Northern Lights M175C2 Generator Set

⚠ Disconnect negative battery terminal before valve adjustment.

Tools: JDE 820 or JDE 81-1 Flywheel Turning Tool, JDE 81-4 Timing Pin, feeler gauge

1. Disconnect negative battery terminal and wiring harness.
2. Remove rocker arm cover with ventilator tube and injector wires.
3. Rotate flywheel clockwise until timing pin engages flywheel hole.
4. Confirm No. 1 cylinder rocker arms are loose at Top Dead Center.
5. Check clearances on No. 1, 3, 5 exhaust and No. 1, 2, 4 intake valves.
6. Adjust intake to 0.018 in (0.46 mm), exhaust to 0.028 in (0.71 mm).
7. Tighten lock nut while holding adjusting screw.
8. Tighten rocker cover capscrews in specified order.

⚠ Do not run engine with air cleaner removed.

1. Inspect air cleaner valve daily.
2. Replace filter when restriction indicator shows 625 mm (25 in.) H2O.
3. Loosen hose clamp and attaching strip.
4. Ensure rubber tube is good and new filter clean and properly installed.
5. Start engine and check for leaks.

⚠ Do not disconnect high-pressure common rail components unless trained.

Tools: pre-fill cup, hand primer

1. Open drain valve on primary and secondary filters.
2. Drain water and contaminants from water separator bowl.
3. Pre-fill fuel filters using pre-fill cup.
4. Loosen fuel outlet on transfer pump.
5. Operate hand primer until steady bubble-free fuel flow.
6. Tighten fuel outlet lines to 24 N·m (18 lb-ft).
7. Loosen high-pressure lines and pump until bubble-free; tighten to 24 N·m.
8. Crank engine no more than 15 seconds; run at 1200 to 1500 RPM for 3 to 5 minutes.

⚠ Do not remove water fill cap of overheated engine; allow cooling first.

1. Stop engine and allow it to cool.
2. Close seacock and remove pressure cap carefully.
3. Open cooling system air vent on turbocharger if fitted.
4. Open drains on exhaust manifold and engine block; remove thermostats.
5. Pour clean water into expansion tank until drain water is clear.
6. Close drains and install thermostats with new gaskets.
7. Fill with recommended coolant mixture and vent air.
8. Open seacock, start engine, check for leaks, and reach operating temperature.

Tools: drain hose, suitable container

1. Run engine five minutes to warm oil, then shut off.
2. Remove base frame outlet plug and install drain hose.
3. Open oil pan outlet valve and drain oil.
4. Close valve, remove hose, and replace plug.
5. Refill with recommended oil.
6. Crank engine 30 seconds without starting to prelubricate.
7. Start engine, check for leaks, stop, and check oil level after 10 minutes.

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

⚠ Overtightening can damage filter housing.

Tools: filter wrench

1. Remove old filter with filter wrench and discard.
2. Remove and discard old filter gasket.
3. Lubricate new filter rubber gasket.
4. Screw filter on until gasket meets sealing surface.
5. Tighten by hand one-half turn farther.
6. Fill engine with oil, start, check for leaks, and check level.

⚠ Keep extra impeller and cover gasket on board.

Tools: water pump pliers

1. Remove pump end cover.
2. Remove impeller with water pump pliers; remove all broken pieces.
3. Clean inside of housing.
4. Press in new impeller and place sealing washer.
5. Replace cover using new gasket.

⚠ Use protective clothing and open filler cap carefully when engine is warm.

1. Check expansion tank water level about 1 3/4 in. below filler cap when cold.
2. Open turbocharger venting cock when filling coolant.
3. Check crankcase oil level between waffled area and oo mark.
4. Check fuel tank level and open fuel valves.
5. Close seacock, clean strainer, and reopen seacock.
6. Place battery switch in ON position.

1. Check oil pressure; normal is 50 PSI at rated load speed.
2. Stop engine if oil pressure is below 15 PSI within 5 seconds.
3. Check DC voltmeter reads 13-14 volts (26-28 volts for 24-volt systems).
4. Check AC voltage and frequency meters if fitted.
5. Run unloaded three to five minutes before applying load.
6. Do not add full load until engine reaches maximum operating temperature.

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

1. Unload generator and run three to five minutes for cool down.
2. Turn Engine Control Switch to OFF.
3. Close seacock and fuel valves for extended shutdown.
4. Place battery switch OFF only after engine stops.

⚠ Excessive cranking with water lift muffler can damage engine.

1. Hold Shutdown Bypass switch ON.
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. Wait at least 2 minutes before re-engaging starter.