OM673L3For Models: M673LD3, M673LD3G, M673L3

and M673L3G

OPERATOR’S MANUALOPERATOR’S MANUAL

www.northern-lights.com

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.* Always start and operate the engine in a well-ventilated area.* If in an enclosed area, vent the exhaust to the outside.* Do not modify or tamper with the exhaust system.* Do not idle the engine except as necessary.For more information, go to www.P65warnings.ca.gov/diesel.

— CALIFORNIA —Proposition 65 Warning:

Northern Lights4420 14th Avenue NWSeattle, WA 98107Tel: (206) 789-3880Fax: (206) 782-5455

Copyright ©2019 Northern Lights, Inc.All rights reserved. Northern Lights™, andthe Northern Lights logo are trademarks ofNorthern Lights, Inc.

Printed in U.S.A.PART NO.: OM673L3 03/20

Read this operator's manual thoroughly before starting to operate your equipment.This manual contains information you will need to run and service your new unit.

OPERATOR'S MANUALfor Models

M673LD3, M673LD3G, M673L3 and M673L3G

Table of Contents

INTRODUCTION ..................................................2 UnitIdentification ...............................................2 ModelNumbers ..................................................2 SerialNumbers ...................................................2

WARRANTY ...........................................................3

SAFETY RULES ..............................................3 - 7

LOCK OUT / TAG OUT PROCEDURE .......... 8

COMPONENT LOCATIONS M673LD3G / M673L3G .................................. 10 M673LD3 / M673L3 ........................................11 CONTROL PANELS .......................................... 12

OPERATING PROCEDURES Break-inPeriod ................................................ 13 BeforeStarting ................................................. 13 Starting ............................................................. 13 Operating ......................................................... 13 Stopping ........................................................... 13 ShutdownsandAlarms .................................... 14 SpareParts ....................................................... 14

SERVICING SCHEDULE CHART ................. 15

SERVICING Lubrication-General ....................................... 16 CheckingOilLevel .......................................... 16 OilChanges ..................................................... 16 ChangingLubeOilFilter ................................. 16 AirCleaner ....................................................... 17 V-Belts ............................................................. 17 ValveClearances .............................................. 17 Fuels-General ................................................. 18

SERVICING (continued) FuelFilters ....................................................... 18 CoolingSystem-General ................................ 19 CheckingCoolantLevel .................................. 19 CoolingSystemFlushing ................................. 19 InjectorService ................................................ 20 InjectionPump ................................................. 20 HeatExchanger ............................................... 22 RawWaterPump ............................................. 22 ExhaustElbow ................................................. 22 GeneratorEnds ................................................ 22 ElectricalSystem-General ............................. 22 GlowPlugs ....................................................... 22 BoosterBatteries .............................................. 23 BatteryCare ..................................................... 23 Winterizing/Out-of-Service ........................... 23

AC GENERATOR - TF-276D General ............................................................. 24 Connections ..................................................... 25 Operation ......................................................... 26 Maintenance ............................................. 26 - 27

TROUBLESHOOTING DCElectricalSystem ....................................... 28 Engine ...................................................... 29 - 31 BleedingtheFuelSystem ................................ 32

DATA SHEET M673LD3(G) / M673L3 (G) ........................... 33 WIRING DIAGRAMS ACElectrical ........................................... 34 - 39 DCElectrical ........................................... 40 - 43 PanelWiringDiagrams ............................ 44 - 47

Proprietary InformationThispublicationisthepropertyofNorthernLights,Inc.

ItmaynotbereproducedinwholeorinpartwithoutthewrittenpermissionofNorthernLights,Inc.©NorthernLights,Inc.Allrightsreserved.LithoU.S.A.PublicationnumberOM673L33/20

OM673L3 3/20

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Servicingofmarineenginesandgeneratorsetspresentsuniqueproblems.Inmanycasesboatscannotbemovedtoarepairfacility.Marineenginescannotbecomparedtotheservicingofautomobiles,trucksorevenfarmequipment.Failuresoftenoccurinremoteareasfarfromcompetentassistance.Marineenginesaretaxedfarmoreseverelythanautoortruckengines;therefore,maintenanceschedulesmustbeadheredtomorestrictly.

Failuresbeginwithminorproblemsthatareoverlookedandbecomeamplifiedwhennotcorrectedduringroutinemaintenance.

Asoperator,itisyourobligationtolearnaboutyourequipmentanditspropermaintenance.Thisisnotacomprehensivetechnicalservicemanual.Norwillitmakethereaderintoanexpertmechanic.Itsaimistoaidyouinmaintainingyourunitproperly.

Introduction

Serial Numberss

MODELS INCLUDEDThismanualcoverstheoperatinginstructionsfor: M673L3, M673L3G, M673LD3 and M673LD3G marine generator sets.

Model Numbers

Modelnumbersgivetheunit'sapplication,blockmodel,aspiration,andRPM:

Unit Identification

Yoursethasthreeserialnumbers:1anenginenumberstampedontheblock,2ageneratorplate,and 3 ageneratorsetplate.

Usetheserialnumberonthegeneratorsetplatewhenorderingpartsorincorrespondence.ThegeneratorsetplateisfoundontheservicesideofthegeneratorandresemblesthedrawinginFigure 1.

Note,anadditionallabelwiththesetserialnumberisplacedontheupperfrontcornerofthegeneratorjunctionbox.

Updated 8-6-19

L, D, G, 3

M - Northern Lights marine generator set

Model number of engine block Bore Cylinders 67 mm 3

L - Long strokeD - Series designationG - GEM series base frame3 - US EPA Tier III compliant

+ +

M 673

Northern Lights marine diesel generator set with a 673 engine long stroke, TF-276D generator end, US EPA Tier III, 6 kW.M673L3 =

Northern Lights marine diesel generator set with a 673 engine long stroke, TF-276D generator end, GEM series base frame, US EPA Tier III, 6 kW.

M673L3G =

Northern Lights marine diesel generator set with a 673 engine long stroke, TF-276D generator end, GEM series base frame, US EPA Tier III, 5 kW.

M673LD3G =

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

OM673L3 3/20

3

Awarrantyregistrationcertificateissuppliedwithyourset.Itentitlestheoriginalpurchaserofourequipmenttoawarrantycoveringmaterialorassemblyfaults.TheextentofcoverageisdescribedintheLimitedWarrantyStatement.Werecommendthatyoustudythestatementcarefully.NOTE:Ifthewarrantyistoapply,theservicinginstructionsoutlinedinthismanualmustbefollowed.Iffurtherinformationisneeded,pleasecontactanauthorizeddealerorthefactory.

Safety Rules

Warranty

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.

IMPORTANTSAFETYINSTRUCTIONS.Electromagneticequipment,includinggeneratorsetsandtheiraccessories,cancausebodilyharmandlifethreateninginjurieswhenimproperlyinstalled,operatedormaintained.Topreventaccidentsbeawareofpotentialdangersandactsafely.

READANDFOLLOWALLSAFETYINSTRUCTIONSINTHISMANUAL,PRIORTOTHEINSTALLATIONOFANYGENERATORSETORACCESSORY.KEEPTHESEINSTRUCTIONSFORFUTUREREFERENCE.

Recognize Safety Symbols and InstructionsInadditiontotheinformationfoundinthissection,thisoperator’smanualusesthreedifferentsignalwordstooutlinepotentialdangersofaspecificnature.

Follow All Safety InstructionsCarefullyreadandunderstandallsafetymessagesinthismanualandonyourmachine’ssafetysigns.Keepsignsingoodandcleancondition.Replacemissingordamagedsigns.Besurenewequipmentcomponentsand

repairpartsincludethecurrentsafetysigns.Forreplacementsigns,properplacementofsafetysignsorclarificationonanysafetyissue,consultyourNorthernLightsdealerorthefactory.Therecanbeadditionalsafetyinformationcontainedonpartsandcomponentsfromoutsidesuppliersthatisnotreproducedinthismanual.Consultthesuppliersforadditionalsafetyinformation.

Learnhowtooperatethemachineandhowtousethecontrolsproperly.Onlytrainedpersonnelshouldoperatemachines,orworkonoraroundthem.

Keepyourmachineinproperworkingcondition.UNAUTHORIZEDMODIFICATIONSTOTHEMACHINERYMAYIMPAIRITSFUNCTIONANDSAFETYPARAMETERS.

Prevent Bypass and Accidental Starting

! WARNINGDonotstartenginebyshortingacrossstartterminal.Enginewillstartifnormalcircuitryisbypassed,creatingahazardbyrunawaymachinery.

Startengineonlyfromoperator’sstation.

! DANGER! WARNING! CAUTION

DANGERindicatesahazardoussituationwhich,ifnotavoided,willresultindeathorseriousinjury.

WARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresultindeathorseriousinjury.

CAUTIONindicatesahazardoussituationwhich,ifnotavoided,couldresultinminorormoderateinjury.

DANGER: Northern Lights generator sets and /or any other diesel powered equipment provided by NLI is not provided with ingintion protected components, and therefore is not to be installed in the presence of combustible gases having a flash point of 43.3 Degrees C (110 Degrees F) or lower, such as Gasoline, Propane, Natural Gas or other similar fuel sources.

Updated 8-6-19

OM673L3 3/20

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Safety Rules (Continued)

Wear Protective Clothing

! WARNINGTopreventcatchinganythinginmovingmachinery,alwayswearclosefittingclothesandsafetyequipmentappropriatetothejob.Prolongedexposuretoloudnoisecancausehearinglossorimpairment.Wearsuitableauthorizedhearingprotection,suchasearmuffsorplugstoprotectagainstloudnoises.

