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' Northernlights: Operator Manual Northernlights M643




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1
0101 1095
0101 M643M673
NL643
OPERATORS MANUAL
Read this operators manual thoroughly before starting to operate your equipment This manual contains
TABLE OF CONTENTS
information you will need to run and service your new 2 Servicing
Fuel Filters 1314
Bleeding the Fuel System 14
Models Included 2
Injector Service 1416
Model Numbers 2
Injection Pump 16
Serial Numbers 2
Cooling System General 16
Warranty 3 Cooling System Flushing 1617
Safety Rules 3 Heat Exchanger Marine 17
Clean Radiator 17
Component Locations Raw Water Pump Marine 17
M643 Marine Generator 4 Generator Ends 17
M673 Marine Generator 4 Electrical System General 17
NL643 NL673 Industrial Generators 5 Glow Plugs 1718
Panels Booster Batteries 18
Battery Care 18
Northern Lights Generator Sets 67 Winterizing 18
Operating Procedures AC Generator TFIII
Breakin Period 8 General 19
Before Starting 8 Connections 2021
Starting 8 Operation 21
Operating 8 Maintenance 2123
Stopping 8
Shutdowns and Alarms 9 Spare Parts 9 Electrical 24
Servicing Schedule Chart 1011 Engine 2425
Data Marine 26
Lubrication General 12 Industrial 27
Oil Changes 12
Changing Oil Filter 12 Wiring Diagrams
Air Filter 12 DC Electrical 28
VBelts 1213 AC Electrical 29
Retightening Cylinder Head Bolts 13
Valve Clearances 13
Fuels General 13
of marine engines and generator sets presents must be adhered to more strictly Failures begin with minor
unique problems In many cases boats cannot be moved to a problems that are overlooked and become amplified when
repair facility Marine engines cannot be compared to the not corrected during routine maintenance As operator it is
servicing of automobiles trucks or even farm equipment your obligation to learn about your equipment and its often occur in remote
areas far from competent maintenance This is not a comprehensive technical Marine engines are taxed far more severely than
manual Nor will it make the reader into an expert or truck engines therefore maintenance schedules Its aim is to aid you in
maintaining your unit properly
UNIT INCLUDED
This manual covers operating instructions for
M643 and M673 marine generator sets and
NL643 industrial generator set
MODEL NUMBERS
Model numbers give units application block model aspiration and RPM
MNL 643673
M Northern Lights marine generator set Model number of engine block
Bore Cylinders
NL Northern Lights industrial generator set 64mm 3
67mm 3
Northern Lights marine diesel generator set Northern Lights industrial diesel generator
M 673 with a 673 engine TFIli18C generator end NL 643 set with a 643 engine TFlli18B generator
and AVR end AVR and a radiator
Northern Lights marine diesel generator set
M 643 with a 643 engine TFIli18B generator end
and AVR
SERIAL NUMBERS
Your set has three serial numbers an engine number stamped on the block a generator plate and a generator set plate Use the
serial number on the generator set plate when ordering parts or in The generator set plate is found on the
service side of the generator and resembles the drawing below
WARRANTY
A warranty registration certificate is supplied with
your set It entitles the original purchaser of our NOTE If the warranty is to apply the servicing
equipment to a warranty covering material or assembly instructions outlined in this manual must be
faults The extent of coverage is described in the followed If further information is needed please
Limited Warranty Statement We recommend that you contact an authorized dealer or the factory
study the statement SAFETY RULES
Avoid wearing loose clothing without a belt when
CAUTION Accident reports show that careless use of
working around engines
Do not oil or grease engine while it is causes a high percentage of accidents You can
Use caution in handling fuel Never refuel a hot or
avoid accidents by observing these safety rules Study these
rules carefully and enforce them on the job
running engine Do not smoke while filling fuel
tank or servicing fuel system
Never leave engine without proper security Keep your hands feet hair and clothing away
Turn the coolant tank cap slowly to relieve pressure from powerdriven parts
before removing Add coolant only when the Check for any loose electrical connections or faulty
engine is stopped and cool wiring
Mount a fire extinguisher near engine Engines should be operated only by
Always disconnect the battery ground strap before qualified personnel
making adjustments Look completely around engine to make sure that
Operate engines in properly ventilated areas everything is dear before starting
Keep trash and other objects away from engine Do not operate an engine that isnt in proper
Escaping fluids under pressure can penetrate your working order If an unsafe operating condition is
skin Use a piece of cardboard or wood not your noted tag the set and control panel so others will
hands to search for leaks also know about the problem
Provide first aid kits
CAUTION This symbol is used throughout this book to
alert you to possible danger areas Please take special notice
of these 2
M643 AND M673 COMPONENT 1 Service side
1 Generator End Cover 7 Lube Oil Fill 14 Secondary Fuel Filter 21 Starter Motor
Remove for Brush Access 8 Lube Oil Dipstick 15 Generator Control Box 22 DC Alternator
2 Base and Drip Pan 9 Block Drain 16 Air Filter Housing 23 Heat Exchanger End Cap
3 Fuel Injection Pump 10 Lube Oil Filter 17 Lube Oil Fill 24 Heat Exchange r
4 Belt Guard 11 Fuel Lift Pump 18 Fuel Injector Expansion Seawater Pump 12 Fuel
Inlet and Return 19 Coolant Fill Manifold
6 Lube Oil Drain 13 Control Panel Plugin 20 DC Regulator 25 Wet Exhaust Elbow
26 Manifold Drain
NL643 COMPONENT 2
1 DC Alternator 6 Bleed Screw 11 Lube Oil Filter 16 Air Filter
