Northern Lights M40C3F 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.

⚠ 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.

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.

1. Check tension and wear every 50 hours.
2. Press belt at midpoint between crankshaft and alternator pulleys.
3. Correct deflection is .39 to .47 in. (10 - 12 mm) with 22 lbs. (10 kg) force.

⚠ Be sure to open the sea-cock after working on the engine cooling system and starting the engine.

1. Flush every 2000 hours or every 12 months, whichever comes first.
2. Remove fill cap and open engine block drains.
3. Pour clean water until draining water is clear.
4. Close drains; refill with recommended coolant mixture.
5. Check hoses and connections; repair leaks.
6. Start engine, run five minutes, stop, cool, and check level.

Tools: needle-nose pliers or two screwdrivers

1. Change impeller every 500 hours or as needed.
2. Remove pump cover; pry out impeller with needle-nose pliers or two screwdrivers.
3. Remove all pieces of failed impeller.
4. Clean inside of housing.
5. Press in new impeller; place sealing plug in outer end.
6. Keep extra impeller and cover gasket on board.

⚠ Escaping diesel fuel under pressure can penetrate skin causing serious personal injury; use cardboard or wood to search for leaks.

Tools: Wrench, Cloth

1. Loosen air vent plug on the fuel filter about 1-1/2 turns, covering the vent with a cloth.
2. Turn priming pump cap counterclockwise to unlatch it and move plunger up and down.
3. Close the air vent plug when no more air bubbles are seen in fuel flowing from the vent hole.
4. To bleed at injection pump, loosen its air vent plug and pump; lock priming pump cap before closing vent plug.
5. If engine does not start, loosen a fuel line at an injector and crank until pure fuel escapes, then tighten.