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  4. NL673L
  5. Operator's Manual

Northern Lights NL673L Operator's Manual

Summary of NL673L

  • 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 ©201...

  • Page 3: Operator'S Manual

    Onl673l 7/13 1 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 model nl673l introduction ....................................................2 model numbers .........

  • Page 4

    Onl673l 7/13 2 servicing of marine engines and generator sets pres- ents 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 competen...

  • Page 5

    Onl673l 7/13 3 a warranty registration certifi 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 care...

  • Page 6

    Onl673l 7/13 4 safety rules revised 6-19-12 operating equipment requires the full attention of the operator. Do not use radio or music headphones while operating machinery. Practice safe maintenance understand all service procedures before starting work. Keep area clean and dry. Never lubricate, ser...

  • Page 7

    Onl673l 7/13 5 safety rules (continued) revised 6-19-12 install all safety guards direct contact with rotating fans, belts, pulley and drives can cause serious injury. Keep all guards in place at all times during engine operation. Wear close-fi tting clothes. Stop the engine and be sure all fans, be...

  • Page 8

    Onl673l 7/13 6 safety rules (continued) added 6-19-12 read and understand the msds for each chemical before you start any job that includes it. Follow the procedures and use appropriate equipment exactly as recommended. Contact your northern lights dealer or northern lights factory for msds’s used o...

  • Page 9

    Onl673l 7/13 7 safety rules (continued) added 6-19-12 material containing asbestos. Keep all bystanders away from any area where asbestos dust may be generated. Use proper lifting equipment and techniques lifting heavy components incorrectly can cause severe injury or damage to machinery. Avoid unba...

  • Page 10

    Onl673l 7/13 8 general policy to avoid dangerous or hazardous situations, refrain from any of the following: • removing or bypassing a guard or other safety device • placing any part of your body in a position where you could be caught by moving machinery. • cleaning or oiling machinery when in oper...

  • Page 11

    Onl673l 7/13 9 notes.

  • Page 12

    Onl673l 7/13 10 1. Dc alternator 2. Muffl er, exhaust outlet 3. Starter 4. Dc regulator 5. Generator control box 6. Ac circuit breaker 13. Fuel lift pump 14. Block water drain 15. Lube oil dipstick 16. Lube oil filter 17. Lube oil drain 18. Secondary fuel filter 7. Air filter 8. Dc circuit breaker 9...

  • Page 13

    Onl673l 7/13 11 figure 6-b: series 3 generator control panel control panels figure 6-a: series 1-b generator control panel figure 6-c: series 4 generator control panel 1. Shutdown bypass-preheat switch there are two functions built into this switch: preheating the engine and bypassing the engine saf...

  • Page 14

    Onl673l 7/13 12 industrial 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. Engine control switch manual start (s-7.1 through s-7.6) move the switch in the manual position a...

  • Page 15

    Onl673l 7/13 13 break-in period 1. The fi 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 gauges (sets with series 3 or 4 panels). 3. Oil consumption is greater during break-in as piston rings take t...

  • Page 16

    Onl673l 7/13 14 operating procedures shutdowns and alarms 1. Your unit may be fi tted 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...

  • Page 17

    Onl673l 7/13 15 service 50 250 500 1000 2500 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 fi lters 1) 5) • • sp4 12 check air cleaner 1) 4) 6) • sp5 12 check v-belt tension 1) • sp6 12 check valve ...

  • Page 18

    Onl673l 7/13 16 service record notes.

  • Page 19

    Onl673l 7/13 17 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. 3. Use the proper weight oil for...

  • Page 20

    Onl673l 7/13 18 servicing sp4. Air cleaner 1. After every 25 hours of operation, take out the ele- ment and clean by blowing in compressed air (7 kg/cm2 max.) from inner side. 2. In case soot or oil is found adhered on element, soak for about 15 minutes in detergent solution, and after washing sever...

  • Page 21

    Onl673l 7/13 19 servicing fuels - general 1. Use only clean, high quality fuels of the following specifi cations, as defi ned by astm designation d975 for diesel fuels: a. Use grade no. 2 diesel at ambient temperatures above freezing 32°f (0°c). B. Use grade no. 1 at ambient temperatures below freez...

  • Page 22

    Onl673l 7/13 20 servicing figure 11-b: nl673l 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...

