Northern Lights NL673L4 Operator's Manual
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Northern Lights NL673L4 Operator's Manual

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OPERATOR'S MANUAL
OPERATOR'S MANUAL
ONL673L4
For Models: NL673L4 and NL673L4E
www.northern-lights.com

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Summary of Contents for Northern Lights NL673L4

  • Page 1 OPERATOR’S MANUAL OPERATOR’S MANUAL ONL673L4 For Models: NL673L4 and NL673L4E www.northern-lights.com...
  • Page 2 This label is to state: ULTRA LOW SULFUR FUEL ONLY Northern Lights is providing this label for application to the fuel inlet of the fuel supply tank for each engine or generator set. This is to be applied by the installer of the engine or gen set, or by the manufacturer of the equipment that the engine or gen set is installed in.

  • Page 3: Table Of Contents

    This publication is the property of Northern Lights, Inc. It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc. © Northern Lights, Inc. All rights reserved. Litho U.S.A. Publication number ONL673L4 5/21...

  • Page 4: Introduction

    E = Electronic controls generator set 67 mm 4 = meets US EPA Tier IV emissions Northern Lights industrial generator set with a 673 Northern Lights industrial generator set with a NL673L4 NL673L4E engine, TF-276D series generator end, AVR, and 673 engine, TF-276D series generator end, AVR, Tier IV compliant.

  • Page 5: Warranty

    For replacement signs, ALWAYS STOP ENGINE proper placement of safety signs or clarification on any BEFORE FUELING safety issue, consult your Northern Lights dealer or the MACHINE. Always fill factory. portable fuel tank outdoors. There can be additional safety information contained Never fuel a hot engine.
  • Page 6 Updated 4-9-12 Safety Rules (Continued) Prevent accidental discharge of starting fluids by Operating equipment requires the full attention of storing all cans in a cool, safe place, away from sparks the operator. Do not use radio or music headphones or open flame. Store with cap securely on container. while operating machinery.
  • Page 7 Among the potentially hazardous with a metal object. Use a volt-meter or hydrometer. chemicals that may be used with Northern Lights Frozen batteries may explode if charged. Never products are lubricants, charge a battery that has not been allowed to warm to at least 16 o C (60 o F).
  • Page 8 Follow the procedures hands. Slowly loosen cap to relieve pressure before and use appropriate equipment exactly as recommended. opening fully. Contact your Northern Lights dealer or Northern Lights factory for MSDS’s used on Northern Lights products. Avoid High Pressure Fluids WARNING...
  • Page 9 The asbestos used in these components is usually environment and lead to unsafe working conditions. found in a resin or otherwise sealed. Normal Potentially harmful waste used in Northern Lights handling of these components is not dangerous, equipment can include oil, fuel, coolant, filters and as long as airborne dust containing asbestos is not batteries.

  • Page 10: Lock Out / Tag Out Procedures

    Scope During maintenance, repairs or retooling of a Northern Lights generator set, simply turning the machine off or unplugging it while it is being worked on does not give enough protection to others who are not performing the maintenance or repair.
  • Page 11 Updated 8-24-15 Industrial Generator Component Locations Figures 2-A and B: NL673L4 Service Side and Non-service side 1. Junction Box 6. Injection Pump 2. S-1B Control Panel 7. Coolant Fill 12. Secondary Fuel Filter 17. Engine DC Breaker 3. Air Filter 8.

  • Page 12: Industrial Generator

    Updated 8-24-15 Industrial Generator Component Locations Figures 2-A and B: NL673L4E Service Side and Non-service side 1. Junction Box 7. Coolant Fill 13. Vibration Mount 19. Engine DC Breaker 2. S-1B Control Panel 8. Radiator Shroud 14. Warning Light 20. AC Circuit Breaker 3.

  • Page 13: S-1B Control Panel

    Control Panel 1. PREHEAT/ SHUTDOWN BYPASS SWITCH This switch serves two functions: 1. Preheats the fuel before beginning the starting process. Press switch for 10-20 seconds before attempting start-up. 2. Bypasses the safety shutdown feature during the starting process. Keep switch engaged while starting engine, and for 2 to 3 seconds afterwards, allowing oil pressure to build beyond the shutdown set point.

