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' Northernlights: Operator Manual Northernlights M643



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     1
0101  10/95
                                                                                                                                     0101                    M643,M673

                                                                                                                                                                      NL643

                                                  OPERATOR'S 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 unit.




Introduction ................................................................... 2         Servicing continued...
Unit Identification                                                                          Fuel Filters . ......................................................... 13-14
                                                                                             Bleeding the Fuel System ......................................... 14
  Models Included ......................................................... 2
                                                                                             Injector Service ................................................... 14-16
  Model Numbers .......................................................... 2
                                                                                             Injection Pump ......................................................... 16
  Serial Numbers ........................................................... 2
                                                                                             Cooling System - General ........................................ 16
Warranty ....................................................................... 3           Cooling System Flushing . .................................. 16-17
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 .......................................................... 17-18
Panels                                                                                       Booster Batteries ...................................................... 18
                                                                                             Battery Care .............................................................. 18
  Northern Lights Generator Sets ............................... 6-7                         Winterizing - Out-of-Service ................................... 18
Operating Procedures                                                                       AC Generator - TFIII
  Break-in Period .......................................................... 8               General ..................................................................... 19
  Before Starting ........................................................... 8              Connections . ....................................................... 20-21
  Starting ....................................................................... 8         Operation .................................................................. 21
  Operating .................................................................... 8           Maintenance ........................................................ 21-23
  Stopping ..................................................................... 8
  Shutdowns and Alarms ............................................... 9                   Troubleshooting
  Spare Parts .................................................................. 9           Electrical ................................................................... 24
Servicing Schedule Chart ...................................... 10-11                        Troubleshooting - Engine .................................... 24-25
                                                                                           Data Sheets
Servicing
                                                                                             Marine ...................................................................... 26
  Lubrication - General ............................................... 12                   Industrial .................................................................. 27
  Oil Changes .............................................................. 12
  Changing Oil Filter ................................................... 12               Wiring Diagrams
  Air Filter ................................................................... 12          DC Electrical ............................................................ 28
  V-Belts ................................................................ 12-13             AC Electrical ............................................................ 29
  Retightening Cylinder Head Bolts ........................... 13
  Valve Clearances ...................................................... 13
  Fuels - General ......................................................... 13




                                                                                       0
                                                          INTRODUCTION

Servicing 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 proper
Failures often occur in remote areas far from competent                    maintenance. This is not a comprehensive technical service
assistance. Marine engines are taxed far more severely than                manual. Nor will it make the reader into an expert mechanic.
auto or truck engines; therefore, maintenance schedules                    Its aim is to aid you in maintaining your unit properly.



                                                     UNIT IDENTIFICATION

MODELS INCLUDED
This manual covers operating instructions for:
                           M643 and M673 marine generator sets, and
                           NL643 industrial generator set.

MODEL NUMBERS
Model numbers give unit's application, block model, aspiration and RPM:
                                            M-NL                                           643,673




                       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, TFIli-18C generator end              NL 643            set with a 643 engine, TFlli-18B generator
                   and AVR.                                                                  end, AVR and a radiator.


                   Northern Lights marine diesel generator set
    M 643          with a 643 engine, TFIli-18B 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 correspondence. The generator set plate is found on the
    service side of the generator and resembles the drawing below.




                                                                       1
                                                        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 carefully.




                                                      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 running.
engines causes a high percentage of accidents. You can
                                                                    Use caution in handling fuel. Never re-fuel 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. power-driven 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                   knowledgeable, 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 isn't 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 sections.




                                                               2
                                 M643 AND M673 COMPONENT LOCATIONS




Figure 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 Tank-Exhaust
5.   Seawater Pump             12.   Fuel Inlet and Return       19.   Coolant Fill                  Manifold
6.   Lube Oil Drain            13.   Control Panel Plug-in       20.   DC Regulator            25.   Wet Exhaust Elbow
                                                                                               26.   Manifold Drain




                                                             3
                                         NL643 COMPONENT LOCATION




Figure 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




                                                      4
                                     CONTROL PANELS



SERIES I-B GENERATOR CONTROL PANEL            1.   SHUTDOWN BYPASS-PREHEAT 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
                                                   10-20 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 3-C 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.   D.C. 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 alternator.
Figure 3B.                                    For Series 4 Control Panels Only:
SERIES 4 GENERATOR CONTROL PANEL              7.   A.C. 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.   AMMETER/VOLTMETER 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, #9.




Figure 3C.


