OM673L3
OM673L3
OM673L3
OPERATOR’S MANUAL
Northern Lights
4420 14th Avenue N.W.
Seattle, WA 98107
Tel: (206) 789-3880
Fax: (206) 782-5455
Printed in U.S.A.
PART NO.: OM673L3 6/10
OPERATOR'S MANUAL
for Models
M673l3 and M673ld3
Read this operator's manual thoroughly before starting to operate your equipment.
This manual contains information you will need to run and service your new unit.
Table of Contents
Proprietary Information
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 OM673L3 06/10
OM673L3 6/10
1
revised 4/9/10
Introduction
Servicing of marine engines and generator sets Failures begin with minor problems that are
presents unique problems. In many cases boats cannot overlooked and become amplified when not
be moved to a repair facility. Marine engines cannot corrected during routine maintenance.
be compared to the servicing of automobiles, trucks or
even farm equipment. Failures often occur in remote As operator, it is your obligation to learn about your
areas far from competent assistance. Marine engines equipment and its proper maintenance. This is not a
are taxed far more severely than auto or truck engines; comprehensive technical service manual. Nor will it
therefore, maintenance schedules must be adhered to make the reader into an expert mechanic. Its aim is
more strictly. to aid you in maintaining your unit properly.
Unit Identification
MODELS INCLUDED
This manual covers the operating instructions for:
M673L3 and M673LD3 marine generator sets.
Model Numbers
Model numbers give the unit's application, block model, aspiration, and RPM:
M 673 L, D, 3
M - Northern Lights marine generator set Model number of engine block L - Long Stroke
+ Bore Cylinders + D - Series designation
67 mm 3 3 - Tier III
M673L3 = Northern Lights marine diesel generator set with a 673 engine long stroke, TF-276D
generator end, Tier III.
M673LD3 = Northern Lights marine diesel generator set with a 673 engine long stroke, TF-276D
generator end, Tier III, 5 kW.
Serial Numbers
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 in Figure 1.
Note, an additional label with the set serial number is placed on the
upper front corner of the generator junction box.
OM673L3 6/10
2
Warranty
A warranty registration certificate is supplied NOTE: If the warranty is to apply, the servicing
with your set. It entitles the original purchaser of instructions outlined in this manual must be
our equipment to a warranty covering material followed. If further information is needed, please
or assembly faults. The extent of coverage is contact an authorized dealer or the factory.
described in the Limited Warranty Statement. We
recommend that you study the statement carefully.
Safety Rules
CAUTION: Accident reports show that careless use of engines causes a high percentage of accidents.
You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.
• Never leave engine without proper security. • Use caution in handling fuel. Never refuel a hot
or running engine. Do not smoke while filling
• Turn the coolant tank cap slowly to relieve
fuel tank or servicing fuel system.
pressure before removing. Add coolant only
when the engine is stopped and cool. • Keep your hands, feet, hair and clothing away
from power-driven parts.
• Mount a fire extinguisher near engine.
• Check for any loose electrical connections or
• Always disconnect the battery ground strap
faulty wiring.
before making adjustments.
• Engines should be operated only by
• Operate engines in properly ventilated areas.
knowledgeable, qualified personnel.
• Keep trash and other objects away from engine.
• Look completely around engine to make sure
• Escaping fluids under pressure can penetrate that everything is clear before starting.
your skin. Use a piece of cardboard or wood,
• Do not operate an engine that isn't in proper
not your hands, to search for leaks.
working order. If an unsafe operating condition is
• Avoid wearing loose clothing without a belt noted, tag the set and control panel so others will
when working around engines. also know about the problem.
• Do not oil or grease engine while it is running. • Provide first aid kits.
OM673L3 6/10
3
Marine Generator Component Locations
13
12 8
11 10 9
2 19
Figure 3: M673L2 Service Side. 18 4
14 15 16 17
20
29 21
22
23
24
28 27 26 25
OM673L3 6/10
4
Updated 6-24-10
13
12 8
11 10 9
2 19
Figure 3: M673L3 Service Side. 18 4
14 15 16 17
20
29 21
22
23
24
28 27 26 25
OM673L3 6/10
5
Updated 6-24-10
Control Panels
3. HOUR METER
Keeps track of engine running time.
7. A.C. VOLTMETER
Shows the generator output voltage.
