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

Copyright ©2003 Alaska Diesel Electric, Inc. All rights reserved. Alaska Diesel Electric™, 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

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 (

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

CONTINUED)

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

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.

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TROUBLESHOOTING

Electrical.......................................................... 23

Engine........................................................ 24-26

DATA SHEETS

Marine ....................................................... 27-28

WIRING DIAGRAMS

DC Electrical ................................................... 29

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

Introduction

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 amplified 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 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:

673

M - Northern Lights marine generator set

Northern Lights marine diesel generator set with a 673 engine, TF-276M generator end,

M673M

M673L

M673D

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

Figure 1: Generator set serial number plate.

Model number of engine block

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

Bore Cylinders

67 mm 3

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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

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 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.

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 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.

• 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 first aid kits.

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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

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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

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.

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).

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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 frequency: 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

12. A.C. AMMETER

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Shows the generator output voltage.

Shows the generator load on each phase. The phase is selected with the Ammeter Selector switch (

Item 9).

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.

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.

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Operating Procedures

SHUTDOWNS AND ALARMS

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.

SPARE PARTS

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,” a handy 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

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.

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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 Check primary fuel filter SP13 Check cooling water level

Check sea strainer (marine only)

AFTER FIRST 50 HOURS:

SP2/3 Change engine oil and filter SP5 Check V-belt tension SP6 Adjust valves SP18 Check electrolyte in batteries

EVERY 50 HOURS:

SP5 Check V-belt tension SP18 Check electrolyte in batteries

EVERY 100 HOURS:

SP4 Check air cleaner

SERVICE 50 100 200 600 2400

POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours

EVERY 200 HOURS:

SP2/3 Change engine oil and filter SP8 Change primary fuel filter element SP9 Change secondary fuel filter SP10 Bleed the fuel system SP21 Inspect condition of exhaust elbow

EVERY 600 HOURS:

SP6 Check valve clearances SP11 Check injectors SP14 Check and flush cooling system SP16 Change impeller (marine only) SP18 Check state of charge of batteries

EVERY 2400 HOURS:

SP12 Check fuel injection pump SP15 Check and clean heat exchanger

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.

2) Consult manufacturer's maintenance schedule, note on chart.

3) Whenever necessary.

4) More often if necessary.

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5) After first 50 hours.

6) Adjust at first 100 hours.

7) Change oil and filter on industrial units every 100 hours.

8) Change oil and filter on marine units every 200 hours.

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