Northern Lights NL844W3 Generator Set

Tools: feeler gauge, wrench

1. Adjust valve clearance after first 50 hours, then at 1000 hours or as needed.
2. Engine should be cold and NOT running.
3. Turn engine by hand until inlet valve starts to open and exhaust valve starts to close.
4. Turn crankshaft one more full turn; align top mark of crank pulley with TOP mark of timing gear case.
5. Loosen lock nut and adjust clearance between rocker arm and valve guide with adjustment screw.
6. Repeat for each cylinder; each set of valves adjusted individually.
7. Replace rocker arm cover and tighten cover nuts.

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

⚠ Always remove grounded (-) battery clamp first and replace ground clamp last.

⚠ Booster and main batteries must have the same voltage rating.

Tools: hydrometer

1. Check electrolyte level daily; add distilled water to manufacturer's recommended level.
2. Check and clean batteries, cables and terminals every 100 hours.
3. Clean corrosion with water and baking soda solution; flush with clean water.
4. Tighten terminals and grease them to inhibit corrosion.
5. Check battery condition with a hydrometer every 250 hours.
6. For boosting: connect positive booster terminal to positive main battery terminal.
7. Connect negative booster terminal to ground on the engine block.
8. Remove booster battery after starting engine.

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

⚠ Use cardboard or wood, not hands, to search for suspected leaks.

Tools: wrench, cardboard

1. Loosen bleed bolt A on top of the filter.
2. Pump hand primer B on fuel lift pump until pure fuel with no bubbles escapes.
3. Tighten bleed screw A.
4. Loosen bleed screw C; pump hand primer until pure fuel escapes, then tighten.
5. If engine does not start, loosen a fuel line at injector and crank until pure fuel escapes; tighten.
6. Do each line one at a time.
7. After starting, use a piece of cardboard to look for fuel leaks.

⚠ Overtightening can damage the filter housing.

⚠ No wrench when tightening.

Tools: filter wrench

1. Change the lube oil filter every 250 hours.
2. Use a filter wrench to remove old filter and dispose of it properly.
3. Make sure old gasket is removed and discarded; clean mount face.
4. Spread thin film of engine oil on new filter gasket and screw on until gasket meets sealing surface.
5. Using hands only, tighten filter one-half turn farther.
6. Fill engine with recommended oil, start, check for leakage; stop, wait 3 minutes, check level.

⚠ Cooling water reaches extremely high temperatures; allow engine to cool before working.

⚠ Open filler cap carefully using protective clothing.

1. Flush cooling system every 2500 hours or every 12 months, whichever comes first.
2. Remove radiator cap, radiator drain and drain engine block.
3. Pour clean water into radiator until water is free of discoloration and sediment.
4. Close radiator drain and continue flushing until engine drain water is clear.
5. Open all drain cocks and drain completely.
6. Close drain cock and refill with recommended mixture.
7. Clean leaves, dust and other debris off radiator fins.

⚠ Never use a flushing oil.

⚠ Dispose of waste oil in an approved manner.

1. Change engine oil and oil filter after 50 hours; use Service CC 30 weight first 100 hours.
2. Change oil and filter again at 100 hours, then every 250 hours.
3. In intermittent cold weather, change oil every 100 hours or six weeks.
4. Loosen clamp on oil change tube, remove cap, drain oil, replace cap and tube.
5. Refill engine with recommended oil for the season.

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

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

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

1. Check water level by removing pressure cap from radiator.
2. Cold level should be about 1 in. (2.5 cm) below filler cap sealing surface.
3. Check crankcase oil level with dipstick; must be in waffled area.
4. Check fuel tank level and open any fuel valves.
5. Battery switch must always be kept ON while engine is running.

1. First 100 hours are critical to engine life and performance.
2. Operate under various conditions, particularly heavy loads with minimal idling.
3. Frequently check engine temperature and oil pressure gauges.
4. Oil consumption is greater during break-in as piston rings seat.
5. Change engine oil and filter at 50 hours.
6. Change oil and filter again at 100 hours, then every 250 hours.

⚠ Holding the switch too long can burn out the glow plugs.

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

1. Remove electrical load from the generator set.
2. Run the engine for a 2 to 3 minute cool down period.
3. Hold the Engine Control switch to STOP until engine comes to a complete stop.

⚠ Do not use pry bars to remove injectors from cylinder head.

⚠ Overtightening can damage injector.

⚠ DO NOT use hand to check for leaks.

Tools: wrench, torque wrench

1. Clean loose dirt from around injectors and fuel lines.
2. Relieve high pressure by loosening delivery line flare nuts at each injector.
3. Remove delivery lines as an assembly; do not remove spacers; cover ends and openings.
4. Remove return line retaining bolts and return line.
5. Unscrew and remove injectors.
6. Discard copper sealing washers and cover holes to prevent dirt entering cylinders.
7. Install new copper sealing washer, screw in injector and tighten.
8. Install return line with new sealing washer; tighten retaining bolts.
9. Install delivery lines loose at injectors for bleeding; crank engine to fill lines; tighten.