OM673L3 6/10
6
Updated 6-23-10
Operating Procedures
1. The first 100 hours on a new or reconditioned 1. Hold the Shutdown Bypass-Preheat switch in the ON
engine are critical to its life and performance. position for 10 to 20 seconds before starting a cold
2. Constantly check the engine temperature and oil engine. Holding the switch too long can burn out the
pressure gauges (sets with Series 3 or 4 panels). glow plugs.
3. Oil consumption is greater during break-in as 2. While holding the Shutdown Bypass-Preheat switch
piston rings take time to seat. in the ON position, push the Engine Control switch to
4. Break-In Oil Changes: Change engine oil and the START position.
filter at 50 hours. Change oil and filter again at 3. As soon as the engine starts, release the start switch.
100 hours, then at every 250 hours (consult Then hold the bypass for 2-3 more seconds. Do not
Lubricants section for oil recommendation). crank the starter for more than 10 seconds consecu-
tively. If the engine fails to start with the first attempt,
Operating Instructions: be sure that it has stopped completely before re-
Maintain at least a 75% load on your generator engaging.
set for the first 100 hours. Vary the load will help NOTE: Excessive cranking of the starter on Marine
seat the rings. sets equipped with a water lift muffler can cause
engine damage. If the engine does not start after three
BEFORE STARTING 10-second cranks, remove the impeller from the raw
water pump. This will prevent the muffler from filling
1. Check the water level by removing the pressure with water and backfilling the exhaust line and engine.
cap from the expansion tank or radiator. In order to Once the engine starts, shut it off immediately and re-
give the cooling water an opportunity to expand, the install the impeller. Re-start the engine and check the
level should be about 1 in. (2.5 cm) below the filler exhaust overboard outlet for gushes of water.
cap sealing surface when the engine is cold. If using
an overflow bottle, the manifold should be full to the OPERATING
cap and the bottle should have coolant in it.
1. Units with Series 3 and Series 4 Control Panels: check
CAUTION: Use protective clothing and open gauges often. Oil pressure must be above 15 PSI. The
the filler cap carefully when the engine is warm D.C. voltmeter should read between 11 and 15 volts at
to prevent burns. 80°F (25°C) ambient temperature. The coolant tempera-
ture gauge must be between 167°F and 194°F (75°C to
2. Check the oil level in the crankcase with the 90°C). Check the A.C. voltage and frequency meters
dipstick. The oil level must be in the waffled area on (Series 4 panel). If the gauges deviate from normal
the stick. Never allow the level to go below this area. levels, shut down the generator set and investigate.
Always add the same viscosity of oil as is already in 2. Let the unit run unloaded for a 3 - 5 minute warm-up
the crankcase. period.
3. Check the fuel tank level and open any fuel valves. 3. Add electrical load.
4. Close the sea-cock, check and clean the sea strainer
and reopen the sea-cock. STOPPING
5. Place the battery switch in the ON position.
NOTE: The battery switch must always be kept 1. Remove electrical load from the generator set.
ON while the engine is running. If the switch is 2. Run the engine for a 3 to 5 minute cool down period.
turned OFF while the engine is running, the 3. Move the Engine Control switch to the STOP
battery charging regulator could be ruined. position momentarily.
4. Shut off the seacock, fuel valve, and battery switch.
OM673L3 6/10
7
page updated 8-27-09
Operating Procedures
1. Generator sets have shutdown systems to stop the 1. Northern Lights recommends that you keep the
engine in the event of high water temperature or low following spare parts on hand for field service. The
oil pressure. parts are available from your local Northern Lights
a. Other alarms and shutdowns are available as dealer.
optional equipment. Some marine models already have “On-Board-Kits,”
NOTE: Do not rely on your warning to the a handy box that contains the most common parts
exclusion of careful gauge monitoring. Watching you will need.