2 Muffler Exhaust Outlet 7 Fuel Injection Pump 12 Fuel Lift Pump 17 Lube Oil Fill
3 Starter 8 Block Water Drain 13 Fuel Inlet and Return 18 Fuel Injector
4 Power Cable Outlet 9 Lube Oil Drain 14 Secondary Fuel Filter 19 Coolant Fill
5 DC Regulator 10 Lube 0il Dipstick 15 Generator Control Box
CONTROL IB GENERATOR CONTROL PANEL 1 SHUTDOWN SWITCH
Two functions are built into this switch The
preheating of the engine and bypassing of the engine
safety shutdown circuit Hold switch in on position
1020 seconds before starting engine and continue
holding on during engine cranking Release the switch
as soon as engine is running Holding the switch on
too long can burn out the heater elements
2 ENGINE CONTROL SWITCH
To start the engine hold switch in start position until
Figure 3A the engine is running After the engine starts release
switch and it will return to the center position To stop
SERIES 3C GENERATOR CONTROL PANEL engine move switch to stop position and release
3 HOUR METER
Keeps track of engine running time
4 OIL PRESSURE GAUGE
The oil pressure gauge shows the oil pressure in the
engine lubricating system
5 ENGINE TEMPERATURE GAUGE
Registers temperature of cooling water
6 DC VOLTMETER
When the engine is stopped the voltmeter indicates
the condition of the battery When the engine is
running the voltmeter indicates the voltage output of
the 3B For Series 4 Control Panels Only
SERIES 4 GENERATOR CONTROL PANEL 7 AC VOLTMETER
Shows the generator output voltage
8 FREQUENCY METER HERTZ
The frequency meter indicates alternating current
frequency 60Hz 1800 RPM or 50Hz l 500 RPM
9 SELECTOR SWITCH
Used to check voltage and current of each phase
Return to Amps Off position when not monitoring
10 A C AMMETER
Shows the generator load on each phase The phase is
selected with the Ammeter Selector Switch 3C
CONTROL PANELS INDUSTRIAL ONLY
SERIES 6 GENERATOR CONTROL PANEL 1 SHUTDOWN BYPASS SWITCH S61 S62
This switch bypasses the safety shutdown feature
during the starting procedure Follow instructions
page 5 item 1
2 ENGINE CONTROL SWITCH S61 S62
Control switch starts and stops the engine Follow
starting instructions page 5 item 2
ENGINE CONTROL SWITCH S63 S64
When switch is placed in autostart position the unit
will automatically start when there is a drop in utility
power
When switch is placed in the manual position the unit
can be tarted manually Special instructions come with
autostart module
3 OIL PRESSURE GAUGE
The oil pressure gauge shows the oil pressure in the
Figure 4A engine lubricating system
4 HOUR METER
Keeps track of engine running time
5 WATER TEMPERATURE GAUGE
Registers temperature of cooling water
6 DC VOLTMETER
When the engine is running the voltmeter indicates
the voltage output of the alternator
7 ENGINE MONITORING ALARMS
Alarm lights S62 and S63 include 7 lights and S64
includes 12 lights
8 ALARM LAMP TEST 4B When pressed alarm lights light if working
9 ALARM RESET BUTTON
Press to reset alarm
10 AC VOLTAGE ADJUSTMENT RHEOSTAT
Voltage has been set at factory and should only be
adjusted by factory trained personnel
11 AMMETER SELECTOR SWITCH
Used to check each phase for load condition
Note Always leave this switch in the ON position
while the unit is running
12 FREQUENCY METER HERTZ
The frequency meter indicates alternating 4 frequency 60 Hz 1200 or 1800 RPM or 50Hz 1500
13 AC VOLTMETER
Shows the generator output voltage
14 AC AMMETER
Shows the generator load on each phase The phase is
selected with the Ammeter Selector switch
OPERATING PERIOD STARTING
1 The first 100 hours on a new or reconditioned engine 1 Hold Shutdown Switch in ON position
are critical to its life and performance for 10 to 20 seconds before starting a cold engine
2 Constantly check the engine temperature and oil Holding switch on too long can bum out the glow
pressure gauges Sets with Series 3 or 4 panels plugs This step is not necessary if the engine is
3 Oil consumption is greater during breakin as piston already warm
rings and cylinder liners take time to scat 2 While holding the Shutdown Switch in
4 BreakIn 011 Changes Change engine oil and filter at ON position push Engine Control Switch to START
50 hours Chance oil and filter again at 100 hours position
Consult Lubricants Section for oil 3 As soon as the engine starts release both switches Do
5 Retighten head bolts at 50 hours See page 13 not crank starter for more than 20 seconds If Instructions
fails to start the first time be sure starter has stopped
before Sets Maintain at least a 75 load on your set for
the first 100 hours If this is not possible maintain no less WARNING Excessive cranking of starter on marine sets
than a 50 load to ensure proper seating of the piston rings equipped with water lift muffler can cause engine damage
Vary the load to help seat rings If engine does not start after three 20 second cranks
remove impeller from the seawater pump This will STARTING the muffler from filling with water
and backfilling the
1 Check the water level by removing the pressure cap exhaust line and engine Once engine starts shut it off
from the expansion tank or radiator In order to give immediately and reinstall the impeller Restart and check
the cooling water an opportunity to expand the level the exhaust overboard outlet for gushes of water
should be about 1 in 25 cm below the filler cap
OPERATING
sealing surface when the engine is cold
1 Units with Series 3 46 Control Panels Check
CAUTION Use protective clothing and open the filler
gauges often Oil pressure must bc above 15PSI The
DC voltmeter should read between 11 and 15 volts at
cap carefully when the engine is warm to prevent burns 8025C ambient temperature Water Check the oil level in the crankcase with the
dipstick gauge must be below 200F 94C Check AC voltage
The oil level must be in the waffled area on stick and frequency meters Series 46 Panels If gauges
