Northern Lights M673 Generator Set

Tools: Feeler gauge, Wrench

1. Engine must be cold and NOT running.
2. Bring No. 1 cylinder to top dead center on compression stroke by aligning timing marks.
3. Remove rocker arm cover.
4. Loosen lock nut and adjust intake and exhaust valve clearance to 0.008 in. (0.2 mm).
5. Repeat for each cylinder.
6. Replace rocker arm cover and tighten nuts to 5 - 8 ft/lbs.

Tools: feeler gauge, wrench

1. Engine cold and not running; turn engine by hand.
2. Turn until #1 inlet starts opening and exhaust starts closing.
3. Turn crankshaft one more full turn; adjust both valves.
4. Loosen lock nut; set clearance with adjustment screw.
5. Set intake and exhaust clearance to 0.008 in. (0.2 mm).
6. Repeat for each cylinder individually.
7. Replace rocker cover; tighten nuts to 7.2 - 8.7 ft/lbs.

Tools: feeler gauge, wrenches

1. Retighten cylinder head bolts first; engine must be cold and NOT running.
2. Turn engine by hand until #1 cylinder inlet valve starts to open and exhaust valve starts to close.
3. Turn the crankshaft one more full turn and adjust both valves for this cylinder.
4. Loosen the lock nut and adjust clearance between rocker arm and valve guide with the adjustment screw.
5. Set clearance to 0.008 in. (0.2 mm) on both intake and exhaust valves.
6. Repeat for each cylinder; each set of valves must be adjusted individually.
7. Replace rocker arm cover and tighten cover nuts to 7.2 - 8.7 ft/lbs (1.0 - 1.2 kg/m).

Tools: D.C. test bulb

1. Loosen current-carrying flat wire between plus-poles of glow plugs.
2. Connect a D.C. test bulb between plus-pole of battery and plus-pole of glow plug.
3. If bulb lights, glow plug is functioning properly.
4. Check all glow plugs and replace faulty ones.

⚠ The AVR must be disconnected when flashing fields or it could be ruined.

Tools: 12 volt DC source, voltmeter

1. If there is no voltage buildup on startup (zero volts measured), the generator may have no residual magnetic field.
2. Disconnect the AVR before flashing fields or it could be ruined.
3. Apply 12 volts DC to terminals K (-) and J (+) as indicated.
4. Reconnect AVR and check voltage buildup.

⚠ Generator sets with wet exhaust installed near or below the vessel's water line must use a siphon break to prevent backflow of water into the engine, which can ruin the engine and possibly sink the vessel

1. Inspect all components for damage and check the packing list before assembly
2. Loosen and rotate down original factory lifting points below the highest point on the engine, then retighten
3. Select mounting location per IM1000 Installation Manual on a rigid, flat surface above a strong structure
4. Position the enclosure so its left side and rear are 6 in recommended (4 in minimum) from bulkheads, avoiding corners with blocked overhead
5. Install toe brackets to each corner of the genset base flanges with machine screws, flat washers, and nylock hex nuts
6. Install the four vertical extrusions with bolting assemblies; leave loose enough for adjustment during building
7. Loosely install front and left-hand side panel retainer blocks to the vertical extrusions
8. Position the pre-assembled top frame with triangular penetration plate toward the front and tighten all bolting assemblies progressively
9. Install the junction box support cover into the cavity of the support bracket until firmly engaged
10. Install the rear sound shield panel, engaging top retaining clips and securing the bottom with bolts, flat washers, and shoulder washers
11. Bend the intake air snorkel hose into the rear panel notch without kinking or restricting airflow
12. Connect exhaust, sea water, fuel, DC control harness, battery, and AC output leads through the rear panel holes
13. If installing a siphon break, replace hole plugs with rubber grommets and route hoses per the IM1000 Installation Manual
14. Start the generator set and run under load to check for leaks of fuel, water, or exhaust gas
15. Install left side, front, top, and right side panels, and insert foam blocks into the base pan mounting foot pockets

⚠ Fuel under pressure can penetrate skin

Tools: cardboard or wood for leak check

1. Loosen bleed screw A on top of filter.
2. Pump hand primer B until pure fuel without bubbles escapes.
3. Tighten bleed screw A.
4. Loosen bleed screw C; pump until pure fuel escapes.
5. If engine does not start, loosen one injector fuel line.
6. Crank until fuel escapes; tighten line; repeat each line.
7. After start, check for fuel leaks.

⚠ Escaping diesel fuel under pressure can penetrate skin.

1. Loosen bleed screw A on top of filter.
2. Pump hand primer B on fuel lift pump until pure fuel escapes from A.
3. Tighten bleed screw A.
4. Loosen bleed screw C and pump until pure fuel escapes; tighten.
5. If engine does not start, loosen a fuel line at injector and crank until pure fuel escapes; tighten.

⚠ Escaping diesel fuel under pressure can penetrate skin causing serious personal injury.

⚠ Use cardboard or wood, not hands, to search for leaks.

Tools: cardboard or wood for leak checking

1. Loosen bleed screw A on top of the filter.
2. Pump hand primer B on the fuel lift pump until pure fuel (no bubbles) escapes; tighten bleed screw A.
3. Loosen bleed screw C and pump hand primer B until pure fuel escapes.
4. If the engine still does not start, loosen a fuel line at the injector, pump until pure fuel escapes and tighten.
5. Do each line one at a time.
6. After starting, use a piece of cardboard to look for fuel leaks.

⚠ Dispose of waste oil in an approved manner.

1. Run engine until warm.
2. Loosen clamp on oil change tube and remove cap.
3. Drain oil, then replace cap and tube.
4. Refill engine with recommended oil.
5. Check level with dipstick after run and wait 3 minutes.

⚠ Do not overtighten; use hands only.

Tools: Filter wrench

1. Remove old filter with a filter wrench and discard old gasket.
2. Clean filter mount face.
3. Spread thin film of engine oil on new filter gasket.
4. Screw filter on until gasket contacts sealing surface.
5. Tighten one-half turn farther by hand only.
6. Fill engine, start, check for leaks, stop and check oil level.

⚠ Overtightening can damage the filter housing.

Tools: filter wrench

1. Use a filter wrench to remove the old filter and dispose of it in an approved manner.
2. Make sure the old gasket is removed and discarded; clean the mount face.
3. Spread a thin film of engine oil on the new filter rubber gasket.
4. Screw the filter on the nipple until the gasket meets the sealing surface.
5. Using hands only, tighten one-half turn farther.
6. Fill engine with oil, start and check for leakage; stop, wait 3 minutes and check level.