Northern Lights OM3-80 Owner's Manual

OM3-80

For Models: M80A13

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constitu-

ents are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

Northern Lights

4420 14th Avenue N.W. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455

Printed in U.S.A. PART NO.: OM3-80 9/15

OPERATOR'S MANUAL

#OM3-80 for Models:

M80A13

Read this operator's manual thoroughly before starting to operate your equipment.

This manual contains information you will need to run and service your new unit.

Table of Contents

INTRODUCTION ..................................................2

Models Included .................................................2

Model Numbers ..................................................2

Serial Numbers ...................................................2

WARRANTY ...........................................................3

SAFETY RULES ..............................................3 - 7

LOCKOUT / TAG OUT PROCEDURES ........ 8

COMPONENT LOCATIONS

M80A13 ........................................................... 10

CONTROL PANELS

Series 3B ...........................................................11

OPERATING PROCEDURES

Emission-Related Instructions .......................... 12

Before Starting .................................................. 12

Shutdowns and Alarms ..................................... 13

ENGINE OPERATION

Normal Engine Operation ................................ 14

Break-In Service ...................................... 14 - 16

Engaging & Disengaging Front PTO (If equipped) ......

Cold Weather Operation

Using a Booster Battery or Charger ............... 17

Welding Near Electronic Control Units .......... 18

Keeping Electronic Control Units Clean

.........................................

.............

16 16

SERVICE INTERVAL CHARTS

Propulsion and Prime Power Units .................. 20

Standby Generator Sets .................................... 21

LUBRICATION AND MAINTENANCE

Daily Pre-starting Checks ........................ 22 - 24

250 Hour/6 Month ................................... 25 - 30

500 Hour/12 Month ................................. 31 - 41

2000 Hour/24 Month Service as Required

TROUBLESHOOTING

General Troubleshooting Information ............. 59

Precautions for Welding ................................... 60

EC Engine Electrical System Layout .............. 61

Wiring Diagrams ...................................... 62 - 77

Engine Troubleshooting ........................... 78 - 82

Electrical Troubleshooting ............................... 83

Diagnostic Trouble Codes ........................ 84 - 87

Intermittent Fault Diagnostics ....................... 88

Displaying Diagnostic Gauge Software ... 88 - 89

STORAGE .................................................... 89 - 91

SPECIFICATIONS ............................................. 92

................................. 42 - 49

................................... 50 - 58

It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc.

Proprietary Information

This publication is the property of Northern Lights, Inc.

OM3-80 9/15

Introduction

Servicing of marine engines and generator sets presents unique problems. In many cases boats cannot be moved to a repair facility. Marine engines cannot be compared to the servicing of automobiles, trucks or even farm equipment. Failures often occur in remote areas far from competent assistance. Marine engines are taxed far more severely than auto or truck engines; therefore, maintenance schedules must be adhered to more strictly.

Model Numberss

M80A13

80 kW Northern Lights® commercial marine generator with a John Deere

Powertech Tier III 6068 engine block and an electronically controlled fuel system.

Failures begin with minor problems that are overlooked

and become amplied when not corrected during

routine maintenance.

As operator, it is your obligation to learn about your equipment and its proper maintenance. This is not a comprehensive technical service manual. Nor will it make the reader into an expert mechanic. Its aim is to aid you in maintaining your unit properly.

Serial Numberss

When referencing Northern Lights equipment by serial number, please refer only to the number stamped on the Northern Lights® serial number plate.

OM3-80 9/15

Warranty

WARNING

DANGER

WARNING

CAUTION

A warranty registration certicate is supplied

with your set. The extent of coverage is described in the Limited Warranty Statement. We recommend that you study the statement carefully.

Safety Rules

NOTICE: Accident reports show that careless use of engines causes a high percentage of accidents.

You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.

IMPORTANT SAFETY INSTRUCTIONS. Electromagnetic equipment, including generator sets and their accessories, can cause bodily harm and life threatening injuries when improperly installed, operated or maintained. To prevent accidents be aware of potential dangers and act safely.

READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL, PRIOR TO THE INSTALLATION OF ANY GENERATOR SET OR ACCESSORY. KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE.

