Northern Lights M38C3F Generator Set

Tools: feeler gauge, wrench

1. Readjust after first 50 hours; check every 500 hours thereafter.
2. Check valves when engine is cold.
3. Rotate crankshaft clockwise to bring No. 1 piston to TDC compression.
4. Align pulley notch with pointer; confirm No. 1 valves rock.
5. Measure clearance with feeler gauge in firing order 1-3-4-2.
6. Loosen lock nut, adjust screw until feeler gauge has slight drag.
7. Tighten lock nut, recheck clearance, and replace rocker cover.

1. Check tension and wear on the V-belt after every 50 hours.
2. Press belt with thumb at midpoint between crankshaft and alternator pulleys.
3. Tension is correct if belt can be depressed about .39 to .47 in. (10 - 12 mm) with 22 lbs. (10 kg) force.

Tools: Feeler gauge

1. Readjust valve clearance after first 50 hours; check every 500 hours thereafter.
2. Check the valves when the engine is cold.
3. Rotate crankshaft clockwise to bring each piston to top dead center on compression stroke in firing order 1-3-4-2.
4. Loosen lock nut on adjustment screw and insert feeler gauge between rocker arm and valve stem cap.
5. Adjust until feeler gauge slides with slight drag; tighten lock nut and recheck clearance.
6. Adjust remaining valves and replace rocker arm cover.

Tools: Feeler gauge

1. Check valves when engine is cold.
2. Rotate crankshaft clockwise at front 1800 to bring each piston to top dead center on compression stroke.
3. Measure valve clearance in firing order 1-3-4-2.
4. Loosen lock nut on adjustment screw and insert feeler gauge between rocker arm and valve stem cap.
5. Adjust until feeler gauge slides with slight drag.
6. Tighten lock nut and recheck clearance.
7. Replace rocker arm cover.

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

Tools: cloth

1. Loosen air vent plug on fuel filter about 1-1/2 turns.
2. Operate priming pump plunger until no air bubbles appear.
3. Close air vent plug.
4. For injection pump, loosen its air vent plug about 1-1/2 turns.
5. Pump feed pump until no bubbles; lock priming pump cap.
6. If engine will not start, loosen injector line and crank until fuel escapes.

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

1. Units have shutdown systems for high water temperature or low oil pressure.
2. Generator sets have shutdown systems, no warning horns.
3. Optional alarms and shutdowns are available.
4. When activated, engage preheat switch to check temperature gauge.
5. If above 205°F (96°C), use Troubleshooting Guide to isolate overheat cause.
6. Make repairs and restart after temperature gauge registers below 200°F (94°C).
7. If shutdown activated but temperature normal, check exhaust temperature/impeller/strainer.
8. Check crankcase oil level; if low, fill with recommended oil and restart.
9. If oil level normal, do not restart; call dealer.

⚠ Escaping diesel fuel under pressure can penetrate skin causing serious personal injury. Relieve pressure before disconnecting lines and use cardboard or wood to check for leaks.

Tools: Cloth

1. Loosen air vent plug on fuel filter about 1-1/2 turns, covering vent with cloth.
2. Unlatch priming pump cap and move priming pump plunger up and down.
3. Close air vent plug when no more air bubbles are seen.
4. To bleed injection pump, loosen its air vent plug about 1-1/2 turns and pump feed pump.
5. Lock priming pump cap in place before closing air vent plug.
6. If engine does not start, loosen a fuel line at an injector and crank until pure fuel escapes; tighten.

1. First 100 hours on new or reconditioned engine are critical.
2. Operate engine under various conditions, including heavy loading and minimal or no load.
3. Constantly check engine temperature and oil pressure gauges.
4. Change engine oil and filter at 50 hours and again at 100 hours.
5. Maintain at least 75% load for first 100 hours; if not possible, maintain no less than 50% load and vary load.

Tools: filter wrench

1. Change engine oil and oil filter after first 50 hours.
2. Use diesel-rated break-in oil during first 100 hours.
3. Change oil and filter again at 100 hours.
4. Thereafter change oil and filter every 250 hours.
5. Warm engine, drain oil, replace plug, refill with recommended oil.

⚠ Overtightening can damage filter housing.

Tools: filter wrench

1. Remove old filter with filter wrench; discard gasket and clean mount face.
2. Coat new filter gasket with engine oil.
3. Screw filter on until gasket contacts sealing surface.
4. Tighten by hand one-half turn farther; do not overtighten.
5. Fill engine with recommended oil, start, and check for leaks.

Tools: filter wrench

1. Change engine-mounted filter every 250 hours or as necessary.
2. Remove filter with filter wrench.
3. Coat new filter O-ring with fuel.
4. Tighten new filter by hand; do not use wrench.
5. Do not prefill filter; bleed air after installation.

⚠ Overtightening can damage filter housing.

Tools: Filter wrench

1. Use a filter wrench to remove old filter.
2. Remove and discard old filter gasket; clean mount face.
3. Spread thin film of engine oil on new filter rubber gasket.
4. Screw filter on nipple until gasket meets sealing surface.
5. Tighten by hand one-half turn farther; do not overtighten.
6. Fill engine with recommended oil; start and check for leakage, stop, wait 3 minutes, and check oil level.