Northern Lights L1276A2 Generator Set

⚠ Escaping diesel fuel under pressure can penetrate skin.

Tools: Special tool #53-50005

1. Normally use hand primer; if engine ran out of fuel use special tool #53-50005.
2. Open drain valve on fuel filter; use hand primer to drain water and contaminants.
3. Attach open line to diagnostic port above hand primer; place end in diesel container.
4. Pump hand primer until steady bubble-free fuel flow.
5. Disconnect line from diagnostic port; close return line.
6. Pump primer until firm.
7. Crank engine until it starts; 15 seconds maximum, 60 seconds rest.
8. Open return line.

⚠ Do not use motor oil or other oils to re-oil filter.

⚠ Do not run engine with air cleaner removed.

1. Inspect air cleaner every 100 hours.
2. Clean and re-oil every 600 hours/yearly or when restriction indicator shows.
3. Use part # 24-20019 Cleaning and Re-Oiling Kit.
4. Replace filter element after 5 to 7 cleaning cycles.
5. Replace oil separator filter every 600 hours/yearly.
6. Check crankcase pressure regulator plumbing hoses and clamps.

⚠ Overtightening can damage filter housing.

Tools: Filter wrench

1. Use a filter wrench to remove old filter.
2. Remove and discard old gasket.
3. Lubricate rubber gasket on new filter and screw on until gasket meets sealing surface.
4. Using hands only, tighten filter one-half turn farther.
5. Fill engine with recommended oil.
6. Start engine, check for leakage; stop and check oil level.

⚠ Do not remove water fill cap of overheated engine; allow to cool.

1. Flush cooling system every 600 hours or yearly; engine must be stopped and cold.
2. Close seacock.
3. Remove pressure cap from expansion tank; open turbocharger air vent if applicable.
4. Open drains on exhaust manifold and engine block; drain fresh water system.
5. Pour clean water into expansion tank until drain water is clear and free of sediment.
6. Close drains; fill fresh water system with recommended coolant mixture.
7. Close cooling system air vent on turbocharger; open seacock.
8. Start engine; check hoses and connections and repair leakage.

1. Drain cooling system.
2. Remove cooling water pipes between heat exchanger and water pump inlet.
3. Disconnect hose to seawater pump.
4. Unscrew attaching bolts holding heat exchanger to expansion tank.
5. Remove bolts holding heat exchanger cover.
6. Wash core inside and out; clean accessible parts of housing.
7. Reassemble using new gaskets and sealing rings.

⚠ Never put additives or flushing oil in crankcase.

1. Change engine oil and filter after first 100 hours and every 250 hours thereafter.
2. In intermittent cold weather, change every 100 hours or six weeks, whichever comes first.
3. Change oil at seasonal temperature change when new viscosity is required.
4. Fill engine with recommended oil; capacity is 42 liters.
5. Start engine, check for leakage; stop and check oil level.

Tools: Water pump pliers

1. Remove pump end cover.
2. Remove impeller with water pump pliers; remove all pieces of failed impeller.
3. Clean inside of housing.
4. Press in new impeller; place sealing washer in outer end of impeller center.
5. Replace cover using new gasket.
6. Keep extra impeller and cover gasket on board.

Tools: Steel brush

1. Check zincs every 250 hours; more often in warm salt water.
2. Drain raw water from heat exchanger.
3. Remove zinc holders from back of tank and front and port side of heat exchanger.
4. Scrape or steel brush zinc electrode clean.
5. Replace zinc if more than 50% eroded.
6. Reinstall zinc holders with clean threads and good metal-to-metal contact.

⚠ Do not turn battery switch OFF while engine is running.

1. Check expansion tank coolant level about 1 3/4 in. below filler cap sealing surface when cold.
2. Open turbocharger venting cock when filling coolant.
3. Check crankcase oil level with dipstick; keep between waffled area and Add.
4. Check fuel tank level and open any fuel valves.
5. Check reverse gear oil level per gear manual.
6. Close seacock, clean sea strainer, reopen seacock.
7. Place battery switch in ON position.

⚠ Shut down engine and investigate if water temperature exceeds 200°F (94°C).

1. Check oil pressure; must be above 15 PSI.
2. Check voltmeter; should read 13 to 14 volts (26-28 volts, 24-volt systems).
3. Water temperature should not rise over 200°F (94°C).
4. Do not exceed 800 RPM when shifting marine gear.
5. Low idle is 650 RPM.
6. Maximum working speed is 2100 RPM High Output, 1900 Medium Duty, 1800 Continuous Duty.
7. Establish maximum cruising RPM by subtracting 200-300 RPM from full-throttle RPM.

⚠ Do not turn battery switch to OFF while engine is running.

1. Run engine three to five minutes in neutral at 1000 RPM.
2. Return engine to low idle.
3. Turn key switch counterclockwise as far as possible to stop engine.
4. Close sea cock and fuel valves.
5. Put battery switch in OFF position after engine stops.

⚠ Never race a cold engine.

1. Put gear control in neutral.
2. Move throttle control to idle.
3. Turn key to first position; check voltmeter not below 12 volts (24 volts for 24-volt systems).
4. Turn key to starting position; release when engine starts.
5. Move throttle to approximately 1000 RPM.
6. Do not crank starter more than 15 seconds consecutively.
7. Warm up at 1000 RPM for 3 to 5 minutes.