  • Page 14: Operating Procedures

    Updated 1-10-13 Operating Procedures STARTING BREAK-IN PERIOD 1. Hold the Shutdown Bypass-Preheat switch in the 1. The first 100 hours on a new or reconditioned ON position for 10 to 20 seconds before starting engine are critical to its life and performance. a cold engine.

  • Page 15: Shutdowns And Alarms

    The parts are (ECU) detects a problem with one of its sensors. available from your local Northern Lights dealer. These problems are indicated by a flashing trouble code on the ECU warning light. For the NL676L4E, 2.

  • Page 16: Servicing Schedule Chart

    Updated 7-9-13 Servicing Schedule Chart The Servicing Schedule Chart 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’ column. DAILY: Change primary fuel filter element Check oil level in engine...
  • Page 17 Service Record Notes ONL673L4 5/21...

  • Page 18: Servicing

    Updated 7-9-13 Servicing SP2. OIL CHANGES LUBRICATION - GENERAL 1. Use only clean, high quality lubricants stored in 1. The set is delivered with special break-in oil. clean containers in a protected area. Change the engine oil and oil filter after 50 hours 2.

  • Page 19: Air Filter

    Updated 7-9-13 Servicing SP4. AIR CLEANER 1. Inspect air cleaner every 200 hours. In dusty conditions, check more often. 2. Industrial sets: the element cannot be cleaned. Replace it when necessary. Part number is: NL673K, L, L2, L3 – #24-27301 4.

  • Page 20: Fuels - General

    Servicing FUELS - GENERAL SP7-9. FUEL FILTERS 1. Use only clean, high quality fuels of the following 1. Your generator set should have a primary fuel filter specifications, as defined by ASTM designation installed. We recommend the Racor brand of fuel D975 for diesel fuels: filter-water separators.

  • Page 21: Bleeding The Fuel System

    Servicing SP10. BLEEDING THE FUEL SYSTEM CAUTION: Escaping diesel fuel under pressure can penetrate skin causing serious personal injury. Before disconnecting lines be sure to relieve all pressure. Before applying pressure, be sure all connections are tight and lines, pipes and hoses aren't damaged. Fuel escaping from a very small hole can be almost invisible.
  • Page 22 Servicing Figure 8: Remove delivery line flare nuts. Figure 12: Unscrew injector. Figure 9: Remove delivery lines. Figure 13: Remove and replace copper sealing washer. Figure 10: Remove return line nuts. Figure 14: Reinstall injector. Torque to proper tightness. Figure 11: Remove return line. ONL673L4 5/21...

  • Page 23: Injector Service

    1. Injectors should be checked every 1000 hours. is difficult to give a definite interval for checking the Check should be made by a Northern Lights dealer injection pump. But as a rule, pump settings, or local injection repair station.

  • Page 24: Cooling System Flushing

    Updated 5-13-21 Servicing SP14. COOLING SYSTEM FLUSHING 2. Here are acceptable water quality specifications: 1. Flush the cooling system every 2500 hours or every Parts Grains Contaminates per Million per Gallon 12 months, whichever comes first. 2. Industrial sets: Maximum Chlorides Remove radiator cap and open drain cocks on radiator and engine block.

  • Page 25: Glow Plugs

    Servicing GLOW PLUGS SP 18-19. BATTERY CARE 1. Each cylinder is supplied with a glow plug which 1. Check electrolyte level daily. Add distilled water to serves to heat the combustion chamber. manufacturer’s recommended level. 2. To check the glow plugs, loosen the current 2.
  • Page 26 Updated 4-9-12 AC Generator - TF-276D GENERAL A Generator Set includes the engine, the generator, and the control or “J” box ( Figure 17 The generator and the control or “J” box produce the electrical power. Generator excitation is provided by residual magnatism and electrical output voltage is controlled by the automatic voltage regulator (AVR) located in the control box (...
  • Page 27 AC Generator - TF-276D CONNECTIONS 1. 120 Volt Output: a. 120 volt output can be selected by connecting the terminals of the control terminal board to 120 Figure 20 Figure 23: Output Terminal Board, 240 Volt Output 3. 120/240 Volt Output a.