your gauges can prevent damage to the unit and 2. All owners should have the following:
dangerous power losses. a. Primary and secondary fuel filter elements
2. Do the following when your warning or shutdown b. Oil filters
system is activated: c. Air filter
a. Engage the preheat switch to check the d. Alternator belt
temperature gauge. e. Thermostat and gaskets
b. If above 205°F (96°C), use the Trouble Shoot- f. Raw water pump impeller & gaskets
ing Guide on page 25 to isolate the cause of the g. Glow plug
overheat. h. Injector and washer
3. If your set is operating a long distance from a
CAUTION: Do not remove the water fill servicing dealer, add the following:
cap of an overheated engine. Escaping high a. Complete set of injectors
temperature steam can cause severe burns. b. Copper washers for injector change
Allow the engine to cool and then remove the c. Complete set of glow plugs
cap slowly using protective clothing. d. Fuel lift pump
OM673L3 6/10
8
page updated 6-22-10
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: EVERY 500 HOURS:
SP1 Check oil level in engine SP8 Change primary fuel filter element
SP5 Check V-belt tension SP9 Change secondary fuel filter
SP7 Check primary fuel filter SP21 Inspect condition of exhaust elbow
SP13 Check cooling water level
Check sea strainer EVERY 1000 HOURS:
SP17 Check electrolyte in batteries SP4 Change air cleaner element
SP6 Check valve clearances
AFTER FIRST 50 HOURS: SP11 Check injectors
SP2/3 Change engine oil and filter SP16 Change impeller in raw water pump
SP6 Adjust valves
EVERY 2500 HOURS:
AFTER FIRST 100 HOURS: SP12 Check fuel injection pump
SP2/3 Change engine oil and filter SP14 Check and flush cooling system
SP15 Check and clean heat exchanger
EVERY 250 HOURS:
SP2/3 Change engine oil and filter
SP4 Check air cleaner
SP10 Bleed the fuel system
SP18 Check state of charge of batteries
OM673L3 6/10
9
Service Record Notes
OM673L3 6/10
10
Servicing
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. These lubricants are acceptable: of operation. Use Service CC 30 weight oil during
a. API Service CC/CD/CE single viscosity oils. the first 100 hours.
b. API Service CC/CD/SF multi-viscosity oils. 2. Change the oil and filter again at 100 hours using the
3. Use the proper weight oil for your average operation oil recommended in Figure 9. After this, change oil
temperature. and filter every 250 hours.
3. During intermittent cold weather operation, change
oil every 100 hours or six weeks, whichever comes
Air Single Multi-
Temperature Viscosity Viscosity first.
4. Change oil at any seasonal change in temperature
Above 32°F
(0°C)
SAE 30W SAE 15-40W when a new viscosity of oil is required.
5. Change oil when engine is warm.
-10 to 32°F 6. Dispose of waste oil in an approved manner.
SAE 10W SAE 10-30W
(-23 to 0°C)
7. Never use a flushing oil.
Below -10°F SAE 5W SAE 5-20W
8. Loosen the clamp on the oil change tube. Remove
(-23°C) cap. Drain oil. Replace the cap and tube.
9. Refill engine with recommended oil.
Figure 9: Lube Oils 10. Engine capacity with new oil filter is:
4. Some increase in oil consumption may be expected M673L3 & LD3 – 3.3 quarts (3.1 liters)
when SAE 5W and SAE 5-20W oils are used. Check
oil level frequently. SP3. CHANGING LUBE OIL FILTER
5. Never put additives or flushing oil in crankcase.
1. Change the lube oil filter every with every oil
SP1. CHECKING OIL LEVEL change.
2. Use a filter wrench to remove old filter. Dispose of
1. Check the oil level in the crankcase with the dip- filter in approved manner.
stick. The oil level must be in the waffled area 3. Make sure the gasket from the old filter is removed
on the stick. Never allow the level to go below this and discarded. Clean mount face.
area. Follow the lubrication recommendations above. 4. Spread a thin film of engine oil on the rubber gasket
on the new filter and screw it on nipple until gasket
meets the sealing surface.
5. Using hands only – no wrench – tighten filter
one-half turn farther. Overtightening can do
damage to filter housing.
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. Oil filter part numbers are:
OM673L3 6/10
11
Updated 6-23-10
Servicing
1. Inspect air cleaner every 250 hours. In dusty 1. Adjust valve clearance every 1000 hours.
conditions check more often. 2. Valve adjustments should be done if the cylinder
2. Inspect the element. If it is dirty, wash the element in head bolts have been re-tightened. Engine should be
soapy water. Rinse and dry thoroughly before cold and NOT running.