Operatingequipmentrequiresthefullattentionoftheoperator.Donotuseradioormusicheadphoneswhileoperatingmachinery.Practice Safe Maintenance

! CAUTIONUnderstandallserviceproceduresbeforestartingwork.Keepareacleananddry.Neverlubricate,service,oradjustmachinewhileitisinoperation.

Keephands,feetandclothingawayfrompower-drivenequipment.Whenshuttingdownanengine,disengageallpowerandoperatorcontrols.Allowtheenginetocoolcompletelybeforebeginninganyservicework.

Securely support any machinery elements that must be raised for service work with support or lifting machinery specifically intended for that purpose.

Keepallpartsingoodconditionsandproperlyinstalled.Fixdamageimmediately.Replaceanywornorbrokenparts.Removeanybuildupofgrease,oilordebris.

Disconnectbatterygroundcable(-)beforemakinganyadjustmentsorservicework.

Handle Fuel Safely - Avoid Flames

! WARNINGDieselishighlyflammableandshouldbetreatedwithcareatalltimes.Dodonotrefuelwhilesmokingorwhennearsparksoropenflame.

ALWAYSSTOPENGINEBEFOREFUELINGMACHINE.Alwaysfillportablefueltankoutdoors.Neverfuelahotengine.Preventaccidentaldischargeofstartingfluidsbystoringallcansinacool,safeplace,awayfromsparksoropenflame.Storewithcapsecurelyoncontainer.Neverincinerateorpunctureafuelcontainer.

Preventfiresbykeepingmachinecleanofaccumulatedtrash,greaseanddebris.Alwayscleananyspilledfuelasswiftlyaspossible.Donotstoreoilyrags,whichcanigniteandburnspontaneously.

Bepreparedifafirestarts.Keepafirstaidkitandfireextinguisherhandy.Keepemergencycontactnumbersforfiredepartment,doctors,ambulanceandhospitalnearthetelephone.

Service Machines Safely

! DANGERDonotwearanecktie,scarf,necklace,ringsorotherjewelry,oranylooseclothingwhenworkingnearmovingparts.Tielonghairbehindyourhead.Ifanyoftheseitemsgetcaughtinmovingmachinery,severeinjuryordeathcouldresult.

Checkforanylooseelectricalconnectionsorfaultywiring. Lookcompletelyaroundenginetomakesurethateverythingisclearbeforestarting.

Updated 4-12-17

OM673L3 3/20

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Stay Clear of Rotating Drivelines

! DANGEREntanglementinrotatingdrivelinescancauseseriousinjuryordeath.Keepshieldsinplaceatalltimes.Makesurethatrotatingshieldsturnfreelyinpacewiththedrivelines.

Donotwearloosefittingequipmentaroundrotatingdrivelines.Stoptheengineandmakesurethatallmovingpartshavestoppedbeforemakinganyadjustments,connections,orperforminganyothertypeofservicetotheengineorotherdrivenequipment. Install all Safety Guards

! WARNINGDirectcontactwithrotatingfans,belts,pulleyanddrivescancauseseriousinjury.

Keepallguardsinplaceatalltimesduringengineoperation.

Wearclose-fittingclothes.Stoptheengineandbesureallfans,belts,pulleysanddrivesarestoppedbeforemakingadjustments,connections,orcleaningnearfansandtheircomponents.

Donotallowanythingonyourpersontodangleintoorcomeincontactwithamovingfan,belt,pulleyordrive.Fanscanactasvacuumsandpullmaterialsupfrombelow,soavoidthatareaaswellwhileinservice.

Safe Battery Handling

! WARNINGPrevent Battery Explosions Batterygasishighlyflammable.Batteryexplosionscancausesevereinjuryordeath.Tohelppreventbatteryexplosions,keepsparks,lightedmatchesandopenflameawayfromthetopofbattery.Whencheckingbatteryelectrolytelevel,useaflashlight.

Safety Rules (Continued)

Nevercheckbatterychargebycontactingthepostswithametalobject.Useavolt-meterorhydrometer.

Frozenbatteriesmayexplodeifcharged.Neverchargeabatterythathasnotbeenallowedtowarmtoatleast16oC(60oF).Alwaysremovegrounded(-)batteryclampfirstandreplacegroundclamplast.

Sulfuricacidinbatteryelectrolyteispoisonousandstrongenoughtoburnskin,eatholesintoclothingandothermaterials,andcauseblindnessifsplashedintoeyes.

To Avoid Hazards:•Fillbatteriesonlyinwell-ventilatedareas.•Wearappropriateeyeprotectionandrubbergloves.•Neveruseairpressuretocleanbatteries.•Wearappropriateventilationequipmenttoavoidinhalingfumeswhenaddingelectrolyte.•Donotspillordripelectrolyte.•Usecorrectjump-startprocedureifrequired.

If acid is spilled on skin or in eyes:1.Flushskinwithwater.2.Applybakingsodaorlimetohelpneutralizeacid.3.Flusheyeswithwaterfor15-30minutes.4.Getmedicalattentionimmediately.Ifacidisswallowed:1.DONOTinducevomiting.2.Drinklargeamountsofwaterormilk,withoutexceeding2liters(2quarts)3.Getmedicalattentionimmediately

Batteryposts,terminals,andrelatedaccessoriescancontainleadandleadcompounds,chemicalsknowntotheStateofCaliforniatocausecancerandreproductiveharm.Washhandsafterhandling.

! WARNING

Updated 4-12-17

OM673L3 3/20

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Safety Rules (Continued)Donotuseachlorinatedsolventinanareawhereweldingwilloccur.Workonlyinareasthatarewellventilated.Disposeofpaintandsolventproperly.

Service Cooling System Safely

! WARNINGOpeningapressurizedcoolingsystemcanreleaseexplosivefluidsandcausingseriousburns.Beforeopeninganypressurizedcoolingsystem,makesuretheenginehasbeenshutoff.Donotremoveafillercapunlessitiscoolenoughtocomfortablygripwithbarehands.Slowlyloosencaptorelievepressurebeforeopeningfully.

Avoid High Pressure Fluids

! WARNINGRelievepressurepriortodisconnectingpressurizedlines.Escapingfluidunderpressurecanpenetratetheskincausingseriousinjury.Alwaysrelievepressurebeforedisconnectinghydraulicorotherpressurizedlines.Tightenallconnectionsfirmlybeforere-applyingpressure.

Ifsearchingforleaks,useapieceofcardboard.Alwaysprotectyourhandsandotherbodypartsfromhigh-pressurefluids.

Ifanaccidentoccurs,seeadoctorimmediately.Anyhighpressuresprayinjectedintotheskinmustberemovedwithinafewhourstopreventtheriskofgangreneorotherinfection.

Avoid Heating Near Pressurized Fluid Lines

! WARNINGFlammablespraycanbegeneratedbyheatingnearpressurizedfluidlines,resultinginsevereburnsandbodilyinjury.Pressurizedlinescanrupturewhenheatgoesbeyondtheimmediateflamearea.Donotweld,solderoruseatorchoropenflamenearpressurizedlinesorotherflammablefluids.

Handle Chemical Products Safely

! WARNINGDirectexposuretohazardouschemicalscancauseseriousinjury.AmongthepotentiallyhazardouschemicalsthatmaybeusedwithNorthernLightsproductsarelubricants,coolants,paintsandadhesives.

AllpotentiallyhazardouschemicalscomewithaMaterialDataSafetySheet(MSDS).TheMSDSprovidesspecificdetailsonchemicalproducts,includingphysicalhazards,safetyproceduresandemergencyresponsetechniques

ReadandunderstandtheMSDSforeachchemicalbeforeyoustartanyjobthatincludesit.Followtheproceduresanduseappropriateequipmentexactlyasrecommended.

ContactyourNorthernLightsdealerorNorthernLightsfactoryforMSDS’susedonNorthernLightsproducts.

Work in Well Ventilated Areas

! CAUTIONExhaustfumesfromenginescontaincarbonmonoxideandcancausesicknessordeath.Workinwellventilatedareastoavoidprolongedexposuretoenginefumes.Ifitisnecessarytorunanengineinanenclosedarea,routetheexhaustfumesoutoftheareawithanapproved,leakproofexhaustpipeextension.

Remove Paint Before Welding or Heating

! WARNINGHazardousfumescanbegeneratedwhenpaintisheatedbywelding,solderingorusingatorch.Toavoidpotentiallytoxicfumesanddust,removepaintbeforeheating.• Removepaintaminimumof100mm(4in.)fromtheareathatwillbeaffectedbyheat.• Ifpaintcannotberemoved,wearanapprovedrespirator.•Ifyousandorgrindpaint,useanapprovedrespirator.•Ifyouusesolventorpaintstripper,removestripperwithsoapandwaterbeforewelding.Removesolventorpaintstrippercontainersfromthearea.•Allowatleast15minutesforfumestodispersebeforeweldingorheating.

Updated 4-12-17

OM673L3 3/20

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Safety Rules (Continued)

Avoidcreatingdust.Neverusecompressedairforcleaning.Avoidbrushingorgrindingmaterialscontainingasbestos.Whenservicing,wearanapprovedrespirator.Aspecialvacuumcleanerisrecommendedtocleanasbestos.Ifthisvacuumisnotavailable,applyamistofoilorwateronthematerialcontainingasbestos.Keepallbystandersawayfromanyareawhereasbestosdustmaybegenerated.

Use Proper Lifting Equipment and Techniques

! WARNINGLiftingheavycomponentsincorrectlycancausesevereinjuryordamagetomachinery.Avoidunbalancedloads.Donotuseliftingeyes.Liftthegeneratorsetusingliftingbarsinsertedthroughtheliftingholesontheskid.FollowallrecommendedremovalandinstallationproceduresinthisandassociatedNorthernLightsmanuals.

