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  5. Operator's Manual

Northern Lights M673L2 Operator's Manual

Manual is about: Northern Lights marine generator sets Operator's manual

Summary of M673L2

  • Page 2

    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 copyright ©200...

  • Page 3: Operator'S Manual

    Om673l2 08/05 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 m673l2 and m673ld2 introduction ....................................................4 models i...

  • Page 4

    Om673l2 08/05 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 a...

  • Page 5

    Om673l2 08/05 5 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 certificate is supplied with your set. It entitles the original purchaser of our equipment to a warranty covering material or...

  • Page 6

    Om673l2 08/05 6 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 16. Dc circuit breaker 17. Air filter housing 18. Secondary fuel filter 19. Fuel injector 20. Fuel...

  • Page 7

    Om673l2 08/05 7 figure 5: series 3 generator control panel figure 4: series 1-b generator control panel figure 6: series 4 generator control panel 1. Shutdown bypass-preheat switch this switch serves two functions: 1. Preheats fuel before beginning the starting process. Press switch for 10-20 second...

  • Page 8

    Om673l2 08/05 8 control panels figure 7: series 7.1 through series 7.6 generator control panels. Figure 8: 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 approximatel...

  • Page 9

    Om673l2 08/05 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 or panels). . Oil consumption is greater during break-in as piston rings take time to s...

  • Page 10

    Om673l2 08/05 10 operating procedures shutdowns and alarms 1. Generator sets have shutdown systems to stop the engine in the event of hight 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 ...

  • Page 11

    Om673l2 08/05 11 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 filters 1) 5) • • sp4 12 check air cleaner 1) 4) 5) • • sp5 12 check v-belt tension 1) 4) • sp6 12 check val...

  • Page 12

    Om673l2 08/05 12 service record service point hours/date daily sp5 check v-belt tension sp8 &12 check oil level sp7 check primary filter sp13 check cooling water level 250 hours sp2 change engine oil and filter sp4 check air cleaner sp18 check electrolyte in batteries sp19 check condition of batteri...

  • Page 13

    Om673l2 08/05 1 servicing lubrication - general 1. Use only clean, high quality lubricants stored in clean containers in a protected area. 2. These lubricants are acceptable: a. Api service cc/cd/ce single viscosity oils. B. Api service cc/cd/sf multi-viscosity oils. . Use the proper weight oil for ...

  • Page 14

    Om673l2 08/05 1 servicing sp4. Air cleaner 1. Inspect air cleaner every 250 hours. In dusty conditions, check more often. 2. Inspect the element. If it is dirty, wash the element in soapy water. Rinse and dry thoroughly before re-installing. Replace if necessary. Part number is: m67l2 & ld2 - #2-280...

  • Page 15

    Om673l2 08/05 15 servicing fuels - general 1. Use only clean, high quality fuels of the following specifications, as defined by astm designation d75 for diesel fuels: a. Use grade no. 2 diesel at ambient temperatures above freezing 2°f (0°c). B. Use grade no. 1 at ambient temperatures below freezing...

  • Page 16

    Om673l2 08/05 16 servicing figure 12: m673 fuel system. Sp10. Bleeding the fuel system caution: escaping diesel fuel under pressure can penetrate skin causing serious personal injury. Before disconnecting lines be sure to relieve all pressure. Before applying pressure, be sure all connections are ti...

  • Page 17

    Om673l2 08/05 17 servicing sp11. Injector service 1. Injectors should be checked every 1000 hours, or more often as necessary. Check should be made by a northern lights dealer or local injection repair station. Caution: escaping diesel fuel under pressure can have sufficient force to penetrate the s...

  • Page 18

    Om673l2 08/05 18 servicing figure 13: remove delivery line flare nuts. Figure 14: remove delivery lines. Figure 15: cover lines, inlets and injection pump outlets. Figure 16: remove return line nuts. Figure 18: unscrew injector. Figure 19: remove and replace copper sealing washer. Figure 20: reinsta...

  • Page 19

    Om673l2 08/05 1 servicing sp14. Cooling system flushing 1. Flush the cooling system every 1000 hours or every 12 months, whichever comes first. A. Remove expansion tank cap and drain engine block. B. Leave all drains open. C. Pour clean water into expansion tank until water coming from drains is fre...

