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

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.

— 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: [phone]
Fax: [phone]

Copyright ©2007 Alaska Diesel Electric, Inc.
All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Alaska Diesel Electric, Inc.

Printed in U.S.A.
PART NO.: ONL673 11/07

OPERATOR'S MANUAL

NL673k, NL673l, NL673l2, and NL673l3

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

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.

© Alaska Diesel Electric, Inc. All rights reserved. Litho U.S.A. Publication number ONL673 11/07

ONL673 11/07

1

Introduction

Servicing of industrial generator sets presents
unique problems. In many cases these generators
are far from a repair facility. Generators cannot be

Failures begin with minor problems that are

overlooked and become amplied when not

corrected during routine maintenance.
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.

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:

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

Model Numbers

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

NL 673

NL - Northern Lights industrial generator set

NL673K

NL673L2

Northern Lights industrial generator set with a

=

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

Northern Lights industrial generator set with a 673

=

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

Model number of engine block

+

Bore Cylinders
67 mm 3

NL673L

NL673L3

Northern Lights industrial generator set with a 673

=

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

Northern Lights industrial generator set with a 673

=

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

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.

L, 2, 3

L = Designates new

+

series of generator set

2 = Tier II compliant

3 = Tier III compliant

Figure 1: Generator set serial number plate.

ONL673 11/07

2

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 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.

-

• 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.

ONL673 11/07

3

Industrial Generator Component Locations

1

13

3

5

4

6

7

2

8

12

Figures 2-A and B: NL673L2

Service Side and Non-service side

1. Junction Box

2. DC Circuit Breaker

3. Air Filter

4. Crankcase Vent

5. Lube Oil Fill

6. Injection Pump

7. Coolant Fill

8. Radiator Shroud

9. Dipstick

10. Oil Filter

11. Fuel Lift Pump

11

10

16

9

14

15

8

12. Secondary Fuel Filter

13. Vibration Mount

14. Exhaust Outlet

15. Starter

16. Alternator

ONL673 11/07

4

Figure 3: Series 1-B Generator Control Panel

1. PREHEAT/ SHUTDOWN BYPASS SWITCH

This switch serves two functions:

Control Panel

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

5

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.

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.

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.

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.

ONL673 11/07

6

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.

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.

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

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.

ONL673 11/07

7

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 lter
SP13 Check cooling water level

AFTER FIRST 50 HOURS:

SP2/3
SP5 Check V-belt tension
SP18 Check electrolyte in batteries

EVERY 250 HOURS:

SP2/3
SP4 Check air cleaner
SP8
SP9 Change secondary fuel lter
SP16 Check radiator ller cap

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)

Change engine oil and lter

Change engine oil and lter

Change primary fuel lter element

EVERY 500 HOURS:

SP11
SP14
SP19 Check state of charge of batteries

EVERY 1000 HOURS:

SP6
SP12 Check fuel injection pump

SP16 Check and clean radiator

Check injectors

Check and ush cooling system

Check valve clearances

•

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

2) Whenever necessary.

3) More often if necessary.

ONL673 11/07

8

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

5) Clean injection nozzles every 1500 hours.

6) Replace element every 1000 hours.

Service Record

Service

Point

SP1 Check oil

SP5 Check V-belt tension

SP18 Check electrolyte
in batteries

OPERATION

SP2 Change engine oil

SP4 Check air cleaner

SP9 Change secondary fuel lter

HOURS/DATE

EVERY 50 HOURS

250 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

SP12 Check fuel injection pump

SP16 Check and clean radiator

500 HOURS

1000 HOURS

ONL673 11/07

9