OM673L2

For Models: M673L2 and M673LD2

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

 — 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: (206) 789-3880
Fax: (206) 782-5455

Copyright ©2012 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.: OM673L2 07/13
 OPERATOR'S MANUAL
for Models
M673l₂, M673ld2, M673l3, and M673ld3
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

INTRODUCTION ....................................................2
Models Included .................................................2 SERVICING (CONTINUED)
Model Numbers ..................................................2 Fuels - General ................................................. 18
Serial Numbers ...................................................2 Fuel Filters ....................................................... 18
Bleeding the Fuel System ................................ 19
WARRANTY ............................................................3 Injector Service ...........................................20-21
Injection Pump ................................................. 21
SAFETY RULES ...............................................3 - 7
Cooling System - General ................................ 21
LOCK OUT / TAG OUT PROCEDURES .......... 8 Cooling System Flushing ................................. 22
Heat Exchanger ............................................... 22
COMPONENT LOCATIONS Raw Water Pump ............................................. 22
M673 Marine Generator .....................................9 Generator Ends ................................................ 22
Electrical System - General ............................. 22
PANELS Glow Plugs....................................................... 23
Northern Lights Generator Sets ................10 - 11 Booster Batteries .............................................. 23
Battery Care ..................................................... 23
OPERATING PROCEDURES Winterizing / Out-of-Service ........................... 23
Break-in Period ................................................ 12
Before Starting ................................................. 12 AC GENERATOR - TF-276D
Starting ............................................................. 12 General ............................................................. 24
Operating ......................................................... 12 Connections ..................................................... 25
Stopping ........................................................... 12 Operation ......................................................... 26
Shutdowns and Alarms .................................... 13 Maintenance ............................................. 26 - 27
Spare Parts ....................................................... 13
TROUBLESHOOTING
SERVICING SCHEDULE CHART ........ 14 - 15
Electrical .......................................................... 28
SERVICING Engine ...................................................... 29 - 31
Lubrication - General ....................................... 16
Checking Oil .................................................... 16 DATA SHEET
Oil Changes ..................................................... 16 Marine .............................................................. 32
Changing Oil Filter .......................................... 16
Air Filter .......................................................... 17 WIRING DIAGRAMS
V-Belts ............................................................. 17 AC Electrical ........................................... 33 - 35
Valve Clearances .............................................. 17 DC Electrical ........................................... 36 - 37

Proprietary Information
This publication is the property of Northern Lights, Inc.
It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc.
© Northern Lights, Inc. All rights reserved. Litho U.S.A. Publication number OM673L2 7/13

OM673L2 7/13
1
 Introduction

Servicing of marine engines and generator sets Failures begin with minor problems that are
presents unique problems. In many cases boats cannot overlooked and become amplified when not
be moved to a repair facility. Marine engines cannot corrected during routine maintenance.
be compared to the servicing of automobiles, trucks or
even farm equipment. Failures often occur in remote As operator, it is your obligation to learn about your
areas far from competent assistance. Marine engines equipment and its proper maintenance. This is not a
are taxed far more severely than auto or truck engines; comprehensive technical service manual. Nor will it
therefore, maintenance schedules must be adhered to make the reader into an expert mechanic. Its aim is
more strictly. to aid you in maintaining your unit properly.

Unit Identification

MODELS INCLUDED
This manual covers the operating instructions for:
M673L2, M673L3, M673LD2, and M673LD3 marine generator sets.

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:
M 673 L, D, 2, 3

M - Northern Lights marine generator set Model number of engine block L - Long Stroke
+ Bore Cylinders + D - Series designation
67 mm 3 2 - Tier II Compliant
3 - Tier III Compliant

M673L2 = Northern Lights marine diesel generator set with a 673 engine long stroke, TF-276D
generator end, Tier II compliant.

M673LD3 = Northern Lights marine diesel generator set with a 673 engine long stroke, TF-276D
generator end, Tier III compliant, 5 kW.

Serial Numbers

Your set has three serial numbers: 1 an engine number stamped

on the block, 2 a generator plate, and 3 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.

OM673L2 7/13
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 Revised 7-10-13

Warranty
A warranty registration certificate is supplied NOTE: If the warranty is to apply, the servicing
with your set. It entitles the original purchaser of instructions outlined in this manual must be
our equipment to a warranty covering material followed. If further information is needed, please
or assembly faults. The extent of coverage is contact an authorized dealer or the factory.
described in the Limited Warranty Statement. We
recommend that you study the statement carefully.

Safety Rules

NOTICE: 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.
IMPORTANT SAFETY INSTRUCTIONS. on parts and components from outside suppliers
Electromagnetic equipment, including generator sets that is not reproduced in this manual. Consult the
and their accessories, can cause bodily harm and suppliers for additional safety information.
life threatening injuries when improperly installed,
operated or maintained. To prevent accidents be aware Learn how to operate the machine and how to use
of potential dangers and act safely. the controls properly. Only trained personnel should
operate machines, or work on or around them.
READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUAL, Keep you machine in proper working condition.
PRIOR TO THE INSTALLATION UNAUTHORIZED MODIFICATIONS TO THE
OF ANY GENERATOR SET OR MACHINERY MAY IMPAIR ITS FUNCTION
ACCESSORY. KEEP THESE AND SAFETY PARAMETERS.
INSTRUCTIONS FOR FUTURE
REFERENCE.
Prevent Bypass and Accidental Starting
Recognize Safety Symbols and Instructions
In addition to the information found in this section, this
operator’s manual uses three different signal words to
outline potential dangers of a specific nature. Do not start engine by shorting
across start terminal. Engine will
DANGER indicates a hazardous situation which, if start if normal circuitry is bypassed,
not avoided, will result in death or serious injury. creating a hazard by runaway
WARNING indicates a hazardous situation which, if machinery.
not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation which, Start engine only from operator’s station.
if not avoided, could result in minor or moderate
injury.

Follow All Safety Instructions Handle Fuel Safely - Avoid Flames

Carefully read and understand
all safety messages in this
manual and on your machine’s
safety signs. Keep signs in good Diesel is highly flammable and should be treated
and clean condition. Replace with care at all times. Do not refuel while smoking
missing or damaged signs. Be or when near sparks or open flame.
sure new equipment components and repair parts
include the current safety signs. For replacement signs, ALWAYS STOP ENGINE
proper placement of safety signs or clarification on any BEFORE FUELING
safety issue, consult your Northern Lights dealer or the MACHINE. Always fill
factory. portable fuel tank outdoors.
There can be additional safety information contained Never fuel a hot engine.

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 Added 6-19-12

Safety Rules
Prevent accidental discharge of starting fluids by Operating equipment requires the full attention of
storing all cans in a cool, safe place, away from sparks the operator. Do not use radio or music headphones
or open flame. Store with cap securely on container. while operating machinery.
Never incinerate or puncture a fuel container.

Prevent fires by keeping machine clean of accumulated Practice Safe Maintenance

trash, grease and debris. Always clean any spilled fuel
as swiftly as possible. Do not store oily rags, which
can ignite and burn spontaneously.
Understand all service procedures
Be prepared if a fire starts. Keep a first aid kit and fire before starting work. Keep area clean and dry.
extinguisher handy. Keep emergency contact numbers Never lubricate, service, or adjust machine while it is
for fire department, doctors, ambulance and hospital in operation.
near the telephone.
Keep hands, feet and clothing away from power-
driven equipment. When shutting down an engine,
Service Machines Safely disengage all power and operator controls. Allow
the engine to cool completely before beginning any
service work.

