Northern Lights Lugger OM673, Lugger M673M, Lugger M673D, Lugger M673L Owner's Manual
OM673
For Models: M673M, M673D, and M673L
OPERATOR’S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators
— 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 ©2009 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 09/09
OPERATOR'S MANUAL
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.
Table of Contents
for Models
M673M, M673D, and M673L
INTRODUCTION ....................................................2
Models Included .................................................2
Model Numbers ..................................................2
Serial Numbers ...................................................2
WARRANTY ............................................................3
SAFETY RULES .....................................................3
COMPONENT LOCATIONS
M673 Marine Generator .....................................4
PANELS
Northern Lights Generator Sets ....................5 - 6
OPERATING PROCEDURES
Break-in Period ...................................................7
Before Starting ....................................................7
Starting ................................................................7
Operating ............................................................7
Stopping ..............................................................7
Shutdowns and Alarms .......................................8
Spare Parts ..........................................................8
SERVICING (CONTINUED)
Fuels - General ................................................. 13
Fuel Filters ....................................................... 13
Bleeding the Fuel System ................................ 14
Injector Service ........................................ 15 - 16
Injection Pump ................................................. 16
Cooling System - General ................................ 16
Cooling System Flushing ................................. 17
Heat Exchanger ............................................... 17
Raw Water Pump ............................................. 17
Generator Ends ................................................ 17
Electrical System - General ............................. 19
Glow Plugs ....................................................... 18
Booster Batteries .............................................. 18
Battery Care ..................................................... 18
Winterizing / Out-of-Service ........................... 18
AC GENERATOR - TF-276M/ TF-276D
General ............................................................. 19
Connections ..................................................... 20
Operation ......................................................... 21
Maintenance ............................................. 21 - 22
SERVICING SCHEDULE CHART .......................9
SERVICING
Lubrication - General ........................................11
Checking Oil .....................................................11
Oil Changes ......................................................11
Changing Oil Filter ...........................................11
Air Filter .......................................................... 12
V-Belts ............................................................. 12
Valve Clearances .............................................. 12
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 09/09
TROUBLESHOOTING
Electrical .......................................................... 23
Engine ...................................................... 24 - 26
DATA SHEETS
Marine ...................................................... 27 - 28
WIRING DIAGRAMS
DC Electrical ................................................... 29
AC Electrical ........................................... 30 - 32
Proprietary Information
This publication is the property of Northern Lights, Inc.
OM673 09/09
1
Introduction
The servicing of marine engines and generator sets
presents unique problems. In many cases boats
cannot be moved to a repair facility. Marine engines
Failures begin with minor problems that are
overlooked and become amplifi ed when not corrected
during routine maintenance.
cannot be compared to the servicing of automobiles, trucks or even farm equipment. Failures often
occur in remote areas far from competent assistance.
Marine engines are taxed far more severely than
auto or truck engines; therefore, maintenance
schedules must be adhered to more strictly.
As operator, it is your obligation to learn about your
equipment and its proper maintenance. This is not a
comprehensive technical service manual. Nor will it
make the reader into an expert mechanic. Its aim is to
aid you in maintaining your unit properly.
Unit Identifi cation
MODELS INCLUDED
This manual covers the operating instructions for:
M673M, M673L, and M673D marine generator sets.
Model Numbers
Model numbers give the unit's application, block model, aspiration, and RPM:
M 673
M - Northern Lights marine generator set
M673M
M673L
M673D
Northern Lights marine diesel generator set with a 673 engine, TF-276M generator end,
=
and an automatic voltage regulator.
Northern Lights marine diesel generator set with a 673 engine, TF-276D generator end,
=
and an automatic voltage regulator.
Northern Lights marine diesel generator set with a 673 engine, TF-276D generator end,
=
and an automatic voltage regulator.
Serial Numbers
Set Serial
Set Model
Model No.
Serial No.
DUTY
RPM
HERTZ
PHASE
°C RISE
RULE
Generator Set Data
AC Generator Data
KW
KVA
Northern Lights, Inc., WA USA
www.northern-lights.com
WIRE
INSUL
AMB°C
PF
VOLTS
VOLTS
AMPS
AMPS
Model number of engine block
Bore Cylinders
+
67 mm 3
Your set has three serial numbers: 1 an engine number stamped
on the block, 2 a generator number, and 3 a generator set number.
Use the serial number on the generator set data plate when ordering
parts or in correspondence. The generator set data plate is found on
the service side of the generator and resembles the drawing in
Figure 1.
