Northern Lights NL844W2 Generator Set

1. Check tension and wear on the V-belt daily.
2. Press on the belt at the midpoint between crankshaft and alternator pulleys; correct tension allows about 3/16 in. (5 mm) deflection.
3. Loosen the alternator adjusting plate bolt and the alternator mounting bolt.
4. Pivot the alternator at the mounting bolt as needed.
5. Tighten the mounting bolt and the adjusting bolt.
6. Operate engine at low idle speed and recheck belt tension.

Tools: adjustment screw, lock nut wrench

1. Adjust valve clearance after first 50 hours and every 1000 hours thereafter.
2. Do adjustments after cylinder head bolts have been re-tightened. Engine must be cold and NOT running.
3. Turn engine by hand until the inlet valve starts to open and exhaust valve starts to close (valves rocking).
4. Turn the crankshaft one more full turn and adjust clearance on both valves for this cylinder. Align top mark of crank pulley with TOP mark of timing gear case.
5. Loosen the lock nut and adjust clearance between rocker arm and valve guide with the adjustment screw.
6. Repeat for each cylinder individually.
7. Replace rocker arm cover and tighten cover nuts to 5 - 8 ft/lbs (0.8 - 2.3 kg/m).

Tools: D.C. test bulb

1. Loosen the current carrying flat wire between the plus-poles of the glow plugs.
2. Connect a D.C. test bulb between the plus-pole of the battery and the plus-pole of the glow plug.
3. If the bulb lights up, the glow plug is functioning properly.
4. Check all glow plugs and replace any faulty ones.

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

Tools: wrenches, cardboard

1. The fuel system is self-bleeding; manual bleeding may be needed after filter change, running out of fuel, or fuel system component removal.
2. Loosen bleed bolt A on top of the filter.
3. Pump hand primer B on the fuel lift pump until pure fuel (no bubbles) escapes. Tighten bleed screw A.
4. Loosen bleed screw C. Pump hand primer B until pure fuel escapes. Tighten bleed screw C.
5. If engine does not start, loosen a fuel line at the injector and crank until pure fuel escapes. Tighten. Do each line one-at-a-time.
6. After starting, use a piece of cardboard to look for fuel leaks.

⚠ Never put additives or flushing oil in crankcase.

1. Change oil when engine is warm.
2. Loosen the clamp on the oil change tube. Remove cap. Drain oil. Replace cap and tube.
3. Refill engine with recommended oil for the season. Capacity with new oil filter is 2.1 gallons (8.2 liters) on NL844W2 & LW2.
4. Change oil every 100 hours or six weeks in intermittent cold weather.
5. Dispose of waste oil in an approved manner. Never use a flushing oil.

⚠ Overtightening can damage the filter housing.

Tools: filter wrench

1. Use a filter wrench to remove old filter. Dispose in approved manner.
2. Make sure the old gasket is removed and discarded. Clean mount face.
3. Spread a thin film of engine oil on the new filter gasket and screw it on until gasket meets sealing surface.
4. Using hands only, tighten filter one-half turn farther.
5. Fill engine with recommended oil. Start engine and check for leakage. Stop, wait 3 minutes, check level.

⚠ Allow the engine to cool before working on the cooling system.

1. Flush the cooling system every 2500 hours or every 12 months, whichever comes first.
2. Remove radiator cap and drain engine block.
3. Pour clean water into radiator until water coming from radiator is free of discoloration and sediment.
4. Close the radiator drain and continue flushing until water from the engine drain is clear.
5. Open all drain cocks and drain completely.
6. Close drain cock and refill with recommended mixture (50% distilled water / 50% ethylene glycol antifreeze).
7. Clean leaves, dust and debris off the radiator fins. Check hoses and connections and repair any leakage.

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

1. Inspect air cleaner every 250 hours; check more often in dusty conditions.
2. Replace the element if necessary. Part number NL844W2 & LW2 (element only): #24-27302.
3. Make absolutely sure no impurities enter the engine while changing the element.

⚠ Do not overtighten.

Tools: filter wrench

1. Change the secondary fuel filter every 500 hours.
2. Remove the spin-on filter by turning counterclockwise with a filter wrench.
3. Fill the new cartridge with fuel and apply engine oil to the gasket surface.
4. Screw on until the gasket contacts the sealing surface, then tighten two-thirds of a turn by hand.
5. Do not overtighten.

Tools: plastic bags, tape

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

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

⚠ If the battery switch is turned OFF while the engine is running, the battery charging regulator could be ruined.

1. Check coolant level; level should be about 1 in. (2.5 cm) below filler cap sealing surface when engine is cold.
2. Check crankcase oil level with dipstick; level must be in the waffled area.
3. Check fuel tank level and open any fuel valves.
4. Keep battery switch ON while the engine is running.

1. Maintain at least 75% load for the first 100 hours; never less than 50% load. Vary the load to seat piston rings.
2. Frequently check engine temperature and oil pressure gauges (Series 3 or 4 panels).
3. Change engine oil and filter at 50 hours.
4. Change oil and filter again at 100 hours.