Use Proper Tools

! CAUTIONMakeshifttoolsandprocedurescancreatesafetyhazards.Alwaysuseappropriatetoolsforthejob.

Usepowertoolsonlytoloosenthreadedpartsandfasteners.Forlooseningandtighteninghardware,alwaysusethecorrectsizedtools.

DonotuseUSmeasurementtoolsonmetricfasteners,orviceversa.UseonlyservicepartsthatmeetNorthernLightsspecifications.

Dispose of Waste Properly

! CAUTIONDisposingofwasteimproperlycanthreatentheenvironmentandleadtounsafeworkingconditions.PotentiallyharmfulwasteusedinNorthernLightsequipmentcanincludeoil,fuel,coolant,filtersandbatteries.

Useleakproofcontainerstodrainfluid.Donotusefoodorbeveragecontainersthatmaymisleadsomeoneintodrinkingfromthem.

Donotpourwasteontotheground,downadrainorintoanywatersource.

Do Not Open High-Pressure Fuel System

! DANGERManyNorthernLightsenginesusehigh-pressurefuelinjection.High-pressurefluidremaininginfuellinescancauseseriousinjury.Donotdisconnectorattemptanyrepairoffuellines,sensors,orother

componentsbetweenthehigh-pressurefuelpumpandnozzlesonengineswithhighpressurefuelsystems.

ONLYAUTHORIZEDTECHNICIANSCANPERFORMREPAIRSONANHIGHPRESSUREFUELINJECTIONSYSTEMS.

Avoid Hot Exhaust

! WARNINGAvoidexposuretoandphysicalcontactwithhotexhaustgases.Exhaustpartsandstreamscanreachhightemperaturesduringoperation,leadingtoburnsorotherseriousinjury.

Cleaningexhaustfilterscanalsoleadtoexposuretohotexhaustgasandtheinjuryriskassociatedwithit.Avoidexposuretoandphysicalcontactwithhotexhaustgaseswhencleaningexhaustfilters.

Duringautoormanual/stationaryexhaustfiltercleaningoperations,theenginewillrunatelevatedtemperaturesforanextendedperiodoftime.Exhaustpartsandstreamscanreachhightemperaturesduringoperation,leadingtoburnsorotherseriousinjury.

Avoid Harmful Asbestos Dust

! WARNINGInhalingasbestosfibersmaycauselungcancer.Avoidbreathinganydustthatmaybegeneratedwhenhandlingcomponentscontainingasbestosfibers,includingsomegaskets.

Theasbestosusedinthesecomponentsisusuallyfoundinaresinorotherwisesealed.Normalhandlingofthesecomponentsisnotdangerous,aslongasairbornedustcontainingasbestosisnotgenerated.

Updated 4-12-17

OM673L3 3/20

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General Policy

To avoid dangerous or hazardous situations, refrain from any of the following:• Removing or bypassing a guard or other safety device• Placing any part of your body in a position where you could be caught by moving machinery.• Cleaning or oiling machinery when in operation.• Adjusting circuits, chillers, pumps, air handlers, valves, circuit breakers or fans while in operation.• Working on piping or high pressure systems.

Lock Out/Tag Out Instructions - Electrical Equipment

Be sure the equipment’s ON/OFF switch is in the OFF position and is unplugged from any electrical source before attempting to perform any type of work on the equipment. Obtain an electrical plug cap cover with a lockset. Secure the plug terminal end using the electrical plug lockout cap. Lock the cap and retain the key.

If the equipment is directly wired into an electrical box with a shut off switch, obtain a lock pad and/or the appropriate 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 is in the OFF position before restarting. NEVER give a lock out key to unauthorized personnel.

If the equipment is directly wired into an electrical box without a shut off switch and lock out capability, then a 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 before restarting.

Lock Out/Tag Out Instructions - Pneumatic and Hydraulic Equipment

For servicing pneumatic and hydraulic equipment, the following additional procedures must be implemented, following completion of lock out/tag out procedures for the unit to be serviced:

Shut off air, water or supply valves at the equipment to be serviced.

Check the local bleed-off point for completed release of pressurized air, water or oil.

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 complete shut-off is achieved.

Affix a DO NOT OPERATE tag to each valve handle that requires shut off. Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment.

Lock Out/Tag Out Instructions - Air Hose Connected Pneumatic Equipment

Equipment connected to the compressed air system 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 repair activities.

Affix a DO NOT OPERATE tag to the air hose near the detachable fitting. Each DO NOT OPERATE tag must be signed and dated by the authorized technician servicing the equipment. Check that the equipment cannot be operated by activating the ON switch.

Stored Energy

Immediately after applying Lock Out or Tag Out devices, ensure that all potentially hazardous stored or residual energy is relieved, disconnected, restrained and otherwise rendered safe.

Verification of Isolation

Verify the machinery or equipment is actually isolated and de-energized prior to beginning work on a machine or on equipment that has been locked out.

Restarting Procedures

Follow the procedures below prior to restoring energy:• Ensure that all machinery or equipment is properly reassembled. Inspect the machinery or equipment to verify non-essential items have been removed.• Ensure that all personnel are safely outside danger zones. Notify personnel that lock out/tag out devices have been removed and energy will be reapplied.• Only authorized personnel may remove lock out/tag out devices or notices.

ScopeDuring 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.

! CAUTION

! WARNING

! WARNING

! WARNING

! WARNING

! CAUTION

! CAUTION

Lock Out / Tag Out Procedures

Updated 4-12-17

OM673L3 3/20

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Notes

OM673L3 3/20

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1. Generator junction box 2. AVR circuit breaker 3. AC circuit breaker 4. DC circuit breaker 5. Air filter housing 6. Secondary fuel filter 7. Oil fill, top 8. Coolant fill, pressure cap

17. Fuel inlet and return18. Coolant recovery bottle19. Control panel plug-in 20. Heat exchanger end cap 21. Heat exchanger/ expansion tank/ expansion manifold

9. Fuel injector 10. Fuel injection pump 11. Fuel lift pump12. Sea water pump13. Lube oil drain 14. Oil fill, side15. Lube oil dipstick 16. Primary fuel filter

22. Starter motor 23. Exhaust elbow 24. Vibration mount25. DC regulator26. DC alternator 27. Belt guard

Marine Generator Component Locations

2

1

3 45 6

78

9

10

1112

13

1415

161718

19

Figure 1 (left): Service side M673L3G/LD3G w/GEM Series base frame (S/N: 6732-54637 and above)

Figure 2 (right): Non-service side M673L3G/LD3G w/GEM Series frame (S/N: 6732-54367 and above)

20 2021 22

23

24

26

27

25

Updated 3-13-18

OM673L3 3/20

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1. Heat Exchanger End Cap 2. Coolant Fill/Pressure Cap 3. Heat Exchanger/Expansion Tank/Exhaust Manifold 4. Lube Oil Fill- Top 5. Wet Exhaust Elbow 6. Generator Junction Box 7. Control Panel Plug-In

16. DC Circuit Breaker 17. Air Filter Housing18. Fuel Filter 19. Fuel Injector 20. Fuel Injection Pump 21. Fuel Lift Pump 22. Sea Water Pump

8. Generator End Cover 9. Vibration Mount 10. Starter Motor 11. DC Regulator12. DC Alternator 13. Belt Guard14. AVR Circuit Breaker15. AC Circuit Breaker

23. Lube Oil Drain24. Lube Oil Fill- Side25. Block Drain 26. Lube Oil Dipstick27. Lube Oil Filter28. Fuel Manifold 29. Coolant Recovery Tank

Marine Generator Component Locations

1 12 3 4 5 6

7

8

91011

12

13

29

14 15 174 2 19

20

18

21

22

23

16

24

26 252728

Figure 3 (left): Service side M673L/LD3 (up to S/N: 6732-54636)

Figure 4 (right): Service side M673L/LD3 (up to S/N: 6732-54636)

Updated 8-6-19

OM673L3 3/20

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Figure 5: Series 3 Generator Control Panel

Figure 4: Series 1-B Generator Control Panel

Figure 6: Series 4 Generator Control Panel

1. SHUTDOWN BYPASS-PREHEAT SWITCH Thisswitchservestwofunctions: 1.Preheatsglowplugsbeforebeginningthestarting

process.Pressswitchfor10secondsbeforeattemptingstart-up.

2.Bypassesthesafetyshutdownfeatureduringthestartingprocess.Keepswitchengagedwhilestartingengine,andfor2to3secondsafterwards,allowingoilpressuretobuildbeyondshutdownsetpoint.

2. ENGINE CONTROL SWITCH Tostarttheengine,holdthisswitchintheSTART position

untiltheengineisrunning. NOTE: Excessive cranking of marine sets equipped with water lift muffler systems can cause engine damage. See

page 7. Aftertheenginestarts,releasetheswitchanditwillreturn

toRUNposition.Tostoptheengine,presstheswitchtotheSTOPposition.

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 Keepstrackofenginerunningtime.

4. OIL PRESSURE GAUGE Showstheoilpressureintheenginelubricatingsystem.

5. WATER TEMPERATURE GAUGE Registersthetemperatureofthecoolingwater.

6. D.C. VOLTMETER Whentheengineisrunning,thevoltmeterindicatesthe

voltageoutputofthealternator.

For Series 4 Control Panels Only:

7. A.C. VOLTMETER Showsthegeneratoroutputvoltage.

8. FREQUENCY METER (Hertz) Thefrequencymeterindicatesenginespeed:1800RPM(60Hz),or1500RPM(50Hz).

9. AMMETER SELECTOR SWITCH Usedtocheckeachphaseforloadcondition. NOTE: Always leave this switch in the ON position while the

unit is running.

10. A.C. AMMETER Showsthegeneratorloadoneachphase.Thephaseis

selectedwiththeAmmeterSelectorswitch(Item 9).