Do not wear a necktie, scarf, Securely support any machinery elements that must
necklace, rings or other be raised for service work with support or lifting
jewelry, or any loose clothing machinery specifically intended for that purpose.
when working near moving
parts. Tie long hair behind your head. If any of these Keep all parts in good conditions and properly
items get caught in moving machinery, severe injury or installed. Fix damage immediately. Replace any
death could result. worn or broken parts. Remove any build up of
grease, oil or debris.
Check for any loose electrical connections or faulty
wiring. Disconnect battery ground cable (-) before making
any adjustments or service work.
Look completely around engine to make sure that
everything is clear before starting.
Stay Clear of Rotating Drivelines

Wear Protective Clothing

Entanglement in rotating drivelines can cause serious

injury or death. Keep shields in place at all times.
To prevent catching anything in moving machinery, Make sure that rotating shields turn freely in pace
always wear close fitting clothes and safety equipment with the drivelines.
appropriate to the job.
Prolonged exposure to loud noise can cause hearing Do not wear loose fitting equipment around rotating
loss or impairment. drivelines. Stop the engine and make sure that all
Wear suitable authorized moving parts have stopped
hearing protection, such before making any adjustments,
as earmuffs or plugs to connections, or performing
protect against loud noises. any other type of service to
the engine or other driven
equipment.

OM673L2 7/13
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 Added 6-19-12

Safety Rules (Continued)

Install all Safety Guards To Avoid Hazards:
• Fill batteries only in well-ventilated areas.
• Wear appropriate eye protection and rubber gloves.
• Never use air pressure to clean batteries.
Direct contact with rotating • Wear appropriate ventilation equipment to avoid
fans, belts, pulley and drives inhaling fumes when adding electrolyte.
can cause serious injury. • Do not spill or drip electrolyte.
• Use correct jump-start procedure if required.
Keep all guards in place at all
times during engine operation. If acid is spilled on skin or in eyes:
1. Flush skin with water.
Wear close-fitting clothes. Stop the engine and be 2. Apply baking soda or lime to
sure all fans, belts, pulleys and drives are stopped help neutralize acid.
before making adjustments, connections, or cleaning 3. Flush eyes with water for
near fans and their components. 15-30 minutes.
4. Get medical attention
Do not allow anything on your person to dangle into immediately.
or come in contact with a moving fan, belt, pulley or If acid is swallowed:
drive. Fans can act as vacuums and pull materials 1. DO NOT induce vomiting.
up from below, so avoid that area as well while in 2. Drink large amounts of
service. water or milk, without
exceeding 2 liters
(2 quarts)
Safe Battery Handling 3. Get medical attention immediately

Battery posts, terminals, and related accessories

Prevent Battery Explosions can contain lead and lead compounds, chemicals
Battery gas is highly known to the State of California to cause cancer and
flammable. Battery reproductive harm. Wash hands after handling.
explosions can cause severe
injury or death. To help
prevent battery explosions, keep sparks, lighted Handle Chemical Products Safely
matches and open flame away from the top of battery.
When checking battery electrolyte level, use a
flashlight.
Direct exposure to hazardous
Never check battery charge by contacting the posts chemicals can cause serious injury.
with a metal object. Use a volt-meter or hydrometer. Among the potentially hazardous
chemicals that may be used
Frozen batteries may explode if charged. Never with Northern Lights
charge a battery that has not been allowed to warm to products are lubricants,
at least 16oC (60oF). coolants, paints and adhesives.
Always remove grounded (-) battery clamp first and
replace ground clamp last. All potentially hazardous chemicals come with a Material
Data Safety Sheet (MSDS). The MSDS provides specific
Sulfuric acid in battery electrolyte is poisonous and details on chemical products, including physical hazards,
strong enough to burn skin, eat holes into clothing and safety procedures and emergency response techniques
other materials, and cause blindness if splashed into eyes.

OM673L2 7/13
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 Added 6-19-12

Safety Rules (Continued)

Read and understand the MSDS for each chemical before engine has been shut off. Do not remove a filler cap
you start any job that includes it. Follow the procedures unless it is cool enough to comfortably grip with bare
and use appropriate equipment exactly as recommended. hands. Slowly loosen cap to relieve pressure before
opening fully.
Contact your Northern Lights dealer or Northern Lights
factory for MSDS’s used on Northern Lights products.
Avoid High Pressure Fluids

Work in Well Ventilated Areas

Relieve pressure prior to

disconnecting pressurized
Exhaust fumes from engines contain carbon monoxide lines. Escaping fluid under
and can cause sickness or death. Work in well ventilated pressure can penetrate the skin causing serious
areas to avoid prolonged exposure to engine fumes. If it injury. Always relieve pressure before disconnecting
is necessary to run an engine in an enclosed area, route hydraulic or other pressurized lines. Tighten all
the exhaust fumes out of the area with an approved, leak connections firmly before re-applying pressure.
proof exhaust pipe extension.
If searching for leaks, use a piece of cardboard.
Always protect your hands and other body parts from
Remove Paint Before Welding or Heating high-pressure fluids.

If an accident occurs, see a doctor immediately. Any

high pressure spray injected into the skin must be
Hazardous fumes can be generated removed within a few hours to prevent the risk of
when paint is heated by welding, gangrene or other infection.
soldering or using a torch. To avoid
potentially toxic fumes and dust,
remove paint before heating. Avoid Heating Near Pressurized Fluid Lines

• Remove paint a minimum of 100

mm (4 in.) from the
area that will be affected by heat. Flammable spray can be generated
• If paint cannot be removed, wear an approved respirator. by heating near pressurized fluid
• If you sand or grind paint, use an approved respirator. lines, resulting in severe burns and
• If you use solvent or paint stripper, remove stripper bodily injury. Pressurized lines can
with soap and water before welding. Remove rupture when heat goes beyond the
solvent or paint stripper containers from the area. immediate flame area. Do not weld, solder or use a
• Allow at least 15 minutes for fumes to disperse torch or open flame near pressurized lines or other
before welding or heating. flammable fluids.

Do not use a chlorinated solvent in an area where welding

will occur. Work only in areas that are well ventilated. Do Not Open High-Pressure Fuel System
Dispose of paint and solvent properly.

Service Cooling System Safely

Many Northern Lights engines use high-pressure
fuel injection. High-pressure fluid remaining in fuel
lines can cause serious injury. Do not disconnect or
Opening a pressurized cooling attempt any repair of fuel lines, sensors, or other
system can release explosive
fluids and causing serious burns.
Before opening any pressurized
cooling system, make sure the

OM673L2 7/13
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 Added 6-19-12

Safety Rules (Continued)

components between the high-pressure fuel pump material containing asbestos. Keep all bystanders
and nozzles on engines with high pressure fuel away from any area where asbestos dust may be
systems. generated.

ONLY AUTHORIZED TECHNICIANS

CAN PERFORM REPAIRS ON AN HIGH Use Proper Lifting Equipment and Techniques
PRESSURE FUEL INJECTION SYSTEMS.

