Northern Lights NL673L3 Operator's Manual

ONL673

For Models: NL673K, NL673L, NL673L2, and NL673L3

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

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.

— CALIFORNIA —

Proposition 65 Warning:

Northern Lights

4420 14th Avenue N.W.

Seattle, WA 98107

Tel: (206) 789-3880

Fax: (206) 782-5455

the Northern Lights logo are trademarks of

Alaska Diesel Electric, Inc.

Printed in U.S.A.

PART NO.: ONL673 11/07

As of January 2008, U.S. EPA regulations require the

application of a permanently applied label near the fuel tank

ll port for diesel driven equipment. This label is to state:

LOW OR ULTRA LOW SULFUR FUEL ONLY

Northern Lights is providing this label for application to the

fuel inlet of the fuel supply tank for each engine or generator

set. This is to be applied by the installer of the engine or gen

set, or by the manufacturer of the equipment that the engine

or gen set is installed in. The location of the label must be

in clear site of personnel that rell the supply tank.

Note: Starting in 2011, the label will state:

ULTRA LOW SULFUR ONLY.

ONL673 11/07

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.

OPERATOR'S MANUAL

for Models

NL673k, NL673l, NL673l2, and NL673l3

INTRODUCTION ....................................................2

Models Included .................................................2

Model Numbers ..................................................2

Serial Numbers ...................................................2

WARRANTY ............................................................3

SAFETY RULES .....................................................3

COMPONENT LOCATIONS

Industrial Generator ............................................4

CONTROL PANEL

S-1B Control Panel .............................................5

OPERATING PROCEDURES

Break-in Period ...................................................6

Before Starting ....................................................6

Starting ................................................................6

Operating ............................................................6

Stopping ..............................................................6

Shutdowns and Alarms .......................................7

Spare Parts ..........................................................7

SERVICING SCHEDULE CHARTS ............... 8 - 9

SERVICING

Lubrication - General ....................................... 10

Checking Oil .................................................... 10

Oil Changes ..................................................... 12

Changing Oil Filter .......................................... 10

Air Filter ...........................................................11

V-Belts ..............................................................11

Valve Clearances ...............................................11

Fuels - General ................................................. 12

Fuel Filters ....................................................... 12

Bleeding the Fuel System ................................ 13

Injector Service ........................................ 14 - 15

Injection Pump ................................................. 15

Cooling System - General ................................ 15

Cooling System Flushing ................................. 16

Clean Radiator ................................................. 16

Electrical System - General ............................. 16

Glow Plugs ....................................................... 17

Booster Batteries .............................................. 17

Battery Care ..................................................... 17

Winterizing / Out-of-Service ........................... 17

Generator End .......................................... 18 - 21

TROUBLESHOOTING

Electrical .......................................................... 22

Engine ...................................................... 23 - 25

WIRING DIAGRAMS

AC Electrical NL673K .............................. 26 - 28

DC Electrical NL673K ...................................... 29

AC Electrical NL673L .............................. 30 - 31

DC Electrical NL673L, L2, & L3 ....................... 32

AC Electrical NL673L2 & L3 .................... 33 - 34

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.

Table of Contents

ONL673 11/07

Servicing of industrial generator sets presents

unique problems. In many cases these generators

are far from a repair facility. Generators cannot be

compared to the servicing of automobiles, trucks or

even farm equipment. Failures often occur in remote

areas far from competent assistance. Generators

can be 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 amplied 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.

Introduction

L, 2, 3

NL - Northern Lights industrial generator set

Model number of engine block

Bore Cylinders

67 mm 3

Serial Numbers

MODELS INCLUDED

This manual covers the operating instructions for:

NL673K, NL673L, NL673L2, and NL673L3 industrial generator sets.

Model Numbers

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

L = Designates new

series of generator set

2 = Tier II compliant

3 = Tier III compliant

Unit Identication

Northern Lights industrial generator set with a

673 engine, TF-276K series generator end, and AVR.

NL 673

NL673K

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.

Northern Lights industrial generator set with a 673

engine, TF-276D series generator end, and AVR.

NL673L

Northern Lights industrial generator set with a 673

engine, TF-276D series generator end, AVR, and

Tier II compliant.

NL673L2

Northern Lights industrial generator set with a 673

engine, TF-276D series generator end, AVR, and

Tier III compliant.

NL673L3

ONL673 11/07

CAUTION: This symbol is used throughout

this book to alert you to possible danger areas.

Please take special notice of these sections.

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

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.

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.

• Use caution in handling fuel. Never re-fuel 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 knowledge

able, 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.

• Provide rst aid kits.

• 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.

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

Safety Rules

Warranty

ONL673 11/07

Industrial Generator Component Locations

12. Secondary Fuel Filter

13. Vibration Mount

14. Exhaust Outlet

15. Starter

16. Alternator

1. Junction Box

2. DC Circuit Breaker

3. Air Filter

4. Crankcase Vent

5. Lube Oil Fill

6. Injection Pump

Figures 2-A and B: NL673L2

Service Side and Non-service side

7. Coolant Fill

8. Radiator Shroud

9. Dipstick

10. Oil Filter

11. Fuel Lift Pump

ONL673 11/07

Control Panel

Figure 3: Series 1-B Generator Control Panel

1. PREHEAT/ SHUTDOWN BYPASS SWITCH

This switch serves two functions:

1. Preheats the 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 the shutdown set point.

NOTE: Three position Engine Control switches must be

in the RUN position during preheating. Preheat switch

must be held in ON position during starting.

