Northern Lights Lugger M673D Page 2 Operator'S Manual Download

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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 ©2009 Northern Lights, Inc.
All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Northern Lights, Inc.

Printed in U.S.A.
PART NO.: OM673 09/09

Summary of Contents for Lugger M673D

Page 1: ...OM673 For Models M673M M673D and M673L OPERATOR S MANUAL Marine Generators Marine Diesel Engines Land Based Generators ...

Page 2: ...d 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 2009 Northern Lights Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Northern Lights Inc Printed in U S A PART NO OM673 09 09 ...

Page 3: ... V Belts 12 Valve Clearances 12 SERVICING CONTINUED Fuels General 13 Fuel Filters 13 Bleeding the Fuel System 14 Injector Service 15 16 Injection Pump 16 Cooling System General 16 Cooling System Flushing 17 Heat Exchanger 17 Raw Water Pump 17 Generator Ends 17 Electrical System General 19 Glow Plugs 18 Booster Batteries 18 Battery Care 18 Winterizing Out of Service 18 AC GENERATOR TF 276M TF 276D ...

Page 4: ...al covers the operating instructions for M673M M673L and M673D marine generator sets Model Numbers Model numbers give the unit s application block model aspiration and RPM Unit Identification Northern Lights marine diesel generator set with a 673 engine TF 276M generator end and an automatic voltage regulator Northern Lights marine diesel generator set with a 673 engine TF 276D generator end and a...

Page 5: ...servicing fuel system Keep your hands feet hair and clothing away from power driven parts Check for any loose electrical connections or faulty wiring Engines should be operated only by knowledge able qualified personnel Look completely around engine to make sure that everything is clear before starting Do not operate an engine that isn t in proper work ing order If an unsafe operating condition is...

Page 6: ...el Lift Pump 19 Lube Oil Drain 20 Sea Water Pump 21 Lube Oil Fill Side 8 Starter Motor 9 DC Regulator 10 Belt Guard 11 DC Alternator 12 DC Circuit Breaker 13 Generator Control Box 14 AC Circuit Breaker 22 Lube Oil Dipstick 23 Block Drain 24 Lube Oil Filter 25 Secondary Fuel Filter 26 Control Panel Plug In 27 Fuel Inlet and Return 28 AVR Circuit Breaker Marine Generator Component Locations 4 Figure...

Page 7: ...e 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 5 WATER TEMPERATURE GAUGE ...

Page 8: ... OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system 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...

Page 9: ...d the Shutdown Bypass Preheat switch in the ON position for 10 to 20 seconds before starting a cold engine Holding the switch too long can burn out the glow plugs 2 While holding the Shutdown Bypass Preheat switch in the ON position push the Engine Control switch to the START position 3 As soon as the engine starts release both switches Do not crank the starter for more than 20 seconds consecutive...

Page 10: ...d turn off the unit if the temperature rises above 205 F 96 C on Marine units 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 6...

Page 11: ...ailed coverage of each Service Point SP is listed on the page noted in the page column DAILY SP1 Check oil level in engine SP5 Check V belt tension SP7 Check primary fuel filter SP13 Check cooling water level Check sea strainer SP17 Check electrolyte level in batteries AFTER FIRST 50 HOURS SP2 3 Change engine oil and filter SP6 Adjust valves AFTER FIRST 100 HOURS SP2 3 Change engine oil and filter...

Page 12: ...OM673 09 09 Notes 10 ...

Page 13: ...on change oil every 100 hours or six weeks whichever comes first 4 Change oil at any seasonal change in temperature when a new viscosity of oil is required 5 Change oil when engine is warm 6 Dispose of waste oil in an approved manner 7 Never use a flushing oil 8 Loosen the clamp on the oil change tube Remove cap Drain oil Replace the cap and tube 9 Refill engine with recommended oil 10 Engine capa...

Page 14: ...rocker arm shaft and adjust valves Torque nuts to 7 9 ft lbs 1 0 1 3 kg m 6 Re install injectors and tubes and rocker cover Torque injectors to 43 51 ft lbs 6 7 kg m Use new injector sealing washers Figure 9 673M Head Torque Sequence Figure 10 Valve Adjustment SP6 VALVE CLEARANCES 1 Re adjust valve clearance after first 50 hours of operation and every 1000 hours thereafter 2 Valve adjustments shou...

Page 15: ...ing fuel for long periods of time c Fill the fuel tank at the end of each day s operation This will reduce condensation SP7 9 FUEL FILTERS 1 Your generator set should have a primary fuel filter installed We recommend the Racor brand of fuel filter water separators a Check the primary fuel filter daily as recommended by the filter manufacturer Empty the collection bowl as necessary b Change the ele...

Page 16: ... t administered immediately 1 The fuel system is self bleeding However any system may need manual bleeding when a A new fuel filter is installed b The engine has run out of fuel c The fuel lines injection pump or any other fuel system component has been removed and installed 2 Loosen bleed screw A Figure 11 on top of the filter Pump hand primer B on fuel lift pump until pure fuel no bubbles escape...