Avoid Hot Exhaust Lifting heavy components incorrectly can cause

severe injury or damage to machinery. Avoid
unbalanced loads. Do not use lifting eyes. Lift the
generator set using lifting bars inserted through the
Avoid exposure to and physical lifting holes on the skid. Follow all recommended
contact with hot exhaust removal and installation procedures in this and
gases. Exhaust parts and streams can reach high associated Northern Lights manuals.
temperatures during operation, leading to burns or
other serious injury.
Use Proper Tools
Cleaning exhaust filters can also lead to exposure to
hot exhaust gas and the injury risk associated with
it. Avoid exposure to and physical contact with hot
exhaust gases when cleaning exhaust filters. Makeshift tools and procedures
can create safety hazards.
During auto or manual/stationary exhaust filter Always use appropriate tools for
cleaning operations, the engine will run at the job.
elevated temperatures for an extended period of
time. Exhaust parts and streams can reach high Use power tools only to loosen threaded parts and
temperatures during operation, leading to burns or fasteners. For loosening and tightening hardware,
other serious injury. always use the correct sized tools.

Do not use US measurement tools on metric

Avoid Harmful Asbestos Dust fasteners, or vice versa. Use only service parts that
meet Northern Lights specifications.

Inhaling asbestos fibers may cause Dispose of Waste Properly

lung cancer. Avoid breathing any
dust that may be generated when
handling components containing
asbestos fibers, including some Disposing of waste improperly can threaten the
gaskets. environment and lead to unsafe working conditions.
Potentially harmful waste used in Northern Lights
The asbestos used in these components is usually equipment can include oil, fuel, coolant, filters and
found in a resin or otherwise sealed. Normal batteries.
handling of these components is not dangerous,
as long as airborne dust containing asbestos is not Use leakproof containers to drain fluid. Do not
generated. use food or beverage containers that may mislead
Avoid creating dust. Never use compressed air for someone into drinking from them.
cleaning. Avoid brushing or grinding materials
containing asbestos. When servicing, wear an Do not pour waste onto the ground, down a drain or
approved respirator. A special vacuum cleaner is into any water source.
recommended to clean asbestos. If this vacuum is
not available, apply a mist of oil or water on the

OM673L2 7/13
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 Added 6-19-12

Lock Out / Tag Out Procedures

Scope
During maintenance, repairs or retooling of a Northern Lights generator set, simply turning the machine off or unplugging
it while it is being worked on does not give enough protection to others who are not performing the maintenance or
repair. Many serious accidents happen when someone thought the machine was turned off, or all of its energy was
safely blocked or released.

General Policy If shutting off of air, water or other material cannot be

achieved at the local supply valve, shut off valves further
back in the system and re-check the bleed-off point until
To avoid dangerous or hazardous situations, refrain from complete shut-off is achieved.
any of the following:
• Removing or bypassing a guard or other safety device Affix a DO NOT OPERATE tag to each valve handle that
• Placing any part of your body in a position where you requires shut off. Each DO NOT OPERATE tag must be
could be caught by moving machinery. signed and dated by the authorized technician servicing
• Cleaning or oiling machinery when in operation. the equipment.
• Adjusting circuits, chillers, pumps, air handlers, valves,
circuit breakers or fans while in operation. Lock Out/Tag Out Instructions -
• Working on piping or high pressure systems. Air Hose Connected Pneumatic Equipment

Lock Out/Tag Out Instructions - Equipment connected to the compressed air system
Electrical Equipment through an air hose with a detachable fitting must be
shutdown and unplugged. Excess air must be bled prior
to removing the air hose, prior to any maintenance or
Be sure the equipment’s ON/OFF switch is in the OFF repair activities.
position and is unplugged from any electrical source before
attempting to perform any type of work on the equipment. Affix a DO NOT OPERATE tag to the air hose near the
Obtain an electrical plug cap cover with a lockset. Secure detachable fitting. Each DO NOT OPERATE tag must be
the plug terminal end using the electrical plug lockout cap. signed and dated by the authorized technician servicing
Lock the cap and retain the key. the equipment. Check that the equipment cannot be
operated by activating the ON switch.
If the equipment is directly wired into an electrical box with
a shut off switch, obtain a lock pad and/or the appropriate Stored Energy
colored tags and place the lock and tag through the shut
off lever. Retain the key until the repair is completed and
the machine is safe to start. Be certain the shut off lever Immediately after applying Lock Out or Tag Out devices,
is in the OFF position before restarting. NEVER give a ensure that all potentially hazardous stored or residual
lock out key to unauthorized personnel. energy is relieved, disconnected, restrained and otherwise
rendered safe.
If the equipment is directly wired into an electrical box
without a shut off switch and lock out capability, then a Verification of Isolation
circuit breaker lock out will be required. Obtain a circuit
lock and tag set. Install the lock onto the circuit breaker
box. Ensure the unit ON/OFF switch is in the OFF position Verify the machinery or equipment is actually isolated and
before restarting. de-energized prior to beginning work on a machine or on
equipment that has been locked out.
Lock Out/Tag Out Instructions -
Pneumatic and Hydraulic Equipment Restarting Procedures

For servicing pneumatic and hydraulic equipment, the Follow the procedures below prior to restoring energy:
following additional procedures must be implemented, • Ensure that all machinery or equipment is properly
following completion of lock out/tag out procedures for reassembled. Inspect the machinery or equipment to
the unit to be serviced: verify non-essential items have been removed.
• Ensure that all personnel are safely outside danger
Shut off air, water or supply valves at the equipment to zones. Notify personnel that lock out/tag out devices have
be serviced. been removed and energy will be reapplied.
• Only authorized personnel may remove lock out/tag out
Check the local bleed-off point for completed release of devices or notices.
pressurized air, water or oil.
OM673L2 7/13
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 Marine Generator Component Locations

Figure 2: M673L2 Non-Service Side.

1 2 3 4 1 5 6

13

12 8

11 10 9
2 19
Figure 3: M673L2 Service Side. 18 4
14 15 16 17

20

29 21

22

23

24

28 27 26 25

1. Heat Exchanger End Cap 8. Generator End Cover

2. Coolant Fill 16. DC Circuit Breaker 23. Lube Oil Drain
9. Vibration Mount
3. Heat Exchanger/Expansion 17. Air Filter Housing 24. Lube Oil Fill- Side
10. Starter Motor
Tank/Exhaust Manifold 18. Secondary Fuel Filter 25. Block Drain
11. DC Regulator
4. Lube Oil Fill- Top 19. Fuel Injector 26. Lube Oil Dipstick
12. DC Alternator
5. Wet Exhaust Elbow 20. Fuel Injection Pump 27. Lube Oil Filter
13. Belt Guard
6. Generator Junction Box 21. Fuel Lift Pump 28. Fuel Inlet and Return
14. AVR Circuit Breaker
7. Control Panel Plug-In 22. Sea Water Pump 29. Coolant Recovery Tank
15. AC Circuit Breaker

OM673L2 7/13
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 Control Panels

1. SHUTDOWN BYPASS-PREHEAT SWITCH

This switch serves two functions:
1. Preheats 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 shutdown setpoint.
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 4: Series 1-B 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.

Figure 5: Series 3 Generator Control Panel 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.

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

Figure 6: Series 4 Generator Control Panel Shows the generator load on each phase. The phase is
selected with the Ammeter Selector switch (Item 9).

