Northern Lights M38CR2 Generator Set

Tools: Feeler gauge, Wrench

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

1. Press belt at midpoint between crankshaft and alternator pulleys with thumb.
2. Correct tension allows about 10-12 mm (0.39-0.47 in.) deflection with 22 lbs (10 kg) force.
3. Adjust or replace belt if tension is incorrect.

⚠ Escaping diesel fuel under pressure can penetrate skin.

Tools: Cloth, Wrench

1. Loosen air vent plug on fuel filter about 1-1/2 turns.
2. Turn priming pump cap counterclockwise to unlatch, then move plunger up and down.
3. Close air vent plug when no more air bubbles appear.
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, then close air vent plug.
6. If engine still will not start, loosen injector fuel lines one at a time while cranking.

1. First 100 hours are critical to engine life and performance.
2. Maintain at least 75% load for first 100 hours; no less than 50% if necessary.
3. Vary load to help seat piston rings.
4. Change engine oil and filter at 50 hours.
5. Change oil and filter again at 100 hours.

⚠ Never use flushing oil.

Tools: Oil drain container

1. Run engine until warm but not hot.
2. Loosen clamp on oil change tube, remove cap, and drain oil.
3. Replace cap and tube.
4. Refill engine with recommended oil; capacity with new filter is 10 liters.
5. Dispose of waste oil in approved manner.

⚠ Overtightening can damage filter housing.

Tools: Filter wrench

1. Use filter wrench to remove old filter.
2. Remove and discard old gasket; clean mounting face.
3. Apply thin film of engine oil to new filter gasket.
4. Screw filter on by hand until gasket meets sealing surface.
5. Tighten one-half turn farther by hand only.
6. Start engine, check for leaks, stop, wait 3 minutes, check oil level.

⚠ Protect pump housing when prying.

Tools: Needle-nose pliers, Screwdrivers

1. Remove pump cover.
2. Pry out impeller using needle-nose pliers or two screwdrivers; remove all pieces.
3. Clean inside of housing.
4. Press in new impeller and place sealing plug in outer end of impeller center.
5. Reinstall cover with new gasket and check for leaks.

Tools: Steel brush, Scraper

1. Remove zinc holder from bottom of heat exchanger; raw water will drain.
2. Scrape or steel brush zinc electrode clean.
3. Replace zinc if more than 50% corroded.
4. Reinstall zinc holder with clean threads; do not use thread sealant.
5. Refill cooling system, start engine, and check for leaks.

⚠ Close sea-cock before opening drain cocks.

1. Change crankcase oil and filter; fill with rust preventative oil.
2. Make 1:1 rust preventative oil and fuel mixture; fill fuel tank.
3. Run engine unloaded 5 to 10 minutes; drain rust preventative oil and fuel.
4. Drain fresh water and seawater cooling systems completely.
5. Drain water supply and wet exhaust lines; cover intake and exhaust ports.
6. Loosen seawater pump cover and alternator belt.
7. Disconnect and clean battery; store in cool dry place.
8. Cover engine and exposed metal surfaces.

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

1. Check expansion tank water level about 1 in. (2.5 cm) below filler cap when cold.
2. Check crankcase oil level with dipstick; keep between high and low marks.
3. Check fuel tank level and open fuel valves at tank and secondary filter.
4. Close sea-cock, clean sea strainer, and reopen sea-cock.
5. Place battery switch in ON position.

⚠ Excessive cranking with water lift muffler can cause engine damage.

1. Hold Shutdown Bypass switch in ON position.
2. Push Engine Control switch to START while holding bypass.
3. Release start switch when engine starts; hold bypass five seconds more.
4. Do not crank starter more than 10 seconds consecutively.
5. If engine does not start after three 10-second cranks, remove seawater pump impeller.
6. Reinstall impeller after engine starts and check exhaust water flow.

1. Remove electrical load from generator set.
2. Run engine two to three minutes for cool-down.
3. Move Engine Control switch to STOP position.