                                          5
                           CONTROL PANELS (INDUSTRIAL ONLY)

      SERIES 6 GENERATOR CONTROL PANEL       1.   SHUTDOWN BYPASS SWITCH S6.1 & S6.2
                                                  This switch bypasses the safety shutdown feature
                                                  during the starting procedure. Follow instructions
                                                  (page 5, item 1).
                                             2.   ENGINE CONTROL SWITCH S6.1 & S6.2
                                                  Control switch starts and stops the engine. Follow
                                                  starting instructions (page 5, item 2).
                                                  ENGINE CONTROL SWITCH S6.3 & S6.4
                                                  When switch is placed in auto-start 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
                                                  auto-start 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.   D.C. VOLTMETER
                                                  When the engine is running, the voltmeter indicates
                                                  the voltage output of the alternator.
                                             7.   ENGINE MONITORING ALARMS:
                                                  Alarm lights. S6.2 and S6.3 include 7 lights and S6.4
                                                  includes 12 lights.
                                             8.   ALARM LAMP TEST BUTTON.
Figure 4B.                                        When pressed, alarm lights light if working.
                                             9.   ALARM RESET BUTTON.
                                                  Press to reset alarm.
                                             10. A.C 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 current
Figure 4 .                                       frequency: 60 Hz (1200 or 1800 RPM or 50Hz (1500
                                                 RPM).
                                             13. A.C. VOLTMETER:
                                                  Shows the generator output voltage.
                                             14. A.C AMMETER
                                                  Shows the generator load on each phase. The phase is
                                                  selected with the Ammeter Selector switch.

                                         6
                                                OPERATING PROCEDURES



BREAK-IN PERIOD                                                      STARTING
1 . The first 100 hours on a new or reconditioned engine             1 . Hold Shutdown Bypass-Preheat 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 break-in as piston                  already warm.
    rings and cylinder liners take time to scat.                     2. While holding the Shutdown Bypass-Preheat Switch in
4. Break-In 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 recommendation.)             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 engine
Operating Instructions                                                   fails to start the first time, be sure starter has stopped
                                                                         before reengaging.
Generator 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 prevent
BEFORE 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. (2.5 cm) below the filler cap
                                                                     OPERATING
   sealing surface when the engine is cold.
                                                                     1 . Units with Series 3, 4&6 Control Panels: Check
!   CAUTION. Use protective clothing and open the filler
                                                                         gauges often. Oil pressure must bc above 15PSI. The
                                                                         D.C. voltmeter should read between 11 and 15 volts at
cap carefully when the engine is warm to prevent burns.                  80(25C) ambient temperature. Water temperature
2. 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 4&6 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.                   warm-up 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             momentarily.
engine is running, the battery charging regulator could be           4. Marine sets: shut off seacock, fuel valve and battery
ruined.                                                                  switch.




                                                                 7
                                                OPERATING PROCEDURES



SHUTDOWNS 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 "OnBoard-Kits",a 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 following:
NOTE: 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 gaskets
dangerous 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 pump
overheated 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 troubleshooting.
3. 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 (20-60 PSI) after a
           few seconds of operation.
     c. If the oil level is normal, DO NOT restart the
           engine. Call your dealer for assistance.




                                                                 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'
                                                                    co1umn.


DAILY:                                                                                                                      EVERY 100 HOURS.
     SP1         Check oil level in engine                                                                                        SP2/3     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
     SP2/3       Change engine oil and filter
     SP5         Check V-belt tension                                                                                       EVERY 600 HOURS:
     SP6         Adjust valves
     SP18        Check electrolyte in batteries                                                                                   SP6       Check valve clearances
                 Re-tighten 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 V-belt tension
     SPI8        Check electrolyte in batteries                                                                             EVERY 2400 HOURS:
                                                                                                                                  SP12      Check fuel injection pump
                                                                                                                                  SP15      Check and clean heat exchanger (marine only)



SERVICE                                                                                                                             DAILY     50             100             200            600    2400
 POINT ......PAGE .............................................................................. ............................. OPER          Hours          Hours           Hours          Hours   Hours
  SP1                 ENGINE:                                                                                                        
             8&12     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            112&13         Check V-Belt tension                                                             1)                            
   SP6                13         Check valve clearances                                                           1)                            5)                                          
   SP7                           FUEL SYSTEM:                                                                                     
                     13          Check primary filter (Racor)
                     2)
   SP8             13&14         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             14-16        Check injectors                                                                  1)                                                                        
  SP 12               16         Check fuel injection pump                                                                                                                                          
   SP13                          COOLING SYSTEM                                                                                   
                   8&16          Check cooling water level
  SP 14            16&17         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 out-of-service                                                    3)

1) Perform all maintenance once a year even if hour level has not been                                                      5) After first 50 hours.
reached.                                                                                                                    6) Adjust at first 100 hours.
2) Consult manufacturer's maintenance schedule, note on chart.
3) Whenever necessary.
4) More often if necessary.