Never allow the level to go below this area Always deviate from normal levels shut down the set and
add the same viscosity of oil as is already in the investigate
crankcase 2 Let the unit run unloaded for a three to five minute
3 Check the fuel tank level and open any fuel valves warmup period
4 Marine sets close the seacock check and clean the sea 3 Add electrical load
strainer and reopen the seacock STOPPING
5 Marine sets place the battery switch in the ON
position 1 Remove electrical load from generator set
2 Run engine for a 3 to 5 minute cool down period
NOTE The battery switch must always be kept ON while 3 Move engine control switch to the STOP position
the engine is running If the switch is turned OFF while the is running the battery charging regulator could be 4 Marine sets
shut off seacock fuel valve and switch
OPERATING AND ALARMS SPARE PARTS
1 Your unit is fitted with a system to protect it from high 1 ADE recommends that you keep the following spare
water temperature or low oil pressure parts on hand for field service The parts are available
a Generator sets have shutdown systems to stop the from your local Northern Lights dealer Some marine
engine They have no warning horns models already have handy box that
b Other alarms and shutdowns are available as contains the most common parts you will need
optional equipment 2 All owners should have the Do not rely on your warning or shutdown system
a Primary and secondary fuel filter elements
b 011 filters
to the exclusion of careful gauge monitoring Watching c Air filter industrial only
your gauges can prevent damage to the unit and d Alternator belt
e Thermostat and power losses f Seawater pump impeller gaskets Marine only
2 Do the following when your warning or shutdown g Glow plug
system is activated h Injector and washer
a Check the temperature gauge If above 205F 3 If your set is operating a long distance from a servicing
97C shut off the engine immediately dealer add the following
b Use the Trouble Shooting Guide on page 21 to a Complete set of injectors
isolate the cause of the overheat b Copper washers for injector change
c Complete set of glow plugs
CAUTION Do not remove the water fill cap of an d Fuel lift engine Escaping high temperature steam can
cause severe burns Allow the engine to cool and then
remove the cap slow1y using protective clothing
d Make repairs and restart after the temperature
gauge registers below 200F 94C
e Watch the temperature gauge regularly and turn
off the unit if the temperature rises above 205F
97C Repeat If the 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 2060 PSI after a
few seconds of operation
c If the oil level is normal DO NOT restart the
engine Call your dealer for 8
SERVICING SCHEDULE CHART
The Servicing Schedule Chan below shows the service schedule required for proper maintenance of your
generator set More detailed coverage of each Service Point SP is listed on the page noted in the page
EVERY 100 HOURS
SP1 Check oil level in engine SP23 Change engine
oil and filter
SP7 Check primary fuel filter SP4 Check air
cleaner
SP13 Check cooling water level SP16 Check and clean
radiator industrial only
Check sea strainer marine EVERY 200 HOURS
AFTER FIRST 50 HOURS SP8 Change
primary fuel filter element
SP9 Change secondary fuel filter
SP23 Change engine oil and filter
SP5 Check Vbelt tension EVERY 600 HOURS
SP6 Adjust valves
SP18 Check electrolyte in batteries SP6 Check valve
clearances
Retighten head bolts sec pg 12 SPI 1 Check injectors
SPI4 Check and flush cooling system
EVERY 50 HOURS SP17 Change
impeller marine
SP19 Check state of charge of batteries
SP5 Check Vbelt tension
SPI8 Check electrolyte in batteries EVERY 2400 HOURS
SP12 Check fuel injection pump
SP15 Check and clean heat exchanger marine
DAILY 50 100 200 600 2400
POINT PAGE OPER Hours Hours Hours Hours Hours
SP1 ENGINE
812 Check oil level
SP2 12 Change engine oil 1 5

SP3 12 Change lube oil filters 1 5
SP4 12 Check air cleaner 1 4
SP5 11213 Check VBelt tension 1
SP6 13 Check valve clearances 1 5

SP7 FUEL SYSTEM
13 Check primary filter Racor
SP8 1314 Change primary filter element Racor 2 3

SP9 14 Change secondary fuel filter 1 3

SP 10 14 Bleed the fuel system 3
SP 11 1416 Check injectors 1

SP 12 16 Check fuel injection pump

SP13 COOLING SYSTEM
816 Check cooling water level
SP 14 1617 Check and flush cooling system

SP 15 17 Check and clean heat exchanger marine

SP 16 17 Check and clean radiator fins industrial

SP 17 17 Change impeller in seawater pump marine 1 3

SP 18 ELECTRICAL SYSTEM
18 Check electrolyte level in batteries 1 4
SP 19 18 Check condition of batteries with hydrorneter 1

SP 20 OUT OF SERVICE
18 Winterizing or 3
1 Perform all maintenance once a year even if hour level has not been 5 After first 50
6 Adjust at first 100 hours
2 Consult maintenance schedule note on chart
3 Whenever necessary
4 More often if 9
SERVICE RECORD
Service OPERATION HOURS DATE
Point
50 HOURS
SP 5 Check Vbelt Check electrolyte in 100 HOURS
SP2 Change engine oil
SP3 Change lubricating oil filters
SP4 Check air cleaner
SP16 Check and clean radiator fins 200 HOURS
SP7 Change primary filter element Racor
SP9 Change secondary fuel filter
EVERY 600 HOURS
SP6 Check valve Check Check and flush cooling system
SP17 Change impeller in seawater pump Check condition of batteries with hydrometer
2400 HOURS
SP11 Check fuel injection pump
SP16 Check and clean heat Check and clean reverse par oil cooler
SERVICING
4 Change oil when engine is GENERAL
5 Dispose of waste oil in an approved manner
1 Use only clean high quality lubricants stored in clean 6 Never use a flushing oil
containers in a protected area 7 Loosen clamp on oil change tube Remove cap Drain
2 These lubricants are acceptable oil Replace cap and tube
