OPERATOR’S MANUAL
ONL673L4
For Models: NL673L4 and NL673L4E
www.northern-lights.com
Page 1: ...OPERATOR S MANUAL OPERATOR S MANUAL ONL673L4 For Models NL673L4 and NL673L4E www northern lights com...
Page 2: ...y tank ULTRA LOW SULFUR FUEL ONLY RE529956 Breathing Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm A...
Page 3: ...ir Filter 17 V Belts 17 Valve Clearances 17 Fuels General 18 Fuel Filters 18 Bleeding the Fuel System 19 Injector Service 20 21 Injection Pump 21 Cooling System General 21 Cooling System Flushing 22 C...
Page 4: ...al Numbers MODELS INCLUDED This manual covers the operating instructions for NL673L4 NL673L4E industrial generator sets Model Numbers Model numbers give the unit s application block model aspiration a...
Page 5: ...your machine s safety signs Keep signs in good and clean condition Replace missing or damaged signs Be sure new equipment components and repair parts include the current safety signs For replacement...
Page 6: ...have stopped before making any adjustments connections or performing any other type of service to the engine or other driven equipment Prevent accidental discharge of starting fluids by storing all c...
Page 7: ...ous and strong enough to burn skin eat holes into clothing and other materials and cause blindness if splashed into eyes To Avoid Hazards Fill batteries only in well ventilated areas Wear appropriate...
Page 8: ...t and solvent properly Service Cooling System Safely WARNING Opening a pressurized cooling system can release explosive fluids and causing serious burns Before opening any pressurized cooling system m...
Page 9: ...mponents between the high pressure fuel pump and nozzles on engines with high pressure fuel systems ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH PRESSURE FUEL INJECTION SYSTEMS Avoid Hot...
Page 10: ...be achieved at the local supply valve shut off valves further back in the system and re check the bleed off point until complete shut off is achieved Affix a DO NOT OPERATE tag to each valve handle t...
Page 11: ...Voltage Regulator Breaker 20 Fuel Supply Return Connections 1 Junction Box 2 S 1B Control Panel 3 Air Filter 4 Fuel Filter Vent 5 Lube Oil Fill On top of Rocker Cover Figures 2 A and B NL673L4 Servic...
Page 12: ...ker 21 Voltage Regulator Breaker 22 Fuel Suple Return Connections 1 Junction Box 2 S 1B Control Panel 3 Air Filter 4 Fuel Filter Vent 5 Lube Oil Fill 6 Injection Pump Figures 2 A and B NL673L4E Servic...
Page 13: ...wing oil pressure to build beyond the shutdown set point NOTE Three position Engine Control switches must be in the RUN position during preheating Preheat switch must be held in ON position during sta...
Page 14: ...el tank level and open any fuel valves NOTE The battery switch must always be kept ON while the engine is running If the switch is turned OFF while the engine is running the battery charging regulator...
Page 15: ...w 225 F 107 C d Watch the temperature gauge regularly and turn off the unit if the temperature rises above 230 F 110 C on Industrial sets Repeat trouble shooting 4 If shutdown is activated and the tem...
Page 16: ...uired for proper maintenance of your generator set More detailed coverage of each Service Point SP is listed on the page noted in the page column DAILY SP1 Check oil level in engine SP5 Check V belt t...
Page 17: ...ONL673L4 5 21 15 Service Record Notes...
Page 18: ...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 approv...
Page 19: ...e mounting bolt and the adjusting bolt 4 Recheckbelttensionaftertighteningboltsand again after running the engine for five minutes at low idle Servicing Figure 6 Valve Adjustment SP6 VALVE CLEARANCES...
Page 20: ...storing 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 i...
Page 21: ...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 an...
Page 22: ...lare nuts Figure 9 Remove delivery lines Figure 10 Remove return line nuts Figure 11 Remove return line Figure 12 Unscrew injector Figure 13 Remove and replace copper sealing washer Figure 14 Reinstal...
Page 23: ...s for bleeding e Pump hand level on fuel pump to fill lines Tighten lines at injectors Start engine and check for leaks using a piece of paper or cardboard DO NOT use hand to check for leaks SP12 INJE...
Page 24: ...ely Close drain cock and refill with recommended coolant mixture Clean fins on radiator 3 Coolant Specifications Use 50 water 50 ethylene glycol antifreeze mix Antifreeze mixture is recommended as a g...
Page 25: ...instructions SP 18 19 BATTERY CARE 1 Check electrolyte level daily Add distilled water to manufacturer s recommended level 2 Batteries cables and cable terminals should be checked and cleaned every 10...
Page 26: ...located in the control box Figure 19 Item 2 GENERATOR Figure 18 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...
Page 27: ...rol terminal board to 240 Figure 22 Figure 22 Control Terminal Board 240 Volt Output b Connect U2 to V1 on the output terminal board Figure 23 Figure 23 Output Terminal Board 240 Volt Output 3 120 240...
Page 28: ...ng 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...
Page 29: ...er 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 28 Remove the screws and unplug leads Figur...
Page 30: ...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 B...
