Northern Lights NL488W2 Generator Set

⚠ Make absolutely sure no impurities enter engine while changing element.

⚠ Do not run engine with air cleaner removed.

1. Check dust trap daily; squeeze rubber cap to remove dirt.
2. Inspect air cleaner every 250 hours; more often in dusty conditions.
3. Replace dirty element when necessary. Part number for 488 outer: #24-28501.
4. Do not clean element; do not run engine with air cleaner removed.

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

Tools: Hydrometer

1. Check electrolyte level every 50 hours or once per month. Add distilled water.
2. Check and clean batteries, cables, terminals every 100 hours. Clean corrosion with baking soda solution.
3. Tighten terminals and grease to inhibit corrosion.
4. Check battery condition with hydrometer every 500 hours.

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

⚠ Use a piece of cardboard or wood, not hands, to search for leaks.

Tools: Cardboard or wood

1. Loosen bleed screw on top of fuel filter.
2. Pump hand primer on fuel lift pump until pure fuel escapes.
3. Tighten bleed screw.
4. Loosen bleed screw on injection pump; pump until pure fuel escapes; tighten.
5. If engine does not start, loosen fuel line at injector and crank until pure fuel escapes; tighten.
6. After start, check for leaks with cardboard; do not use hands.

⚠ Overtightening can damage filter housing.

Tools: Filter wrench

1. Change lube oil filter every 250 hours.
2. Remove old filter with filter wrench; discard.
3. Remove and discard old gasket; clean mount face.
4. Coat new gasket with engine oil; screw on until gasket meets sealing surface.
5. Tighten by hand one-half turn farther. Do not overtighten.
6. Fill engine with oil, start, check for leaks. Stop, wait 3 minutes, check level.

Tools: Dipstick

1. Check oil level daily with dipstick.
2. Oil level must be between high and low marks.
3. Fill with recommended oil only to high mark.

⚠ Allow engine to cool before working on cooling system. Open filler cap carefully.

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

Tools: Filter wrench

1. Check primary fuel filter daily; empty collection bowl as necessary.
2. Change primary element as necessary or every 250 hours.
3. If bowl fills with water, change primary and secondary elements immediately.
4. Change secondary fuel filter every 250 hours.
5. For element type: turn off fuel valve; remove bowl retaining ring; install new element; fill bowl with fuel.
6. For spin-on: turn off fuel valve; remove filter; fill new cartridge with fuel; coat gasket with oil; install; do not overtighten.
7. Part numbers: 488 final #24-57304; primary #119802-55710.

⚠ Escaping diesel fuel under pressure can penetrate skin causing serious personal injury. Do not use pry bars to remove injectors.

Tools: 6 mm wrench or socket

1. Check injectors every 500 hours by Northern Lights dealer or injection repair station.
2. Clean loose dirt around injectors and fuel lines.
3. Relieve high pressure by loosening delivery line flare nuts.
4. Remove delivery lines as assembly; cover ends and injector inlets.
5. Remove return line clamps and return lines.
6. Remove nuts on each side of injector body; remove hold-down bracket; pull injector.
7. Discard sleeves from injector hole; cover holes.
8. Install new sleeve, injector, hold-down bracket. Tighten nuts to 5 - 6.5 ft-lbs.
9. Install fuel lines, return lines, delivery lines. Bleed and check for leaks.

⚠ Dispose of waste oil in an approved manner. Never use a flushing oil.

1. Change engine oil and oil 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.
4. After this, change oil and filter every 250 hours.
5. In cold weather, change every 100 hours or six weeks.
6. Change oil when engine is warm but not hot.
7. Loosen oil pan plug and drain oil.
8. Refill with recommended oil. Capacity with new filter: 7.4 liters (7.82 quarts).

Tools: Torque wrench

1. Retighten head bolts after first 50 hours.
2. Tighten when engine is cold.
3. Loosen nuts and remove rocker arm cover.
4. Tighten head bolts in sequence (Figure 7) in 2 or 3 passes.
5. First step: 41.1 to 46.9 N•m (4.2 to 4.8 kgf•m).
6. Second step: 85.3 to 91.1 N•m (8.7 to 9.3 kgf•m).
7. Replace rocker arm cover.

1. Check V-belt tension every 50 hours.
2. Press belt at midpoint between crankshaft and alternator pulleys.
3. Correct deflection: 10-14 mm at point A, 7-10 mm at point B, 9 to 13 mm at point C.
4. Adjust by loosening tensioning arm bolt and moving alternator.
5. If replaced, run engine 5 minutes and re-adjust.

Tools: Thickness gauge, Wrench

1. Readjust valve clearance after first 50 hours; then every 1000 hours.
2. Do after cylinder head bolts are 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. Adjust clearance on both valves for this cylinder.
6. Use thickness gauge between rocker arm and valve cap; loosen lock nut and adjust.
7. Clearance: 0.006 - .01 in. (0.15 - 0.25 mm).
8. Turn crankshaft 180°; adjust No. 3 cylinder, then No. 4 and No. 2.
9. Replace rocker arm cover.