re-installing. Replace if necessary. Part number is: 3. To bring the No. 1 cylinder to top dead center in the
M673L3 & LD3 - #24-28003 compression stroke, align the timing mark; the top
mark of the crank pulley with that of the timing gear
NOTE: Make absolutely sure no impurities enter case. Remove the rocker arm cover and turn the
the engine while changing the element. Do NOT crankshaft foward and backward. If the inlet and
run the engine with the air cleaner removed. exhaust valves of the No. 1 cylinder do not move
it is in top dead center position. When the valves
SP5. V-BELTS move, or rock, turn the crankshaft one full turn and
align the top mark of the crank pulley with the top
1. Check the tension and wear on the V-belt daily. mark of the timing gear case.
2. Use your thumb to press on the belt at the midpoint 4. Loosen the lock nut and adjust the clearance between
between the crankshaft and alternator pulleys. The the rocker arm and valve guide of both the intake
tension is correct if the belt can be depressed about and exhaust valves with the adjustment screw (Figure
3/16 in. (5 mm). 10). Clearance on both intake and exhaust valves
should be 0.008 in. (0.2 mm).
5. Repeat steps 3 and 4 for each cylinder. Each set of
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).
Cylinder No. 1 2 3
Valve Arrangement
OM673L3 6/10
12
Servicing
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.
a. Use Grade No. 2 diesel at ambient temperatures a. Check the primary fuel filter daily as
above freezing 32°F (0°C). recommended by the filter manufacturer.
b. Use Grade No. 1 at ambient temperatures below Empty the collection bowl as necessary.
freezing and for all temperatures at an altitude of b. Change the element as often as necessary or
above 5,500 ft. (1500 meters). every 500 hours.
2. Use fuel having less than 1% sulphur (preferably c. If the bowl fills with water, change the primary
less than 0.5%). and secondary element immediately.
3. The cetane number should be a minimum of 45. 2. Change secondary fuel filter every 500 hours.
4. DO NOT use these unsuitable grades of fuel: a. Remove the spin-on filter by turning it
a. Domestic heating oils, all types. counterclockwise with a filter wrench. Fill the
b. Class B engine. new cartridge with fuel and install it after
c. Class D domestic fuels. applying engine oil to gasket surface. Screw on
d. Class E, F, G or H industrial or marine fuels. until the gasket surface comes into contact with
e. ASTM-D975-60T No. 4-D and higher number sealing surface of filter base. Then, tighten it
fuels. two-thirds of a turn by hand. Do not overtighten.
5. Storing fuel: b. Fuel filter part number is:
a. Keep dirt, scale, water, and other foreign matter
out of fuel. M673L3 & LD3 - 24-52020
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.
OM673L3 6/10
13
Updated 6-23-10
Servicing
CAUTION: Escaping diesel fuel under pressure can penetrate skin causing serious personal injury.
Before disconnecting lines be sure to relieve all pressure. Before applying pressure, be sure all
connections are tight and lines, pipes and hoses aren't damaged. Fuel escaping from a very small hole
can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected
leaks. If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if
proper medical treatment isn't administered immediately.
1. The fuel system is self-bleeding. However, any 4. If the engine does not start after the above
system may need manual bleeding when: bleeding process, loosen a fuel line at the
a. A new fuel filter is installed; injector. Crank the engine until pure fuel escapes,
b. The engine has run out of fuel; then tighten the connection. Do each line one at a
c. The fuel lines, injection pump or any other fuel time.
system component has been removed and installed. 5. After the engine has started, check for fuel leaks
2. Loosen bleed screw “A” (Figure 12) on top of the using a piece of cardboard.
filter. 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 “C”.
OM673L3 6/10
14
Servicing
1. Injectors should be checked every 1000 hours, or 1. Since operating conditions may vary considerably, it
more often as necessary. Check should be made by a is difficult to give a definite interval for checking the
Northern Lights dealer or local injection repair injection pump. But as a rule, pump settings,
station. maximum speed, idle speed and exhaust smoke
should be checked after every 2400 hours of
CAUTION: Escaping diesel fuel under pressure operation. Service of the fuel injection pump should
can have sufficient force to penetrate the skin only be done if checks indicate pump malfunction.
causing serious personal injury. If injured by 2. Black smoke can be an indication of pump
escaping diesel fuel, see a doctor at once. malfunction. Before servicing the pump, check other
possible causes:
2. Injector removal: a. Check cleanliness of air filter.
a. Clean loose dirt from around the injectors and b. Check valve clearances.
the fuel lines. c. Clean and check injectors.
b. Relieve high pressure in the fuel lines by 3. Any repair which involves disassembly of the
loosening the delivery line flare nuts at each injection pump must be carried out by specially
injector (Figure 13). trained mechanics with the proper tools and test
c. Remove delivery lines by disconnecting from equipment.
injectors and injection pump (Figure 14). Remove NOTE: All warranties on the engine become null
all lines as an assembly; do not remove the and void if the injection pump seals are broken by
clamp. Cover the ends of the lines, the injector unauthorized persons.
inlets and injection pump outlets to keep dirt out
(Figure 15). COOLING SYSTEM - GENERAL
d. Remove the return line retaining bolts (Figure 16).