Figure 1: Generator set serial number data plate.
OM673 09/09
2
Warranty
A warranty registration certifi cate 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
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
CAUTION:
You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.
• Never leave engine without proper security.
• Turn the coolant tank cap slowly to relieve
pressure before removing. Add coolant only
when the engine is stopped and cool.
• Mount a fi re extinguisher near engine.
• Always disconnect the battery ground strap
before making adjustments.
• Operate engines in properly ventilated areas.
• Keep trash and other objects away from engine.
• Escaping fl uids under pressure can penetrate
your skin. Use a piece of cardboard or wood,
not your hands, to search for leaks.
• Avoid wearing loose clothing without a belt
when working around engines.
Accident reports show that careless use of engines causes a high percentage of accidents.
• Use caution in handling fuel. Never refuel a hot
or running engine. Do not smoke while fi lling
fuel tank or servicing fuel system.
• Keep your hands, feet, hair and clothing away
from power-driven parts.
• Check for any loose electrical connections or
faulty wiring.
• Engines should be operated only by knowledgeable, qualifi ed personnel.
• Look completely around engine to make sure
that everything is clear before starting.
• Do not operate an engine that isn't in proper working order. If an unsafe operating condition is noted,
tag the set and control panel so others will also
know about the problem.
• Do not oil or grease engine while it is running.
• Provide fi rst aid kits.
CAUTION: This symbol is used throughout
this book to alert you to possible danger areas.
Please take special notice of these sections.
OM673 09/09
3
Marine Generator Component Locations
Figure 2: M673 Non-Service Side.
Figure 3: M673 Service Side.
1. Heat Exchanger End Cap
2. Coolant Fill
3. Heat Exchanger/Expansion
Tank/Exhaust Manifold
4. Lube Oil Fill- Top
5. Wet Exhaust Elbow
6. Generator End Cover
7. Base and Drip Pan
8. Starter Motor
9. DC Regulator
10. Belt Guard
11. DC Alternator
12. DC Circuit Breaker
13. Generator Control Box
14. AC Circuit Breaker
15. Air Filter Housing
16. Fuel Injector
17. Fuel Injection Pump
18. Fuel Lift Pump
19. Lube Oil Drain
20. Sea Water Pump
21. Lube Oil Fill- Side
22. Lube Oil Dipstick
23. Block Drain
24. Lube Oil Filter
25. Secondary Fuel Filter
26. Control Panel Plug-In
27. Fuel Inlet and Return
28. AVR Circuit Breaker
OM673 09/09
4
Control Panels
1. SHUTDOWN BYPASS-PREHEAT SWITCH
There are three functions built into this switch:
preheating the engine, fl ashing the generator fi eld, and
bypassing the engine safety shutdown circuit enabling
a start. Hold the switch in the ON position for approximately 10 to 20 seconds before starting a cold engine.
Holding the switch ON for too long can burn out the
glow 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.
Figure 6-A: Series 1-B Generator Control Panel
Figure 6-B: Series 3 Generator Control Panel
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 muffl er 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.
Figure 6-C: Series 4 Generator Control Panel
For Series 4 Control Panels Only:
7. A.C. 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 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 09/09
5
Control Panels
Figure 7-A: Series 7.1 through Series 7.6 Generator
Control Panels.
1. 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-7.4, 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.
2. OIL PRESSURE GAUGE
Shows the oil pressure in the engine lubricating system.
3. HOUR METER
Keeps track of engine running time.
4. ENGINE TEMPERATURE GAUGE
Registers the temperature of the coolant.
5. D.C. VOLTMETER
When the engine is running, the voltmeter indicates the
voltage output of the alternator.
6. STATUS INDICATOR PANEL
Engine monitoring alarms and lamps for monitoring
engine functions.
7. ALARM LAMP TEST AND RESET BUTTON
Press UP to test the indicator lights and press DOWN
to reset the alarm.
8. A.C. VOLTAGE ADJUSTMENT RHEOSTAT
Voltage has been set at the factory and should only be
adjusted by factory-trained personnel.
9. 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.
10. FREQUENCY METER (HERTZ)
The frequency meter indicates alternator current fre-
quency: 60 Hz (1200 or 1800 RPM), or 50 Hz (1500
RPM).
Figure 7-B: Status Indicators for Series 7.3 through
Series 7.6 Generator Control Panels.
11. A.C. VOLTMETER
Shows the generator output voltage.
12. A.C. AMMETER
Shows the generator load on each phase. The phase is
OM673 09/09
6
selected with the Ammeter Selector switch (
Item 9).