  • Page 23

    Onl673l 7/13 21 figure 12: remove delivery line fl are nuts. Figure 13: remove delivery lines. Figure 14: cover lines, inlets and injection pump outlets. Figure 15: remove return line nuts. Figure 17: unscrew injector. Figure 18: remove and replace copper sealing washer. Figure 19: reinstall injecto...

  • Page 24

    Onl673l 7/13 22 sp11. Injector service 1. Injectors should be checked every 1000 hours. Check should be made by a northern lights dealer or local injection repair station. Caution: escaping diesel fuel under pressure can have suffi cient force to penetrate the skin caus- ing serious personal injury....

  • Page 25

    Onl673l 7/13 23 servicing sp14. Cooling system flushing 1. Flush the cooling system every 2500 hours or every 12 months, whichever comes fi rst. 2. Cooling system flushing: a. Remove radiator cap and open drain cocks on radiator and engine block. B. Pour clean water into radiator until water coming ...

  • Page 26

    Onl673l 7/13 24 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 fl at wire between the plus-poles of the glow plugs ( figure 20 ). Connect a d.C. Test bulb between the plus-pole...

  • Page 27

    Onl673l 7/13 25 general 1. A generator set includes the engine, the generator, and the control or “j” box ( figure 22 ). 2. The generator and the control or “j” box produce the electrical power. 3. Generator excitation is provided by residual magnetism and electrical output voltage is controlled by ...

  • Page 28

    Onl673l 7/13 26 connections 1. 120 volt output: a. 120 volt output can be selected by connecting the terminals of the control terminal board to 120 ( figure 25 , also see page 29 ). Figure 25: control terminal board, 120 volt output b. Connect u1 to u2 and v1 to v2 on the output terminal board ( fig...

  • Page 29

    Onl673l 7/13 27 ac generator - tf-276d operation in order to ensure a long, trouble-free life, the gen- erator must be operated properly and the specifi ed maintenance must be performed. Operating environment always keep electrical equipment clean. Moisture, salt, dust, and oil will damage the gener...

  • Page 30

    Onl673l 7/13 28 figure 34: breaker locations. 9. Parts: see parts book for complete list a. Bearing part #22-68305 b. Brush assembly part #22-68304 10. Test specifi cations: 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 ...

  • Page 31

    Onl673l 7/13 29 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 bat...

  • Page 32

    Onl673l 7/13 30 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 • che...

  • Page 33

    Onl673l 7/13 31 troubleshooting engine problem possible cause recommendation(s) engine overheats low coolant level • fill tank or radiator to proper level. • check hoses for loose connections and leaks. Keel cooling tubes have been • remove paint from tubes. Painted (marine) cooling system needs fl ...

  • Page 34

    Onl673l 7/13 32 troubleshooting engine problem possible cause recommendation(s) high oil consumption break-in period • oil consumption decreases after break in. Crankcase oil too light • use proper viscosity oil. Oil leaks • check for leaks in lines around gaskets and drain plug. Engine emits black ...

  • Page 35

    Onl673l 7/13 33 northern lights industrial data model: nl673l rpm 1800 1500 kw rating 6.0 5.0 frequency (hz) 60 50 kw output @ 60 hz, 1800 rpm 1 120/240 volt amperage 25 a - 120 volt amperage 50 a - phase/optional phase 1 / – - kw output @ 50 hz, 1500 rpm 1 110/220 volt amperage - 22.7 110 volt ampe...

  • Page 36

    Onl673l 7/13 34 dc wiring diagrams dc engine w iring diagram drawing #b-6102j wiring diagrams are subject to change without notice..

  • Page 37

    Onl673l 7/13 35 ac wiring diagrams ac wiring diagram drawing #b-6105d wiring diagrams are subject to change without notice..

  • Page 38

    Onl673l 7/13 36 ac wiring diagram drawing #b-6103g wiring diagrams are subject to change without notice. Ac wiring diagrams.

  • Page 39

    Onl673l 7/13 37 ac wiring diagrams ac wiring diagram drawing #b-6104e wiring diagrams are subject to change without notice..

  • Page 40

    Www.Northern-lights.Com 4420 14th ave. Nw., seattle wa 98107 tel: (206) 789-3880 • 1-800-762-0165 • fax: (206) 782-5455 northern lights and lugger are registered trademarks of northern lights, inc. © 2013 all rights reserved. Litho usa..