Remove the return line (Figure 17). NOTE: Be sure to close the sea-cock before
e. Unscrew and remove the injectors (Figure 18). working on the engine cooling system.
NOTE: Do not use pry bars to remove injectors
from cylinder head. CAUTION: The cooling water in the engine
f. After removing the injectors, discard the copper reaches extremely high temperatures. You must
sealing washers from the injector hole in the head use extreme caution when working on hot
(Figure 19). Cover holes to prevent dirt and debris engines to avoid burns. Allow the engine to cool
from entering the cylinders. before working on the cooling system. Open the
filler cap carefully, using protective clothing
3. Injector installation: when the engine is warm.
a. Install a new copper sealing washer in each
injector hole (Figure 19). SP13. CHECK THE COOLANT LEVEL
b. Screw in injector and tighten to 43 or 50 ft/lbs
(6 to 7 kgm) (Figure 20). 1. Check the coolant level each day before starting the
NOTE: Overtightening can damage injector. engine. Check the water level by removing the pres-
c. Install return line using new copper sealing below sure cap from the expansion tank or radiator.
each connection. Tighten return line retaining In order to give the cooling water an opportunity to
bolts to 22 - 30 ft/lbs. expand, the level should be about 1 in. (2.5 cm) below
d. Install delivery lines. Leave loose at injectors for the filler cap sealing surface when the engine is cold.
bleeding. 2. The pressure valve in the filler cap releases when the
e. Crank the engine to fill lines. Tighten lines at pressure is approximately 7 PSI (0.5 bar). Use a cap
injectors. Start engine and check for leaks using a pressure tester to check cap if you suspect it is faulty.
piece of paper or cardboard.
DO NOT use hand to check for leaks.
OM673L3 6/10
15
Servicing
Figure 13: Remove delivery line flare nuts. Figure 17: Remove return line.
Figure 15: Cover lines, inlets and injection pump outlets. Figure 19: Remove and replace copper sealing washer.
Figure 16: Remove return line nuts. Figure 20: Reinstall injector. Torque to proper tightness.
OM673L3 6/10
16
Servicing
1. Flush the cooling system every 2500 hours or every 1. Change the seawater pump impeller every 1000
12 months, whichever comes first. hours, or as needed.
a. Remove expansion tank cap and drain engine 2. Remove the pump end cover. Pry out the impeller
block. using needle-nose pliers or two screwdrivers.
b. Leave all drains open. Be sure you remove all pieces of failed impeller.
c. Pour clean water into expansion tank until NOTE: Place some kind of protection under the
water coming from drains is free of screwdrivers in order not to damage the pump
discoloration and sediment. housing.
d. Let water drain completely. 3. Clean the inside of the housing.
e. Close drains and refill with recommended 4. Press in the new impeller and place the sealing
mixture. washers in the outer end of the impeller center if this
NOTE: Open sea cock before running engine. has not already been done.
5. Replace the cover using a new gasket or o-ring.
2. Coolant Specifications: NOTE: Make sure that there is always an extra
Use 50% water / 50% ethylene glycol antifreeze impeller and cover gasket in reserve on board.
mix. Antifreeze mixture is recommended as a good
year-round coolant, but not methyl alcohol based GENERATOR ENDS
antifreeze because of its low boiling point. Also,
antifreeze with high silicate should not be used as it The maintenance and operation recommendations
could cause silica gelation problems. for the generator end are located on pages 19-22
3. Check hoses and connections and repair any leakage. under the heading “AC Generator”.
1. Clean the heat exchanger core once a year or after 1. Never switch battery switch off or break the circuit
2500 hours of operation. between the alternator and batteries while the engine
2. Drain expansion tank and heat exchanger. is running. Regulator damage can result.
3. Remove heat exchanger end covers and remove 2. Do NOT reverse the polarity of battery cables when
core. installing the battery.