  • Page 20

    Om673l2 08/05 20 glow plugs 1. Each cylinder is supplied with a glow plug which serves to heat the combustion chamber for starting. 2. To check the glow plugs, loosen the current carrying flat wire between the plus-poles of the glow plugs ( figure 21 ). Connect a d.C. Test bulb between the plus-pole...

  • Page 21

    Om673l2 08/05 21 general 1. A generator set includes the engine, the generator, and the control or “j” box ( figure 23 ). 2. The generator and the control or “j” box produce the electrical power. . Generator excitation is provided by activation of the pre-heat circuit and electrical output voltage i...

  • Page 22

    Om673l2 08/05 22 connections 1. 120 volt output: a. 120 volt output can be selected by connecting the terminals of the control terminal board to 120 ( figure 26 ). Figure 26: control terminal board, 120 volt output b. Connect u1 to u2 and v1 to v2 on the output terminal board ( figure 27 ). Connect ...

  • Page 23

    Om673l2 08/05 2 ac generator - tf-276d operation in order to ensure a long, trouble-free life, the gen- erator must be operated properly and the specified maintenance must be performed. Operating environment always keep electrical equipment clean. Moisture, salt, dust, and oil will damage the genera...

  • Page 24

    Om673l2 08/05 2 . Parts: see parts book for complete list a. Bearing part #22-6805 b. Brush assembly part #22-680 10. Test specifications: see wiring diagram(s) a. Resistance of j-k 16.6 ohm at 20°c (68°f) b. Resistance of a-b 0.25 ohm at 20°c (68°f) c. Resistance of u1-v2 0.56 ohm at 20°c (68°f) d....

  • Page 25

    Om673l2 08/05 25 if you cannot correct problems with these procedures, see your northern lights dealer. Troubleshooting dc electrical system problem possible cause recommendation(s) battery will not charge loose or corroded connections • clean and tighten battery connections. Sulfated or worn out ba...

  • Page 26

    Om673l2 08/05 26 troubleshooting engine problem possible cause recommendation(s) engine hard to start improper starting procedure • see starting section of this manual. Take or will not start special note of bypass switch operation. No fuel • check level of fuel in fuel tank. Low battery output • ch...

  • Page 27

    Om673l2 08/05 27 troubleshooting engine problem possible cause recommendation(s) lack of engine power cylinder compression pressure low, • adjust valve clearance. (continued) cylinder compression pressure • adjust nozzle holder alignment. Leakage • check cylinder bore wear. Engine overheats low cool...

  • Page 28

    Om673l2 08/05 28 troubleshooting engine problem possible cause recommendation(s) low oil pressure low oil level • fill crankcase to proper level. Clogged filter and strainer or • repair or replace. Worn bearings and oil pump improper type of oil • drain and fill crankcase with correct oil. Partially...

  • Page 29

    Om673l2 08/05 2 northern lights marine data model: m673l2 & ld2 rpm 1800 1500 kw rating 5.0 4.5 frequency (hz) 60 50 general information cylinders 3 3 displacement 46.4 in 3 46.4 in 3 (0.761 ltr) (0.761 ltr) cycle 4 4 bore 2.64 in 2.64 in (67 mm) (67 mm) stroke 2.83 in 2.83 in (72 mm) (72 mm) rotati...

  • Page 30

    Om673l2 08/05 0 ac wiring diagrams wiring diagrams are subject to change without notice. A c engine w iring d iagram 120/240 v olts ac drawing #b-6103f.

  • Page 31

    Om673l2 08/05 1 ac wiring diagrams wiring diagrams are subject to change without notice. A c engine w iring d iagram 240 v olts ac drawing #b-6104e.

  • Page 32

    Om673l2 08/05 2 ac wiring diagrams wiring diagrams are subject to change without notice. A c engine w iring d iagram 120 v olts ac drawing #b-6105c.

  • Page 33

    Om673l2 08/05 dc wiring diagrams wiring diagrams are subject to change without notice. Dc engine w iring d iagram 12 v olts dc standard ground drawing #b-6102h.

  • Page 34

    Om673l2 08/05 dc wiring diagrams wiring diagrams are subject to change without notice. Dc engine w iring d iagram 12 v olts dc isolated ground drawing #b-8247.