Recognize Safety Symbols and Instructions

In addition to the information found in this section, this

operator’s manual uses three dierent signal words to outline potential dangers of a specic nature.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTE: If the warranty is to apply, the servicing instructions outlined in this manual must be followed. If further information is needed, please contact an authorized dealer or the factory.

on parts and components from outside suppliers that is not reproduced in this manual. Consult the suppliers for additional safety information.

Learn how to operate the machine and how to use the controls properly. Only trained personnel should operate machines, or work on or around them.

Keep you machine in proper working condition. UNAUTHORIZED MODIFICATIONS TO THE MACHINERY MAY IMPAIR ITS FUNCTION AND SAFETY PARAMETERS.

Prevent Bypass and Accidental Starting

Do not start engine by shorting across start terminal. Engine will start if normal circuitry is bypassed, creating a hazard by runaway machinery.

Start engine only from operator’s station.

Follow All Safety Instructions

Carefully read and understand all safety messages in this manual and on your machine’s safety signs. Keep signs in good and clean condition. Replace missing or damaged signs. Be sure new equipment components and repair parts include the current safety signs. For replacement signs,

proper placement of safety signs or clarication on any

safety issue, consult your Northern Lights dealer or the factory. There can be additional safety information contained

Handle Fuel Safely - Avoid Flames

Diesel is highly ammable and should be treated

with care at all times. Do do not refuel while

smoking or when near sparks or open ame.

ALWAYS STOP ENGINE BEFORE FUELING

MACHINE. Always ll

portable fuel tank outdoors. Never fuel a hot engine.

OM3-80 9/15

Safety Rules (Continued)

CAUTION

DANGER

WARNING

Prevent accidental discharge of starting uids by

storing all cans in a cool, safe place, away from sparks

or open ame. Store with cap securely on container.

Never incinerate or puncture a fuel container.

Prevent res by keeping machine clean of accumulated

trash, grease and debris. Always clean any spilled fuel as swiftly as possible. Do not store oily rags, which can ignite and burn spontaneously.

Be prepared if a re starts. Keep a rst aid kit and re

extinguisher handy. Keep emergency contact numbers

for re department, doctors, ambulance and hospital

near the telephone.

Service Machines Safely

Do not wear a necktie, scarf, necklace, rings or other jewelry, or any loose clothing when working near moving parts. Tie long hair behind your head. If any of these items get caught in moving machinery, severe injury or death could result.

Check for any loose electrical connections or faulty wiring.

Look completely around engine to make sure that everything is clear before starting.

Operating equipment requires the full attention of the operator. Do not use radio or music headphones while operating machinery.

Practice Safe Maintenance

Understand all service procedures before starting work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is in operation.

Keep hands, feet and clothing away from powerdriven equipment. When shutting down an engine, disengage all power and operator controls. Allow the engine to cool completely before beginning any service work.

Securely support any machinery elements that must be raised for service work with support or lifting

machinery specically intended for that purpose.

Keep all parts in good conditions and properly installed. Fix damage immediately. Replace any worn or broken parts. Remove any build up of grease, oil or debris.

Disconnect battery ground cable (-) before making any adjustments or service work.

Stay Clear of Rotating Drivelines

Wear Protective Clothing

To prevent catching anything in moving machinery,

always wear close tting clothes and safety equipment

appropriate to the job. Prolonged exposure to loud noise can cause hearing loss or impairment. Wear suitable authorized hearing protection, such

as earmus or plugs to

protect against loud noises.

Entanglement in rotating drivelines can cause serious injury or death. Keep shields in place at all times. Make sure that rotating shields turn freely in pace with the drivelines.

Do not wear loose tting equipment around rotating

drivelines. Stop the engine and make sure that all moving parts have stopped before making any adjustments, connections, or performing any other type of service to the engine or other driven equipment.

OM3-80 9/15

Safety Rules (Continued)

WARNING

Install all Safety Guards

Direct contact with rotating fans, belts, pulley and drives can cause serious injury.

Keep all guards in place at all times during engine operation.