4. Clean the inside of exchanger core tubes using 3. When welding on the unit, disconnect the AC and
a metal rod. Flush, inspect and clean again if DC voltage regulator and battery. Isolate the leads.
necessary. 4. Disconnect the battery cables when servicing the
5. Reassemble. Fill the cooling system, start the engine D.C. alternator.
and check for leaks. 5. Never test with a screwdriver, etc., against any
terminal to see if it emits sparks.
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.
OM673L3 6/10
17
Servicing
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 for starting. manufacturer’s recommended level.
2. To check the glow plugs, loosen the current 2. Batteries, cables and cable terminals should
carrying flat wire between the plus-poles of the be checked and cleaned every 100 hours.
glow plugs (Figure 21). Connect a D.C. test bulb Clean corrosion with a water and baking soda
between the plus-pole of the battery and the solution. Flush with clean water. Tighten terminals
plus-pole of the glow plug. If the bulb lights up, and grease them to inhibit corrosion.
the glow plug is functioning properly. 3. Check the battery condition with a hydrometer every
3. Check all glow plugs and replace any faulty ones. 250 hours.
Figure 22:
Battery connections.
OM673L3 6/10
18
page updated 6-22-10
AC Generator - TF-276D
GENERAL
1. A Generator Set includes the engine, the generator,
and the control or “J” box (Figure 23).
2. The generator and the control or “J” box produce
the electrical power.
3. Generator excitation is provided by activation of
the pre-heat circuit and electrical output voltage is
controlled by the automatic voltage regulator (AVR)
located in the control box (Figure 25, Item 2).
OM673L3 6/10
19
AC Generator - TF-276D
CONNECTIONS
OM673L3 6/10
20
AC Generator - TF-276D
VENTILATION
Good ventilation is important for proper genera-
tor operation. When installing the generator set, be
sure the ambient temperature does not exceed 40°C
(104°F) during operation.
OM673L3 6/10
21
page updated 6-22-10
AC Generator - TF-276D
OM673L3 6/10
22
page updated 6-22-10
Troubleshooting
DC ELECTRICAL SYSTEM
PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)
Battery Will Not Charge Loose or corroded connections • Clean and tighten battery connections.
Sulfated or worn out batteries • Check specific gravity of each battery.
• Check electrolyte level of each battery.
Loose or defective alternator belt • Adjust belt tension.
• Replace belt.
Starter Inoperative Check DC circuit breaker • If the breaker is tripped, reset it.
Loose or corroded connections • Clean and tighten loose battery and
harness plug connection.
Low battery output • Check specific gravity of each battery.
• Check electrolyte level of each battery.
Defective electrical system • Repair or replace.
ground wire
Entire Electrical System Check DC circuit breaker • If breaker is tripped, reset it.
Does Not Function
Faulty connection • 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.
OM673L3 6/10
23
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 • Check electrolyte level and condition.
Excessive resistance • Clean and tighten all battery connections.
in starting circuit
Crankcase oil too heavy • Use oil of proper viscosity.
Improper type of fuel • Consult fuel supplier and use proper type
of fuel for operating condition.
Water, dirt or air in fuel system • Drain, flush, fill and bleed system.
Clogged primary or secondary • Clean or replace primary filter element,
fuel filter element replace secondary filter element.
Dirty or faulty injection nozzles • Have your dealer check injection nozzles.
Engine Runs Irregularly Below normal engine temperature • Remove and check thermostat.
or Stalls Frequently
Clogged primary or secondary • Clean or replace primary filter element,
fuel filter element replace secondary filter element.
Water or dirt in the fuel system • Drain, flush, fill and bleed system.
Dirty or faulty injection nozzles • Have your dealer check injection nozzles.
Air in fuel system • Inspect clamps and hoses on suction side
of fuel pump for air leak.
Improper type of fuel • Consult fuel supplier and use proper type
of fuel for operating condition.
OM673L3 6/10
24
page updated 6-22-10
Troubleshooting
ENGINE
PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)
Lack of Engine Power Cylinder compression pressure low • Adjust valve clearance.
(continued) • Adjust nozzle holder alignment.
Engine Overheats Low coolant level or cooling • Fill tank or radiator to proper level.
system defective • Check hoses for loose connections
and leaks.
• Fan belt slipping.
Keel cooling tubes have been • Remove paint from tubes.
painted
Cooling system needs flushing • Flush cooling system.
Defective thermostat • Remove and check thermostat.
Defective temperature gauge • Check water temperature with thermometer
and replace gauge if necessary.
