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Northern Lights ONL673L4 Operator's Manual

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OPERATOR'S
MANUAL
ONL673L4
For Models:
NL673L4 & NL673L4E

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Summary of Contents for Northern Lights ONL673L4

  • Page 1 OPERATOR’S MANUAL ONL673L4 For Models: NL673L4 & NL673L4E...
  • 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 8/15...

  • Page 4: Introduction

    Cylinders series of generator set 67 mm 4 = Tier IV compliant E = Electronic 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 Wear suitable authorized moving parts have stopped hearing protection, such before making any adjustments, as earmuffs or plugs to connections, or performing protect against loud noises. any other type of service to the engine or other driven equipment. ONL673L4 8/15...
  • 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 Slowly loosen cap to relieve pressure before 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 4. Fuel Filter Vent 9. Dipstick 14. Exhaust Outlet 19. Voltage Regulator Breaker 5. Lube Oil Fill 10. Oil Filter 15. Starter 20. Fuel Supply & Return Connections (On top of Rocker Cover) 11. Fuel Lift Pump 16. Alternator ONL673L4 8/15...

  • Page 12: Industrial Generator

    21. Voltage Regulator Breaker 4. Fuel Filter Vent 10. Oil Filter 16. Starter 22. Fuel Suple & Return 5. Lube Oil Fill 11. Fuel Lift Pump 17. Electrical Control Unit Connections 6. Injection Pump 12. Secondary Fuel Filter 18. Alternator ONL673L4 8/15...

  • Page 13: S-1B Control Panel

    RUN position. To stop the engine, hold the switch in the STOP position. NOTE: The rocker switch is used on Series 1 panels only, and has a light that glows when the set is running. 3. HOUR METER Keeps track of engine running time. ONL673L4 8/15...

  • Page 14: Operating Procedures

    4. Turn the control switch to off. NOTE: The battery switch must always be kept ON while the engine is running. If the switch is turned OFF while the engine is running, the battery charging regulator could be ruined. ONL673L4 8/15...

  • 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

    1) Perform all maintenance once a year even if hour level has not been reached. 4) After first 50 hours and at 100 hours. 2) Whenever necessary. 5) Clean injection nozzles every 1500 hours. 3) More often if necessary. 6) Replace element every 1000 hours. ONL673L4 8/15...
  • Page 17 Service Record Notes ONL673L4 8/15...

  • Page 18: Servicing

    6. Fill engine with recommended oil. Start engine and check for leakage. Stop engine, wait 3 minutes, and check oil level. Add additional oil if necessary. 7. The oil filter part numbers are: #24-08001 - NL673L2 and NL673L3 #24-02001 - NL673K and NL673L ONL673L4 8/15...

  • Page 19: Air Filter

    5. Repeat steps 3 and 4 for each cylinder. Each set of low idle. valves must be adjusted individually. 6. Replace the rocker arm cover. Tighten cover nuts to 5 - 8 ft/lbs (0.8 - 2.3 kg/m). Figure 5: Belt Tension ONL673L4 8/15...

  • Page 20: Fuels - General

    Keep dirt, scale, water, and other foreign matter NL673K, L, L2, L3, L4 – #24-52020 out of fuel. b. Avoid storing fuel for long periods of time. c. Fill the fuel tank at the end of each day’s operation. This will reduce condensation. ONL673L4 8/15...

  • Page 21: Bleeding The Fuel System

    Pump hand primer “B” on fuel lift pump until pure fuel (no bubbles) escapes from bleed screw “A”. Tighten bleed screw “A”. 3. Loosen bleed screw “C”. Pump hand primer “B” on fuel lift pump until pure fuel (no bubbles) escapes from bleed screw “A”. ONL673L4 8/15...
  • Page 22 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 8/15...

  • 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

    6. Do not polarize the alternator or regulator. 7. A D.C. circuit breaker protects your control panel and wiring harness. It is located in the side of the generator junction box. ONL673L4 8/15...

  • Page 25: Glow Plugs

    (+) terminal of main battery. Then, connect negative (-) terminal of booster battery to ground on the engine block ( see Figure 16 4. Remove booster battery after starting engine. 5. Sealed batteries: See manufacturer charging and booster instructions. Figure 16: Battery connections. ONL673L4 8/15...
  • Page 26 11. Shaft 12. Ventilation Cover CONTROL BOX (Figure 19) Control Terminal Board Automatic Voltage Regulator (AVR) 12 Volt DC Circuit Breaker AC Circuit Breaker AVR Circuit Breaker Output Terminal Board Figure 18: Generator Components. Figure 19: Control Box Components. ONL673L4 8/15...
  • Page 27 240 Figure 22 Figure 22: Control Terminal Board, 240 Volt Output Figure 25: Output Terminal Board, 120/240 Volt Output b. Connect U2 to V1 on the output terminal board Figure 23 ONL673L4 8/15...

  • 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 To protect the generator and AVR from unbalanced loads and over loads, two 20 amp breakers are placed in the output circuit and one 3 amp breaker is placed in the AVR sensing circuit ( Figure 29 Figure 29: Breaker Locations. ONL673L4 8/15...

  • 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 8/15...

  • Page 31: Lamp Codes

    Case 2. Error combination (when 2 errors occur at the same time): Code 13: 13 means Long, Short, Short, Short Code 04: 04 means Short, Short, Short, Short Long Short Short Short Short Short Short Short 1 Cycle ONL673L4 8/15...

  • Page 32: Engine

    • See “Engine Overheats” in next category. Below normal engine temperature • Remove and check thermostat. Improper valve clearance • Reset valves. Best done by dealer. Dirty or faulty injection nozzles • Replace injectors. Best done by dealer. • See your local dealer. ONL673L4 8/15...
  • 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 8/15...
  • 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 8/15...

  • Page 35: Wiring Diagrams

    8-16-11 Wiring Diagrams ONL673L4 8/15...
  • Page 36 8-16-11 Wiring Diagrams ONL673L4 8/15...
  • Page 37 4-30-18 Wiring Diagrams ONL673L4 8/15...
  • Page 38 4-30-18 Wiring Diagrams ONL673L4 8/15...
  • Page 39 4-30-18 Wiring Diagrams ONL673L4 8/15...
  • Page 40 8-16-11 Wiring Diagrams ONL673L4 8/15...
  • Page 41 8-16-11 Wiring Diagrams ONL673L4 8/15...
  • Page 42 Wiring Diagrams ONL673L4 8/15...
  • Page 43 8-16-11 Wiring Diagrams ONL673L4 8/15...
  • Page 44 4-9-12 Wiring Diagrams ONL673L4 8/15...
  • Page 45 7-9-13 Wiring Diagrams ONL673L4 8/15...
  • Page 46 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. © 2015 All rights reserved. Litho USA.

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