a API Service CCCDCE single viscosity oils 8 Refill engine with recommended oil
b API Service CCCDSF oils 9 Engine capacity oil filter is
3 Use the proper weight oil for your average operation 643 and 673 32 quarts 3 liters
temperature
SP3 CHANGING OIL FILTER
1 Change the lube oil filter every 100 hours
Air Single Multi Oil filter part number is 2402001
2 Use a filter wrench to remove old filter Dispose of
Temperature Viscosity Viscosity
filter in approved manner
Above 320F SAE30W SAE 1540W 3 Make sure the gasket from the old filter is removed
0C and discarded Clean mount face
4 Spread a thin film of engine oil on the rubber gasket
10 to 320F SAE10W SAE 1030W on the new filter and screw it on nipple until gasket
23 to OC meets the sealing surface
5 Using hands only no wrench tighten filter onehalf
Below 1 OOF SAE5W SAE 520W turn farther can do damage to filter
23C housing
6 Fill engine with recommended oil Start engine and
check for leakage Stop engine wait 3 minutes and
Figure 5 Lube Oils check oil levelAdd additional oil if necessary
4 Some increase in oil consumption may be expected SP4 AIR CLEANER
when SAE 5W and SAE 520W oils are used Check 1 Inspect air cleaner every 100 hours In dusty
oil level frequently conditions check more often
5 Never put additives or flushing oil in crankcase
M643 AND M673 Remove plate on bottom of air intake
SP1 CHECKING OIL LEVEL manifold Inspect clement If dirty wash element in
1 Check the oil level inthe crankease with the dipstick soapy water Rinse and dry thoroughly before
The oil level must be in the waffled area on stick Never allow the level to go below this area Follow the NL643
lubrication above Element cannot be cleaned Replace it when necessary
Part number OIL CHANGES IMPORTANT Make absolutely sure no impurities enter the
1 The set is delivered with special breakin oil Change engine while changing the element Do not run the
the engine oil and oil filter after 50 hours of operation engine with the air cleaner removed
Use RPM Delo Series 100 30 weight or equivalent
SP5 VBELTS
Service CC 30 weight oil during the first 100 hours
Change the oil and filter again at 100 hours using the 1 Check the tension and wear on the Vbelt after every
oil recommended in the above diagram After 50 hours
this change oil and filter every 100 hours 2 Use your thumb to press on the belt at the midpoint
2 During intermittent cold weather operation change oil between the crankshaft and altemator
every 100 hours or six weeks whichever comes first
3 Change oil at any seasonal change in temperature
when a new viscosity of oil is 11
SERVICING
pulleys The tension is correct if the belt can be
depressed about 316 in CYLINDER HEAD BOLTS
1 Retighten the head bolts after the first 50 hours
2 Tighten bolts when the engine is cold
3 Loosen the nuts and remove rocker arm cover
4 Tighten head bolts with a torque wrench in order
shown in figures below Tighten bolts evenly in 2 or 3
passes ending at specified torque in final pass
a 643 and 673 2629 ftIbs 3540 kgm Figure 7 Valve Adjustment
1 Use only clean high quality fuels of the following
as defined by ASTM designation D975
for diesel fuels
a Use grade no 2 diesel at ambient temperatures
above freezing 32F OC
b Use grade no 1 at ambient temperatures below
freezing and for all temperatures at an altitude of
Figure 6 Head Torque Sequence above 5500 ft 1500 meters
2 Use fuel having less that 1 sulphur preferably less
SP6 VALVE CLEARANCES
that 05
1 Readjust valve clearance after first 50 hours of 3 The cetane number should bc a minimum of 45
operation and every 600 hours thereafter 4 DO NOT use these unsuitable grades of fuel
2 Valve adjustments should bc done after the cylinder a Domestic heating oils all types
head bolts have been retightened Engine should be cold and b Class B engine
NOT running c Class D Domestic fuels
d Class E F G or H industrial or marine fuels
3 Watch the valves while turning the engine over by and e ASTMD97560T No 4D and higher
Turn until the 1 cylinder inlet valve starts to open and the number valve starts to close the valves are rocking Then
5 Storing fuel
turn the crankshaft one more full turn and adjust the a Keep dirt scale water and other foreign on both valves for this cylinder
out of fuel
4 Loosen the lock nut and adjust the clearance between b Avoid storing fuel for long periods of time
the rocker arm and valve guide of both the intake and c Fill the fuel tank at the end of each days
exhaust valves with the adjustment screw Clearance on operation This will reduce intake and exhaust valves should be 0008
in 02 SP79 FUEL FILTERS
mm 1 Your generator set should have a primary fuel filter
installed We recommend the Racor brand of fuel filter
5 Repeat steps 3 and 4 for each cylinder Each set of water must be adjusted individually a
Check the primary fuel filter dally as
recommended by the filter manufacturer Empty
6 Replace rocker arm cover Tighten cover nuts to
the collection bowl as ftlb 112 kgm
b Change the element as often as necessary or
every 200 hours
SERVICING
c If the bowl fills with water change the primary and 6 After engine has started use a piece of cardboard to look
secondary element Change secondary fuel filter every 200 hours for leaks
a Remove the spinon filter by turning it
with a filter wrench Fill the
new cartridge with fuel and install A after
applying engine oil to gasket surface Screw on
until the gasket surface comes into contact with
sealing surface of filter base Then tighten it
twothirds of a turn by hand Do not Fuel filter part number is
M643 and 673 2452020
NL643 BLEEDING THE FUEL Escaping diesel fuel under pressure can
penetrate skin causing serious personal injury lines be sure to relieve all pressure Before Figure 8 Fuel pressure be sure all connections
are tight and
lines pipes and hoses arent damaged Fuel escaping from