Water pump impeller worn/broken • Check impeller and replace if necessary.
High Fuel Consumption Improper type of fuel • Use correct fuel for temperature.
Clogged or dirty air cleaner • Service air cleaner.
Improper valve clearance • See your dealer.
Injection nozzles dirty • See your dealer.
Injection pump out of time • See your dealer.
If you cannot correct problems with these procedures, see your Northern Lights dealer.
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Troubleshooting
ENGINE
PROBLEM POSSIBLE CAUSE RECOMMENDATION(S)
Low Oil Pressure Low oil level • Fill crankcase to proper level.
Clogged filter and strainer or • Repair or replace.
worn bearings and oil pump
Improper type of oil • Drain and fill crankcase with correct oil.
Partially plugged oil filter • Replace filter.
High Oil Consumption Break-in period • Oil consumption decreases after break in.
Crankcase oil too light • Use proper viscosity oil.
Oil leaks • Check for leaks in lines around gaskets
and drain plug.
Engine Emits Black Clogged or dirty air cleaner • Service air cleaner.
or Gray Exhaust Smoke
Defective muffler • Have dealer check back pressure.
(back pressure too high)
Improper fuel • Use correct fuel for temperature.
Injection nozzles dirty • See your dealer.
Engine out of time • See your dealer.
If you cannot correct problems with these procedures, see your Northern Lights dealer.
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revised 4/12/10
GENERAL INFORMATION
Cylinders 3 3 3 3
Displacement 46.4 in3 46.4 in3 46.4 in3 46.4 in3
(0.761 ltr) (0.761 ltr) (0.761 ltr) (0.761 ltr)
Cycle 4 4 4 4
Bore 2.64 in 2.64 in 2.64 in 2.64 in
(67 mm) (67 mm) (67 mm) (67 mm)
Stroke 2.83 in 2.83 in 2.83 in 2.83 in
(72 mm) (72 mm) (72 mm) (72 mm)
Rotation (facing flywheel) CCW CCW CCW CCW
Compression Ratio 23.5:1 23.5:1 23.5:1 23.5:1
Crankcase Capacity w/ Oil Filter 3.2 qts 3.2 qts 3.2 qts 3.2 qts
(3.0 ltr) (3.0 ltr) (3.0 ltr) (3.0 ltr)
Aspiration Natural Natural Natural Natural
Dry Weight / Complete Unit 362 lbs 362 lbs 362 lbs 362 lbs
(164 kg) (164 kg) (164 kg) (164 kg)
Height 20.25 in 20.25 in 20.25 in 20.25 in
(514.5 mm) (514.5 mm) (514.5 mm) (514.5 mm)
Width 19.5 in 19.5 in 19.5 in 19.5 in
(495 mm) (495 mm) (495 mm) (495 mm)
Length 28.5 in 28.5 in 28.5 in 28.5 in
(725 mm) (725 mm) (725 mm) (725 mm)
COOLING SYSTEM
Approximate Cooling System Capacity .5 gal .5 gal .5 gal .5 gal
(2 ltr) (2 ltr) (2 ltr) (2 ltr)
Heat Rejection to Jacket Water 350 BTU/min 250 BTU/min 350 BTU/min 250 BTU/min
Fresh Water Pump Capacity 5.0 gal/min 4.2 gal/min 5.0 gal/min 4.2 gal/min
(18.92 ltr/min) (15.77 ltr/min) (18.92 ltr/min) (15.77 ltr/min)
Maximum Seawater Pump Suction Head 39 in 39 in 39 in 39 in
(1 m) (1 m) (1 m) (1 m)
Seawater Pump Capacity 8.0 gal/min 7.0 gal/min 8.0 gal/min 7.0 gal/min
(30 ltr/min) (26 ltr/min) (30 ltr/min) (26 ltr/min)
Keel Cooler Turbo Tube Length 4 ft 4 ft 4 ft 4 ft
(1.2 m) (1.2 m) (1.2 m) (1.2 m)
Keel Cooler Head Diameter 0.75 in NPT 0.75 in NPT 0.75 in NPT 0.75 in NPT
(19.1 mm) (19.1 mm) (19.1 mm) (19.1 mm)
Keel Cooler Water Hose I.D.
Discharge and Suction 1.0 in 1.0 in 1.0 in 1.0 in
(25 mm) (25 mm) (25 mm) (25 mm)
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OM673L3 6/10
AC Wiring Diagrams