANY 03119915 Y3INOLSND 3LVIIGNI SINN NOLLAYOSIO 5 43 015 3 LV YSWOLSND JHL JQVW 5 0123 09 GNNOYNS 11 SLINN 53005 W501 8 ANY 3009 1 21812313 JHL 3 929 38 OL SI 9 A INO SLINA 15 LNIOd LV YSEWNN AG 31415301 38 LSAW ANV 14349 OL 544 G3TIVLSNI 3 0 V 71 03002 80102 SSJINN 7 OVA 009 ONVYLSILINN MLW 9 601 SMV OL SYOLONGNOD NOILVTIVISNI 1 3LON 335 SALON 39018 JNONI 3 1 N39 3359 18 ZH 09
27. ce 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 SP7 Check primary fuel filter SP9 Change secondary fuel filter SP5 Check V belt tension SP21 Inspect condition of exhaust elbow SP13 Check cooling water level Check sea strainer EVERY 1000 HOURS SP17 Check electrolyte level in batteries SP4 Check air cleaner element possibly replace SP6 Check valve clearances AFTER FIRST 50 HOURS SP11 Check injectors SP2 3 Change engine oil and filter SP16 Change 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 if necessary 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 16 C
28. cing 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 set using lifting bars inserted through the ifting holes on the skid Follow all recommended removal and installation procedures in this and associated Northern Lights manuals Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware always use the correct sized tools Use Proper Tools CAUTION Makeshift tools and procedures can create safety hazards Always use appropriate tools for the job Do not use US measurement tools on metric fasteners or vice versa Use only service parts that meet Northern Lights specifications Dispose of Waste Properly CAUTION Disposing of waste improperly can threaten the 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
29. d 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 output c Wiping is the only effective method for removing dust and foreign materials Use a clean lint free piece of cloth 3 Ifthe 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 If the bearing is 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 O 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 is important c Normally the brushes will have to be replaced with a new brush assembly within 3 000 hours PIGTAIL Figure 33 Brush Pigtail OM673L2 7 13 26 Generator TF 27
30. e 2 M673L2 Non Service Side 5 Figure 3 M673L2 Service Side 12 19 1 22 22 Fna Cover 16 DC Circuit Breaker 23 Lube Oil Drain Vibration Mount Air Filter a ae 3 Heat Exchanger Expansion 10 Starter Motor 17 Air Filter Housing 24 Lube Fill Side Tank Exhaust Manifold 11 DC Regulator 2 Fuel Filter 25 Block Drain _ 4 Lube Oil Fill Top 12 DC Alternator a ae ie or 26 Lube Oil Dipstick 5 Wet Exhaust Elbow 13 Belt Guard Fue nection 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 OM673L2 7 13 9 PREHEAT amp SHUT GENERATOR GENERATOR DOWN BYPASS STAR HOURS Hobbs o o owe TOTAL NOVES 4 Series 4 Generator Set Control Panel Figure 6 Series 4 Generator Control Panel Control Panels 7 10 OM673L2 7 13 10 SHUTDOWN BYPASS PREHEAT SWITCH This switch serves two functions 1 Preheats fuel before beginning the starting process Press switch for 10 20 seconds before attempting Start up 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 NOTE Three position Engine Control switches must be in the RUN posi
31. e 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 problems 3 Check hoses and connections and repair any leakage SP15 HEAT EXCHANGER 1 Clean the heat exchanger core once a year or after 2400 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 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
32. es i NE 5 amp 4 Figure 24 Generator Components RE 120 YELLOW 240 BROWN Figure 25 Control Box Components OM673L2 7 13 24 Generator TF 276D 5 1 120 Volt Output 120 volt output can be selected by connecting the terminals of the control terminal board to 120 Figure 26 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 2 240 BROWN Figure 26 Control Terminal Board 120 Volt Output AVR DS 71 2M 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 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 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 27 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 28 AVR
33. f 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 e Fill crankcase to proper level Repair or replace e Drain and fill crankcase with correct oil Replace filter e Oil consumption decreases after break in e Use proper viscosity oil e Check for leaks in lines around gaskets and drain plug e Service air cleaner e Have dealer check back pressure e Use correct fuel for temperature e See your dealer e See your dealer Use correct fuel for temperature e 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 OM673L2 7 13 31 Northern Lights Marine Data 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 Minimum Through Hull Diameter Raw Water Pump Inlet Hose I D Minimum Seawater Discharge Heat Rejecti
34. ged 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 16 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 near sparks or open flame oy ALWAYS STOP ENGINE BEFORE FUELING MACHINE Always fill portable fuel tank outdoors Never fuel a hot engine OM673L2 7 13 3 Added 6 19 12 Safety Rules Prevent accidental discharge of starting fluids by storing all cans in a cool safe place away from sparks or open flame Store with cap sec
35. h 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 or 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 bleed off point until complete shut off is achieved Affix 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 Instructi