Control Panels

Updated 8-6-19

OM673L3 3/20

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BREAK-IN PERIOD

1. Thefirst100hoursonaneworreconditionedenginearecriticaltoitslifeandperformance.

2. Operatetheengineundervariousconditions,particularlyheavyloadstohelpseatenginecomponentsproperly.50%overloadisrequired;75%ispreferred.

3. Constantlychecktheenginetemperatureandoilpressuregauges(setswithSeries3or4panels).

4. Oilconsumptionisgreaterduringbreak-inaspistonringstaketimetoseat.

5. Break-InOilChanges:Changeengineoilandfilterat50hours.Changeoilandfilteragainat100hours,thenatevery200hours(consultLubricantssectionforoilrecommendation).

BEFORE STARTING

1. Checkthewaterlevelbyremovingthepressure capfromtheexpansiontankorradiator.Inorderto

givethecoolingwateranopportunitytoexpand,theexpansiontankshouldbefull.Overflowbottleshouldbehalffull.

Do not open the filler cap when the engine is warm. Opening a warm filler cap can cause severe burns.

2. Checktheoillevelinthecrankcasewiththe dipstick.Theoillevelmustbeinthewaffledareaon

thestick.Neverallowtheleveltogobelowthisarea.Alwaysaddthesameviscosityofoilasisalreadyinthecrankcase.Donotremovedipstickwhenengineisrunning.

3. Checkthefueltanklevelandopenanyfuelvalves.4. Checkandcleantheseastrainerandreopenthesea-

cock.5. PlacethebatteryswitchintheONposition. 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 could be ruined.

STARTING

1. HoldtheShutdownBypass-PreheatswitchintheONpositionfor10secondsbeforestartingacoldengine.Holdingtheswitchtoolongcanburnouttheglowplugs.

2. WhileholdingtheShutdownBypass-PreheatswitchintheONposition,pushtheEngineControlswitchtotheSTARTposition.

3. Assoonastheenginestarts,releasethestartswitchandcontinuetoholdthebypass/preheatswitchforupto5additionalseconds.Donotcrankthestarterformorethan10secondsconsecutively.Iftheenginefailstostartwiththefirstattempt,besurethatithasstoppedcompletelybeforere-engaging.

NOTE: Excessive cranking of the starter on Marine sets equipped with a water lift muffler can cause engine damage. If the engine does not start after three 10-second cranks, close the sea-cock, and remove the impeller from the raw water pump. This will prevent the muffler from filling with water and backfilling the exhaust line and engine. Once the engine starts, shut it off immediately and re-install the impeller and open the sea-cock. Re-start the engine and check the exhaust overboard outlet for gushes of water.

OPERATING

1. UnitswithSeries3andSeries4ControlPanels:checkgaugesoften.Oilpressuremustbeabove15PSI.TheD.C.voltmetershouldreadbetween11and15voltsat80°F(25°C)ambienttemperature.Thecoolanttemperaturegaugemustbebetween167°Fand194°F(75°Cto90°C).ChecktheA.C.voltageandfrequencymeters(Series4panel).Ifthegaugesdeviatefromnormallevels,shutdownthegeneratorsetandinvestigate.

2. Afterstarting,addelectricalloadupto50%forfirstfewminutes.Loadnormallyafter5minutes.

STOPPING

1. Removeelectricalloadfromthegeneratorset.2. Runtheenginefora3to5minutecooldownperiod.3. MovetheEngineControlswitchtotheSTOPposition

momentarily.4. Closethesea-cock,fuelvalve,andbatteryswitch.

Operating Procedures

Updated 8-6-19

! DANGER

OM673L3 3/20

14

Operating Procedures

SHUTDOWNS AND ALARMS

1. Generatorsetshaveshutdownsystemstostoptheengineintheeventofhighwatertemperature,lowoilpressureorhighexhausttemperature.

a. Otheralarmsandshutdownsareavailableasoptionalequipment.

Contact your Northern Lights dealer for trouble-shooting assistance if not equipped with optional gauge panels.

2. Ifoptionalgaugepanelsareinstalled,dothefollowingwhenyourwarningorshutdownsystemisactivated:

a. Engagethepreheatswitchtocheckthetemperature gauge,ifinstalled.

b. Ifabove205°F(96°C),usetheTroubleshooting Guideonpage32toisolatethecauseofthe

overheat.

Do not open the filler cap when the engine is warm. Opening a warm filler cap can cause severe burns.

c. Makerepairs.Restartyourgeneratorsetafterthe temperaturegaugeregistersbelow200°F(94°C). d. Watchthetemperaturegaugeregularlyand turnofftheunitifthetemperaturerisesabove 205°F(96°C).Repeattroubleshooting.

3. Ifshutdownisactivatedandthetemperaturegaugeshowstemperaturewithinnormaltemperaturerange:

a. Thisshutdowncouldhavehappenedbecauseof atoohighexhausttemperature.Thiscouldhave beencausedbyadamagedimpellerorapartially blockedseawaterstrainer.Checktheseawater strainerfirst.Ifitisclear,thencheckthe

conditionoftheseawaterimpeller. b. Checktheenginecrankcaseoillevel. c. Iftheoillevelislow,fillwithrecommended lubricatingoilandrestart.Watchtheoilpressure gaugecarefullyandshutofftheengineifitdoes notshowanormalreading(20-60PSI)aftera fewsecondsofoperation. d. Iftheoillevelisnormal,DONOTrestartthe engine.Callyourdealerforassistance.

SPARE PARTS

1. NorthernLightsrecommendsthatyoukeepthe followingsparepartsonhandforfieldservice.Spare

partsandworldclasssparepartskitsareavailablefromyourlocalNorthernLightsdealer.

.2. NorthernLightsstandardsparepartskit(P/N

38-08015)* contains: a. Primaryandsecondaryfuelfilterelements b. Oilfilters c. Airfilterelement d. Drivebelt e. Thermostatandgaskets f. Rawwaterpumpimpellerwithgaskets g.Waterpumpcovero-ring h. Rockerarmcovergasket i.Exhaustmanifoldgasket 3. Intendedforlong-distancecruisers,NorthernLights

worldclasssparepartskit(P/N38-08019)*contains: a. Primaryandsecondaryfuelfilterelements b. Oilfilters c. Airfilterelement d. Drivebelt e. Thermostatandgaskets f. Rawwaterpumpimpellerwithgaskets g.Waterpumpcovero-ring h. Rockerarmcovergasket i.Exhaustmanifoldgasket j. Injectorpump k. Impellerkitwithgasket l.Injectorassembly m.12vglowplug n.Gasketset o.Fuelliftpumpandmtg.gasket p.O-ring q.Brushandholderassembly r.Relay,SPDT12v50A s.Workshopmanual

Updated 8-6-19

! DANGER

*-ForusewithM673LD3,M673LD3G,M673L3andM673L3Ggen-eratorsetswithheatexchangers.ConsultyourNorthernLightsdealerforyourunit’sspecificsparepartsrequirements.

OM673L3 3/20

15

After After Every Every Every Every Every SERVICE 50 100 100 200 500 1000 2500 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours Hours Hours

ENGINE: SP1 16 Check oil level • SP2 16 Change engine oil 1) 4) • • • SP3 16 Change lube oil filters 1) 4) • • • SP4 17 Check air cleaner 1) • SP4 17 Change air cleaner 1) •

SP5 17 Check V-belt tension 1) • SP6 17 Check valve clearance 1) 2) • FUEL SYSTEM: SP7 18 Check primary filter (Racor) 2) 3) • SP8 18 Change primary filter element 2) 3) • SP9 18 Change secondary fuel filter 1) 3) • SP12 20 Check injectors 1) 3) 5) • SP13 20 Check fuel injection pump 6) • COOLING SYSTEM: SP10 19 Check cooling water level • SP11 19 Check and flush cooling system • SP14 22 Check and clean heat exchanger • SP15 22 Change impeller in raw water pump 1) 3) • SP16 22 Check exhaust elbow • ELECTRICAL SYSTEM: SP17 23 Check electrolyte level in batteries 1) • SP18 23 Check condition of batteries 1) • OUT OF SERVICE: SP19 23 Winterizing or out-of-service 3)

TheServicingScheduleChartbelowshowstheserviceschedulerequiredforpropermaintenanceofyourgeneratorset.MoredetailedcoverageofeachServicePoint(SP)islistedonthepagenotedinthe‘page’column.

DAILY: SP1 Checkoillevelinengine SP7 Checkprimaryfuelfilter SP10 Checkcoolingwaterlevel AFTER FIRST 50 HOURS: SP2/3 Changeengineoilandfilter

AFTER FIRST 100 HOURS: SP2/3 Changeengineoilandfilter

EVERY 100 HOURS: SP6 Checkv-belttension SP17 Checkelectrolytelevelinbatteries EVERY 200 HOURS: SP2/3 Changeengineoilandfilter SP4 Checkaircleaner SP18 Checkconditionofbatteries

EVERY 500 HOURS: SP8 Changeprimaryfuelfilterelement SP9 Changesecondaryfuelfilter SP15 Changeimpellerinrawwaterpump SP16 Checkexhaustelbow

EVERY 1000 HOURS: SP5 Changeaircleanerelement SP12 Checkinjectors

EVERY 2500 HOURS: SP13 Checkfuelinjectionpump SP11 Checkandflushcoolingsystem SP14 Checkandcleanheatexchanger

1) Perform all maintenance every two years at minimum, even if hour level has not been reached.

2) Consult manufacturer's maintenance schedule, note on chart.3) Whenever necessary.4) After first 50 hours, then at 100 hours, then every 200 hours.