a very small hole can be almost invisible Use a piece of SP11 INJECTOR or wood rather than hands to search for
suspected leaks If injured by escaping fuel see a doctor at 1 Injectors should be checked every 600 hours Check
once Serious infection or reaction can develop if proper should bc made by Northern Lights dealer or local
medical treatment isnt administered immediately injection repair station
1 The fuel system is However any system CAUTION Escaping diesel fuel under pressure can have
may need manual bleeding when sufficient force to penetrate the skin causing serious
a A new fuel filter is installed personal injury If injured by escaping diesel fuel see a
b The engine has run out of fuel doctor at once
c The fuel lines injection pump or any other fuel
2 Injector removal
system component has been removed and
installed a Clean loose dirt from around the injectors and the fuel
2 Loosen bleed screw A Fig 8 on top of the filter lines
Pump hand primer B on fuel lift pump until pure fuel
b Relieve high pressure in the fuel lines by
no bubbles escapes from bleed screw A Tighten
loosening the delivery line flare nuts at each injector Figure
bleed screw A
3 Loosen bleed screw C Pump hand primer B on
fuel lift pump until pure fuel no bubbles escapes c Remove delivery lines by disconnecting from
from bleed screw A injectors and injection pump Figure 10 Remove all lines
4 If the engine does not start after the above bleeding as an assembly do not remove the spacers Cover the ends
process loosen a fuel line at the injector Pump hand of the lines the injector inlets and injection pump outlets to
primer B until pure fuel escapes then tighten keep dirt out
connection Do each line d Remove the return line retaining bolts Figure 11
Remove the retum line Figure 12
e Unscrew and remove the injectors Figure
NOTE Do not use pry bars to remove injectors from
cylinder head
SERVICING
f After removing injectors discard the copper
COOLING SYSTEM GENERAL
sealing washers from the injector hole in the head
Figure 14 Cover holes to prevent dirt and NOTE Marine setsBe sure to close the seacock before
debris from entering cylinders working on the engine cooling system
4 Injector repair and cleaning Take injectors to your
Northern Lights dealer or local injection repair station
for testing and service
Injector CAUTION The cooling water in the engine reaches
a Install a new copper sealing washer in each extremely high temperatures You must use extreme
injector hole Figure 14 caution when working on hot engines to avoid burns
b Screw in injector and tighten to 43 or 50 ftIbs 6 Allow the engine to cool before working on the cooling
to 7 Kgm Figure 15 system Open the filler cap carefully using protective
clothing when the engine is warm
NOTE can damage injector
c Install return line using new copper sealing above and SP13 CHECKING THE COOLANT LEVEL
below each connection Tighten return line retaining
bolts to 2230 ftbs 1 Check the coolant level each day before starting the
d Install delivery lines Leave loose at injectors for engine
bleeding 2 Check the coolant level by removing the pressure cap
e Pump hand level on fuel pump to fill lines Tighten from the expansion tank or radiator
lines at injectors Start engine and check for leaks
using a piece of paper or cardboard DO NOT use CAUTION The cooling water in the engine reaches
hand to check for leaks extremely high temperatures You must use
caution when working on hot engines to avoid burns
Allow the engine to cool before working on the
1 Since operating conditions may vary considerably it is cooling system Open the filler cap carefully using
difficult to give a definite interval But as a rule the protective clothing when the engine is warm
pump settings maximum speed idle speed and 3 In order to give the cooling water an opportunity to
exhaust smoke should be checked after every 2400 expand the level should bc about 1 in 25 cm below
hours of operation Service of the fuel injection pump the filler cap sealing surface when the engine is cold
should only bc done if checks indicate pump 4 The pressure valve in the filler cap releases when
malfunction the pressure is approximately 7 PSI 05 bar Use a
2 Black smoke can be an indication of pump cap pressure tester to check cap if you suspect it is
malfunctions Before servicing pump check the other faulty
possible causes
a Check cleanliness of air filter SP14 COOLING SYSTEM FLUSHING
b Check valve clearances 1 Flush the cooling system every 600 hours or every 12
c Clean and check injectors months whichever comes first
3 Any repair which 1nvolves disassembly of theinjection
pump must bc carried out by MARINE
mechanics with the proper tools and test devices a Remove expansion tank cap and open drain cock
NOTE All warranties on the engine become null and on engine block
void if the injection pump seals are broken by b Pour clean water into expansion tank until water
unauthorized persons coming from drain is free of discoloration and
sediment
c Let water drain completely
d Close drains and refill with recommended
mixture
Note Open sea cock before running engine
SERVICING
5 Replace the cover using a new a Remove radiator cap and open drain cocks on NOTE Make sure that there is always an extra
impeller
radiator and engine block and cover gasket in reserve on board
b Pour clean water into radiator until water coming
GENERATOR ENDS
from radiator is clear of c Close the radiator drain and continue flushing The maintenance and operation for
until water from engine drain is clear Open all the generator end are in a separate Owners Manual If
drain cocks and drain completely Close drain you do not have one of these manuals contact your
cock and refill with recommended coolant local dealer
mixture Clean fins on radiator ELECTRICAL SYSTEM AND INDUSTRIAL 1 Never
switch battery switch off or break the circuit
