Northern Lights NL488x Generator Set

1. Check tension and wear on the V-belt after every 50 hours.
2. Press on the belt at the midpoint between crankshaft and alternator pulleys with your thumb.
3. Tension is correct if belt can be depressed about 3/8 in. (10 - 15 mm).

Tools: thickness gauge, wrench

1. Readjust valve clearance after first 50 hours of operation; adjust valves every 600 hours thereafter.
2. Do adjustment after cylinder head bolts have been re-tightened; engine should be cold and not running.
3. Remove the rocker arm cover.
4. Turn engine by hand until inlet valve starts to open and exhaust valve starts to close (valves rocking), then turn crankshaft one more full turn and adjust clearance on both valves for this cylinder.
5. Insert thickness gauge between rocker arm and valve cap; loosen lock nut and adjust with adjustment screw.
6. Clearance on both intake and exhaust valves should be 0.006 - 0.010 in. (0.15 - 0.25 mm).
7. Repeat for each cylinder.
8. Replace the rocker arm cover.

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

⚠ Do not run the engine with the air cleaner removed.

1. Check dust trap on bottom of air cleaner daily; squeeze rubber cap lips to let dirt fall out.
2. Visually inspect air cleaner every 100 hours; check more often in dusty conditions.
3. An element cannot be cleaned; replace dirty elements when necessary.

⚠ 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 for leak check

1. Loosen bleed screw on top of the fuel filter.
2. Pump hand primer on fuel lift pump until pure fuel (no bubbles) escapes from bleed screw; tighten bleed screw.
3. Loosen bleed screw on the injection pump.
4. Pump hand primer until pure fuel escapes; tighten bleed screw.
5. If engine does not start, loosen a fuel line at the injector while cranking the engine until pure fuel escapes, then tighten.
6. Do each line one-at-a-time.

1. First 100 hours on a new or reconditioned engine are critical to life and performance.
2. Constantly check engine temperature and oil pressure gauges.
3. Oil consumption is greater during break-in as piston rings take time to seat.
4. Change engine oil and filter at 50 hours.
5. Change oil and filter again at 100 hours.
6. Retighten head bolts at 50 hours.
7. Maintain at least a 75% load for the first 100 hours; if not possible, no less than 50% load.
8. Vary the load to help seat the rings.

⚠ Overtightening can damage the filter housing.

⚠ Do not use a wrench to tighten the filter.

Tools: filter wrench

1. Use a filter wrench to remove old filter; dispose of filter in approved manner.
2. Make sure gasket from old filter is removed and discarded; clean mount face.
3. Spread a thin film of engine oil on the new filter rubber gasket.
4. Screw filter on nipple until gasket meets the sealing surface.
5. Tighten filter one-half turn farther using hands only.
6. Fill engine with recommended oil.
7. Start engine and check for leakage.
8. Stop engine, wait 3 minutes, and check oil level; add oil if necessary.

1. Flush the cooling system every 600 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 coming from radiator is clear of discoloration.
4. Close radiator drain and continue flushing until water from engine drain is clear.
5. Open all drains and drain engine and radiator completely.
6. Close drains and refill radiator with recommended coolant mixture (50% water / 50% ethylene glycol antifreeze).
7. Check hoses and connections and repair any leakage.
8. Start engine and check for leaks; run engine for five minutes, then shut it down.
9. Let engine cool, then check coolant level and add as needed.

Tools: torque wrench

1. Retighten the head bolts after the first 50 hours.
2. Tighten bolts when the engine is cold.
3. Loosen nuts and remove rocker arm cover.
4. Tighten head bolts with a torque wrench in the order shown in figures.
5. Tighten bolts evenly in 2 or 3 passes, ending at specified torque in final pass.
6. Replace rocker arm cover.

Tools: plastic bags, tape

1. Drain and flush radiator and cooling system; leave dry or refill with antifreeze-water mixture.
2. If refilling, start engine and run to circulate antifreeze.
3. Fill fuel tank or add biocide as per manufacturer's instructions.
4. Seal air cleaner inlet, exhaust opening, crankcase breather pipe, and fuel tank vent with plastic bags and tape.
5. Change crankcase oil and filter.
6. Loosen alternator belt.
7. Disconnect and clean battery; remove to warm storage place if possible.
8. Clean outside of unit; paint scratched or chipped surfaces; put corrosion preventative on exposed metal.
9. Store set in a dry, protected place; if outside, protect well with a cover.

⚠ Use protective clothing and open the filler cap carefully when the engine is warm to prevent burns.

1. Check the water level by removing the pressure cap from the radiator; level about 1 in. (2.5 cm) below filler cap sealing surface when cold.
2. Check oil level in crankcase with dipstick; level must be between high and low marks.
3. Check fuel tank level and open any fuel valves on the tank and at the secondary fuel filter.
4. Turn on any optional battery switch that may have been installed.

⚠ If gauges deviate from normal levels, shut down the generator set and investigate.

1. Check gauges often; oil pressure must be above 15 PSI.
2. D.C. voltmeter should read between 11 and 15 volts at 80°F (25°C) ambient.
3. Water temperature gauge must be below 200°F (94°C).
4. Check A.C. voltage and frequency meters (Series 7 panel).
5. Let unit run unloaded for a three to five minute warm-up period.
6. Add electrical load.

⚠ Holding the switch too long can burn out the heater elements.

1. Hold the Shutdown Bypass-Preheat switch in the ON position for 10 to 20 seconds before starting a cold engine.
2. While holding the Shutdown Bypass-Preheat switch ON, push the Engine Control switch to START.
3. As soon as the engine starts, release both switches.
4. Do not crank the starter for more than 20 seconds consecutively.
5. If engine fails to start, be sure it has stopped completely before re-engaging.