Northern Lights NL382W Generator Set

Tools: thickness gauge, wrench

1. Readjust after first 50 hours, then every 1000 hours.
2. Do after head bolts retightened; engine cold and not running.
3. Remove rocker arm cover.
4. Turn engine by hand until valves rock; turn crankshaft one more full turn.
5. Insert thickness gauge between rocker arm and valve cap.
6. Loosen lock nut; adjust intake and exhaust to 0.006-.01 in. (0.15-0.25 mm).
7. Turn crankshaft 240° and adjust No. 3 cylinder, then No. 2.
8. Replace rocker arm cover.

⚠ Escaping diesel fuel under pressure can penetrate skin and cause serious injury.

Tools: cardboard or wood

1. Loosen bleed screw on top of fuel filter.
2. Pump hand primer on fuel lift pump until pure fuel without bubbles escapes.
3. Tighten bleed screw.
4. Loosen bleed screw on injection pump; pump until pure fuel; tighten.
5. If engine does not start, loosen one fuel line at injector while cranking until pure fuel; tighten.
6. After start, check for leaks using cardboard or wood, not hands.

⚠ Never use flushing oil.

Tools: basin

1. Change engine oil and filter after first 50 hours.
2. Use Service CC 30 weight oil during first 100 hours.
3. Change oil and filter again at 100 hours, then every 250 hours.
4. During intermittent cold weather, change every 100 hours or six weeks, whichever comes first.
5. Change oil when warm but not hot.
6. Loosen oil pan plug and drain oil into basin.
7. Refill with recommended oil; capacity with new filter is 5.5 liters (5.81 quarts).

⚠ Overtightening can damage filter housing.

Tools: filter wrench

1. Use filter wrench to remove old filter; dispose properly.
2. Remove and discard old gasket; clean mount face.
3. Spread thin film of engine oil on new filter gasket.
4. Screw filter on nipple until gasket meets sealing surface.
5. Tighten by hand one-half turn farther; do not use wrench.
6. Fill engine with recommended oil, start, and check for leaks.
7. Stop engine, wait 3 minutes, check oil level; add if needed.

1. Check tension and wear every 50 hours.
2. Press belt at midpoint between crankshaft and alternator pulleys.
3. Correct deflection: 10-14 mm at A, 7-10 mm at B, 9-13 mm at C for belt run >5 minutes.
4. To adjust, loosen bolt in tensioning arm and move alternator.
5. If replaced, adjust, run engine 5 minutes, and re-adjust if needed.

⚠ Allow engine to cool; open filler cap carefully with protective clothing.

1. Flush every 2000 hours or 12 months, whichever comes first.
2. Remove radiator cap; open radiator and engine block drains.
3. Pour clean water into radiator until water from radiator is clear.
4. Close radiator drain; continue flushing until water from engine drain is clear.
5. Open all drains and drain engine and radiator completely.
6. Close drains and refill with 50% water / 50% ethylene glycol antifreeze.
7. Check hoses and connections; repair leaks.
8. Start engine, run five minutes, shut down, cool, check coolant level; add as needed.

Tools: torque wrench

1. Retighten after first 50 hours when engine is cold.
2. Loosen nuts and remove rocker arm cover.
3. Tighten head bolts with torque wrench in sequence, evenly in 2 or 3 passes.
4. First step 30.0-34.0 N·m; final step 61.7-65.7 N·m.
5. Replace rocker arm cover.

Tools: plastic bags, tape

1. Drain and flush radiator/cooling system; leave dry or refill with antifreeze-water mixture.
2. Fill fuel tank or add biocide as per manufacturer instructions.
3. Seal air cleaner inlet, exhaust opening, crankcase breather pipe, and fuel tank vent with plastic bags and tape.
4. Change crankcase oil and filter.
5. Loosen alternator belt.
6. Disconnect and clean battery; remove to warm storage if possible.
7. Clean outside; paint scratches; apply corrosion preventative.
8. Store in dry protected place; cover if stored outside.

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

1. Check water level about 1 in. (2.5 cm) below filler cap sealing surface when cold.
2. Check crankcase oil level; keep between high and low dipstick marks.
3. Check fuel tank level; open fuel valves at tank and secondary filter.
4. Turn on optional battery switch if installed.

⚠ Battery gas can explode; keep all flames and sparks away from batteries.

1. Check battery electrolyte level; add distilled water if necessary.
2. Use booster and main batteries with same voltage rating.
3. Connect positive booster terminal to positive main battery terminal.
4. Connect negative booster terminal to ground on engine block.
5. Remove booster battery after starting engine.

1. First 100 hours are critical; maintain at least 75% load, or no less than 50% if necessary.
2. Vary load to help seat piston rings.
3. Constantly check engine temperature and oil pressure gauges.
4. Change engine oil and filter at 50 hours.
5. Change oil and filter again at 100 hours.
6. Change oil and filter every 250 hours thereafter.
7. Retighten head bolts at 50 hours.

⚠ If gauges deviate from normal, shut down and investigate.

1. Check gauges often.
2. Oil pressure must be above 15 PSI.
3. D.C. voltmeter should read 11 to 15 volts at 80°F (25°C).
4. Water temperature must be below 200°F (94°C).
5. Let unit run unloaded for three to five minutes.
6. Add electrical load.