2. ENGINE CONTROL SWITCH

To start the engine, hold this switch in the START

position until the engine is running.

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.

ONL673 11/07

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.

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 (consult Lubricants section for oil

recommendation).

Operating Instructions:

Maintain at least a 75% load on your generator

set for the rst 100 hours. If this is not possible,

maintain no less than a 50% load to ensure proper

seating of the piston rings. Vary the load to 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.

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 dip-

stick. 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.

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

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. This duration is not

necessary if the engine is already warm.

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 10 seconds

consecutively. If the engine fails to start with the

rst attempt, be sure that it has stopped completely

(stationary at least 30 seconds) before

re-engaging.

OPERATING

1. Check oil pressure often. Oil pressure must be

above 15 PSI. Normal coolant temperature is 75

to 90°C (167 to 194°F). Check the AC voltage

and frequency. If these deviate from normal

levels, shut down the generator set and

investigate.

2. Let the unit run unloaded for about 10 minutes

for a warm-up period.

3. Add electrical load.

STOPPING

1. Cool down the engine by operating at low idle

speed for 3 minutes.

2. Check the engine noise and oil pressure for

abnormalities.

3. Remove electrical load from the generator set.

4. Turn the control switch to off.

Operating Procedures

ONL673 11/07

SHUTDOWNS AND ALARMS

1. Generator sets have shutdown systems to stop the

engine in the event of high water temperature or low

oil pressure.

Other alarms and shutdowns are available as

optional equipment.

NOTE: Do not rely on your shutdown 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.

Industrial sets: If above 230°F (110°C), shut

off the engine immediately.

b. Use the Trouble Shooting Guide on page 24 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.

c. Make repairs.

Restart your Industrial set after the temperature

gauge registers below 225°F (107°C).

d. Watch the temperature gauge regularly and

turn off the unit if the temperature rises above

230°F (110°C) on Industrial sets. Repeat trouble

shooting.

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.

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.

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. 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

Operating Procedures

ONL673 11/07

SERVICE 50 250 500 1000

POINT PAGE OPERATION DAILY Hours Hours Hours Hours

ENGINE:

SP1 6 & 10 Check oil level •

SP2 10 Change engine oil 1) 4) •

SP3 10 Change lube oil lters 1) 4) •

SP4 11 Check air cleaner 1) 3) 6) •

SP5 11 Check V-belt tension 1) 3) •

SP6 11 Check valve clearances •

FUEL SYSTEM:

SP7 12 Check primary lter (Racor) 2) •

SP8 12 Change primary lter element (Racor) 2) •

SP9 12 Change secondary fuel lter 1) 2) •

SP10 13 Bleed the fuel system 2)

SP11 15 Check injectors 1) 2) 5)

•

SP12 15 Check fuel injection pump •

COOLING SYSTEM:

SP13 15 Check cooling water level •

SP14 16 Check and ush cooling system •

SP16 16 Check and clean radiator ns   •

Check radiator ller cap  •

ELECTRICAL SYSTEM:

SP18 17 Check electrolyte level in batteries 1) 3) • •

SP19 17 Check condition of batteries with hydrometer 1) 3) • •

OUT OF SERVICE:

SP20 17 Winterizing or out-of-service 2)

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 lter

SP13 Check cooling water level

AFTER FIRST 50 HOURS:

SP2/3

Change engine oil and lter

SP5 Check V-belt tension

SP18 Check electrolyte in batteries

EVERY 250 HOURS:

SP2/3

Change engine oil and lter

SP4 Check air cleaner

SP8

Change primary fuel lter element

SP9 Change secondary fuel lter

SP16 Check radiator ller cap

EVERY 500 HOURS:

SP11

Check injectors

SP14

Check and ush cooling system

SP19 Check state of charge of batteries

EVERY 1000 HOURS:

SP6

Check valve clearances

SP12 Check fuel injection pump

SP16 Check and clean radiator

1) Perform all maintenance once a year even if hour level has not been reached.

2) Whenever necessary.

3) More often if necessary.

4) After rst 50 hours and at 100 hours.

5) Clean injection nozzles every 1500 hours.

6) Replace element every 1000 hours.

Servicing Schedule Chart

ONL673 11/07

Service

Point

HOURS/DATE

EVERY 50 HOURS

SP1 Check oil

SP5 Check V-belt tension

SP18 Check electrolyte

in batteries

250 HOURS

SP2 Change engine oil

SP4 Check air cleaner

SP9 Change secondary fuel lter

500 HOURS

SP3 Change lubricating oil lters

SP6 Check valve clearances

SP8 Change primary lter element (Racor)

SP11 Check injectors

SP14 Check and ush cooling system

SP19 Check condition of batteries with hydrometer

1000 HOURS

SP12 Check fuel injection pump

SP16 Check and clean radiator

Service Record

OPERATION

+ 25 hidden pages