Northern Lights M673L3, M673LD3 Operator's Manual

OM673L3

For Models: M673L3 and M673LD3

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

Printed in U.S.A. PART NO.: OM673L3 01/08

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

M673l3 and M673ld3

INTRODUCTION ....................................................4

Models Included .................................................4

Model Numbers ..................................................4

Serial Numbers ...................................................4

WARRANTY ............................................................5

SAFETY RULES .....................................................5

COMPONENT LOCATIONS

M673 Marine Generator .....................................6

PANELS

Northern Lights Generator Sets ....................7 - 8

OPERATING PROCEDURES

Break-in Period ...................................................9

Before Starting ....................................................9

Starting ................................................................9

Operating ............................................................9

Stopping ..............................................................9

Shutdowns and Alarms .................................... 10

Spare Parts ....................................................... 10

SERVICING (continued)

Fuels - General ................................................. 15

Fuel Filters ....................................................... 15

Bleeding the Fuel System ................................ 16

Injector Service ........................................ 17 - 18

Injection Pump ................................................. 18

Cooling System - General ................................ 18

Cooling System Flushing ................................. 19

Heat Exchanger ............................................... 19

Raw Water Pump ............................................. 19

Generator Ends ................................................ 19

Electrical System - General ............................. 19

Glow Plugs ....................................................... 20

Booster Batteries .............................................. 20

Battery Care ..................................................... 20

Winterizing / Out-of-Service ........................... 20

AC GENERATOR - TF-276D

General ............................................................. 21

Connections ..................................................... 22

Operation ......................................................... 23

Maintenance ............................................. 23 - 24

SERVICING SCHEDULE CHART .............11 - 12

SERVICING

Lubrication - General ....................................... 13

Checking Oil .................................................... 13

Oil Changes ..................................................... 13

Changing Oil Filter .......................................... 13

Air Filter .......................................................... 14

V-Belts ............................................................. 14

Valve Clearances .............................................. 14

Proprietary Information

This publication is the property of Alaska Diesel Electric, Inc.

It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc.

OM673L3 01/08

TROUBLESHOOTING

Electrical .......................................................... 25

Engine ...................................................... 26 - 28

DATA SHEET

Marine .............................................................. 29

WIRING DIAGRAMS

AC Electrical ........................................... 30 - 32

DC Electrical ........................................... 33 - 34

Introduction

Servicing of marine engines and generator sets presents unique problems. In many cases boats cannot be moved to a repair facility. Marine engines cannot

Failures begin with minor problems that are

overlooked and become amplied when not

corrected during routine maintenance. 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 Identication

MODELS INCLUDED

This manual covers the operating instructions for:

M673L3 and M673LD3 marine generator sets.

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:

673

L, D, 3

M - Northern Lights marine generator set

M673L3

M673LD3

Northern Lights marine diesel generator set with a 673 engine long stroke, TF-276D

generator end, Tier III.

Northern Lights marine diesel generator set with a 673 engine long stroke, TF-276D

generator end, Tier III, 5 kW.

Model number of engine block

Bore Cylinders

67 mm 3

L - Long Stroke

D - Series designation 3 - Tier III

Serial Numbers

Your set has three serial numbers: 1 an engine number stamped on the block, 2 a generator plate, and

Use the serial number on the generator set plate when ordering parts or in correspondence. The generator set plate is found on the service side of the generator and resembles the drawing in Figure 1.

a generator set plate.

Figure 1: Generator set serial number plate.

OM673L3 01/08

Warranty

A warranty registration certi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: 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.

• 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 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 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.

• Use caution in handling fuel. Never refuel a hot

or running engine. Do not smoke while 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, quali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.

CAUTION: This symbol is used throughout this book to alert you to possible danger areas. Please take special notice of these sections.

• Provide rst aid kits.

OM673L3 01/08

Marine Generator Component Locations

Figure 2: M673L3 Non-Service Side.

1 1

4 5

Figure 3: M673L3 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 Junction Box

7. Control Panel Plug-In

8. Generator End Cover

9. Vibration Mount

10. Starter Motor

11. DC Regulator

12. DC Alternator

13. Belt Guard

14. AVR Circuit Breaker

15. AC Circuit Breaker

OM673L3 01/08

16. DC Circuit Breaker

17. Air Filter Housing

18. Secondary Fuel Filter

19. Fuel Injector

20. Fuel Injection Pump

21. Fuel Lift Pump

22. Sea Water Pump

26 25

23. Lube Oil Drain

24. Lube Oil Fill- Side

25. Block Drain

26. Lube Oil Dipstick

27. Lube Oil Filter

28. Fuel Inlet and Return

29. Coolant Recovery Tank

Control Panels

1. 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 position during preheating. Preheat switch must be held in ON position during starting.