Page 31: ...ode 04 Actuator drive wire disconnected Engine ECU Power ON Lamp action only Cranking Engine doesn t start Lamp Flashing Pattern when Error has Occurred Lamp Code Analysis Before starting the engine 1...
Page 32: ...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 secon...
Page 33: ...l 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 ove...
Page 34: ...s 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 bac...
Page 35: ...ONL673L4 5 21 33 AC Engine Wiring Diagram 20 240 VAC DST 61 DFN NL673L4 Drawing B 10683C Wiring diagrams are subject to change without notice AC Wiring Diagrams Updated 3 4 20...
Page 36: ...ONL673L4 5 21 34 AC Engine Wiring Diagram 240 DST 61 DFN NL673L4 Drawing B 10968A Wiring diagrams are subject to change without notice AC Wiring Diagrams Updated 3 4 20...
Page 37: ...ONL673L4 5 21 35 AC Engine Wiring Diagram 120 VAC DST 61 DFN NL673L4 Drawing B 10669D Wiring diagrams are subject to change without notice AC Wiring Diagrams Updated 3 4 20...
Page 38: ...ONL673L4 5 21 36 AC Engine Wiring Diagram 120 VAC with TSC NL673L4 Drawing B 10738F Wiring diagrams are subject to change without notice AC Wiring Diagrams Updated 3 4 20...
Page 39: ...ONL673L4 5 21 37 AC Engine Wiring Diagram 120 240 VAC with TSC NL673L4 Drawing B 11096D Wiring diagrams are subject to change without notice AC Wiring Diagrams Updated 3 4 20...
Page 40: ...ONL673L4 3 18 38 DC Engine Wiring Diagram 12 VDC Standard NL673L4 Drawing B 11455A Wiring diagrams are subject to change without notice DC Wiring Diagrams Updated 3 4 20...
Page 41: ...ONL673L4 3 18 39 Updated 3 4 20 DC Wiring Diagrams DC Engine Wiring Diagram 12 VDC Isolated Ground NL673L4 Drawing B 11472 Wiring diagrams are subject to change without notice...
Page 42: ...ONL673L4 3 18 40 DC Engine Wiring Diagram 12 VDC Standard NL673L4E Drawing C 7260D Wiring diagrams are subject to change without notice Updated 3 4 20 DC Wiring Diagrams...
Page 43: ...ONL673L4 5 21 41 Panel Wiring Diagrams Panel Wiring Diagram 12 VDC S 3C Drawing A 12790D Wiring diagrams are subject to change without notice Updated 3 4 20...
Page 44: ...ONL673L4 5 21 42 Panel Wiring Diagrams Updated 4 20 20 Panel Wiring Diagram 12 VDC S 1B Drawing A 12791C Wiring diagrams are subject to change without notice...
Page 45: ...ONL673L4 5 21 43 Panel Wiring Diagrams Updated 4 20 20 Panel Wiring Diagram 12 VDC S 1 Drawing A 12798B Wiring diagrams are subject to change without notice...
Page 46: ...ONL673L4 5 21 44 AC Wiring Diagrams AC Engine Wiring Diagram 120 240 Volt NL673L4 60 Hz Drawing B 6103J Wiring diagrams are subject to change without notice NON CURRENT MODEL Updated 8 16 11...
Page 47: ...ONL673L4 5 21 45 NON CURRENT MODEL AC Engine Wiring Diagram 120 240 VAC 50 Hz NL673L4 Drawing B 7373C Wiring diagrams are subject to change without notice AC Wiring Diagrams...
Page 48: ...ONL673L4 5 21 46 NON CURRENT MODEL AC Engine Wiring Diagram 240 VAC NL673L4 Drawing B 6104F Wiring diagrams are subject to change without notice AC Wiring Diagrams Updated 8 6 11...
Page 49: ...ONL673L4 5 21 47 NON CURRENT MODEL AC Engine Wiring Diagram 120 VAC NL673L4 Drawing B 6105G Wiring diagrams are subject to change without notice AC Wiring Diagrams Updated 8 6 11...
Page 50: ...ONL673L4 5 21 48 NON CURRENT MODEL DC Wiring Diagrams DC Engine Wiring Diagram 12 VDC Standard NL673L NL673L4 Drawing B 9873 Wiring diagrams are subject to change without notice Updated 8 6 11...
Page 51: ...ONL673L4 5 21 49 NON CURRENT MODEL DC Wiring Diagrams DC Wiring Diagram 12 VDC NL673L4E Drawing C 6968B Wiring diagrams are subject to change without notice Updated 7 9 13...
Page 52: ...ONL673L4 5 21 50 NON CURRENT MODEL Panel Wiring Diagram 12 Volt S 1B Merc plug Drawing A 3170 Wiring diagrams are subject to change without notice Panel Wiring Diagrams Updated 8 6 11...
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Page 54: ...4420 14th Ave NW Seattle WA 98107 Tel 206 789 3880 1 800 762 0165 www northern lights com Northern Lights and Lugger are registered trademarks of Northern Lights Inc 2021 All rights reserved Litho USA...