2 Use 50 water50 ethylene glycol antifreeze mix between the alternator and batteries while the engine is
Antifreeze mixture is recommended as a good running Regulator damage can result
yearround coolant 2 Do NOT reverse the polarity of battery cables when
3 Check hoses and connections and repair any leakage installing the battery
3 When welding on the unit disconnect the regulator
SP 15 HEA T EXCHANGER MARINE and battery Isolate the leads
1 Clean the heat exchanger core once a year or after 4 Disconnect battery cables when servicing the DC
2400 hours of operation Drain expansion tank and heat exchanger 5 Never test with a
screwdriver etc against any
3 Remove heat exchanger end covers and remove core terminal to sec if it emits sparks
4 Clean the inside of exchanger core tubes using a metal 6 Do not polarize the alternator or regulator
rod Flush inspect and clean again if necessary 7 A DC circuit breaker protects your control panel and
5 Reassemble Fill the cooling system start the engine wiring harness It is located in the side of the generator
and check for leaks junction box
SPI6 CLEAN RADIATOR INDUSTRIAL GLOW PLUGS
1 Remove debris from radiator fins daily 1 Each cylinder is supplied with a glow plug which
2 In very dusty applications clean the radiator with serves to heat the combustion chamber
compressed air or steam cleaner every 100 hours
Clean in the reverse direction of airflow
SP 17 RAW WATER PUMP MARINE
1 Change the seawater pump impeller every 600 hours
or as needed
2 Remove the pump end cover Pry out the impeller with
the help of two screwdrivers Be sure you remove all pieces
of failed Place some kind of protection under in order not to damage the housing
3 Clean the inside of the housing
4 Press in the new impeller and place the sealing
washers in the outer end of the impeller center if this
has not already been done Figure 16 Glow Plug Strip
SERVICING
2 To check the glow plugs loosen the current carrying
SP1819 BATTERY CARE
flat wire between the pluspoles of the glow poles
Figure 16 Connect a DC test bulb between the 1 Check electrolyte level every 50 hours or once per
pluspole of the battery and the pluspole of the glow month Add distilled water to plug If the bulb lights up the glow plug is
functioning recommended level
properly 2 Batteries cables and cable terminals should be
3 Check all glow plugs and replace any faulty ones checked and cleaned every 100 hours Clean corrosion
with a water and baking soda solution Flush with
BOOSTER BATTERIES clean water Tighten terminals and grease them to
inhibit corrosion
3 Check the battery condition with a hydrometer every
CAUTION Battery Gas Can Explode Keep all flames 600 hours
and sparks away from batteries
SP20 WINTERIZING Before changing or using booster batteries check
MARINE
battery electrolyte level Add distilled water if
1 Drain fresh water and seawater cooling systems
necessary
completely Flush fresh water system and refill with
3 Booster and main batteries must have the same voltage
proper antifreeze mixture Remember to shut off
rating
seacocks before opening drain cocks
4 First connect positive terminal of booster battery
2 Drain water supply lines and wet exhaust line
to positive terminal of main battery Then connect
3 Loosen the seawater pump cover and drain pump
negative terminal of booster battery to ground on
INDUSTRIAL
the engine block Sec Figure 17
1 Drain and flush radiator and cooling system Leave dry
5 Remove booster battery after starting engine
or refill with mixture If refilling start
6 Sealed batteries See manufacturer charging and
the engine and run to circulate the antifreeze
booster 2 Fill fuel tank or add biocide as per
3 Seal air cleaner inlet exhaust
opening crankcase
breather pipe and fuel tank vent with plastic bags and
tape
4 Store the set in a dry protected place If unit must be
stored outside be sure it is well protected with a cover
MARINE AND INDUSTRIAL
1 Change the crankcase oil and filter
2 Loosen the alternator belt
3 Disconnect and clean battery Remove to warm storage
place if possible
4 Clean outside of unit Paint any scratched or chipped
surfaces Put corrosion preventative on all exposed
metal 17 Battery 17
AC GENERATOR Fig 19 10 Coupling boss Control Box Fig 20
11 Coupling boit with washer
1 Stator assembly 12 Coupling nut 1 Fuse for main circuit
2 Rotor assembly MNL 643 PN 2268312
3 Frame M673 PN 2248011
4 Ventilation cover 2 Fuse for AVR PN 2268309
5 Attaching screw 3 Output terminal board
6 Carbon brush assembly PN 2268304 4 Circuit breaker
7 Attaching screw 5 Control panel and hour meter ind only
8 Ball bearing PN 2268305 6 Automatic voltage regulator AVR
9 Ventilation cover 7 Control terminal board
8 A Generator Set includes the engine the generator 3 Generator voltage builds up from the residual
and the control or Y box Fig 18 magnetic field of the rotator located in the generator
2 The generator and the control or Y box produce the Fig 192 and electrical output voltage is controlled
electrical power by the automatic voltage regulator AVR located in
the control box Fig 206
AC GENERATOR The generator can bc wired to produce 120 volts
2 120 Volt Output
a 120 volt output can be selected by connecting the
VI and 120 terminals of the control terminal
board Fig 21
b Connect Ul to U2 and VI to V2 on the output
terminal board Fig 22 Connect 120 volt output
leads to terminals Ul and V2
Figure 23 Control Terminal Board 240 Volt 21 Control Terminal Board 120 Volt Output
Figure 24 Output Terminal Board 240 Volt output
4 120240 Volt Output
a Connect the control terminal board for 240 volts Figure
Figure 22 Output Terminal Board 120 Volt Output
3 240 Volt Output
a Connect V2 to 240 on the control terminal board
Fig 23
b Connect U2 to VI on the output terminal board
Fig 24
Figure 25 Control Terminal Board 1201240 Volt Output