                                                                                                              9
                                                          SERVICE RECORD



 Service                             OPERATION                               HOURS / DATE
  Point


                                                              50 HOURS

SP 5       Check V-belt tension



SP18       Check electrolyte in batteries




                                                              100 HOURS

SP2        Change engine oil

SP3        Change lubricating oil filters

SP4        Check air cleaner

SP16       Check and clean radiator fins (industrial)


                                                              200 HOURS

SP7        Change primary filter element (Racor)

SP9        Change secondary fuel filter


                                                           EVERY 600 HOURS
SP6        Check valve clearances

SP11       Check injectors
SP14       Check and flush cooling system

SP17       Change impeller in seawater pump (marine)

SP19       Check condition of batteries with hydrometer


                                                             2400 HOURS

SP11       Check fuel injection pump

SP16       Check and clean heat exchanger
SP17       Check and clean reverse par oil cooler




                                                                10
                                                           SERVICING

                                                                       4.   Change oil when engine is warm.
LUBRICATION - 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 CC/CD/CE single viscosity oils.                    8.   Refill engine with recommended oil.
     b. API Service CC/CD/SF multi-viscosity oils.                     9.   Engine capacity oil filter is:
3. Use the proper weight oil for your average operation                     643 and 673           3.2 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: 24-02001
                                                                       2. Use a filter wrench to remove old filter. Dispose of
   Temperature             Viscosity           Viscosity
                                                                            filter in approved manner.
    Above 320F             SAE-30W             SAE 15-40W              3. Make sure the gasket from the old filter is removed
        (0-C)                                                               and discarded. Clean mount face.
                                                                       4. Spread a thin film of engine oil on the rubber gasket
     -10 to 320F           SAE-10W             SAE 10-30W                   on the new filter and screw it on nipple until gasket
     (-23 to O'C)                                                           meets the sealing sur-face.
                                                                       5. Using hands only, no wrench, tighten filter one-half
   Below -1 OOF             SAE-5W              SAE 5-20W                   turn farther. Overtightening can do damage to filter
       (-23-C)                                                              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 level.Add additional oil if necessary.
4. Some increase in oil consumption may be expected                    SP4. AIR CLEANER
     when SAE 5W and SAE 5-20W 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 in,the crankease with the dipstick.                  soapy water. Rinse and dry thoroughly before
     The oil level must be in the waffled area on stick.                    reinstalling.
     Never allow the level to go below this area. Follow the           NL643:
     lubrication recommendations above.                                     Element cannot be cleaned. Replace it when necessary.
                                                                            Part number: 408620002
SP2. OIL CHANGES                                                       IMPORTANT: Make absolutely sure no impurities enter the
1. The set is delivered with special break-in 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. V-BELTS
     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 V-belt 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 required.




                                                                  11
                                                           SERVICING


     pulleys. The tension is correct if the belt can be
     depressed about 3/16 in. (5rrim.)
RETIGHTENING CYLINDER HEAD BOLTS
1 . Re-tighten 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. 26-29 ft/Ibs (3.5-4.0 kg/m)                       Figure 7. Valve Adjustment

                                                                      FUELS-GENERAL
                                                                      1. Use only clean, high quality fuels of the following
                                                                           specifications, 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 5,500 ft. (1500 meters.)
                                                                      2. Use fuel having less that 1 % sulphur (preferably less
SP6. VALVE CLEARANCES
                                                                           that 0.5%.)
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. ASTM-D975-60T No. 4-D and higher
Turn until the # 1 cylinder inlet valve starts to open and the                           number fuels.
exhaust 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 matter
clearance 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 day's
exhaust valves with the adjustment screw. Clearance on                           operation. This will reduce condensation.
both intake and exhaust valves should be 0.008 in. (0.2               SP7-9. 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 separator.
valves 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 necessary.
7.2-8.7 ft/lb (1-1.2 kg/m).
                                                                           b. Change the element as often as necessary or
                                                                                 every 200 hours
.