Page 17: ...dcheckforleaksusinga piece of paper or cardboard DO NOT use hand to check for leaks SP12 INJECTION PUMP 1 Since operating conditions may vary considerably it is difficult to give a definite interval for checking the injection pump But as a rule pump settings maxi mum speed idle speed and exhaust smoke should be checked after every 2400 hours of operation Service of the fuel injection pump should o...

Page 18: ...3 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 injector Torque to proper tightness Figure 16 Remove return line ...

Page 19: ...gain if neces sary 5 Reassemble Fill the cooling system start the engine and check for leaks SP16 RAW WATER PUMP 1 Change the seawater pump impeller every 1000 hours or as needed 2 Remove the pump end cover Pry out the impeller using needle nose pliers or two screwdrivers Be sure you remove all pieces of failed impeller NOTE Place some kind of protection under the screwdrivers in order not to dama...

Page 20: ...r starting engine 5 Sealed batteries See manufacturer charging and booster instructions SP 17 18 BATTERY CARE 1 Check electrolyte level every 50 hours or once per month Add distilled water to manufacturer s recommended level 2 Batteries cables and cable terminals should be checked and cleaned every 100 hours Clean corrosion with a water and baking soda solu tion Flush with clean water Tighten term...

Page 21: ...ator AVR located in the control box Figure 24 Item 2 GENERATOR Figure 23 1 Stator Core 2 Stator Coil 3 End Cover 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 24 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...

Page 22: ...minal board to 240 Figure 27 Figure 27 Control Terminal Board 240 Volt Output b Connect U2 to V1 on the output terminal board Figure 28 Figure 28 Output Terminal Board 240 Volt Output 3 120 240 Volt Output a Connect the control terminal board for 240 volts Figure 29 Figure 29 Control Terminal Board 120 240 Volt Output b Connect U2 and V1 on the output board Figure 30 Connect output leads to U1 and...

Page 23: ...ucing voltage output c Wiping is the only effective method for removing dust and foreign materials Use a clean lint free piece of cloth 3 If the generator has not been operated for an extended period of time check the insulation resis tance of each stator coil and the rotor Disconnect the AVR from the generator when per forming this test 4 Voltage Adjustment a If there is some voltage but it does ...

Page 24: ...r Remove four screws and end cover of the generator b Brush assembly is white plastic with two wires leading to it It is located at ten o clock and is held in position by two screws Figure 33 Remove the screws and unplug leads Figure 33 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 termi...

Page 25: ...n 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 Cran...

Page 26: ...rature Remove and check thermostat or Stalls Frequently Clogged primary Clean or replace filter element fuel filter element Clogged secondary Replace secondary filter element fuel 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 ...

Page 27: ...erature 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 not at proper temperature Check your ...

Page 28: ...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 th...

Page 29: ... 688 mm 688 mm 688 mm 688 mm COOLING SYSTEM Approximate Cooling System Capacity 5 gal 5 gal 5 gal 5 gal 5 gal 5 gal 2 ltr 2 ltr 2 ltr 2 ltr 2 ltr 2 ltr Minimum Through Hull Diameter 0 75 in 0 75 in 0 75 in 0 75 in 0 75 in 0 75 in 19 mm 19 mm 19 mm 19 mm 19 mm 19 mm Raw Water Pump Inlet Hose I D 0 75 in 0 75 in 0 75 in 0 75 in 0 75 in 0 75 in 19 mm 19 mm 19 mm 19 mm 19 mm 19 mm Minimum Seawater Dis...

Page 30: ... 48 in H2 O 48 in H2 O 48 in H2 O 48 in H2 O 48 in H2 O 122 cm H2 O 122 cm H2 O 122 cm H2 O 122 cm H2 O 122 cm H2 O 122 cm H2 O Wet Exhaust Elbow OD 1 5 in OD 1 5 in OD 1 5 in OD 1 5 in OD 1 5 in OD 1 5 in OD 38 mm 38 mm 38 mm 38 mm 38 mm 38 mm Dry Exhaust Elbow ID 1 25 in NPT 1 25 in NPT 1 25 in NPT 1 25 in NPT 1 25 in NPT 1 25 in NPT 32 mm 32 mm 32 mm 32 mm 32 mm 32 mm MAXIMUM INTERMITTENT ENGIN...

Page 31: ...OM673 09 09 29 DC Wiring Diagrams DC Engine Wiring Diagram Drawing B 6102J Wiring diagrams are subject to change without notice ...

Page 32: ...OM673 09 09 30 AC Wiring Diagrams AC Wiring Diagram Drawing B 6103G Wiring diagrams are subject to change without notice ...

Page 33: ...OM673 09 09 AC Wiring Diagram Drawing B 6104E Wiring diagrams are subject to change without notice AC Wiring Diagrams 31 ...

Page 34: ...OM673 09 09 32 AC Wiring Diagrams AC Wiring Diagram Drawing B 6105D Wiring diagrams are subject to change without notice ...

Page 35: ...hern 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 2009 All rights reserved Litho USA ...

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