5) Clean injection nozzles every 1500 hours.6) For EPA emission standards fuel nozzle needs to be

cleaned every 1500 hours, the fuel nozzle and fuel pump need to be cleaned, adjusted, or repaired every 3000 hours, and the quality guarantee for these parts is 1500 hours or 2 years.

Servicing Schedule Chart

Updated 8-6-19

OM673L3 3/20

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Servicing

LUBRICATION - GENERAL

1. Useonlyclean,highqualitylubricantsstoredincleancontainersinaprotectedarea.

2. UsethemostcurrentAPIservicecategorydieselratedoil.NorthernLightsrecommendstheuseofmulti-viscosityoil.

3. Usetheproperweightoilforyouraverageoperationtemperature.

Figure 9: Lube Oils

4. SomeincreaseinoilconsumptionmaybeexpectedwhenSAE5WandSAE5-20Woilsareused.Checkoillevelfrequently.

5. Neverputadditivesorflushingoilincrankcase.

SP-1. CHECKING OIL LEVEL

1. Checktheoillevelinthecrankcasewiththedipstick.Theoillevelmustbeinthewaffledarea

onthestick.Neverallowtheleveltogobelowthisarea.Followthelubricationrecommendationsabove.

SP-2. OIL CHANGES

1. Thesetisdeliveredwithspecialbreak-inoil. Changetheengineoilandoilfilterafter50hours ofoperation.Usediesel-ratedbreakinoil(JohnDeere

pre-packagedorequivalent)duringthefirst100hours.Consultyourdealerformoreinformation.

2. Changetheoilandfilteragainat100hoursusingtheoilrecommendedinFigure9.Afterthis,changeoilandfilterevery200hours.

3. Duringintermittentcoldweatheroperation,changeoilevery100hoursorsixweeks,whichevercomesfirst.

4. Changeoilatanyseasonalchangeintemperaturewhenanewviscosityofoilisrequired.

5. Changeoilwhenengineiswarm.6. Disposeofwasteoilinanapprovedmanner.7. Neveruseaflushingoil.8. Loosentheclampontheoilchangetube.Removecap.

Drainoil.Replacethecapandtube.9. Refillenginewithrecommendedoil.10.Enginecapacitywithnewoilfilteris:

M673L3(G) & LD3(G) – 3.17 quarts (3.0 liters) SP-3. CHANGING LUBE OIL FILTER

1. Changethelubeoilfilterwitheveryoilchange.2. Useafilterwrenchtoremoveoldfilter.Disposeof

filterinapprovedmanner.3. Makesurethegasketfromtheoldfilterisremoved

anddiscarded.Cleanmountingsurface.4. Spreadathinfilmofengineoilontherubbergasket

onthenewfilterandscrewitonnippleuntilgasketmeetsthesealingsurface.

5. Usinghandsonly–nowrench–tightenfilterone-halfturnfarther.Overtighteningcandodamagetofilterelement.

6. Fillenginewithrecommendedoil.Startengineandcheckforleakage.Stopengine,wait3minutes,andcheckoillevel.Addadditionaloilifnecessary.

7. Oilfilterpartnumbersare:

M673L3(G) & LD3 (G) – #24-08001

Air Single Multi- Temperature Viscosity Viscosity

Above 32°F SAE 30W SAE 15-40W (0°C)

-10 to 32°F SAE 10W SAE 10-30W (-23 to 0°C)

Below -10°F SAE 5W SAE 5-20W (-23°C)

Updated 8-7-19

OM673L3 3/20

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Servicing

SP-4. AIR CLEANER

1. Inspectaircleanerevery200hours.Industyconditionscheckmoreoften.

2. Inspecttheelement.Ifitisdirty,washtheelementinsoapywater.Rinseanddrythoroughlybeforere-installing.Replaceifnecessary.Partnumberis:

M673L3 & LD3 - #24-28003

NOTE: Failure to change air cleaner at recommended times can cause severe engine damage. Change every 1000 hours or two years, whichever comes first.

NOTE: Make absolutely sure no impurities enter the engine while changing the element. Do NOT run the engine with the air cleaner removed.

SP-5. V-BELTS

1. CheckthetensionandwearontheV-beltdaily.2. Useyourthumbtopressonthebeltatthemidpoint

betweenthecrankshaftandalternatorpulleys.Thetensioniscorrectifthebeltcanbedepressedabout3/16in.(5mm).

Figure 10: Valve Adjustment

SP-6. VALVE CLEARANCES

1. Adjustvalveclearanceevery1000hours.2. TobringtheNo.1cylindertotopdeadcenterinthe

compressionstroke,alignthetimingmark;thetopmarkofthecrankpulleywiththatofthetiminggearcase.Removetherockerarmcoverandturnthecrankshaftfowardandbackward.IftheinletandexhaustvalvesoftheNo.1cylinderdonotmoveitisintopdeadcenterposition.Whenthevalvesmove,orrock,turnthecrankshaftonefullturnandalignthetopmarkofthecrankpulleywiththetopmarkofthetiminggearcase.

3. Loosenthelocknutandadjusttheclearancebetweentherockerarmandvalveguideofboththeintakeandexhaustvalveswiththeadjustmentscrew(Figure 10). Clearanceonbothintakeandexhaustvalvesshouldbe0.008in.(0.2mm).

4. Repeatsteps3and4foreachcylinder.Eachsetofvalvesmustbeadjustedindividually.

5. Replacetherockerarmcover.Tightencovernutsto5-8ft/lbs(0.8-2.3kg/m).

Figure 11: Timing MarkCylinder No. 1 2 3

Valve Arrangement Int. Exh. Int. Exh. Int. Exh.

When No.1 cylinderis at Top Dead Centerin the compressionstroke

With the crankshaftturned 3600 innormal direction fromabove

Valve Arrangement

Updated 8-7-19

OM673L3 3/20

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Servicing

FUELS - GENERAL

1. Useonlyclean,highqualityfuelsofthefollowingspecifications,asdefinedbyASTMdesignationD975fordieselfuels:

a. UseGradeNo.2dieselatambienttemperatures abovefreezing32°F(0°C). b. UseGradeNo.1atambienttemperaturesbelow freezingandforalltemperaturesatanaltitudeof above5,500ft.(1500meters).2. Uselowsulphurorultralowsulphurfuel.3. Thecetanenumbershouldbeaminimumof45.4. DONOTusetheseunsuitablegradesoffuel: a. Domesticheatingoils,alltypes. b. ClassBengine. c. ClassDdomesticfuels. d. ClassE,F,GorHindustrialormarinefuels. e. ASTM-D975-60TNo.4-Dandhighernumber fuels.5. Storingfuel: a. Keepdirt,scale,water,andotherforeignmatter

outoffuel. b. Avoidstoringfuelforlongperiodsoftime. c. Fillthefueltankattheendofeachday’s operation.Thiswillreducecondensation.

FUEL FILTERS

1. Yourgeneratorsetshouldhaveaprimaryfuelfilterinstalled.WerecommendtheRacorbrandoffuelfilter-waterseparators.

SP-7. PRIMARY FUEL FILTER a. Checktheprimaryfuelfilterdailyas recommendedbythefiltermanufacturer. Emptythecollectionbowlasnecessary.

SP-8. PRIMARY FUEL FILTER ELEMENT b. Changetheelementasoftenasnecessaryor every500hours. c. Ifthebowlfillswithwater,changetheprimary andsecondaryelementimmediately.

SP-9. SECONDARY FUEL FILTER2. Changesecondaryfuelfilterevery500hours. a. Removethespin-onfilterbyturningit counterclockwisewithafilterwrench.Fillthe newcartridgewithfuelandinstallitafter applyingengineoiltogasketsurface.Screwon untilthegasketsurfacecomesintocontactwith sealingsurfaceoffilterbase.Then,tightenit two-thirdsofaturnbyhand.Donotovertighten. b. Fuelfilterpartnumberis:

M673L3(G) & LD3(G) - #24-52020

Updated 8-7-19

OM673L3 3/20

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Servicing

COOLING SYSTEM - GENERAL

NOTE: Be sure to close the sea-cock before working on the engine cooling system.

CAUTION: The cooling water in the engine reaches extremely high temperatures. You must use extreme caution when working on hot engines to avoid burns. Allow the engine to cool before working on the cooling system. Do not open the filler cap when the engine is warm.

WATER QUALITY1. Distilled,softwaterispreferredforuseincooling

systems.Bottleddistilledwaterfromafoodstoreorwatersupplierisrecommended.Tapwateroftenhasahighmineralcontent.TapwatershouldNEVER beputinacoolingsystemunlessfirsttestedbyawaterqualitylaboratory.DonotusewatermadebythereverseosmosismethodunlessithasbeenPHneutralized.

2.Acceptablewaterqualityspecificationsareshownbelow:

SP-10. CHECKING COOLANT LEVEL

1. Checkthecoolantleveleachdaybeforestartingtheengine.Checkthewaterlevelbyremovingthepressurecapfromtheexpansiontank.

Inordertogivethecoolingwateranopportunitytoexpand,thelevelshouldbeabout1in.(2.5cm)belowthefillercapsealingsurfacewhentheengineiscold.

2. Thepressurevalveinthefillercapreleaseswhenthepressureisapproximately7PSI(0.5bar).Useacappressuretestertocheckcapifyoususpectitisfaulty.

SP-11. COOLING SYSTEM FLUSHING

1. Flushthecoolingsystemevery2500hoursorevery24months,whichevercomesfirst.

a.Removeexpansiontankcapanddrainengine block. b.Leavealldrainsopen. c.Pourcleanwaterintoexpansiontankuntil

watercomingfromdrainsisfreeof discolorationandsediment. d.Letwaterdraincompletely. e.Closedrainsandrefillwithrecommended mixture.