Figure 4: Series 1-B Generator Control Panel

Figure 5: Series 3 Generator Control Panel

2. ENGINE CONTROL SWITCH

To start the engine, hold this switch in the START

position until the engine is running.

NOTE: Excessive cranking of marine sets equipped

 withwaterliftmuf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: 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).

OM673L3 01/08

Control Panels

Figure 7: 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

frequency: 60 Hz (1200 or 1800 RPM), or 50 Hz (1500

RPM).

Figure 8:

Series 7.6 Generator Control Panels.

Status Indicators for Series 7.3 through

11. A.C. VOLTMETER

Shows the generator output voltage.

12. A.C. AMMETER

Shows the generator load on each phase. The phase is

selected with the Ammeter Selector switch (Item 9).

OM673L3 01/08

Operating Procedures

BREAK-IN PERIOD

1. The 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

lter at 50 hours. Change oil and lter again at

100 hours, then at every 250 hours (consult Lubricants section for oil recommendation).

Operating Instructions:

Maintain at least a 75% load on your generator

set for the 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 ller

cap sealing surface when the engine is cold.

STARTING

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 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 muf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 mufer from lling with water and backlling the exhaust line and engine.

Once the engine starts, shut it off immediately and reinstall the impeller. Re-start the engine and check the exhaust overboard outlet for gushes of water.

OPERATING

CAUTION: Use protective clothing and open

the 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 waf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. Close the sea-cock, check and clean the sea strainer and reopen the sea-cock.

5. 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.

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 coolant temperature gauge must be between 167°F and 194°F (75°C to 90°C). Check the A.C. voltage and frequency 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.

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.

3. Move the Engine Control switch to the STOP

position momentarily.

4. Shut off the seacock, fuel valve, and battery switch.

OM673L3 01/08

Operating Procedures

SHUTDOWNS AND ALARMS

1. Generator sets have shutdown systems to stop the engine in the event of high 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.

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 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 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 lter elements b. Oil lters c. Air lter

d. Alternator belt e. Thermostat and gaskets f. Raw water pump impeller & gaskets g. Glow plug h. 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 generator 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). Repeat troubleshooting.

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, 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.

OM673L3 01/08

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 SP7 SP13 Check cooling water level Check sea strainer (marine only)

AFTER FIRST 50 HOURS:

SP2/3 Change engine oil and lter SP5 Check V-belt tension SP6 Adjust valves SP18

EVERY 250 HOURS:

SP2/3 Change engine oil and lter SP4 SP8 Change primary fuel lter element SP18 Check electrolyte in batteries SP19 Check state of charge of batteries

SERVICE 50 250 500 1000 2400 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lters 1)  5)

SP4 12 Check air cleaner 1) 4) 5) • • SP5 12 Check V-belt tension 1) 4) • SP6 12 Check valve clearances 1) 2) 5) •

FUEL SYSTEM:

 SP7 13 Checkprimarylter(Racor) 2)3) •  SP8 13 Changeprimarylterelement(Racor) 2)3)    •  SP9 13 Changesecondaryfuellter 1)3)    •

SP10 14 Bleed the fuel system 3)

SP11 15-16 Check injectors 1) 3) 6) SP12 16 Check fuel injection pump 7) •

COOLING SYSTEM: SP13 16 Check cooling water level •

 SP14 17 Checkandushcoolingsystem      •

SP15 17 Check and clean heat exchanger • SP16 17 Change impeller in raw water pump 1) 3) •

SP21 Inspect condition of exhaust elbow 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)

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rst50hours,thenat100hours,thenevery250hours.

Check primary fuel lter

Check electrolyte in batteries

Check air cleaner

OM673L3 01/08

EVERY 500 HOURS:

SP3 Change engine oil lter SP8 SP9 Change secondary fuel lter SP21 Inspect condition of exhaust elbow

EVERY 1000 HOURS:

SP4 Check air cleaner SP6 Check valve clearances SP11 Check injectors SP14 SP16 Change impeller in raw water pump

EVERY 2400 HOURS:

SP12 Check fuel injection pump SP15 Check and clean heat exchanger

Change primary fuel lter element

Check and ush cooling system

• •

•

6) Clean injection nozzles every 1500 hours.

7) For EPA emission standards fuel nozzle needs to be

cleaned every 1500 hours, the fuel nozzle and fuel pump need to be cleaned, adjusted, or repaired every 3000 hours, and the quality guarantee for these parts is 1500 hours or 2 years.

•

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Northern Lights M673L3, M673LD3 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual