Northern Lights M150A13 Generator Set

Tools: feeler gauge

1. Lock No. 1 piston at TDC compression stroke.
2. Adjust No. 1 and 3 exhaust and No. 1 and 2 intake valves.
3. Rotate engine to No. 4 piston TDC compression stroke.
4. Adjust No. 2 and 4 exhaust and No. 3 and 4 intake valves.
5. Set cold intake clearance to 0.35 mm.
6. Set cold exhaust clearance to 0.45 mm.

Tools: cooling system pressure tester

1. Warm engine, then allow to cool.
2. Carefully remove coolant filler cap.
3. Fill tank to normal operating level.
4. Test coolant filler cap with tester.
5. Apply pressure to cooling system.
6. Check all hoses, tank, and engine for leaks.

Tools: oil filter wrench, torque wrench

1. Run engine about 5 minutes to warm oil; shut off.
2. Remove oil pan drain plug and drain crankcase.
3. Remove oil filter element.
4. Wipe sealing surfaces and install new element and seals.
5. Install drain plug with correct torque.
6. Fill crankcase with correct engine oil.
7. Crank engine 30 seconds without starting.
8. Start, check leaks, stop and check level after 10 minutes.

Tools: torque wrench

1. Remove belt guard.
2. Swing tensioner arm to remove belt slack.
3. Remove and inspect belt for cracks, fraying, stretching.
4. Inspect pulleys and bearings while belt is off.
5. If tensioner removed, tighten mounting cap screw to 70 N·m.
6. Install belt guard.

Tools: caliper

1. Remove zinc rod from each heat exchanger end cap.
2. Inspect condition; replace if deteriorated.
3. Measure length and outer diameter.
4. Replace all zinc plugs if length below 15.9 mm.
5. Replace all zinc plugs if diameter below 4.8 mm.

Tools: pliers, impeller puller

1. Close sea cock and drain sea water system.
2. Remove cover plate cap screws and cover plate.
3. Remove impeller end cap.
4. Carefully remove impeller with cam plate.
5. Inspect impeller for tears, cracks, abrasion, missing material.
6. Order impeller repair kit if replacement needed.

Tools: brass rod 4.76 mm, torque wrench

1. Close sea cocks and drain sea water system.
2. Drain about two gallons engine coolant; close drain cock.
3. Remove hoses and end caps with heat exchanger core.
4. Clean buildup from end caps and inspect zinc plugs.
5. Clean each tube with 4.76 mm brass rod.
6. Flush tubes with clean water.
7. Install end caps and tighten screws to 24 N·m.
8. Fill cooling system, open sea cock, run and check leaks.

Tools: breaker bar, socket

1. Remove cap screws and belt guard.
2. Release belt tension using breaker bar on tension arm.
3. Remove poly-vee belt from pulleys.
4. Inspect belt and replace if cracked, frayed, or stretched.
5. Install new belt seated in all pulley grooves.
6. Apply tension with tensioner and remove socket.
7. Start engine and check belt alignment.

1. Close fuel shut-off valve at tank.
2. Clean filter area to keep debris out.
3. Loosen drain plug and air vent; drain fuel.
4. Remove filter element from base.
5. Install new element indexed in base.
6. Install retaining ring until it snaps.
7. Open fuel valve and bleed fuel system.

1. Close fuel shut-off valve.
2. Clean area and disconnect water-in-fuel sensor.
3. Drain fuel into suitable container.
4. Remove element and install new one.
5. Index element in mounting base.
6. Install retaining ring until it snaps.
7. Connect water-in-fuel sensor.
8. Open fuel valve and bleed fuel system.

1. Move Engine Control Switch to OFF.
2. Close sea cock and fuel valves.
3. Place battery switch OFF only for extended shutdown.

1. Hold Shutdown Bypass switch in ON position.
2. Push Engine Control switch to START.
3. Release both switches as soon as engine starts.
4. Do not crank starter more than 20 seconds.
5. If engine fails to start, wait 2 minutes before retry.
6. Run high idle 1 to 2 minutes before adding load.