Wear close-tting clothes. Stop the engine and be

sure all fans, belts, pulleys and drives are stopped before making adjustments, connections, or cleaning near fans and their components.

Do not allow anything on your person to dangle into or come in contact with a moving fan, belt, pulley or drive. Fans can act as vacuums and pull materials up from below, so avoid that area as well while in service.

Safe Battery Handling

To Avoid Hazards:

• Fill batteries only in well-ventilated areas.

• Wear appropriate eye protection and rubber gloves.

• Never use air pressure to clean batteries.

• Wear appropriate ventilation equipment to avoid inhaling fumes when adding electrolyte.

• Do not spill or drip electrolyte.

• Use correct jump-start procedure if required.

If acid is spilled on skin or in eyes:

1. Flush skin with water.

2. Apply baking soda or lime to help neutralize acid.

3. Flush eyes with water for 15-30 minutes.

4. Get medical attention immediately. If acid is swallowed:

1. DO NOT induce vomiting.

2. Drink large amounts of water or milk, without exceeding 2 liters (2 quarts)

3. Get medical attention immediately

Prevent Battery Explosions Battery gas is highly

ammable. Battery

explosions can cause severe injury or death. To help prevent battery explosions, keep sparks, lighted

matches and open ame away from the top of battery.

When checking battery electrolyte level, use a

ashlight.

Never check battery charge by contacting the posts with a metal object. Use a volt-meter or hydrometer.

Frozen batteries may explode if charged. Never charge a battery that has not been allowed to warm to at least 16oC (60oF).

Always remove grounded (-) battery clamp rst and

replace ground clamp last.

ulfuric acid in battery electrolyte is poisonous and

S strong enough to burn skin, eat holes into clothing and other materials, and cause blindness if splashed into eyes.

Battery posts, terminals, and related accessories can contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause serious injury. Among the potentially hazardous chemicals that may be used with Northern Lights products are lubricants, coolants, paints and adhesives.

All potentially hazardous chemicals come with a Material

Safety Data Sheet (MSDS). The MSDS provides specic

details on chemical products, including physical hazards, safety procedures and emergency response techniques

OM3-80 9/15

Safety Rules (Continued)

CAUTION

WARNING

DANGER

Read and understand the MSDS for each chemical before you start any job that includes it. Follow the procedures and use appropriate equipment exactly as recommended.

Contact your Northern Lights dealer or Northern Lights factory for MSDS’s used on Northern Lights products.

Work in Well Ventilated Areas

Exhaust fumes from engines contain carbon monoxide and can cause sickness or death. Work in well ventilated areas to avoid prolonged exposure to engine fumes. If it is necessary to run an engine in an enclosed area, route the exhaust fumes out of the area with an approved, leak proof exhaust pipe extension.

Remove Paint Before Welding or Heating

Hazardous fumes can be generated when paint is heated by welding, soldering or using a torch. To avoid potentially toxic fumes and dust, remove paint before heating.

Remove paint a minimum of 100

• mm (4 in.) from the

area that will be aected by heat.

•

If paint cannot be removed, wear an approved respirator.

• If you sand or grind paint, use an approved respirator.

• If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers from the area.

• Allow at least 15 minutes for fumes to disperse before welding or heating.

Do not use a chlorinated solvent in an area where welding will occur. Work only in areas that are well ventilated. Dispose of paint and solvent properly.

engine has been shut o. Do not remove a ller cap

unless it hands. Slowly loosen cap to relieve pressure before opening fully.

Avoid High Pressure Fluids

is cool enough to comfortably grip with bare

Relieve pressure prior to disconnecting pressurized lines.

Escaping uid under pressure

can penetrate the skin causing serious injury. Always relieve pressure before disconnecting hydraulic or other pressurized lines.

Tighten all connections rmly before re-applying

pressure.

If searching for leaks, use a piece of cardboard. Always protect your hands and other body parts from

high-pressure uids.

If an accident occurs, see a doctor immediately. Any high pressure spray injected into the skin must be removed within a few hours to prevent the risk of gangrene or other infection.

Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated

by heating near pressurized uid

lines, resulting in severe burns and bodily injury. Pressurized lines can rupture when heat goes beyond the immediate

ame area. Do not weld, solder or use a torch or open ame near pressurized lines or other ammable uids.

Do Not Open High-Pressure Fuel System

Service Cooling System Safely

Opening a pressurized cooling system can release explosive

uids and causing serious burns.

Before opening any pressurized cooling system, make sure the

Many Northern Lights engines use high-pressure

fuel injection. High-pressure uid remaining in fuel

lines can cause serious injury. Do not disconnect or attempt any repair of fuel lines, sensors, or other

OM3-80 9/15

Safety Rules (Continued)

WARNING

CAUTION

WARNING

components between the high-pressure fuel pump and nozzles on engines with high pressure fuel systems.

ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH PRESSURE FUEL INJECTION SYSTEMS.

material containing asbestos. Keep all bystanders away from any area where asbestos dust may be generated.

Use Proper Lifting Equipment and Techniques

Avoid Hot Exhaust

Avoid exposure to and physical contact with hot exhaust gases. Exhaust parts and streams can reach high temperatures during operation, leading to burns or other serious injury.

Cleaning exhaust lters can also lead to exposure to

hot exhaust gas and the injury risk associated with it. Avoid exposure to and physical contact with hot

exhaust gases when cleaning exhaust lters.

During auto or manual/stationary exhaust lter

cleaning operations, the engine will run at elevated temperatures for an extended period of time. Exhaust parts and streams can reach high temperatures during operation, leading to burns or other serious injury.

Avoid Harmful Asbestos Dust

Inhaling asbestos bers may cause

lung cancer. Avoid breathing any dust that may be generated when handling components containing

asbestos bers, including some

gaskets.

The asbestos used in these components is usually found in a resin or otherwise sealed. Normal handling of these components is not dangerous, as long as airborne dust containing asbestos is not generated. Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding materials containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If this vacuum is not available, apply a mist of oil or water on the

Lifting heavy components incorrectly can cause severe injury or damage to machinery. Avoid unbalanced loads. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid. Follow all recommended removal and installation procedures in this and associated Northern Lights manuals.

Use Proper Tools

Makeshift tools and procedures can create safety hazards. Always use appropriate tools for the job.

Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, always use the correct sized tools.

Do not use US measurement tools on metric fasteners, or vice versa. Use only service parts that

meet Northern Lights specications.

Dispose of Waste Properly

Disposing of waste improperly can threaten the environment and lead to unsafe working conditions. Potentially harmful waste used in Northern Lights

equipment can include oil, fuel, coolant, lters and

batteries.

Use leakproof containers to drain uid. Do not

use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain or into any water source.

OM3-80 9/15

CAUTION

WARNING

CAUTION

Lock Out / Tag Out Procedures

Scope

During maintenance, repairs or retooling of a Northern Lights generator set, simply turning the machine o󰀨 or unplugging

it while it is being worked on does not give enough protection to others who are not performing the maintenance or

repair. Many serious accidents happen when someone thought the machine was turned o󰀨, or all of its energy was

safely blocked or released.

General Policy

To avoid dangerous or hazardous situations, refrain from any of the following:

• Removing or bypassing a guard or other safety device

• Placing any part of your body in a position where you could be caught by moving machinery.

• Cleaning or oiling machinery when in operation.

• Adjusting circuits, chillers, pumps, air handlers, valves, circuit breakers or fans while in operation.

• Working on piping or high pressure systems.

Lock Out/Tag Out Instructions Electrical Equipment

Be sure the equipment’s ON/OFF switch is in the OFF position and is unplugged from any electrical source before attempting to perform any type of work on the equipment. Obtain an electrical plug cap cover with a lockset. Secure the plug terminal end using the electrical plug lockout cap. Lock the cap and retain the key.

If the equipment is directly wired into an electrical box with

a shut o󰀨 switch, obtain a lock pad and/or the appropriate

colored tags and place the lock and tag through the shut

o󰀨 lever. Retain the key until the repair is completed and the machine is safe to start. Be certain the shut o󰀨 lever

is in the OFF position before restarting. NEVER give a lock out key to unauthorized personnel.