NOTE: Open sea-cock before running engine.

2. CoolantSpecifications: Use50%water/50%ethyleneglycolantifreezemix.

Antifreezemixtureisrecommendedasagoodyear-roundcoolant,butnotmethylalcoholbasedantifreezebecauseofitslowboilingpoint.Also,antifreezewithhighsilicateshouldnotbeused.

3. Checkhosesandconnectionsandrepairanyleakage.

Parts GrainsContaminates per Million per Gallon

Maximum Chlorides 40 2.5

Maximum Sulfates 100 5.9

Maximum Dissolved Solids 340 20.0

Maximum Total Hardness 170 10.0

PH Level 5.5 to 9.0

Updated 8-7-19

OM673L3 3/20

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Servicing

Updated 11-8-13

SP-12. INJECTOR SERVICE

1. Injectorsshouldbecheckedevery1000hours,ormoreoftenasnecessary.CheckshouldbemadebyaNorthernLightsdealerorlocalinjectionrepair

station.

CAUTION: Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury. If injured by escaping diesel fuel, see a doctor at once.

2. Injectorremoval: a. Cleanloosedirtfromaroundtheinjectorsand thefuellines. b. Relievehighpressureinthefuellinesby looseningthedeliverylineflarenutsateach injector(Figure 13). c. Removedeliverylinesbydisconnectingfrom injectorsandinjectionpump(Figure 14).Remove alllinesasanassembly;donotremovethe clamp.Covertheendsofthelines,theinjector inletsandinjectionpumpoutletstokeepdirtout (Figure 15). d. Removethereturnlineretainingbolts(Figure 16). Removethereturnline(Figure 17). e. Unscrewandremovetheinjectors(Figure 18). NOTE: Do not use pry bars to remove injectors from cylinder head. f. Afterremovingtheinjectors,discardthecopper sealingwashersfromtheinjectorholeinthehead (Figure 19).Coverholestopreventdirtanddebris fromenteringthecylinders.

3. Injectorinstallation: a. Installanewcoppersealingwasherineach injectorhole(Figure 19). b. Screwininjectorandtightento43or50ft/lbs (6to7kgm)(Figure 20). NOTE: Overtightening can damage injector. c. Installreturnlineusingnewcoppersealingbelow

eachconnection.Tightenreturnlineretaining boltsto22-30ft/lbs.

d. Installdeliverylines.Leavelooseatinjectorsfor bleeding. e. Cranktheenginetofilllines.Tightenlinesat

injectors.Startengineandcheckforleaksusinga pieceofpaperorcardboard.

DO NOT use hand to check for leaks.

SP-13. INJECTION PUMP

1. Sinceoperatingconditionsmayvaryconsiderably,itisdifficulttogiveadefiniteintervalforcheckingtheinjectionpump.Butasarule,pumpsettings,

maximumspeed,idlespeedandexhaustsmokeshouldbecheckedafterevery2500hoursof

operation.Serviceofthefuelinjectionpumpshouldonlybedoneifchecksindicatepumpmalfunction.

2. Blacksmokecanbeanindicationofpump malfunction.Beforeservicingthepump,checkother

possiblecauses: a. Checkcleanlinessofairfilter. b. Checkvalveclearances. c. Cleanandcheckinjectors.3. Anyrepairwhichinvolvesdisassemblyofthe injectionpumpmustbeperformedONLYbyan

authorizeddealer.Disassemblybynon-authorizedpersonnelmayvoidthewarranty.

NOTE: All warranties on the engine become null and void if the injection pump seals are broken by unauthorized persons.

OM673L3 3/20

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Servicing

Figure 13: Remove delivery line flare nuts.

Figure 14: Remove delivery lines.

Figure 15: Cover lines, inlets and injection pump outlets.

Figure 16: Remove return line nuts.

Figure 18: Unscrew injector.

Figure 19: Remove and replace copper sealing washer.

Figure 20: Reinstall injector. Torque to proper tightness.

Figure 17: Remove return line.

OM673L3 3/20

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Servicing

SP-14. HEAT EXCHANGER

1. Cleantheheatexchangercoreevery24months,orafter2500hoursofoperation,orasneeded.

2. Drainexpansiontankandheatexchanger.3. Removeheatexchangerendcoversandremovecore.4. Cleantheinsideofexchangercoretubesusing ametalrod.Flush,inspectandcleanagainif

necessary.5. Reassemble.Fillthecoolingsystem,starttheengine

andcheckforleaks.

SP-15. RAW WATER PUMP

1. Changetheseawaterpumpimpellerevery500hours,orasneeded.

2. Removethepumpendcover.Pryouttheimpellerusingneedle-nosepliersortwoscrewdrivers.

Besureyouremoveallpiecesoffailedimpeller. NOTE: Place some kind of protection under the

screwdrivers in order not to damage the pump housing.

3. Cleantheinsideofthehousing.4. Pressinthenewimpellerandplacethesealing

washersintheouterendoftheimpellercenterifthishasnotalreadybeendone.

5. Replacethecoverusinganewgasketoro-ring. NOTE: Make sure that there is always an extra

impeller and cover gasket in reserve on board.

SP-16. EXHAUST ELBOW

1. Visuallyinspecttheexhaustelbowevery500hoursofoperation,orsoonerifneeded.Ifanyrustorotherdamageisnoted,replacetheelbow.

GENERATOR ENDS

Themaintenanceandoperationrecommendationsforthegeneratorendarelocatedonpages24-27undertheheading“ACGenerator”.

ELECTRICAL SYSTEM - GENERAL

1. Neverswitchbatteryswitchofforbreakthecircuitbetweenthealternatorandbatterieswhiletheengineisrunning.Regulatordamagecanresult.

2. DoNOTreversethepolarityofbatterycableswheninstallingthebattery.

3. Whenweldingneartheunit,disconnecttheACandDCvoltageregulatorandbattery.Isolatetheleads.

4. DisconnectthebatterycableswhenservicingtheD.C.alternator.

5. Nevertestwithascrewdriver,etc.,againstany terminaltoseeifitemitssparks.7. AD.C.circuitbreakerprotectsyourcontrolpanel

andwiringharness.Itislocatedinthesideofthegeneratorjunctionbox.

GLOW PLUGS

1. Eachcylinderissuppliedwithaglowplugwhichservestoheatthecombustionchamberforstarting.

2. Tochecktheglowplugs,measuretheresistancebetweenterminalandengineblock,usingahighqualitymeter.Resistanceshouldbeunder1ohm.

3. Checkallglowplugsandreplaceanythatarefaulty.

Figure 21: Glow plugs

Updated 8-7-19

OM673L3 3/20

23

BOOSTER BATTERIES

CAUTION: Battery gas can explode. Keep all flames and sparks away from batteries.

1. Beforechangingorusingboosterbatteries,check batteryelectrolytelevel.Adddistilledwaterifnecessary.2. Boosterandmainbatteriesmusthavethesame voltagerating.3. First,connectpositive(+)terminalofboosterbattery

topositive(+)terminalofmainbattery.Then,connectnegative(-)terminalofboosterbatterytogroundontheengineblock(see Figure 22).

4. Removeboosterbatteryafterstartingengine.5. Sealedbatteries:Seemanufacturerchargingand

boosterinstructions.

SP-17 and 18. BATTERY CARE

1. Adddistilledwatertomanufacturer’srecommendedlevel.

2. Batteries,cablesandcableterminalsshould becheckedandcleanedevery100hours. Cleancorrosionwithawaterandbakingsoda solution.Flushwithcleanwater.Tightenterminals

andgreasethemtoinhibitcorrosion.3. Checkthebatteryconditionwithahydrometerevery

500hours.

SP-19. WINTERIZING, OUT-OF-SERVICE

Ifthegeneratorsetwillnotbeusedformorethan3monthsthefollowingpreparationsshouldbetakenforlongtermstorage.• Changeengineoilandfilter,asperrecommendations

onpage16.• Runtheengineuptoatleast140oFfromasmall,

cleansourceoffueldosedwitheither“Stab-il”brandfuelsystemstabilizer(dieselengineformula),orStanadynePerformancefuelsystemconditioner.Ifneitherofthesefueltreatmentsisavailable,youmayalsouseJohnDeerefuelsystemconditioner.

• Completelydrain,flush,andfillthecoolingsystemwithpre-mixed,50/50,conventionalethylene-glycolheavy-dutydieselenginecoolant.

• Loosenalternatordrivebelt.• Completelysealoffintakeandexhaustopeningswith

heavyplasticbagsandducttape.• Coverentireengineinlargeplasticbagandtape

closedatbottomofbag-placeseveralmoistureabsorbingdesiccantpacksinsideplasticbag

• Storeengineinsideabuilding(preferablyclimatecontrolled)topreventcorrosion.

ToRemoveGeneratorSetfromLong-TermStorage:1. Takeoffallprotectivecoveringsandunsealallthe

openingsthatwerecoveredup.2. Installbatteriesthatarefullychargedandconnectthe

terminals.3. Re-installthealternatorbeltifithadbeenremoved.4. Fillthefueltank.5. Performallpre-startchecks.6. Cranktheenginefor10secondswiththestarter,

withoutlettingtheenginestart.Wait2minutesandcranktheengineanadditional10secondstomakesureallbearingsurfacesarewellcoated.

7. Starttheengineandrunatnoloadinalowidleforseveralminutes.Makesuretheengineiswarmedupandcheckgaugesbeforegoingunderload.

8. Checkallgaugesandcheckforleaks.Figure 22:Battery connections.

Servicing

Updated 8-7-19

OM673L3 3/20

24

GENERAL1. AGeneratorSetincludestheengine,thegenerator,

andthecontrolor“J”box(Figure 23).2. Thegeneratorandthecontrolor“J”boxproduce

theelectricalpower.3. Generatorexcitationisprovidedbyresidual magnetismandelectricaloutputvoltageiscon-

trolledbytheautomaticvoltageregulator(AVR)locatedinthecontrolbox(Figure 25, Item 2).