b Connect U2 and VI on the output board Figure 26
Connect output leads to U2 and V2 and neutral lead to
VI or U2 240 volt output is available from the leads
connected to Ul and V2 The 120 volt load should be
divided as equally as possible between two 120 volt
AC GENERATOR TFIII
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 resistance of each
stator coil and the rotor Disconnect the AVR from the
generator when performing this test Figure 26 Output Terminal Board 1201240 Volt Output
Figure 28 A VR Connector
4 Voltage Adjustment
a If there is some voltage but it does not build up
OPERA TION
to rated voltage voltage adjustment can be made
In order to ensure long troublefree life the generator using the hand trimmer in the AVR Figure
must be operated properly and the specified 29
maintenance must be performed b The normal voltage setting at no load is 121 volts
OPERA TING ENVIRONMENT at 62 Hertz or 242 volts at 62 Hertz
Always keep electrical equipment clean Moisture
salt dust and oil will damage the generator The
operating environment must bc kept as clean and
moisture free as Good ventilation is important for proper generation
operating When installing the generator set bc
sure the ambient temperature does not exceed
40C104F during Proper and effective maintenance is required to ensure Figure 29 Hand Trimmer Location
troublefree operation In addition to the above
items the following are required
1 Periodically check all bolts and nuts for proper torque 5 Flashing the Fields a If there is no voltage
This is especially true for coupling bolts buildup on startup zero volts measured with a
2 Be sure to keep the generator area clean and dry voltmeter the generator may have no residual
a Dust and foreign material may reduce the flow of magnetic field
cooling air reducing heat dissipation and causing
the generator to overheat
b If electrically conductive debris accumulates on
the windings or if moisture or salt water are
absorbed into the windings the windings may
short or ground reducing voltage output
AC GENERATOR TFIII
b To flash the field and build the residual 12 volts DC to terminals K and J as indicated
in Figure 30
c AVR must be disconnected when flashing fields or it
could be 30 Flashing the Fields
Figure 32 Brush Location
6 Check the ball bearing in the generator end
a Listen for unusual noise c Attach leads to new brush assembly and install it
b Abnormal temperature rise can be noted by with the plastic cars towards the front of the
generator
c If the bearing is failing it must be replaced Note Be sure to connect wire J to terminal J and connect
d Generator bearings should be replaced by your wire K to terminal K
Northern Lights dealer at 10000 hours 9 Replacing Fuses
7 Check the brushes a To protect the generator and AVR from
a The carbon brushes gradually wear with use so unbalanced loads and over loads two 20 amp
they must be inspected periodically and replaced fuses are placed in the output circuit and one 3
as necessary amp fuse is placed in the AVR sensing circuit
b If the brushes are excessively worn as to expose b Always replace fuses with the same brand and
the pigtail Figure 31 sparking will occur at the the same circuit interruption surface of the slip ring causing surface
damage
Therefore periodic inspection of the brushes is
important
c Normally the brushes will have to be replaced
with a new brush assembly within 3000 31 Brush Pigtail
Figure 33 Fuse Locations
8 Replacing brushes
a Shut down generator 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 oclock and is
held in position by 2 screws Figure 32 Remove
screws and unplug leads
AC GENERATOR 34 A VR Fuse Holder
10 Parts See Parts Book for Complete List
a Fuse for main circuit
MNL 643 PN 2268312
M673 PN 2248011
b Fuse for AVR sensing circuit
PN 2268309
c Bearing PN 2268305
d Brush assembly PN 2268304
11 Test Sec Wiring Diagram
a Resistance of JK 166 ohm at 20C 68F
b Resistance of AB 025 ohm at 20C 68F
c Resistance of UIV2 056 ohm at 20C 68F
d No load voltage setting 242V or 121V at 62 Hz
with cold 22
If you cannot correct problems with these procedures see your Northern Lights dealer
No fuel
DC ELECTRICAL SYSTEM Check level of fuel in fuel tank
Battery will not charge Low battery output
Check electrolyte level and condition
Loose or corroded connections
Clean and tighten battery connections Excessive resistance in starting circuit
Clean and tighten all battery connections
Sulfated or worn out batteries
Check specific gravity of each battery Crankcase oil too heavy
Use oil of proper viscosity
Check electrolyte level of each battery
Improper type of fuel
Loose or defective alternator belt
Consult fuel supplier and use proper type of fuel for
Adjust belt tension
operating condition
Replace belt Water dirt or air in fuel system
Drain flush fill and bleed system
Starter inoperative
Clogged primary fuel filter element
Check DC circuit breaker
Clean or replace filter element
If the breaker is tripped reset it
Clogged secondary fuel filter element
Loose or corroded connections
Replace filter element
Clean and tighten loose battery and harness plug
connection Dirty or faulty injection nozzles
Have your dealer check injection nozzles
Low battery output
Check specific gravity of each battery Engine runs irregularly or stalls frequently
Check electrolyte level of each battery Below normal engine temperature
Defective electrical system ground wire Remove and check thermostat
Repair or replace Clogged primary fuel filter element
Clean or replace filter element
Starter cranks slowly
Clogged secondary fuel filter element
Low battery output
Replace secondary filter element
Batteries too small
Water or dirt in the fuel system
Battery cables too small
Drain flush fill and bleed system
Check specific gravity of each battery
Dirty or faulty injection nozzles