OM673L2 7/13
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 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
Figure 7: Series 7.1 through Series 7.6 Generator Shows the oil pressure in the engine lubricating system.
Control Panels.
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).
11. A.C. VOLTMETER
Shows the generator output voltage.
12. A.C. AMMETER
Figure 8: Status Indicators for Series 7.3 through Shows the generator load on each phase. The phase is
Series 7.6 Generator Control Panels. selected with the Ammeter Selector switch (Item 9).

OM673L2 7/13
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 Operating Procedures

BREAK-IN PERIOD STARTING

1. The first 100 hours on a new or reconditioned 1. Hold the Shutdown Bypass-Preheat switch in the ON
engine are critical to its life and performance. position for 10 to 20 seconds before starting a cold
2. Constantly check the engine temperature and oil engine. Holding the switch too long can burn out the
pressure gauges (sets with Series 3 or 4 panels). glow plugs.
3. Oil consumption is greater during break-in as 2. While holding the Shutdown Bypass-Preheat switch
piston rings take time to seat. in the ON position, push the Engine Control switch to
4. Break-In Oil Changes: Change engine oil and the START position.
filter at 50 hours. Change oil and filter again at 3. As soon as the engine starts, release both switches.
100 hours, then at every 250 hours (consult Do not crank the starter for more than 20 seconds
Lubricants section for oil recommendation). consecutively. If the engine fails to start with the first
attempt, be sure that it has stopped completely before
Operating Instructions: re-engaging.
Maintain at least a 75% load on your generator NOTE: Excessive cranking of the starter on Marine
set for the first 100 hours. Vary the load will help sets equipped with a water lift muffler can cause
seat the rings. engine damage. If the engine does not start after three
20-second cranks, remove the impeller from the raw
BEFORE STARTING water pump. This will prevent the muffler from filling
with water and backfilling the exhaust line and engine.
1. Check the water level by removing the pressure Once the engine starts, shut it off immediately and re-
cap from the expansion tank or radiator. In order to install the impeller. Re-start the engine and check the
give the cooling water an opportunity to expand, the exhaust overboard outlet for gushes of water.
level should be about 1 in. (2.5 cm) below the filler
cap sealing surface when the engine is cold. OPERATING

CAUTION: Use protective clothing and open 1. Units with Series 3, Series 4, and Series 7 Control
the filler cap carefully when the engine is warm Panels: check gauges often. Oil pressure must be above
to prevent burns. 15 PSI. The D.C. voltmeter should read between 11
and 15 volts at 80°F (25°C) ambient temperature. The
2. Check the oil level in the crankcase with the coolant temperature gauge must be between 167°F and
dipstick. The oil level must be in the waffled area on 194°F (75°C to 90°C). Check the A.C. voltage and
the stick. Never allow the level to go below this area. frequency meters (Series 4 panel). If the gauges deviate
Always add the same viscosity of oil as is already in from normal levels, shut down the generator set and
the crankcase. investigate.
3. Check the fuel tank level and open any fuel valves. 2. Let the unit run unloaded for a 3 - 5 minute warm-up
4. Close the sea-cock, check and clean the sea strainer period.
and reopen the sea-cock. 3. Add electrical load.
5. Place the battery switch in the ON position.
NOTE: The battery switch must always be kept STOPPING
ON while the engine is running. If the switch is
turned OFF while the engine is running, the 1. Remove electrical load from the generator set.
battery charging regulator could be ruined. 2. Run the engine for a 3 to 5 minute cool down period.
3. Move the Engine Control switch to the STOP
position momentarily.
4. Shut off the seacock, fuel valve, and battery switch.

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 Operating Procedures

SHUTDOWNS AND ALARMS SPARE PARTS

1. Generator sets have shutdown systems to stop the 1. Northern Lights recommends that you keep the
engine in the event of hight water temperature or low following spare parts on hand for field service. The
oil pressure. parts are
a. Other alarms and shutdowns are available as available from your local Northern Lights dealer.
optional equipment. Some marine models already have “On-Board-Kits,”
NOTE: Do not rely on your warning to the a handy box that contains the most common parts
exclusion of careful gauge monitoring. Watching you will need.
your gauges can prevent damage to the unit and 2. All owners should have the following:
dangerous power losses. a. Primary and secondary fuel filter elements
2. Do the following when your warning or shutdown b. Oil filters
system is activated: c. Air filter
a. Check the temperature gauge. d. Alternator belt
If above 205°F (96°C), shut off the e. Thermostat and gaskets
engine immediately. f. Raw water pump impeller & gaskets
b. Use the Trouble Shooting Guide on page 25 to g. Glow plug
isolate the cause of the overheat. h. Injector and washer
3. If your set is operating a long distance from a
CAUTION: Do not remove the water fill servicing dealer, add the following:
cap of an overheated engine. Escaping high a. Complete set of injectors
temperature steam can cause severe burns. b. Copper washers for injector change
Allow the engine to cool and then remove the c. Complete set of glow plugs
cap slowly using protective clothing. d. Fuel lift pump

c. Make repairs. Restart your generator 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). Repeat troubleshooting.

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: EVERY 500 HOURS:
SP1 Check oil level in engine SP8 Change primary fuel filter element
SP7 Check primary fuel filter SP9 Change secondary fuel filter
SP5 Check V-belt tension SP21 Inspect condition of exhaust elbow
SP13 Check cooling water level
Check sea strainer EVERY 1000 HOURS:
SP17 Check electrolyte level in batteries SP4 Check air cleaner element; possibly replace
SP6 Check valve clearances
AFTER FIRST 50 HOURS: SP11 Check injectors
SP2/3 Change engine oil and filter SP16 Change impeller in raw water pump
SP6 Adjust valves
EVERY 2500 HOURS:
AFTER FIRST 100 HOURS: SP12 Check fuel injection pump
SP2/3 Change engine oil and filter SP14 Check and flush cooling system
SP15 Check and clean heat exchanger
EVERY 250 HOURS:
SP2/3 Change engine oil and filter
SP4 Check air cleaner
SP10 Bleed the fuel system if necessary
SP18 Check condition of batteries with a hydrometer

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) 3) •
SP3 11 Change lube oil filters 1) 3) •
SP4 12 Check air cleaner 1) 2) 3) • 
SP5 12 Check V-belt tension •
SP6 12 Check valve clearances 1)   •
FUEL SYSTEM:
SP7 13 Check primary filter (Racor) •
SP8 13 Change primary filter element (Racor) 2) •
SP9 13 Change secondary fuel filter 2) •
SP10 14 Bleed the fuel system 2)
SP11 15-16 Check injectors 1) 5) •
SP12 16 Check fuel injection pump 5) •
COOLING SYSTEM:
SP13 16 Check cooling water level •
SP14 17 Check and flush cooling system 2) •
SP15 17 Check and clean heat exchanger •
SP16 17 Change impeller in raw water pump 1) 2)  •
SP21 Inspect condition of exhaust elbow 2) •
ELECTRICAL SYSTEM:
SP17 18 Check electrolyte level in batteries 2) •
SP18 18 Check condition of batteries with hydrometer 2) •
OUT OF SERVICE:
SP20 18 Winterizing or out-of-service 2)
1) Perform all maintenance once a year even if hour level has not been reached. 5) For EPA emission standards fuel nozzle needs to be
2) More often if necessary. cleaned every 1500 hours, the fuel nozzle and fuel pump
3) After first 50 hours, then at 100 hours, then every 250 hours. need to be cleaned, adjusted, or repaired every 3000
4) Clean injection nozzles every 1500 hours. hours, and the quality guarantee for these parts is 1500
hours or 2 years.

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Service Record Notes

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 Servicing

LUBRICATION - GENERAL SP2. OIL CHANGES

1. Use only clean, high quality lubricants stored in 1. The set is delivered with special break-in oil.
clean containers in a protected area. Change the engine oil and oil filter after 50 hours
2. These lubricants are acceptable: of operation. Use Service CC 30 weight oil during
a. API Service CC/CD/CE single viscosity oils. the first 100 hours.
b. API Service CC/CD/SF multi-viscosity oils. 2. Change the oil and filter again at 100 hours using the
3. Use the proper weight oil for your average operation oil recommended in Figure 9. After this, change oil
temperature. and filter every 250 hours.
3. During intermittent cold weather operation, change
oil every 100 hours or six weeks, whichever comes
Air Single Multi-
Temperature Viscosity Viscosity first.
4. Change oil at any seasonal change in temperature
Above 32°F
(0°C)
SAE 30W SAE 15-40W when a new viscosity of oil is required.
5. Change oil when engine is warm.
-10 to 32°F 6. Dispose of waste oil in an approved manner.
SAE 10W SAE 10-30W
(-23 to 0°C)
7. Never use a flushing oil.
Below -10°F SAE 5W SAE 5-20W
8. Loosen the clamp on the oil change tube. Remove
(-23°C) cap. Drain oil. Replace the cap and tube.
9. Refill engine with recommended oil.
Figure 9: Lube Oils 10. Engine capacity with new oil filter is:

4. Some increase in oil consumption may be expected M673L2, L3, LD2, & LD3 – 3.3 quarts (3.1 liters)
when SAE 5W and SAE 5-20W oils are used. Check
oil level frequently. SP3. CHANGING LUBE OIL FILTER
5. Never put additives or flushing oil in crankcase.
1. Change the lube oil filter every with every oil
SP1. CHECKING OIL LEVEL change.
2. Use a filter wrench to remove old filter. Dispose of
1. Check the oil level in the crankcase with the dip- filter in approved manner.
stick. The oil level must be in the waffled area 3. Make sure the gasket from the old filter is removed
on the stick. Never allow the level to go below this and discarded. Clean mount face.
area. Follow the lubrication recommendations above. 4. Spread a thin film of engine oil on the rubber gasket
on the new filter and screw it on nipple until gasket
meets the sealing surface.
5. Using hands only – no wrench – tighten filter
one-half turn farther. Overtightening can do
damage to filter housing.
6. Fill engine with recommended oil. Start engine and
check for leakage. Stop engine, wait 3 minutes, and
check oil level. Add additional oil if necessary.
7. Oil filter part numbers are:

M673L2, LD2, L3, & LD3 – #24-08001

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 Servicing

SP4. AIR CLEANER SP6. VALVE CLEARANCES

1. Inspect air cleaner every 250 hours. In dusty 1. Adjust valve clearance every 1000 hours.
conditions, check more often. 2. Valve adjustments should be done if the cylinder
2. Inspect the element. If it is dirty, wash the element in head bolts have been re-tightened. Engine should be
soapy water. Rinse and dry thoroughly before cold and NOT running.
re-installing. Replace if necessary. Part number is: 3. To bring the No. 1 cylinder to top dead center in the
M673L2, LD2, L3, & LD3 - #24-28003 compression stroke, align the timing mark; the top
mark of the crank pulley with that of the timing gear
NOTE: Make absolutely sure no impurities enter case. Remove the rocker arm cover and turn the
the engine while changing the element. Do NOT crankshaft foward and backward. If the inlet and
run the engine with the air cleaner removed. exhaust valves of the No. 1 cylinder do not move
it is in top dead center position. When the valves
SP5. V-BELTS move, or rock, turn the crankshaft one full turn and
align the top mark of the crank pulley with the top
1. Check the tension and wear on the V-belt daily. mark of the timing gear case.
2. Use your thumb to press on the belt at the midpoint 4. Loosen the lock nut and adjust the clearance between
between the crankshaft and alternator pulleys. The the rocker arm and valve guide of both the intake
tension is correct if the belt can be depressed about and exhaust valves with the adjustment screw (Figure
3/16 in. (5 mm). 10). Clearance on both intake and exhaust valves
should be 0.008 in. (0.2 mm).
5. Repeat steps 3 and 4 for each cylinder. Each set of
valves must be adjusted individually.
6. Replace the rocker arm cover. Tighten cover nuts to
5 - 8 ft/lbs (0.8 - 2.3 kg/m).

Figure 10: Valve Adjustment

Figure 11: Timing Mark

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 Servicing

FUELS - GENERAL SP7-9. FUEL FILTERS

1. Use only clean, high quality fuels of the following 1. Your generator set should have a primary fuel filter
specifications, as defined by ASTM designation installed. We recommend the Racor brand of fuel
D975 for diesel fuels: filter-water separators.
a. Use Grade No. 2 diesel at ambient temperatures a. Check the primary fuel filter daily as
above freezing 32°F (0°C). recommended by the filter manufacturer.
b. Use Grade No. 1 at ambient temperatures below Empty the collection bowl as necessary.
freezing and for all temperatures at an altitude of b. Change the element as often as necessary or
above 5,500 ft. (1500 meters). every 500 hours.
2. Use fuel having less than 1% sulphur (preferably c. If the bowl fills with water, change the primary
less than 0.5%). and secondary element immediately.
3. The cetane number should be a minimum of 45. 2. Change secondary fuel filter every 500 hours.
4. DO NOT use these unsuitable grades of fuel: a. Remove the spin-on filter by turning it
a. Domestic heating oils, all types. counterclockwise with a filter wrench. Fill the
b. Class B engine. new cartridge with fuel and install it after
c. Class D domestic fuels. applying engine oil to gasket surface. Screw on
d. Class E, F, G or H industrial or marine fuels. until the gasket surface comes into contact with
e. ASTM-D975-60T No. 4-D and higher number sealing surface of filter base. Then, tighten it
fuels. two-thirds of a turn by hand. Do not overtighten.
5. Storing fuel: b. Fuel filter part number is:
a. Keep dirt, scale, water, and other foreign matter
out of fuel. M673L2, LD2, L3, & LD3 - 24-52020
b. Avoid storing fuel for long periods of time.
c. Fill the fuel tank at the end of each day’s
operation. This will reduce condensation.

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 Servicing

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 tight and lines, pipes and hoses aren't damaged. Fuel escaping from a very small hole
can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected
leaks. If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if
proper medical treatment isn't administered immediately.

Figure 12: M673 Fuel System.

1. The fuel system is self-bleeding. However, any 4. If the engine does not start after the above
system may need manual bleeding when: bleeding process, loosen a fuel line at the
a. A new fuel filter is installed; injector. Crank the engine until pure fuel escapes,
b. The engine has run out of fuel; then tighten the connection. Do each line one at a
c. The fuel lines, injection pump or any other fuel time.
system component has been removed and installed. 5. After the engine has started, check for fuel leaks
2. Loosen bleed screw “A” (Figure 12) on top of the using a piece of cardboard.
filter. Pump hand primer “B” on fuel lift pump until
pure fuel (no bubbles) escapes from bleed screw
“A”. Tighten bleed screw “A”.
3. Loosen bleed screw “C”. Pump hand primer “B” on
fuel lift pump until pure fuel (no bubbles) escapes
from bleed screw “A”.

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 Servicing

SP11. INJECTOR SERVICE SP12. INJECTION PUMP

1. Injectors should be checked every 1000 hours, or 1. Since operating conditions may vary considerably, it
more often as necessary. Check should be made by a is difficult to give a definite interval for checking the
Northern Lights dealer or local injection repair injection pump. But as a rule, pump settings,
station. maximum speed, idle speed and exhaust smoke
should be checked after every 2400 hours of
CAUTION: Escaping diesel fuel under pressure operation. Service of the fuel injection pump should
can have sufficient force to penetrate the skin only be done if checks indicate pump malfunction.
causing serious personal injury. If injured by 2. Black smoke can be an indication of pump
escaping diesel fuel, see a doctor at once. malfunction. Before servicing the pump, check other
possible causes:
2. Injector removal: a. Check cleanliness of air filter.
a. Clean loose dirt from around the injectors and b. Check valve clearances.
the fuel lines. c. Clean and check injectors.
b. Relieve high pressure in the fuel lines by 3. Any repair which involves disassembly of the
loosening the delivery line flare nuts at each injection pump must be carried out by specially
injector (Figure 13). trained mechanics with the proper tools and test
c. Remove delivery lines by disconnecting from equipment.
injectors and injection pump (Figure 14). Remove NOTE: All warranties on the engine become null
all lines as an assembly; do not remove the and void if the injection pump seals are broken by
clamp. Cover the ends of the lines, the injector unauthorized persons.
inlets and injection pump outlets to keep dirt out
(Figure 15). COOLING SYSTEM - GENERAL
d. Remove the return line retaining bolts (Figure 16).
Remove the return line (Figure 17). NOTE: Be sure to close the sea-cock before
e. Unscrew and remove the injectors (Figure 18). working on the engine cooling system.
NOTE: Do not use pry bars to remove injectors
from cylinder head. CAUTION: The cooling water in the engine
f. After removing the injectors, discard the copper reaches extremely high temperatures. You must
sealing washers from the injector hole in the head use extreme caution when working on hot
(Figure 19). Cover holes to prevent dirt and debris engines to avoid burns. Allow the engine to cool
from entering the cylinders. before working on the cooling system. Open the
filler cap carefully, using protective clothing
3. Injector installation: when the engine is warm.
a. Install a new copper sealing washer in each
injector hole (Figure 19). SP13. CHECK THE COOLANT LEVEL
b. Screw in injector and tighten to 43 or 50 ft/lbs
(6 to 7 kgm) (Figure 20). 1. Check the coolant level each day before starting the
NOTE: Overtightening can damage injector. engine. Check the water level by removing the pres-
c. Install return line using new copper sealing below sure cap from the expansion tank or radiator.
each connection. Tighten return line retaining In order to give the cooling water an opportunity to
bolts to 22 - 30 ft/lbs. expand, the level should be about 1 in. (2.5 cm) below
d. Install delivery lines. Leave loose at injectors for the filler cap sealing surface when the engine is cold.
bleeding. 2. The pressure valve in the filler cap releases when the
e. Crank the engine to fill lines. Tighten lines at pressure is approximately 7 PSI (0.5 bar). Use a cap
injectors. Start engine and check for leaks using a pressure tester to check cap if you suspect it is faulty.
piece of paper or cardboard.
DO NOT use hand to check for leaks.

OM673L2 7/13
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 Servicing

Figure 13: Remove delivery line flare nuts. Figure 17: Remove return line.

Figure 14: Remove delivery lines. Figure 18: Unscrew injector.

Figure 15: Cover lines, inlets and injection pump outlets. Figure 19: Remove and replace copper sealing washer.

Figure 16: Remove return line nuts. Figure 20: Reinstall injector. Torque to proper tightness.

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 Servicing

SP14. COOLING SYSTEM FLUSHING SP16. RAW WATER PUMP

1. Flush the cooling system every 2500 hours or every 1. Change the seawater pump impeller every 1000
12 months, whichever comes first. hours, or as needed.
a. Remove expansion tank cap and drain engine 2. Remove the pump end cover. Pry out the impeller
block. using needle-nose pliers or two screwdrivers.
b. Leave all drains open. Be sure you remove all pieces of failed impeller.
c. Pour clean water into expansion tank until NOTE: Place some kind of protection under the
water coming from drains is free of screwdrivers in order not to damage the pump
discoloration and sediment. housing.
d. Let water drain completely. 3. Clean the inside of the housing.
e. Close drains and refill with recommended 4. Press in the new impeller and place the sealing
mixture. washers in the outer end of the impeller center if this
NOTE: Open sea cock before running engine. has not already been done.
5. Replace the cover using a new gasket or o-ring.
2. Coolant Specifications: NOTE: Make sure that there is always an extra
Use 50% water / 50% ethylene glycol antifreeze impeller and cover gasket in reserve on board.
mix. Antifreeze mixture is recommended as a good
year-round coolant, but not methyl alcohol based GENERATOR ENDS
antifreeze because of its low boiling point. Also,
antifreeze with high silicate should not be used as it The maintenance and operation recommendations
could cause silica gelation problems. for the generator end are located on pages 19-22
3. Check hoses and connections and repair any leakage. under the heading “AC Generator”.

SP15. HEAT EXCHANGER ELECTRICAL SYSTEM - GENERAL

1. Clean the heat exchanger core once a year or after 1. Never switch battery switch off or break the circuit
2400 hours of operation. between the alternator and batteries while the engine
2. Drain expansion tank and heat exchanger. is running. Regulator damage can result.
3. Remove heat exchanger end covers and remove 2. Do NOT reverse the polarity of battery cables when
core. installing the battery.
4. Clean the inside of exchanger core tubes using 3. When welding on the unit, disconnect the AC and
a metal rod. Flush, inspect and clean again if DC voltage regulator and battery. Isolate the leads.
necessary. 4. Disconnect the battery cables when servicing the
5. Reassemble. Fill the cooling system, start the engine D.C. alternator.
and check for leaks. 5. Never test with a screwdriver, etc., against any
terminal to see if it emits sparks.
6. Do not polarize the alternator or regulator.
7. A D.C. circuit breaker protects your control panel
and wiring harness. It is located in the side of the
generator junction box.

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 Servicing

GLOW PLUGS SP 17-18. BATTERY CARE

1. Each cylinder is supplied with a glow plug which 1. Check electrolyte level every 50 hours or once per
serves to heat the combustion chamber for starting. month. Add distilled water to manufacturer’s
2. To check the glow plugs, loosen the current recommended level.
carrying flat wire between the plus-poles of the 2. Batteries, cables and cable terminals should
glow plugs (Figure 21). Connect a D.C. test bulb be checked and cleaned every 100 hours.
between the plus-pole of the battery and the Clean corrosion with a water and baking soda
plus-pole of the glow plug. If the bulb lights up, solution. Flush with clean water. Tighten terminals
the glow plug is functioning properly. and grease them to inhibit corrosion.
3. Check all glow plugs and replace any faulty ones. 3. Check the battery condition with a hydrometer every
250 hours.

SP19. WINTERIZING / OUT-OF-SERVICE

1. Drain fresh water and seawater cooling systems

completely. Remember to shut off seacocks
before opening drain cocks if the vessel is in the
water.
2. Drain water supply lines and wet exhaust line.
3. Loosen the seawater pump cover and drain pump.
Figure 21: Glow plugs. 4. Fill the fuel tank or add biocide as per
manufacturer’s instructions.
BOOSTER BATTERIES 5. Seal the air cleaner inlet, exhaust opening, crankcase
breather pipe, and fuel tank vent with plastic bags
CAUTION: Battery gas can explode. and tape.
Keep all flames and sparks away from batteries. 6. Store the set in a dry protected place. If unit must
be stored outside, be sure it is well protected with a
1. Before changing or using booster batteries, check cover.
battery electrolyte level. Add distilled water if necessary. 7. Change the crankcase oil and filter.
2. Booster and main batteries must have the same 8. Loosen the alternator belt.
voltage rating. 9. Disconnect and clean battery. Remove to warm
3. First, connect positive (+) terminal of booster battery storage place if possible.
to positive (+) terminal of main battery. Then, connect 10. Clean outside of unit. Paint any scratched or
negative (-) terminal of booster battery to ground on chipped surfaces. Put corrosion preventative on
the engine block (see Figure 22). all exposed metal surfaces.
4. Remove booster battery after starting engine.
5. Sealed batteries: See manufacturer charging and
booster instructions.

Figure 22:
Battery connections.

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 revised 6-19-12

AC Generator - TF-276D

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.
3. Generator excitation is provided by residual
magnetism and electrical output voltage is
controlled by the automatic voltage regulator (AVR)
located in the control box (Figure 25, Item 2).

GENERATOR (Figure 24)

1. Stator Core
2. Stator Coil
3. End Cover Figure 23: Composition.
4. Brush
5. Ball Bearing
6. Slip Ring
7. Frame
8. Coupling Plate
9. Field Coil
10. Field Core
11. Shaft
12. Ventilation Cover

CONTROL BOX (Figure 25)

1. Control Terminal Board
2. Automatic Voltage Regulator (AVR)
3. 12 Volt DC Circuit Breaker
4. AC Circuit Breaker
5. AVR Circuit Breaker
6. Output Terminal Board

Figure 24: Generator Components.

Figure 25: Control Box Components.

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 AC Generator - TF-276D

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 29: Output Terminal Board, 240 Volt Output

3. 120/240 Volt Output

a. Connect the control terminal board for 240 volts
Figure 26: Control Terminal Board, 120 Volt Output (Figure 30).

b. Connect U1 to U2 and V1 to V2 on the output

terminal board (Figure 27). Connect 120 volt
output leads to terminals U1 and V2.

Figure 30: Control Terminal Board, 120/240 Volt Output

b. Connect U2 and V1 on the output board

(Figure 31). Connect output leads to U1 and V2
Figure 27: Output Terminal Board, 120 Volt Output and neutral lead to V1 (or U2). 240 volt output is
available from the leads connected to U1 and V2.
2. 240 Volt Output: The 120 volt load should be divided as equally as
a. 240 volt output can be selected by connecting possible between two 120 volt circuits.
the terminals of the control terminal board to 240
(Figure 28).

Figure 28: Control Terminal Board, 240 Volt Output

b. Connect U2 to V1 on the output terminal board
(Figure 29). Figure 31: Output Terminal Board, 120/240 Volt Output

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 AC Generator - TF-276D

OPERATION 4. Voltage Adjustment

In order to ensure a long, trouble-free life, the gen- a. If there is some voltage, but it does not build up
erator must be operated properly and the to rated voltage, voltage adjustment can be made
specified maintenance must be performed. using the “hand trimmer” in the AVR (Figure 32).
b. The normal voltage setting at no load is 121 volts
OPERATING ENVIRONMENT at 62 Hertz or 242 volts at 62 Hertz.
Always keep electrical equipment clean. Moisture,
salt, dust, and oil will damage the generator. The
operating environment must be kept as clean and
moisture free as possible.

VENTILATION
Good ventilation is important for proper genera-
tor operation. When installing the generator set, be
sure the ambient temperature does not exceed 40°C
(104°F) during operation.

MAINTENANCE Figure 32: Hand Trimmer Location on AVR.

Proper and effective maintenance is required to
ensure trouble-free operation. In addition to the 5. Check the ball bearing in the generator end.
above items, the following are required: a. Listen for unusual noise.
1. Periodically check all bolts and nuts for proper b. Abnormal temperature rise can be noted by
torque. This is especially true for coupling bolts. discoloration.
2. Be sure to keep the generator area clean and dry. c. If the bearing is failing, it must be replaced.
a. Dust and foreign material may reduce the flow of d. Generator bearing should be replaced by your
cooling air, reducing heat dissipation and causing Northern Lights dealer at 10,000 hours.
the generator to overheat. 6. Check the brushes
b. If electrically conductive debris accumulates on a. The carbon brushes gradually wear with use, so
the windings, or if moisture or salt water are they must be inspected periodically and replaced
absorbed into the windings, the windings may as necessary.
short or ground, reducing voltage output. b. If the brushes are excessively worn as to expose
c. Wiping is the only effective method for removing the pigtail (Figure 33), sparking will occur at the
dust and foreign materials. Use a clean, lint-free surface of the slip ring, causing surface damage.
piece of cloth. Therefore, periodic inspection of the brushes is
3. If the generator has not been operated for an important.
extended period of time, check the insulation c. Normally, the brushes will have to be replaced
resistance of each stator coil and the rotor. with a new brush assembly within 3,000 hours.
Disconnect the AVR from the generator when
performing this test.

Figure 33: Brush Pigtail.

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 AC Generator - TF-276D

7. Replacing Brushes 9. Parts: See Parts Book for complete list

a. Shut down the generator. Remove four screws a. Bearing
and end cover of the generator. Part #22-68305
b. Brush assembly is white plastic with two wires b. Brush assembly
leading to it. It is located at ten o’clock and is Part #22-68304
held in position by two screws (Figure 34). 10. Test Specifications: See Wiring Diagram(s)
Remove the screws and unplug leads. 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. No load voltage setting
242V or 121V at 62 Hz with cold generator

Figure 34: Brush Location.

c. Attach leads to new brush assembly and install it

with the plastic ears towards the front of the
generator.
NOTE: Be sure to connect wire J to terminal J,
and connect wire K to terminal K.
8. Generator Protection
To protect the generator and AVR from
unbalanced loads and over loads, two 20 amp
breakers are placed in the output circuit and one
3 amp breaker is placed in the AVR sensing
circuit (Figure 35).

Figure 35: Breaker Locations.

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 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 batteries • Check specific gravity of each battery.
• Check electrolyte level of each battery.
Loose or defective alternator belt • Adjust belt tension.
• Replace belt.

Starter Inoperative Check DC circuit breaker • If the breaker is tripped, reset it.
Loose or corroded connections • Clean and tighten loose battery and
harness plug connection.
Low battery output • Check specific gravity of each battery.
• Check electrolyte level of each battery.
Defective electrical system • Repair or replace.
ground wire

Starter Cranks Slowly Low battery output • Battery is too small.

• Battery cables are too small.
Check specific gravity • Replace battery if necessary.
of each battery
Check electrolyte level • If low, fill cells with distilled water.
of each battery
Crankcase oil too heavy • Fill with oil of appropriate viscosity.
Loose or corroded connections • Clean and tighten loose connections.

Entire Electrical System Check DC circuit breaker • If breaker is tripped, reset it.
Does Not Function
Faulty connection • Clean and tighten battery and harness
plug connections.
Sulfated or worn out batteries • Check specific gravity and electrolyte
level of each battery.
Dead Battery • Charge battery.

If you cannot correct problems with these procedures, see your Northern Lights dealer.

OM673L2 7/13
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 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 • Check electrolyte level and condition.
Excessive resistance • Clean and tighten all battery connections.
in starting circuit
Crankcase oil too heavy • Use oil of proper viscosity.
Improper type of fuel • Consult fuel supplier and use proper type
of fuel for operating condition.
Water, dirt or air in fuel system • Drain, flush, fill and bleed system.
Clogged primary or secondary • Clean or replace primary filter element,
fuel filter element replace secondary filter element.
Dirty or faulty injection nozzles • Have your dealer check injection nozzles.

Fuel injected but no ignition • Glow plug malfunction.

• Injection timing not correct.
• Low cylinder compression pressure.

Engine Runs Irregularly Below normal engine temperature • Remove and check thermostat.
or Stalls Frequently
Clogged primary or secondary • Clean or replace primary filter element,
fuel filter element replace secondary filter element.

Water or dirt in the fuel system • Drain, flush, fill and bleed system.
Dirty or faulty injection nozzles • Have your dealer check injection nozzles.
Air in fuel system • Inspect clamps and hoses on suction side
of fuel pump for air leak.
Improper type of fuel • Consult fuel supplier and use proper type
of fuel for operating condition.

Low idle, not stable • Uneven compression cylinders.

Lack of Engine Power Intake air restriction • Service air cleaner.

Clogged primary or secondary • Clean or replace primary filter element,
fuel filter element replace secondary filter element.
 Improper type of fuel • Consult fuel supplier and use proper type of
fuel for operating conditions.
Overheated engine • See “Engine Overheats” in next category.
Below normal engine temperature • Remove and check thermostat.
Improper valve clearance • Reset valves. Best done by dealer.
Dirty or faulty injection nozzles • Replace injectors. Best done by dealer.
• See your local dealer.

OM673L2 7/13
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 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 coolant level or cooling • Fill tank or radiator to proper level.
system defective • Check hoses for loose connections
and leaks.
• Fan belt slipping.
Keel cooling tubes have been • Remove paint from tubes.
painted
Cooling system needs flushing • Flush cooling system.
Defective thermostat • Remove and check thermostat.
Defective temperature gauge • Check water temperature with thermometer
and replace gauge if necessary.
Water pump impeller worn/broken • Check impeller and replace if necessary.

Engine Knocks Insufficient oil • Call your dealer.

Injection pump out of time • Call your dealer.
Below normal engine temperature • Check your thermostats.
• Check water temperature to see if
temperature gauge is working properly.
Engine overheating • See “Engine Overheating” section.

High Fuel Consumption Improper type of fuel • Use correct fuel for temperature.
Clogged or dirty air cleaner • Service air cleaner.
Improper valve clearance • See your dealer.
Injection nozzles dirty • See your dealer.
 Injection pump out of time • See your dealer.

Engine overloaded • Check load usage.

Engine not at proper temperature • Check your thermostats.
• Check water temperature with thermometer
and replace gauge if necessary.

Below Normal Thermostats not working properly • Check thermostats.

Engine Temperature
Temperature gauge • Check water temperature with thermometer.
 not working properly

If you cannot correct problems with these procedures, see your Northern Lights dealer.

OM673L2 7/13
30
 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 plugged oil filter • Replace filter.

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 Clogged or dirty air cleaner • Service air cleaner.
or Gray Exhaust Smoke
Defective muffler • Have dealer check back pressure.
(back pressure too high)
Improper fuel • Use correct fuel for temperature.
Injection nozzles dirty • See your dealer.
Engine out of time • See your dealer.

Engine Emits Improper fuel • Use correct fuel for temperature.

White Smoke
Cold engine • Warm up engine to normal operating
temperature.
Defective thermostat • Remove and check thermostat.
Engine out of time • See your dealer.

If you cannot correct problems with these procedures, see your Northern Lights dealer.

OM673L2 7/13
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 Northern Lights Marine Data

Model: M673L2, L3, LD2, LD3

RPM 1800 1500
kW Rating 5.0 4.5
Frequency (Hz) 60 50

GENERAL INFORMATION
Cylinders 3 3
Displacement 46.4 in3 46.4 in3
(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)
Rotation (facing flywheel) CCW CCW
Compression Ratio 23.5:1 23.5:1
Crankcase Capacity w/ Oil Filter 3.3 qts 3.3 qts
(3.1 ltr) (3.1 ltr)
Aspiration Natural Natural
Dry Weight / Complete Unit 362 lbs 362 lbs
(164 kg) (164 kg)
Height 20.25 in 20.25 in
(514.5 mm) (514.5 mm)
Width 17.1 in 17.1 in
(434 mm) (434 mm)
Length 27.1 in 27.1 in
(688 mm) (688 mm)

COOLING SYSTEM
Approximate Cooling System Capacity .5 gal .5 gal
(2 ltr) (2 ltr)

Minimum Through-Hull Diameter 0.75 in 0.75 in

(19 mm) (19 mm)
Raw Water Pump Inlet Hose I.D. 0.75 in 0.75 in
(19 mm) (19 mm)
Minimum Seawater Discharge 0.75 in 0.75 in
(19 mm) (19 mm)

Heat Rejection to Jacket Water 350 BTU/min 250 BTU/min

Fresh Water Pump Capacity 5.0 gal/min 4.2 gal/min
(18.92 ltr/min) (15.77 ltr/min)
Maximum Seawater Pump Suction Head 39 in 39 in
(1 m) (1 m)

Seawater Pump Capacity 8.0 gal/min 7.0 gal/min

(30 ltr/min) (26 ltr/min)
Keel Cooler Turbo Tube Length 4 ft 4 ft
(1.2 m) (1.2 m)

Keel Cooler Head Diameter 0.75 in NPT 0.75 in NPT

(19.1 mm) (19.1 mm)
Keel Cooler Water Hose I.D.
Discharge and Suction 1.0 in 1.0 in
(25 mm) (25 mm)

OM673L2 7/13
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33
OM673L2 7/13
AC Wiring Diagrams

AC Engine Wiring Diagram

100-120/ 200-240 Volts AC
50/60 Hz
Drawing #B-6103F
Wiring diagrams are subject to change without notice.
34
OM673L2 7/13
AC Wiring Diagrams

AC Engine Wiring Diagram

200-240 Volts AC
Drawing #B-6104E

Wiring diagrams are subject to change without notice.

35
OM673L2 7/13
AC Wiring Diagrams

AC Engine Wiring Diagram

120 Volts AC
Drawing #B-6105C
Wiring diagrams are subject to change without notice.
36
OM673L2 7/13
DC Wiring Diagrams

DC Engine Wiring Diagram

12 Volts DC Standard Ground
Drawing #B-6102J
Wiring diagrams are subject to change without notice.
37
OM673L2 7/13
DC Wiring Diagrams

DC Engine Wiring Diagram

12 Volts DC Isolated Ground
Drawing #B-8247A
Wiring diagrams are subject to change without notice.
 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 Alaska Diesel Electric, Inc.
www.northern-lights.com © 2013 All rights reserved. Litho USA.