GENERATOR (Figure 24) 1. StatorCore 2. StatorCoil 3. EndCover 4. Brush 5. BallBearing 6. SlipRing 7. Frame 8. CouplingPlate 9. FieldCoil 10. FieldCore 11. Shaft 12. VentilationCover

CONTROL BOX (Figure 25) 1. VoltageSelectorTerminal 2. AutomaticVoltageRegulator(AVR) 3. 12VoltDCCircuitBreaker 4. ACCircuitBreaker 5. AVRCircuitBreaker 6. OutputTerminalBoard

AC Generator - TF-276D

Figure 23: Composition.

Figure 25: Control Box Components.

Figure 24: Generator Components.

Updated 1-14-15

OM673L3 3/20

25

CONNECTIONS

1. 120VoltOutput: a. 120voltoutputcanbeselectedbyconnecting theterminalsofthecontrolterminalboardto120 (Figure 26).

Figure 26: Control Terminal Board, 120 Volt Output

b. ConnectU1toU2andV1toV2ontheoutput terminalboard(Figure 27).Connect120volt outputleadstoterminalsU1andV2.

Figure 27: Output Terminal Board, 120 Volt Output

2. 240VoltOutput: a. 240voltoutputcanbeselectedbyconnecting theterminalsofthecontrolterminalboardto240 (Figure 28).

Figure 28: Voltage Selector Terminal, 240 Volt Output b. ConnectU2toV1ontheoutputterminalboard (Figure 29).

Figure 29: Output Terminal Board, 240 Volt Output

3. 120/240VoltOutput a. Connectthecontrolterminalboardfor240volts (Figure 30).

.

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

b. ConnectU2andV1ontheoutputboard (Figure 31).ConnectoutputleadstoU1andV2 andneutralleadtoV1(orU2).240voltoutputis availablefromtheleadsconnectedtoU1andV2. The120voltloadshouldbedividedasequallyas possiblebetweentwo120voltcircuits.

Figure 31: Output Terminal Board, 120/240 Volt Output

AC Generator - TF-276D

Updated 1-14-15

OM673L3 3/20

26

AC Generator - TF-276D

OPERATION Inordertoensurealong,trouble-freelife,the generatormustbeoperatedproperlyandthe specifiedmaintenancemustbeperformed.

OPERATING ENVIRONMENT Alwayskeepelectricalequipmentclean.Moisture,

salt,dust,andoilwilldamagethegenerator.Theoperatingenvironmentmustbekeptascleanandmoisturefreeaspossible.

VENTILATION Goodventilationisimportantforpropergenera-

toroperation.Wheninstallingthegeneratorset,besuretheambienttemperaturedoesnotexceed40°C(104°F)duringoperation.

MAINTENANCE Properandeffectivemaintenanceisrequiredto

ensuretrouble-freeoperation.Inadditiontotheaboveitems,thefollowingarerequired:

1. Periodicallycheckallboltsandnutsforpropertorque.Thisisespeciallytrueforcouplingbolts.

2. Besuretokeepthegeneratorareacleananddry. a. Dustandforeignmaterialmayreducetheflowof coolingair,reducingheatdissipationandcausing thegeneratortooverheat. b. Ifelectricallyconductivedebrisaccumulateson thewindings,orifmoistureorsaltwaterare absorbedintothewindings,thewindingsmay shortorground,reducingvoltageoutput. c. Wipingistheonlyeffectivemethodforremoving dustandforeignmaterials.Useaclean,lint-free pieceofcloth.3. Ifthegeneratorhasnotbeenoperatedforan

extendedperiodoftime,checktheinsulation resistanceofeachstatorcoilandtherotor. DisconnecttheAVRfromthegeneratorwhen performingthistest.

4. VoltageAdjustment a. Ifthereissomevoltage,butitdoesnotbuildup toratedvoltage,voltageadjustmentcanbemade usingthe“handtrimmer”intheAVR(Figure 32). b. Thenormalvoltagesettingatnoloadis121volts at62Hertzor242voltsat62Hertz.

Figure 32: Hand Trimmer Location on AVR.

5. Checktheballbearinginthegeneratorend. a. Listenforunusualnoise. b. Abnormaltemperaturerisecanbenotedby discoloration. c. Ifthebearingisfailing,itmustbereplaced. d. Generatorbearingshouldbereplacedbyyour NorthernLightsdealerat10,000hours.6. Checkthebrushes a. Thecarbonbrushesgraduallywearwithuse,so theymustbeinspectedperiodicallyandreplaced asnecessary. b. Ifthebrushesareexcessivelywornastoexpose thepigtail(Figure 33),sparkingwilloccuratthe surfaceoftheslipring,causingsurfacedamage. Therefore,periodicinspectionofthebrushesis important. c. Normally,thebrusheswillhavetobereplaced withanewbrushassemblywithin3,000hours.

Figure 33: Brush Pigtail.

Updated 1-14-15

OM673L3 3/20

27

9. Parts:SeePartsBookforcompletelist a. Bearing Part#22-68305 b. Brushassembly Part#22-6830410.TestSpecifications:SeeWiringDiagram(s) a. ResistanceofJ-K 16.6ohmat20°C(68°F) b. ResistanceofA-B 0.25ohmat20°C(68°F) c. ResistanceofU1-V2 0.56ohmat20°C(68°F) d. Noloadvoltagesetting 242Vor121Vat62Hzwithcoldgenerator

AC Generator - TF-276D

7. ReplacingBrushes a. Shutdownthegenerator.Removefourscrews andendcoverofthegenerator. b. Brushassemblyisblackplasticwithtwowires leadingtoit.Itislocatedatteno’clockandis heldinpositionbytwoscrews(Figure 34). Removethescrewsandunplugleads.

Figure 34: Brush Location.

c. Attachleadstonewbrushassemblyandinstallit withtheplasticearstowardsthefrontofthe generator. NOTE: Be sure to connect wire J to terminal J, and connect wire K to terminal K.8. GeneratorProtection ToprotectthegeneratorandAVRfrom unbalancedloadsandoverloads,two20amp breakersareplacedintheoutputcircuitandone 3ampbreakerisplacedintheAVRsensing circuit(Figure 35).

Figure 35: Breaker Locations.

Updated 1-14-15

OM673L3 3/20

28

Ifyoucannotcorrectproblemswiththeseprocedures,seeyourNorthern Lights dealer.

Troubleshooting

DC ELECTRICAL SYSTEM PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)

Battery Will Not Charge Looseorcorrodedconnections •Cleanandtightenbatteryconnections.

Sulfatedorwornoutbatteries •Checkspecificgravityofeachbattery. •Checkelectrolytelevelofeachbattery.

Looseordefectivealternatorbelt •Adjustbelttension. •Replacebelt.

Starter Inoperative CheckDCcircuitbreaker •Ifthebreakeristripped,resetit.

Looseorcorrodedconnections •Cleanandtightenloosebatteryand harnessplugconnection.

Lowbatteryoutput •Checkspecificgravityofeachbattery. •Checkelectrolytelevelofeachbattery.

Defectiveelectricalsystem •Repairorreplace. groundwire

Starter Cranks Slowly Lowbatteryoutput •Batteryistoosmall. •Batterycablesaretoosmall.

Checkspecificgravity •Replacebatteryifnecessary. ofeachbatterycell (leadacidbatteriesonly)

Checkelectrolytelevel •Iflow,fillcellswithdistilledwater. ofeachbattery

Looseorcorrodedconnections •Cleanandtightenlooseconnections.

Crankcaseoiltooheavy •Fillwithoilofappropriateviscosity.

Entire Electrical System CheckDCcircuitbreaker •Ifbreakeristripped,resetit.Does Not Function Faultyconnection •Cleanandtightenbatteryandharness plugconnections.

Sulfatedorwornoutbatteries •Checkspecificgravityandelectrolyte levelofeachbattery.

DeadBattery •Chargebattery.

Updated 8-7-19

OM673L3 3/20

29

TroubleshootingENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)

Engine Hard to Start Improperstartingprocedure •Seestartingsectionofthismanual.Takeor Will Not Start specialnoteofBypassSwitchoperation.

Nofuel •Checkleveloffuelinfueltank.

Lowbatteryoutput •Checkelectrolytelevelandcondition.

Excessiveresistance •Cleanandtightenallbatteryconnections. instartingcircuit

Crankcaseoiltooheavy •Useoilofproperviscosity.

Impropertypeoffuel •Consultfuelsupplierandusepropertype offuelforoperatingcondition.

Water,dirtorairinfuelsystem •Drain,flush,fillandbleedsystem.

Cloggedprimaryorsecondary •Cleanorreplaceprimaryfilterelement, fuelfilterelement replacesecondaryfilterelement.

Dirtyorfaultyinjectionnozzles •Haveyourdealercheckinjectionnozzles.

Fuelinjectedbutnoignition •Glowplugmalfunction. •Lowcylindercompressionpressure.

Engine Runs Irregularly Belownormalenginetemperature •Removeandcheckthermostat.or Stalls Frequently Cloggedprimaryorsecondary •Cleanorreplaceprimaryfilterelement, fuelfilterelement replacesecondaryfilterelement.

Waterordirtinthefuelsystem •Drain,flush,fillandbleedsystem.

Dirtyorfaultyinjectionnozzles •Haveyourdealercheckinjectionnozzles.

Airinfuelsystem •Inspectclampsandhosesonsuctionside offuelpumpforairleak.

Impropertypeoffuel •Consultfuelsupplierandusepropertype offuelforoperatingcondition.