Replace battery if necessary
Have your dealer check injection nozzles
Check electrolyte level of each battery
Air in fuel system
If low fill cells with distilled water
Inspect clamps and hoses on suction side of fuel
Crankcase oil too heavy pump for air leak
Fill with oil of appropriate viscosity Improper type of fuel
Loose or corroded connections Consult fuel supplier and use proper type of fuel for
Clean and tighten loose connections operating condition
Entire electrical system does not function Lack of engine power
Check DC circuit breaker Engine overloaded
If breaker is tripped reset it Reduce load
Faulty connection Intake air restriction
Clean and tighten battery and harness plug Service air cleaner
connections Clogged primary fuel filter element
Sulfated or worn out batteries Clean or replace filter element
Check specific gravity and electrolyte level of each Clogged secondary fuel filter element
battery
Replace filter Improper type of fuel
Consult fuel supplier and use proper type of fuel for
Engine hard to start or will not start operating conditions
Improper starting procedure Overheated engine
See starting section of this manual Take special See Engine Overheats in next category
note of Bypass Switch 23
If you cannot correct problems with these procedures see your Northern Lights dealer
Below normal engine temperature Engine not at proper temperature
Remove and check thermostat Check your thermostats
Improper valve clearance Check water temperature with thermometer and
Reset valves Best done by dealer replace gauge if necessary
Dirty or faulty injection nozzles
Replace injectors Best done by dealer Below normal engine temperature
Thermostats not working properly
Sec your local dealer
Check overheats Temperature gauge not working properly
Engine overloaded Check water temperature with thermometer
Reduce electrical load Low oil pressure
Low coolant level Low oil level
Fill tank or radiator to proper level Fill crankcase to proper level
Check hoses for loose connections and leaks Improper type of oil
Keel cooling tubes have been painted marine Drain and fill crankcase with correct oil
Remove paint from tubes Partially plugged oil filter
Cooling system needs flushing Replace filter
Flush cooling system
High oil consumption
Defective thermostat
Remove and check thermostat Breakin period
Oil consumption decreases after break in
Defective temperature gauge
Check water temperature with thermometer and Crankcase oil too light
replace gauge if necessary Use proper viscosity oil
Water pump impeller worn broken marine Oil leaks
Check impeller and replace if necessary Check for leaks in lines around gaskets and drain
plug
Engine knocks Engine overheats
Insufficient oil See Engine Overheats
Call your dealer
Engine emits black or gray exhaust smoke
Injection pump out of time
Call your dealer Clogged or dirty air cleaner
Service air cleaner
Below normal engine temperature
Check your thermostats Defective muffler back pressure too high
Have dealer check back pressure
Check water temperature to see if temperature
gauge is working properly Improper fuel
Use correct fuel for temperature
Engine overheating
See Engine Overheating section Engine overloaded
Reduce electrical load
High fuel consumption Injection nozzles dirty
Improper type of fuel See your dealer
Use correct fuel for temperature Engine out of time
Clogged or dirty air cleaner Sec your dealer
Service air cleaner
Engine emits white smoke
Engine overloaded
Reduce electrical load Improper fuel
Use correct fuel for temperature
Improper valve clearance
See your dealer Cold engine
Warm up engine to normal operating temperature
Injection nozzles dirty
See your dealer Defective thermostat
Remove and check thermostat
Injection pump out of time
See your dealer Engine out of time
See your dealer
NORTHERN LIGHTS MARINE M643 RPM Hz 5 1800 60 1500 50 6 1800 60 1500 50
General in3617L 411 in3 676L
Cycle 4
Bore in 64mm in 67mm
Stroke 252 in Facing Flywheel 29 US qts Weight Complete Unit lbs 157 352 lbs 160 kg
Height in 498 mm
Width 172 in 437 mm
Length 296 in Cooling System Capacity 2 US qt ThroughHull Diameter 75 in Pump Inlet Hose 75 in Seawater 75 in 19mm
Heat Rejection to Jacket BTUmin 600 Pump Capacity US GPM 41 US GPM US GPM US GPM
1577 Lmin 1577 Lmin 1892 Lmin
Max Seawater Pump Suction Head 39 in 1 m
Seawater Pump Capacity 9 US GPM U S GPM 9 US 75 US GPM
34 Lmin 34 Lmin Lmin
Keel Cooler Round Tube 5 ft 15m
Keel Cooler Head 34 in NPT 191 mm
Keel Cooler Water Hose ID
Discharge and Suction in 25 Battery Capacity 0F cca
Battery Cable 2 up to 10 ft
Instrmnt Harness Length 20 ft Voltage Negative Ground Cooling Air 200 ft3 ft3 47 200 ft3 ft3 47 ft3 56m3min ft3 ft3 61m3min ft3 Engine
Roorn Vent in2 34 cm2 in2 37 cm2
Maximum Exhaust Back Pressure 48 in 122 cmH2O
Wet Exhaust Elbow OD in 38 mm OD
Dry Exhaust Elbow 125 in NPT
Max Intrmtnt Eng Oper Angle
Front or Rear Down Suction Line 14 in Return Line 14 in 635mm
Max Fuel Pump Head 39 in Data
Rated Flywheel HP 50 Rating 5 kW 60hz 50hz 60hz 48 Fuel Maximum Load Fuel 045 US GPH O3I US GPH 054 US 043 US GPH
l 181 Lhr 20 166 Maximum Load 173 Lhr
NORTHERN LIGHTS INDUSTRIAL DATA
Model Number NL643
kW Output at 60 Hz 1800 RPM 1 5
120240 Volt Amperage 208A
120 Volt Amperage 1
kW output at 50 Hz 1500 RPNI 1 Amperage 159A
240 Volt NA
110 Volt Amperage Phase model diesel in 3 L 376 061
Bore in mm in mm 2564
HP 1800 RPM fuel rate 1800 RPM
with a full load galhr Lhr 051 19
with a half load US galhr Lhr Data
Exhaust outlet in mm 32
Fuel inlet and return in mm 8 hose
Length in mm 33 1834
Width in mm 15 386
Height in mm 25 650
Approx dry weight kg 370 169
Note 1 Based on 10 unity power factor Deratings 3 per 1000 ft over 500 ft above sea level 1 for every 10 over 85F
DC WIRING DIAGRAM
AC WIRING DIAGRAM

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