If the equipment is directly wired into an electrical box

without a shut o󰀨 switch and lock out capability, then a

circuit breaker lock out will be required. Obtain a circuit lock and tag set. Install the lock onto the circuit breaker box. Ensure the unit ON/OFF switch is in the OFF position before restarting.

Lock Out/Tag Out Instructions Pneumatic and Hydraulic Equipment

If shutting o󰀨 of air, water or other material cannot be achieved at the local supply valve, shut o󰀨 valves further back in the system and re-check the bleed-o󰀨 point until complete shut-o󰀨 is achieved.

A󰀩x a DO NOT OPERATE tag to each valve handle that requires shut o󰀨. Each DO NOT OPERATE tag must be

signed and dated by the authorized technician servicing the equipment.

Lock Out/Tag Out Instructions Air Hose Connected Pneumatic Equipment

Equipment connected to the compressed air system

through an air hose with a detachable tting must be

shutdown and unplugged. Excess air must be bled prior to removing the air hose, prior to any maintenance or repair activities.

A󰀩x a DO NOT OPERATE tag to the air hose near the detachable tting. Each DO NOT OPERATE tag must be

signed and dated by the authorized technician servicing the equipment. Check that the equipment cannot be operated by activating the ON switch.

Stored Energy

Immediately after applying Lock Out or Tag Out devices, ensure that all potentially hazardous stored or residual energy is relieved, disconnected, restrained and otherwise rendered safe.

Verication of Isolation

Verify the machinery or equipment is actually isolated and de-energized prior to beginning work on a machine or on equipment that has been locked out.

Restarting Procedures

For servicing pneumatic and hydraulic equipment, the following additional procedures must be implemented, following completion of lock out/tag out procedures for the unit to be serviced:

Shut o󰀨 air, water or supply valves at the equipment to

be serviced.

Check the local bleed-o󰀨 point for completed release of

pressurized air, water or oil.

Follow the procedures below prior to restoring energy:

• Ensure that all machinery or equipment is properly reassembled. Inspect the machinery or equipment to verify non-essential items have been removed.

• Ensure that all personnel are safely outside danger zones. Notify personnel that lock out/tag out devices have been removed and energy will be reapplied.

• Only authorized personnel may remove lock out/tag out devices or notices.

OM3-80 9/15

Notes

OM3-80 9/15

Component Locations

1. AC Junction Box

2. Air Cleaner

3. Coolant Fill

4. Alternator

5. Belt Guard

6. Lube Oil Dipstick

7. Lube Oil Filter

8. Lube Oil Fill

9. Fuel Filter

10. DC/Control Junction Box

M80A13 (Shown with optional equipment)

11. Fuel Injection Lines

12. Starter

13. Thermostat Cover

14. Expansion Tank

15. Exhaust Elbow

16. Turbocharger

OM3-80 9/15

Northern Lights Control Panels

Figure 7: Series 3B Generator Control Panel

1. SHUTDOWN BYPASS SWITCH

This switch bypasses the safety shutdown feature

during the starting process.

2. ENGINE CONTROL SWITCH

To start the engine, hold this switch in the START

position until the engine is running.

NOTE: Excessive cranking of marine sets equipped

with water lift muer systems can cause engine

damage.

After the engine starts, release the switch and it will

return to RUN position. To stop the engine, hold the switch in the STOP position.

3. OIL PRESSURE GAUGE

The oil pressure gauge shows the oil pressure in

the engine lubricating system. If the pressure drops below 15 PSI at a speed higher than idling, stop the engine and investigate.

4. COOLANT TEMPERATURE GAUGE

Water temperature gauge shows the temperature of

the cooling water. If the gauge registers over 200°F (93.30C) or drops below 140°F (600C), stop the engine and investigate.

5. HOUR METER

Keeps track of the engine running time.

6. DC VOLTMETER

When the engine is running, it indicates the

voltage output of the alternator.

OM3-80 9/15

Emission-Related Installation & Instructions

Failing to follow these instructions when installing

a certied engine in a vessel violates federal law (40 CFR 1068.105(b)), subject to nes or other penalties as

described in the Clean Air Act.