Lowidle,notstable •Unevencompressioncylinders.

Lack of Engine Power Intakeairrestriction •Serviceaircleaner. •Ifinsoundenclosure-ensureproperpositionof snorklehose

Cloggedprimaryorsecondary •Cleanorreplaceprimaryfilterelement, fuelfilterelement replacesecondaryfilterelement.

Impropertypeoffuel •Consultfuelsupplierandusepropertypeof fuelforoperatingconditions.

Overheatedengine •See“EngineOverheats”innextcategory.

Belownormalenginetemperature •Removeandcheckthermostat.

Impropervalveclearance •Resetvalves.Bestdonebydealer.

Dirtyorfaultyinjectionnozzles •Contactyourdealertoreplaceinjectors. Cylindercompressionpressurelow •Adjustvalveclearance. •Adjustnozzleholderalignment.

Updated 2-10-20

OM673L3 3/20

30

Troubleshooting

ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)

Engine Overheats Lowcoolantlevelorcooling •Filltankorradiatortoproperlevel. systemdefective •Checkhosesforlooseconnections andleaks. •Fanbeltslipping.

Keelcoolingtubeshavebeen •Removepaintfromtubes. painted

Coolingsystemneedsflushing •Flushcoolingsystem.

Defectivethermostat •Removeandcheckthermostat.

Defectivetemperaturegauge •Checkwatertemperaturewiththermometer andreplacegaugeifnecessary.

Waterpumpimpellerworn/broken •Checkimpellerandreplaceifnecessary.

Engine Knocks Insufficientoil •ContactyourauthorizedNLdealer.

Injectionpumpoutoftime •ContactyourauthorizedNLdealer.

Belownormalenginetemperature •Checkyourthermostats. •Checkwatertemperaturetoseeif temperaturegaugeisworkingproperly.

Engineoverheating •See“EngineOverheating”section.

High Fuel Consumption Impropertypeoffuel •Usecorrectfuelfortemperature.

Cloggedordirtyaircleaner •Serviceaircleaner.

Impropervalveclearance •ContactyourauthorizedNLdealer.

Injectionnozzlesdirty •ContactyourauthorizedNLdealer.

Injectionpumpoutoftime •ContactyourauthorizedNLdealer.

Engineoverloaded •Checkloadusage.

Enginenotatpropertemperature •Checkyourthermostats. •Checkwatertemperaturewiththermometer andreplacegaugeifnecessary.

Below Normal Thermostatsnotworkingproperly •Checkthermostats.Engine Temperature Temperaturegauge •Checkwatertemperaturewiththermometer. notworkingproperly

Ifyoucannotcorrectproblemswiththeseprocedures,seeyourNorthern Lights dealer.

Updated 8-7-19

OM673L3 3/20

31

Troubleshooting

Ifyoucannotcorrectproblemswiththeseprocedures,seeyourNorthern Lights dealer.

Updated 8-7-19

ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)

Low Oil Pressure Lowoillevel •Fillcrankcasetoproperlevel.

Cloggedfilterandstraineror •Repairorreplace. wornbearingsandoilpump

Impropertypeofoil •Drainandfillcrankcasewithcorrectoil.

Partiallypluggedoilfilter •Replacefilter.

High Oil Consumption Break-inperiod •Oilconsumptiondecreasesafterbreakin.

Crankcaseoiltoolight •Useproperviscosityoil.

Oilleaks •Checkforleaksinlinesaroundgaskets anddrainplug.

Engine Emits Black Cloggedordirtyaircleaner •Serviceaircleaner.or Gray Exhaust Smoke Defectivemuffler •ContactyourauthorizedNLdealerto (backpressuretoohigh) checkbackpressure.

Improperfuel •Usecorrectfuelfortemperature.

Injectionnozzlesdirty •ContactyourauthorizedNLdealer.

Engineoutoftime •ContactyourauthorizedNLdealer.

Engine Emits Improperfuel •Usecorrectfuelfortemperature.White Smoke Coldengine •Warmupenginetonormaloperating temperature.

Defectivethermostat •Removeandcheckthermostat.

Cloggedintakehose •Removeandcheckintakehose. Engineoutoftime •ContactyourauthorizedNLdealer.

OM673L3 3/20

32

Troubleshooting

Figure 12: M673 Fuel System.

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.

1. Thefuelsystemisself-bleeding.However,anysystemmayneedmanualbleedingwhen:

a. Anewfuelfilterisinstalled; b. Theenginehasrunoutoffuel; c. Thefuellines,injectionpumporanyotherfuel systemcomponenthasbeenremovedandinstalled.2. Loosenbleedscrew“A”(Figure 12)ontopofthe

filter.Pumphandprimer“B”onfuelliftpumpuntilpurefuel(nobubbles)escapesfrombleedscrew“A”.Tightenbleedscrew“A”.

3. Loosenbleedscrew“C”.Pumphandprimer“B”onfuelliftpumpuntilpurefuel(nobubbles)escapesfrombleedscrew“C”.

4. Iftheenginedoesnotstartaftertheabovebleedingprocess,loosenafuellineattheinjector.Cranktheengineuntilpurefuelescapes,thentightenthecon-nection.Doeachlineone at a time.

5. Aftertheenginehasstarted,checkforfuelleaksusingapieceofcardboard.

Updated 6-23-10

OM673L3 3/20

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Northern Lights Marine Data

Model: M673L3 (G) M673LD3 (G) RPM 1800 1500 1800 1500 kWRating 6.0 5.0 5.0 4.5 Frequency(Hz) 60 50 60 50

GENERAL INFORMATION Cylinders 3 3 3 3

Displacement 46.4 in3 46.4 in3 46.4 in3 46.4 in3 (0.761 ltr) (0.761 ltr) (0.761 ltr) (0.761 ltr)

Cycle 4 4 4 4

Bore 2.64 in 2.64 in 2.64 in 2.64 in (67 mm) (67 mm) (67 mm) (67 mm)

Stroke 2.83 in 2.83 in 2.83 in 2.83 in (72 mm) (72 mm) (72 mm) (72 mm)

Rotation(facingflywheel) CCW CCW CCW CCW

CompressionRatio 23.5:1 23.5:1 23.5:1 23.5:1

CrankcaseCapacityw/OilFilter 3.2 qts 3.2 qts 3.2 qts 3.2 qts (3.0 ltr) (3.0 ltr) (3.0 ltr) (3.0 ltr)

Aspiration Natural Natural Natural Natural

DryWeight/CompleteUnit 377 lbs 377 lbs 377 lbs 377 lbs (171 kg) (171 kg) (171 kg) (171 kg)

Height 20.9 in 20.9 in 20.9 in 20.9 in (530 mm) (530 mm) (530 mm) (530 mm)

Width 19.5 in 19.5 in 19.5 in 19.5 in (495 mm) (495 mm) (495 mm) (495 mm)

Length 28.5 in 28.5 in 28.5 in 28.5 in (724 mm) (724 mm) (724 mm) (724 mm)

COOLING SYSTEM ApproximateCoolingSystemCapacity .5 gal .5 gal .5 gal .5 gal (2 ltr) (2 ltr) (2 ltr) (2 ltr) MinimumThrough-HullDiameter 0.75 in 0.75 in 0.75 in 0.75 in (19 mm) (19 mm) (19 mm) (19 mm)

RawWaterPumpInletHoseI.D. 0.75 in 0.75 in 0.75 in 0.75 in (19 mm) (19 mm) (19 mm) (19 mm)

MinimumSeawaterDischarge 0.75 in 0.75 in 0.75 in 0.75 in (19 mm) (19 mm) (19 mm) (19 mm) HeatRejectiontoJacketWater 350 BTU/min 250 BTU/min 350 BTU/min 250 BTU/min

FreshWaterPumpCapacity 5.0 gal/min 4.2 gal/min 5.0 gal/min 4.2 gal/min (18.92 ltr/min) (15.77 ltr/min) (18.92 ltr/min) (15.77 ltr/min)

MaximumSeawaterPumpSuctionHead 39 in 39 in 39 in 39 in (1 m) (1 m) (1 m) (1 m) SeawaterPumpCapacity 8.0 gal/min 7.0 gal/min 8.0 gal/min 7.0 gal/min (30 ltr/min) (26 ltr/min) (30 ltr/min) (26 ltr/min)

KeelCoolerTurboTubeLength 4 ft 4 ft 4 ft 4 ft (1.2 m) (1.2 m) (1.2 m) (1.2 m) KeelCoolerHeadDiameter 0.75 in NPT 0.75 in NPT 0.75 in NPT 0.75 in NPT (19.1 mm) (19.1 mm) (19.1 mm) (19.1 mm) KeelCoolerWaterHoseI.D. DischargeandSuction 1.0 in 1.0 in 1.0 in 1.0 in (25 mm) (25 mm) (25 mm) (25 mm)

Updated 8-8-19

OM673L3 3/20

34

AC Wiring Diagrams

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OM673L3 3/20

35

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OM673L3 3/20

36

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OM673L3 3/20

37

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OM673L3 3/20

38

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OM673L3 3/20

39

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OM673L3 3/20

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DC Wiring Diagrams

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OM673L3 3/20

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OM673L3 3/20

43

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OM673L3 3/20

44

Wiring Diagrams

Updated 8-12-19

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OM673L3 3/20

45

Wiring Diagrams

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OM673L3 3/20

46

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OM673L3 3/20

47

Wiring Diagrams

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Service Notes

4420 14th Ave. NW., Seattle WA 98107 Tel: (206) 789-3880 • 1-800-762-0165 • www.northern-lights.comNorthern Lights and Lugger are registered trademarks of Northern Lights, Inc. © 2020 All rights reserved. Litho USA.