Northern Lights M673M, M673D, M673L Operator's Manual

OPERATOR’S

MANUAL

Publication #OM673 for models:

M673M, M673D, and M673L

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Alaska Diesel Electric, Inc.

4420 14th Avenue N.W.

P.O. Box 70543

Seattle, WA 98107

Tel: (206) 789-3880

Fax: (206) 782-5455

the Alaska Diesel Electric logo, Northern Lights™, and the Northern Lights logo are all trademarks of Alaska Diesel Electric, Inc.

Printed in U.S.A.

PART NO.: OM673 8/03

OPERATOR'S MANUAL

for Models

M673M, M673D, and M673L

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

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 SCHEDULE CHART .................	9-10
SERVICING
Lubrication - General ......................................	11
Checking Oil ...................................................	11
Oil Changes .....................................................	11
Changing Oil Filter..........................................	11
Air Filter ..........................................................	12
V-Belts ............................................................	12
Retightening Cylinder Head Bolts ..................	12
Valve Clearances .............................................	12

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
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 Alaska Diesel Electric, Inc.

It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc. © Alaska Diesel Electric, Inc. All rights reserved. Litho U.S.A. Publication number OM673 08/03

OM673 08/03

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 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.

Failures begin with minor problems that are overlooked and become amplified when not corrected during routine maintenance.

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 Identification

MODELS INCLUDED

This manual covers the operating instructions for:

M673M, M673L, and M673D marine generator sets.

Model Numbers

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

	M			673

M - Northern Lights marine generator set			Model number of engine block
		+	Bore		Cylinders
			67 mm	3

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.

Serial Numbers

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

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.

Figure 1: Generator set serial number plate.

OM673 08/03

Warranty

A warranty registration certificate is supplied with your set. It entitles the original purchaser of our equipment to a warranty covering material or assembly faults. The extent of coverage is described in the Limited Warranty Statement. We

recommend that you study the statement carefully.

NOTE: If the warranty is to apply, the servicing instructions outlined in this manual must be followed. If further information is needed, please contact an authorized dealer or the factory.

Safety Rules

CAUTION: Accident reports show that careless use of engines causes a high percentage of accidents.

You can avoid 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 fire 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 fluids 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.

•Do not oil or grease engine while it is running.

•Use caution in handling fuel. Never refuel a hot or running engine. Do not smoke while filling 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, qualified 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.

•Provide first 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 08/03

Northern Lights M673M, M673D, M673L Operator's Manual

Marine Generator Component Locations

Figure 2: M673 Non-Service Side.
Figure 3: M673 Service Side.
			12
1.	Heat Exchanger End Cap	8.	Starter Motor	15.	Air Filter Housing	22.	Lube Oil Dipstick
2.	Coolant Fill	9.	DC Regulator	16.	Fuel Injector	23.	Block Drain
3.	Heat Exchanger/Expansion	10.	Belt Guard	17.	Fuel Injection Pump	24.	Lube Oil Filter
	Tank/Exhaust Manifold	11.	DC Alternator	18.	Fuel Lift Pump	25.	Secondary Fuel Filter
4.	Lube Oil FillTop	12.	DC Circuit Breaker	19.	Lube Oil Drain	26.	Control Panel Plug-In
5.	Wet Exhaust Elbow	13.	Generator Control Box	20.	Sea Water Pump	27.	Fuel Inlet and Return
6.	Generator End Cover	14.	AC Circuit Breaker	21.	Lube Oil FillSide	28.	AVR Circuit Breaker
7.	Base and Drip Pan
			OM673	08/03
			4

Control Panels

1.SHUTDOWN BYPASS-PREHEAT SWITCH

There are three functions built into this switch: preheating the engine, flashing the generator field, and bypassing the engine safety shutdown circuit enabling a start. Hold 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

Figure 6-C: Series 4 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 muffler systems can cause engine damage. See page 7.

After the engine starts, release the switch and it will return to RUN position. To stop the engine, hold the switch in the STOP position.

NOTE: The rocker switch is used on Series 1 panels only, and has a light that glows when the set is running.

3.HOUR METER

Keeps track of engine running time.

4.OIL PRESSURE GAUGE

Shows the oil pressure in the engine lubricating system.

5.WATER TEMPERATURE GAUGE

Registers the temperature of the cooling water.

6.D.C. VOLTMETER OR AMMETER

When the engine is stopped, the voltmeter indicates the condition of the battery. When the engine is running, the voltmeter indicates the voltage output of the alternator.