                                                                 12
                                                          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 immediately.
2.   Change secondary fuel filter every 200 hours.                   for leaks.
     a. Remove the spin-on filter by turning it
            counter-clockwise 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
            two-thirds of a turn by hand. Do not overtighten.
3.   Fuel filter part number is:
     M643 and 673            24-52020
     NL643                   360720020
SP1O. BLEEDING THE FUEL SYSTEM

CAUTION: Escaping diesel fuel under pressure can
penetrate skin, causing serious personal injury. Before
disonnecting lines, be sure to relieve all pressure. Before          Figure 8. Fuel System
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            SP11. INJECTOR SERVICE
cardboard 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 isn't administered immediately.                         injection repair station.
1. The fuel system. is self-bleeding. 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".
                                                                     9.)
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 one-at-a-time.
                                                                     d.      Remove the return line retaining bolts (Figure 11.)
                                                                     Remove the retum line (Figure 12.)
                                                                     e.             Unscrew and remove the injectors (Figure
                                                                               13.)
                                                                     NOTE: Do not use pry bars to remove injectors from
                                                                     cylinder head
.




                                                                13
SERVICING




  14
                                                          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 sets-Be 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

5.
     for testing and service.
     Injector installation:
                                                                      !    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 ft/Ibs (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: Overtightening 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 22-30 ft/bs.                                            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 extreme
SP12.INJECTIONPUMP                                                           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. (2.5 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 (0.5 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 specially-trained                     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




                                                                 15
                                                           SERVICING



                                                                    5.   Replace the cover using a new gasket.
INDUSTRIAL:
   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 discoloration.
   c. Close the radiator drain and continue flushing                   The maintenance and operation recommendations for
       until water from engine drain is clear. Open all                the generator end are in a separate Owner's 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 - GENERAL
MARINE AND INDUSTRIAL:                                              1 . Never switch battery switch off or break the circuit
2. Use 50% water/50% 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.
   year-round 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.                                           alternator.
2. 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. Re-assemble. 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 impeller.
NOTE: Place some kind of protection under the
screwdrivers 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




                                                               16
                                                            SERVICING

2.     To check the glow plugs, loosen the current carrying
                                                                        SP18-19. BATTERY CARE
       flat wire between the plus-poles of the glow poles
       (Figure 16.) Connect a DC test bulb between the                  1. Check electrolyte level every 50 hours or once per
       plus-pole of the battery and the plus-pole of the glow               month. Add distilled water to manufacturer's
       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, OUT-OF-SERVICE
2. 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 antifreeze-water mixture. If refilling, start
6. Sealed batteries: See manufacturer charging and
                                                                            the engine and run to circulate the antifreeze.
     booster instructions.
                                                                        2. Fill fuel tank or add biocide as per manufacturer's
                                                                            instructions.
                                                                        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 surfaces.
Figure 17. Battery Connections




                                                                   17
                                              A.C. GENERATOR - TFIII




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                                                                                   M/NL 643 P/N 22-68312
3. Frame                                                                                            M673 P/N 22-48011
4. Ventilation cover                                                                         2. Fuse for AVR, P/N 22-68309
5. Attaching screw                                                                           3. Output terminal board
6. Carbon brush assembly, P/N 22-68304                                                       4. Circuit breaker
7. Attaching screw                                                                           5. Control panel and hour meter (ind. only)
8. Ball bearing, P/N 22-68305                                                                6. Automatic voltage regulator (AVR)
9. Ventilation cover                                                                         7. Control terminal board
                                                                                             8. Connector

GENERAL
1. 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. 19,2) and electrical output voltage is controlled
   electrical power.                                                       by the automatic voltage regulator (AVR) located in
                                                                           the control box (Fig. 20,6.)




                                                             18
                                              A.C. GENERATOR - TFIII

CONNECTIONS
1. 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 Output.




Figure 21. Control Terminal Board, 120 Volt Output,




                                                                 Figure 24. Output Terminal Board, 240 Volt output.


                                                                 4. 120/240 Volt Output
                                                                 a) Connect the control terminal board for 240 volts (Figure
                                                                     25).

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
                                                                      circuits.




                                                            19
                                                A.C. 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 28).




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 trouble-free 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 possible.
VENTILATION
   Good ventilation is important for proper generation
       operating. When installing the generator set, bc
       sure the ambient temperature does not exceed
       40C(104F) during operation.
MAINTENANCE
   Proper and effective maintenance is required to ensure          Figure 29. Hand Trimmer Location
         trouble-free 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.




                                                              20
                                                  A.C. GENERATOR - TFIII

b. To flash the field and build the residual    magnetism,
apply 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 ruined.