36. h is turned OFF while the engine is running the battery charging regulator could be ruined STARTING 1 Hold the Shutdown Bypass Preheat switch in the 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 immediately and re install the impeller Re start the engine and check the exhaust overboard outlet for gushes of water OPERATING 1 2 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 coolant temperature gauge must be between 167 F and 194 F 75 C to 90 C Check the A C voltage and fre
37. heck 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 2 1 SP20 18 Winterizing or out of service 2 Perform all maintenance once a year even if hour level has not been reached 5 For EPA emission standards fuel nozzle needs to be More often if necessary cleaned every 1500 hours the fuel nozzle and fuel pump 1 2 3 After first 50 hours then at 100 hours then every 250 hours need to be cleaned adjusted or repaired every 3000 4 hours and the quality guarantee for these parts is 1500 hours or 2 years Clean injection nozzles every 1500 hours OM673L2 7 13 14 Service Record Notes OM673L2 7 13 15 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
38. 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 first 4 Change oil at any seasonal change in temperature aE SAE 30W 15 40 when new viscosity of oil is 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 F 23 SAE 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 Figure 9 Lube Oils 10 Engine capacity with new oil filter 15 4 Some increase in oil consumption may be expected M673L2 L3 LD2 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 lubricati
39. 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 engine Class D domestic fuels Class G or H industrial 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 Fill 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 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 M673L2 LD2 L3 amp LD3 24 52020
40. loves e Never use air pressure to clean batteries e Wear appropriate ventilation equipment to avoid inhaling fumes when adding electrolyte e Do not spill or drip electrolyte Use correct jump start procedure if required Direct contact with rotating fans belts pulley and drives can cause serious injury Keep all guards in place at all times during engine operation If acid is spilled on skin or in eyes 1 Flush skin with water Wear close fitting clothes Stop the engine and be 2 Apply baking soda or lime to sure all fans belts pulleys and drives are stopped help neutralize acid before making adjustments connections or cleaning 3 Flush eyes with water for W near fans and their components 15 30 minutes 1 2 4 Get medical attention Do not allow anything on your person to dangle into immediately come in contact with a moving fan belt pulley or If acid is swallowed eps drive Fans can act as vacuums and pull materials 1 DO NOT induce vomiting up from below so avoid that area as well while in 2 Drink large amounts of Service water or milk without exceeding 2 liters 2 quarts Safe Battery Handling 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 Prevent Battery Explosions Ba
41. nder compression pressure Remove and check thermostat e Clean or replace primary filter element e Drain flush fill and bleed system Have your dealer check injection nozzles Inspect clamps and hoses on suction side of fuel pump for air leak e Consult fuel supplier and use proper type of fuel for operating condition e Uneven compression cylinders Service air cleaner e Clean or replace primary filter element replace secondary filter element e Consult fuel supplier and use proper type of fuel for operating conditions See Engine Overheats next category Remove and check thermostat Reset valves Best done by dealer Replace injectors Best done by dealer e See your local dealer PROBLEM Lack of Engine Power continued Engine Overheats Engine Knocks High Fuel Consumption Below Normal Engine Temperature Troubleshooting POSSIBLE CAUSE RECOMMENDATION S Cylinder compression pressure low Adjust valve clearance cylinder compression pressure leakage 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 oil Injection pump out of time Below normal engine temperature Engine overheating Improper type of fuel Clogged or dirty air cleaner Improper valve clearance
42. on 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 Oil filter part numbers are M673L2 LD2 L3 amp LD3 24 08001 OM673L2 7 13 16 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 15 3 To bring the No cylinder to top dead center in the M673L2 LD2 L3 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
43. on 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 M673L2 L3 LD2 LD3 0 761 Itr 4 2 64 in 67 mm 2 83 in 72 mm CCW 23 5 1 3 3 qts 3 1 Itr Natural 362 Ibs 164 kg 20 25 in 514 5 mm 17 1 in 434 mm 27 1 688 5 2 Itr 0 75 19 0 75 19 0 75 19 350 5 0 gal min 0 761 Itr 4 2 64 67 2 83 72 CCW 23 5 1 3 3 qts 3 1 Itr Natural 362 Ibs 164 kg 20 25 in 514 5 mm 17 1 434 mm 27 1 688 5 2 ltr 0 75 in 19 mm 0 75 in 19 mm 0 75 in 19 mm 250 BTU min 4 2 gal min 18 92 15 77 Itr min 39 in 1 8 0 gal min 30 Itr min 4 ft 1 2 m 0 75 in NPT 19 1 mm 1 0 in 25 mm OM673L2 7 13 22 39 1 7 0 gal min 26 4 ft 1 2 m 0 75 in NPT 19 1 mm 1 0 in 25 mm 4 019 2 09 04 OV SHOA 07 00 061 001 BLON 335 weibeig Hum oy 038 3339 MOV 1d dYuvOd Wiring Diagrams
44. ons 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 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 e Ensure that all machinery or equipment is properly reassembled Inspect the machinery or equipment to verify non essential items have been removed e Ensure that all personnel are safely outside danger zones Notify personnel that lock out tag out devices have been removed and energy will be reapplied e Only authorized personnel may remove lock out tag out devices or notices OM673L2 7 13 8 Marine Generator Component Locations Figur