For Series 4 Control Panels Only:

7.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 08/03

Control Panels

Figure 7-A: Series 7.1 through Series 7.6 Generator Control Panels.

Figure 7-B: Status Indicators for Series 7.3 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).

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).

OM673 08/03

Operating Procedures

BREAK-IN PERIOD

1.The first 100 hours on a new or reconditioned engine are critical to its life and performance.

2.Constantly check the engine temperature and oil pressure gauges (sets with Series 3 or 4 panels).

3.Oil consumption is greater during break-in as piston rings take time to seat.

4.Break-In Oil Changes: Change engine oil and filter at 50 hours. Change oil and filter again at 100 hours (consult Lubricants section for oil 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 is 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.

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.

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 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 20second 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.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 08/03

Operating Procedures

SHUTDOWNS AND ALARMS

SPARE PARTS

1.Your unit may be fitted with a warning horn to protect it from high water temperature or low oil pressure.

a.Generator sets have shutdown systems to stop the engine. They have no warning horns.

b.Other alarms and shutdowns are available as

optional equipment.

NOTE: Do not rely on your warning to the 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 fill cap of an overheated engine. Escaping high

temperature steam can cause severe burns. Allow the engine to cool and then remove the cap slowly using protective clothing.

c.Make repairs. Restart your Marine set after the temperature gauge registers below 200°F (94°C).

d.Watch the temperature gauge regularly and

turn off the unit if the temperature rises above 205°F (96°C) on Marine units.

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, 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.

1.ADE recommends that you keep the following spare parts on hand for field service. The parts are available from your local Northern Lights dealer. Some marine models already have “On-Board-Kits,”

ahandy box that contains the most common parts you will need.

2.All owners should have the following:

a.Primary and secondary fuel filter elements

b.Oil filters

c.Air filter (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

OM673 08/03

Servicing Schedule Chart

The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your generator set. More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’ column.

DAILY:		EVERY 200 HOURS:
SP1	Check oil level in engine	SP2/3 Change engine oil and filter
SP7	Check primary fuel filter	SP8	Change primary fuel filter element
SP13	Check cooling water level	SP9	Change secondary fuel filter
	Check sea strainer (marine only)	SP10	Bleed the fuel system
AFTER FIRST 50 HOURS:		SP21	Inspect condition of exhaust elbow
AFTER FIRST 50 HOURS:
SP2/3 Change engine oil and filter		EVERY 600 HOURS:
SP5	Check V-belt tension	SP6	Check valve clearances
SP6	Adjust valves	SP11	Check injectors
SP18	Check electrolyte in batteries	SP14	Check and flush cooling system
		SP16	Change impeller (marine only)
EVERY 50 HOURS:		SP18	Check state of charge of batteries
SP5	Check V-belt tension	EVERY 2400 HOURS:
SP18	Check electrolyte in batteries	EVERY 2400 HOURS:
SP18	Check electrolyte in batteries	SP12	Check fuel injection pump
		SP12	Check fuel injection pump
EVERY 100 HOURS:		SP15	Check and clean heat exchanger
SP4	Check air cleaner

SERVICE		50	100	200	600	2400
POINT PAGE OPERATION	DAILY	Hours	Hours	Hours	Hours	Hours

		ENGINE:
SP1	11	Check oil level		●
SP2	11	Change engine oil	1)	5)	7)	8)
SP3	11	Change lube oil filters	1)	5)	●	8)

SP4	12	Check air cleaner	1) 4)		●

SP5	12	Check V-belt tension	1) 4)	●

SP6	12	Check valve clearances	1) 2)	5)		●

		FUEL SYSTEM:
SP7	13	Check primary filter (Racor)	2) 3)	●
SP8	13	Change primary filter element (Racor)	2) 3)	●

SP9	13	Change secondary fuel filter	1) 3)	●

SP10	14	Bleed the fuel system	3)

SP11	15-16	Check injectors	1) 3)	●

SP12	16	Check fuel injection pump		●

		COOLING SYSTEM:
SP13	16	Check cooling water level		●

SP14	17	Check and flush 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.		5)	After first 50 hours.
2)	Consult manufacturer's maintenance schedule, note on chart.		6)	Adjust at first 100 hours.
3)	Whenever necessary.		7)	Change oil and filter on industrial units every 100 hours.
4)	More often if necessary.		8)	Change oil and filter on marine units every 200 hours.

	OM673	08/03
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