Figure 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
           discoloration.                                                        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 10,000 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 characteristics.
           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 3,000 hours.




Figure 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 o'clock and is
           held in position by 2 screws (Figure 32). Remove
           screws and unplug leads.




                                                                 21
                                            A.C. GENERATOR - TFIII




Figure 34. A VR Fuse Holder


10. Parts: See Parts Book for Complete List
     a. Fuse for main circuit:
           M/NL 643 P/N 22-68312
           M673 P/N 22-48011
     b. Fuse for AVR sensing circuit:
           P/N 22-68309
     c. Bearing: P/N 22-68305
     d. Brush assembly: P/N 22-68304
11. Test Specifications: Sec Wiring Diagram.
     a. Resistance of J-K: 16.6 ohm at 20C (68F)
     b. Resistance of A-B: 0.25 ohm at 20C (68F)
     c. Resistance of UI-V2: 0.56 ohm at 20C (68F)
     d. No load voltage setting: 242V or 121V at 62 Hz
           with cold generator.




                                                         22
                                                      TROUBLESHOOTING

               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 element.
ENGINE                                                                   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 operation.



                                                                  23
                                                   TROUBLESHOOTING

                       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 thermostats.
Engine 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.                                          Break-in 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.




                                                              24
                                                                                     NORTHERN LIGHTS MARINE DATA

MODEL..............................................................................ALL ....................................................... M643 ...........................................................................M673

kW/ RPM / Hz ....................................................................... ............................... 5 / 1800 / 60 .......................3.5 / 1500 / 50 ................. 6 / 1800 / 60 ....................4.8 / 1500 / 50

General Information
Cylinders ................................................................................ 3
Displacement .......................................................................... .............................37.6 in3(.617L) ................................. .......................... 41.1 in3 (.676L)
Cycle ..................................................................................... 4
Bore ......................................................................................... .............................2.52 in (64mm) .................................. ...........................2.64 in (67mm)
Stroke ........................................................................ 2.52 in (64mm)
Rotation (Facing Flywheel) ......................................counterclockwise
Compression Ratio.............................................................. 24:1
Crankcase Capacity.................................................. 2.9 US qts. (2.8L)
Aspiration..........................................................................Natural
Dry Weight Complete Unit .......................................345 lbs (157 kg)............................ ............................................... ......................... 352 lbs. (160 kg)
Height .......................................................................19.6 in (498 mm)
Width ....................................................................... 17.2 in (437 mm)
Length ...................................................................... 29.6 in (683nim)

Cooling System
Approx. Cooling System Capacity ........................... 2 US qt (1.89L)
Minimum Through-Hull Diameter ............................. .75 in (19mm)
Seawater Pump Inlet Hose I.D.................................... .75 in (19min)
Minimum Seawater Discharge.................................... .75 in (19mm)
Heat Rejection to Jacket Water............................................... ..............................500 BTU/min. ................................... ............................ 600 BTU/min
Freshwater Pump Capacity .................................................... ..............................5.0 U.S. GPM ....................... 4.1 U.S. GPM ................5.0 U.S. GPM ...................4.1 U.S. GPM
...... .......................................................................................... ............................. (15.77 L/min.).......................(18.92 L/min.) ............... (15.77 L/min.) .................. (18.92 L/min.)
Max. Seawater Pump Suction Head ............................ 39 in. (1 m)
Seawater Pump Capacity ....................................................... ............................... 9 U.S. GPM ........................7.5 U. S. GPM ................. 9 U.S. GPM..................... 7.5 U.S. GPM
...... .......................................................................................... ................................ (34 L/min.) ..........................(28.4 L/min.).................... (34 L/min.) .......................(28.4 L/min.)
Keel Cooler (Round) Tube Length................................ 5 ft (1.5m)
Keel Cooler Head Diameter.................................. 3/4 in NPT (19.1 mm)
Keel Cooler Water Hose ID
Discharge and Suction ................................................1.0 in (25 mm)

Electrical
Min. Battery Capacity @0F (-17C)...............................440 cca
Battery Cable Size........................................................ #2 up to 10 ft
Instrmnt. Harness Length (Standard)............................ 20 ft (6.1m)
Starting Voltage, Negative Ground ...................................... 12