45. quency meters Series 4 panel If the gauges deviate from normal levels shut down the generator set and investigate Let the unit run unloaded for a 3 5 minute warm up period Add electrical load STOPPING 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 position momentarily Shut off the seacock fuel valve and battery switch OM673L2 7 13 12 Operating Procedures SHUTDOWNS AND ALARMS 1 Generator sets have shutdown systems to stop the engine in the event of hight water temperature or low oil pressure a Other alarms and shutdowns are available as optional equipment NOTE Do not rely on your warning to the exclusion of careful gauge monitoring Watching your gauges can prevent damage to the unit and dangerous power losses Do the following when your warning or shutdown system is activated 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 generator set after the temperature gauge registers below 200 F 94 C d Watch the temperature gauge regularly and
46. r 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 Irregularly Below normal engine temperature or Stalls Frequently Clogged primary or 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 OM673L2 7 13 29 RECOMMENDATION S e See starting section of this manual Take special note of Bypass Switch operation e Check level of fuel in fuel tank e Check electrolyte level and condition e Clean and tighten all battery connections e Use oil of proper viscosity e Consult fuel supplier and use proper type of fuel for operating condition e Drain flush fill and bleed system e Clean or replace primary filter element replace secondary filter element e Have your dealer check injection nozzles e Glow plug malfunction e Injection timing not correct e Low cyli
47. 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 Oil consumption is greater during break in as piston rings take time to seat Break In Oil Changes Change engine oil and filter at 50 hours Change oil and filter again at 100 hours then at every 250 hours consult Lubricants section for recommendation Operating Instructions Maintain at least a 75 load on your generator set for the first 100 hours Vary the load will help seat the rings BEFORE STARTING 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 1 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 dipstick 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 the crankcase Check the fuel tank level and open any fuel valves Close the sea cock check and clean the sea strainer and reopen the sea cock Place the battery switch in the ON position NOTE The battery switch must always be kept ON while the engine running If the switc
48. spiration and RPM 673 2 3 Northern Lights marine generator set M673L2 Northern Lights marine diesel generator set with a 673 engine long stroke TF 276D generator end Tier Il compliant Model number of engine block L Long Stroke Bore Cylinders D Series designation 67 mm 3 2 Tier II Compliant 3 Tier Compliant M673LD3 Northern Lights marine diesel generator set with a 673 engine long stroke TF 276D generator end Tier IIl compliant 5 kW Serial Number Your set has three serial numbers 1 an engine number stamped on the block 2 generator plate and 3 a generator set plate Use the serial number on the generator set plate when ordering parts Serial No nel or in correspondence The generator set plate is found on the service side of the generator and resembles the drawing in Figure 1 Northern Lights 4420 14th Ave NW Seattle WA 98107 Figure 1 Generator set serial number plate OM673L2 7 13 2 Revised 7 10 13 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
49. the generator end are located on pages 19 22 under the heading 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 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 A D C circuit breaker protects your control panel and wiring harness It 1 located in the side of the generator junction box OM673L2 7 13 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 21 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 plus pole of the glow plug If the bulb lights up solution Flush
50. tion during preheating Preheat switch must be held in ON position during starting ENGINE CONTROL SWITCH To start the engine hold this switch in the START position until the engine is running NOTE Excessive cranking of marine sets equipped with water lift muffler systems can cause engine damage See page 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 I panels only and has a light that glows when the set is running HOUR METER Keeps track of engine running time OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system WATER TEMPERATURE GAUGE Registers the temperature of the cooling water D C VOLTMETER OR AMMETER When the engine is stopped the voltmeter indicates the condition of the battery When the engine is running the voltmeter indicates the voltage output of the alternator For Series 4 Control Panels Only A C VOLTMETER Shows the generator output voltage FREQUENCY METER Hertz The frequency meter indicates engine speed 1200 or 1800 RPM 60 Hz or 1500 RPM 50 Hz AMMETER SELECTOR SWITCH Used to check each phase for load condition NOTE Always leave this switch in the ON position while the unit is running A C AMMETER Shows the generator load on each phase The phase is selected with the Ammeter Selector switch Item 9 Figure