Operating Procedures
BREAK-IN PERIOD
1. The fi rst 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
fi lter at 50 hours. Change oil and fi lter 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 fi rst 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 fi ller
cap sealing surface when the engine is cold.
STARTING FOR S-1, S-1B, S-3, AND S-4, SEE
PAGE 6 FOR S-7
1. 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.
2. While holding the Shutdown Bypass-Preheat switch
in the ON position, push the Engine Control switch
to the START position.
3. 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
fi rst 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 muffl er 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 muffl er from
fi lling with water and backfi lling 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.
CAUTION: Use protective clothing and open the
fi ller 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 waffl ed 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.
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 position.
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 battery charging regulator could be ruined.
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.
2. Run the engine for a 3 to 5 minute cool down period.
2. Move the Engine Control switch to the STOP position momentarily.
3. Marine Sets: shut off the seacock, fuel valve, and
battery switch.
OM673 09/09
7
Operating Procedures
SHUTDOWNS AND ALARMS
1. Your unit may be fi tted 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 dangerous power losses.
2. 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 fi ll
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.
SPARE PARTS
1. ADE recommends that you keep the following spare
parts on hand for fi eld 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.
2. All owners should have the following:
a. Primary and secondary fuel fi lter elements
b. Oil fi lters
c. Air fi lter (industrial units only)
d. Alternator belt
e. Thermostat and gaskets
f. Raw water pump impeller & gaskets (marine only)
f. Glow plug
g. Injector and washer
3. If your set is operating a long distance from a servicing dealer, add the following:
a. Complete set of injectors
b. Copper washers for injector change
c. Complete set of glow plugs
d. Fuel lift pump
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.
3. 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, fi ll 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.
OM673 09/09
8
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:
SP1 Check oil level in engine
SP5 Check V-belt tension
SP7 Check primary fuel fi lter
SP13 Check cooling water level
Check sea strainer
SP17 Check electrolyte level in batteries
AFTER FIRST 50 HOURS:
SP2/3 Change engine oil and fi lter
SP6 Adjust valves
AFTER FIRST 100 HOURS:
SP2/3 Change engine oil and fi lter
EVERY 250 HOURS:
SP2/3 Change engine oil and fi lter
SP4 Check air cleaner
SP10 Bleed the fuel system
SP18 Check condition of batteries with a hydrometer
SERVICE 50 250 500 1000 2500
POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours
ENGINE:
SP1 11 Check oil level •
SP2 11 Change engine oil 1) 5) • •
SP3 11 Change lube oil fi lters 1) 5) • •
SP4 12 Check air cleaner 1) 4) 5) 6) •
SP5 12 Check V-belt tension 1) 4) •
SP6 12 Check valve clearances 1) 2) •
FUEL SYSTEM:
SP7 13 Check primary fi lter (Racor) 2) 3) •
SP8 13 Change primary fi lter element (Racor) 2) 3) •
SP9 13 Change secondary fuel fi lter 1) 3) •
SP10 14 Bleed the fuel system 3)
SP11 15-16 Check injectors 1) 3) •
SP12 15 Check fuel injection pump •
COOLING SYSTEM:
SP13 15 Check cooling water level •
SP14 17 Check and fl ush cooling system 1) •
SP15 17 Check and clean heat exchanger •
SP16 17 Change impeller in raw water pump 1) 3) •
SP21 Inspect condition of exhaust elbow 1) 4) •
ELECTRICAL SYSTEM:
SP17 18 Check electrolyte level in batteries 1) 4) •
SP18 18 Check condition of batteries with hydrometer 1) 4) •
OUT OF SERVICE:
SP20 18 Winterizing or out-of-service 3)
EVERY 500 HOURS:
SP8 Change primary fuel fi lter element
SP9 Change secondary fuel fi lter
SP21 Inspect condition of exhaust elbow
EVERY 1000 HOURS:
SP4 Change air cleaner element
SP6 Check valve clearances
SP11 Check injectors
SP16 Change impeller
EVERY 2500 HOURS:
SP12 Check fuel injection pump
SP14 Check and fl ush cooling system
SP15 Check and clean heat exchanger
1) Perform all maintenance once a year even if hour level has not been reached.
2) Consult manufacturer's maintenance schedule, note on chart.
3) Whenever necessary.
4) More often if necessary.
5) After fi rst 50 hours, and again after fi rst 100 hours, then every
250 hours.
6) Change air cleaner element at 1000 hours.
OM673 09/09
9
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