Air
Generator Cooling Air Flow................................................... ......................... 200 ft3 (5.7m3)/min...............166 ft3 (4.7 m3)/min........ 200 ft3 (5.7m3)/min............166 ft3 (4.7 m3)/min.
Consumption ........................................................................... .........................19.6 ft3 (.56m3)/min. .............16.3 ft3 (.46m3)/min........21.4 ft3 (.61m3)/min. ...........17.8 ft3 (.5m3)/min.
Minimum Engine Roorn Vent, .............................................. .............................5.2 in2 (34 cm2) .....................5.7 in2 (37 cm2)
Maximum Exhaust Back Pressure, ........................ 48 in (122 cm)H2O
Wet Exhaust Elbow OD ..........................................1.5 in (38 mm) OD
Dry Exhaust Elbow ID.................................................. 1.25 in NPT

Max. Intrmtnt. Eng. Oper. Angle
Front or Rear Down ............................................................. 15

Fuel
Minimum Suction Line ........................................................... ............................ 1/4 in (6.35mm)
Minimum Return Line ............................................................ ............................ 1/4 in (6.35mm)
Max. Fuel Pump Head  Suction............................................ ............................... 39 in (1.0m)

Performance Data
Rated Flywheel HP ................................................................. ...................................... 7..3......................................... 5.0 ..................................8.7 ......................................7.0
Generator Rating .................................................................... ............................... 5 kW (60hz) ...........................3..5 (50hz) .....................6kW (60hz) ......................... 4.8 (50hz)
Specific Fuel Consumption......................................... 0.444lbs/hp/hr
......at Maximum Load .................................................(270 g/kw/hr)
Approximate Fuel Rate...........................................................            ................. 0.45 US GPH ....................... O.3I US GPH ................. 0.54 US GPH..................... 0.43 US GPH
                                                                                                                         ............... (l. 181 L/hr.) ..................... (2.0 L/hr).......................... (1.66 L/hr)
......at Maximum Load ............................................................ ................................ (1.73 L/hr)




                                                                                                                                  25
                                                                                     NORTHERN LIGHTS INDUSTRIAL DATA

Model Number ...................................................................... ......................................... ............................................... ................................. NL643

kW Output at 60 Hz, 1800 RPM 1 .................................................................. 5
120/240 Volt Amperage ......................................................... ......................................... ............................................... .................................. 20.8A
120 Volt Amperage ................................................................ ......................................... ............................................... .................................. 41.6A
Phase/Optional Phase.............................................................. ......................................... ............................................... .................................... 1/--

kW output at 50 Hz, 1500 RPNI 1 ............................................................... 3.5
110/220Volt Amperage . ........................................................ ......................................... ............................................... .................................. 15.9A
240 Volt Amperage................................................................. ......................................... ............................................... .................................... NA
110 Volt Amperage ................................................................ ......................................... ............................................... ..................................31.8 A
Phase/Optional Phase ............................................................. ......................................... ............................................... .................................... 1/--

Engine
Lugger model diesel ............................................................... ......................................... ............................................... ................................... L643
Cylinders ................................................................................ ......................................... ............................................... ...................................... 3
Displacement .................................................................... in 3 (L) .................................. ............................................... .............................. 37.6 (0.61)
Bore ................................................................................. in (mm) .................................. ............................................... ................................. 2.5(64)
Stroke .............................................................................. in (mm) .................................. ............................................... ................................. 2.5(64)
HP @ 1800 RPM .................................................................. ......................................... ............................................... .....................................7.5
Approx. fuel rate @ 1800 RPM,
with a full load ..........................................................US gal/hr (L/hr) ............................ ............................................... ............................... 0.51 (1.9)
with a half load ....................................................................... ................................ .......................................... US gal/hr (L/hr) ................... 0.3(l.1)

Dimensions Data
Exhaust outlet ................................................................. in (mm) .................................. ............................................... ....................................... ....................................1.25 (32)
Fuel inlet and return ........................................................ in (mm) .................................. ............................................... ....................................... .................................5/16 (8) hose
Length ............................................................................. in (mm) .................................. ............................................... ....................................... ................................... 33 (1834)
Width ............................................................................... in (mm) .................................. ............................................... ....................................... .................................... 15 (386)
Height .............................................................................. in (mm) .................................. ............................................... ....................................... .................................... 25 (650)
Approx. dry weight ..........................................................lbs (kg) .................................. ............................................... ....................................... ................................... 370 (169)

Note 1. Based on 1.0 unity power factor. Deratings: 3% per 1000 ft. over 500 ft. above sea level. 1% for every 10 over 85F.




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D.C. WIRING DIAGRAM




       27
A.C. WIRING DIAGRAM




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