51. ts 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 1 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 5 potentially toxic fumes and dust remove paint before heating e 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 you sand or grind paint use an approved respirator If you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers from the area e 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 ye system can release explosive 2 fluids and causing serious burns Before opening any pressurized cooling system make sure the
52. ttery gas is highly flammable Battery explosions can cause severe injury or death To help prevent battery explosions keep sparks lighted Handle Chemical Products Safely matches and open flame away from the top of battery When checking battery electrolyte level use a flashlight Direct exposure to hazardous Never check battery charge by contacting the posts chemicals can cause serious injury with a metal object Use volt meter or hydrometer Among the potentially hazardous chemicals that may be used Frozen batteries may explode if charged Never with Northern Lights charge a battery that has not been allowed to warm to products are lubricants at least 16 C 60 F coolants paints and adhesives Always remove grounded battery clamp first and replace ground clamp last All potentially hazardous chemicals come with a Material Data Safety Sheet MSDS The MSDS provides specific Sulfuric acid in battery electrolyte is poisonous and details on chemical products including physical hazards strong enough to burn skin eat holes into clothing and safety procedures and emergency response techniques other materials and cause blindness if splashed into eyes OM673L2 7 13 5 Added 6 19 12 Safety Rules Continued Read and understand the MSDS for each chemical before you start any job that includes it Follow the procedures and use appropriate equipment exactly as recommended Contact your Northern Ligh
53. ued components between the high pressure fuel pump and nozzles on engines with high pressure fuel systems ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH PRESSURE FUEL INJECTION SYSTEMS Avoid Hot Exhaust seco Avoid exposure to and physical contact with hot exhaust gases Exhaust parts and streams can reach high temperatures during operation leading to burns or other serious injury Cleaning exhaust filters can also lead to exposure to hot exhaust gas and the injury risk associated with it Avoid exposure to and physical contact with hot exhaust gases when cleaning exhaust filters During auto or manual stationary exhaust filter cleaning operations the engine will run at elevated temperatures for an extended period of time Exhaust parts and streams can reach high temperatures during operation leading to burns or other serious injury Avoid Harmful Asbestos Dust Inhaling asbestos fibers may cause lung cancer Avoid breathing any dust that may be generated when handling components containing asbestos fibers including some gaskets The asbestos used in these components is usually found in a 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 servi
54. urely on container Never incinerate or puncture a fuel container Prevent fires by keeping machine clean of accumulated trash grease and debris Always clean any spilled fuel as swiftly as possible Do not store oily rags which can ignite and burn spontaneously Be prepared if a fire starts Keep a first aid kit and fire extinguisher handy Keep emergency contact numbers for fire department doctors ambulance and hospital near the telephone Service Machines Safely Do not wear a necktie scarf necklace rings or other jewelry or any loose clothing when working near moving parts Tie long hair behind your head If any of these items get caught in moving machinery severe injury or death could result Check for any loose electrical connections or faulty wiring Look completely around engine to make sure that everything is clear before starting Wear Protective Clothing To prevent catching anything in moving machinery always wear close fitting clothes and safety equipment appropriate to the job Prolonged exposure to loud noise can cause hearing loss or impairment Wear suitable authorized hearing protection such as earmuffs or plugs to Y protect against loud noises A i CO connections performing Operating equipment requires the full attention of the operator Do not use radio or music headphones while operating machinery Practice Safe Maintenance CAUTI
55. with clean water Tighten terminals the glow plug is functioning properly and grease them to inhibit corrosion 3 Check all glow plugs and replace any faulty ones 3 Check the battery condition with a hydrometer every 250 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 vessel is in the water 2 Drain water supply lines and wet exhaust line 3 Loosen the seawater pump cover and drain pump Figure 21 Glow plugs 4 Fill the fuel tank or add biocide as per manufacturer s instructions BOOSTER BATTERIES 5 Seal the air cleaner inlet exhaust opening crankcase breather pipe and fuel tank vent with plastic bags A CAUTION Battery gas can explode and tape Keep all flames and sparks away from batteries 6 Store the set in a dry protected place If unit must be stored outside be sure it is well protected with a 1 Before changing or using booster batteries check cover battery electrolyte level Add distilled water if necessary 7 Change the crankcase oil and filter 2 Booster and main batteries must have the same 8 Loosen the alternator belt voltage rating 9 Disconnect and clean battery Remove to warm 3 First connect positive terminal of booster battery storage place if possible to positive terminal of main battery Then connect 10 Clean outside of unit Paint any scratched or negative
Download Pdf Manuals
Related Search