  • Page 28: Generator End

    Dust and foreign material may reduce the flow of d. Generator bearing should be replaced by your cooling air, reducing heat dissipation and causing Northern Lights dealer at 10,000 hours. the generator to overheat. 6. Check the brushes b. If electrically conductive debris accumulates on a.
  • Page 29 AC Generator - TF-276D 7. Replacing Brushes 9. Parts: See Parts Book for complete list a. Shut down the generator. Remove four screws a. Bearing and end cover of the generator. Part #22-68305 b. Brush assembly is white plastic with two wires b.

  • Page 30: Troubleshooting

    • Clean and tighten battery and harness plug connections. Sulfated or worn out batteries • Check specific gravity and electrolyte level of each battery. Dead Battery • Charge battery. If you cannot correct problems with these procedures, see your Northern Lights dealer. ONL673L4 5/21...

  • Page 31: Lamp Codes

    Updated 11-26-13 Troubleshooting Lamp Flashing Pattern when Error has Occurred Before starting the engine: 1. Check all connections before powering the Engine ECU on. 2. When the Engine ECU is powered on (assuming no failures), the lamp will flash one time and then off. 3.

  • Page 32: Engine

    Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION(S) Engine Hard to Start Improper starting procedure • See starting section of this manual. Take or Will Not Start special note of Bypass Switch operation. No fuel • Check level of fuel in fuel tank. Low battery output •...
  • Page 33 Below Normal Thermostats not working properly • Check thermostats. Engine Temperature Temperature gauge • Check water temperature with thermometer. not working properly If you cannot correct problems with these procedures, see your Northern Lights dealer. ONL673L4 5/21...
  • Page 34 Cold engine • Warm up engine to normal operating temperature. Defective thermostat • Remove and check thermostat. Engine injection timing off • See your dealer. If you cannot correct problems with these procedures, see your Northern Lights dealer. ONL673L4 5/21...

  • Page 35: Wiring Diagrams (Current Production) Ac Electrical

    Updated 3-4-20 AC Wiring Diagrams ONL673L4 5/21...
  • Page 36 Updated 3-4-20 AC Wiring Diagrams ONL673L4 5/21...
  • Page 37 Updated 3-4-20 AC Wiring Diagrams ONL673L4 5/21...
  • Page 38 Updated 3-4-20 AC Wiring Diagrams ONL673L4 5/21...
  • Page 39 Updated 3-4-20 AC Wiring Diagrams ONL673L4 5/21...

  • Page 40: Dc Electrical

    Updated 3-4-20 DC Wiring Diagrams ONL673L4 3/18...
  • Page 41 Updated 3-4-20 DC Wiring Diagrams ONL673L4 3/18...
  • Page 42 Updated 3-4-20 DC Wiring Diagrams ONL673L4 3/18...

  • Page 43: Panel Diagrams

    Updated 3-4-20 Panel Wiring Diagrams ONL673L4 5/21...
  • Page 44 Updated 4-20-20 Panel Wiring Diagrams ONL673L4 5/21...
  • Page 45 Updated 4-20-20 Panel Wiring Diagrams ONL673L4 5/21...

  • Page 46: Appendix (Non-Current Production Diagrams) Ac Electrical

    Updated 8-16-11 AC Wiring Diagrams ONL673L4 5/21...
  • Page 47 AC Wiring Diagrams ONL673L4 5/21...
  • Page 48 Updated 8-6-11 AC Wiring Diagrams ONL673L4 5/21...
  • Page 49 Updated 8-6-11 AC Wiring Diagrams ONL673L4 5/21...

  • Page 50: Dc Electrical

    Updated 8-6-11 DC Wiring Diagrams ONL673L4 5/21...
  • Page 51 Updated 7-9-13 DC Wiring Diagrams ONL673L4 5/21...

  • Page 52: Panel Diagrams

    Updated 8-6-11 Panel Wiring Diagrams ONL673L4 5/21...
  • Page 54 4420 14th Ave. NW., Seattle WA 98107 Tel: (206) 789-3880 • 1-800-762-0165 • www.northern-lights.com Northern Lights and Lugger are registered trademarks of Northern Lights, Inc. © 2021 All rights reserved. Litho USA.

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Nl673l4e

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