The installed exhaust system should not create exhaust

back pressure greater than 30” (760 mm) of water for

Operating Procedures

BEFORE STARTING

1. Check the water level by removing the pressure cap from the expansion tank. In order to give the

cooling water room to expand, the level should be

about 1 3/4 in. (4-5 cm) below the ller cap sealing surface when the engine is cold. When lling with

coolant, the venting cock on top of the turbocharger should be opened to ensure that no air pockets form in the cooling system (see Service Point #14).

CAUTION: Use protective clothing and open

the ller cap carefully when the engine is warm

to prevent burns.

2. Check the oil level in the crankcase with the dipstick.

The oil level should be between the “waed area” and the “oo”. Never allow the level to go below the “oo”. Always add the same viscosity of oil as is

already in the crankcase (see Service Point #1).

3. Check the fuel tank level and open any fuel valves.

4. Disengage clutch, if equipped.

5. Close the seacock, check and clean the strainer and reopen the seacock.

6. Place the battery switch in the ON position.

NOTE: The battery switch must always be kept ON

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

a turbocharged engine and 48” (1200 mm) for a non-

turbocharged unit, measured at the engine exhaust elbow.

If you install the engine in a way that makes the engine’s emission control information label hard to read during normal engine maintenance, you must place a duplicate label on the vessel, as described in 40 CFR 1068.105.

NOTE: If there is a governor locked at a specic

speed on the generator set, there may not be a slow idle function, so in that case operate the engine at high idle for 1 to 2 minutes before adding load. If the stand-by generator set is loaded as soon as it reaches rated speed, this procedure would not apply.

Operating

1. Check Gauges Often: Oil pressure must be above 29 PSI (if not above 15 PSI within 5 seconds of

starting, the engine should be stopped and the problem should be explored). Normal oil pressure is 50 PSI at rated load speed (1800 to 2500 RPM). Oil temperature should be 1150C (2400F) for normal operating temperature. The D.C. voltmeter should read between 13 and 14 volts (26-28 volts, 24 volt systems).

2. Check AC voltage and frequency meters (Series 4 Panel). If gauges deviate from normal levels, shut down the set and investigate.

3. Check belt for good alignment.

4. Let the unit run unloaded for a three to ve minute

warm-up period before applying load.

5. Do not add full electrical load until engine is at maximum operating temperature.

NOTE: If engine dies while under load, immediately

remove load and restart engine. Turbocharger parts could overheat if the oil ow stopped.

Starting

1. While holding the Shutdown Bypass switch in the ON position, push the Engine Control switch to the START position.

2. As soon as the engine starts, release both switches.

Do not crank the starter for more than 20 seconds.

3. If the engine fails to start the rst time, be sure

the starter has stopped before re-engaging. Wait 2 minutes before starting engine again.

Shutdown

1. Move the Engine Control Switch to the OFF position.

2. Close the sea cock and fuel valves, and put the

battery switch in the OFF position if the unit will be

o for an extended period.

NOTE: Do not turn the battery switch to OFF while

the engine is running.

OM3-80 9/15

Operating Procedures

3. Fill the fuel tank to minimize possible water condensation problems. Filling tanks at end of day drives out moisture-laden air.

4. For Heat Exchanger Engines: If the engine will be subjected to temperatures at or below 0°C(32°F), open the sea water pump end cover to drain the sea water from the system to prevent freezing. The sea water pump will require priming before starting the

engine.

5. Observe the hour meter reading on diagnostic gauge/ hourmeter to determine if periodic maintenance is necessary. Make appropriate entries in maintenance logs. (See LUBRICATION AND MAINTENANCE RECORDS Section.)

6. Perform required periodic maintenance on all other equipment, as recommended by the equipment manufacturers.

SHUTDOWNS AND ALARMS

1. Your unit is tted with a system to protect it from

high water temperature or low oil pressure. a. Generator sets have shutdown systems to stop the engine. They have no warning horns. b. Other alarms and shutdowns are available as optional equipment.

NOTE: Do not rely on your warning or shutdown

system to the exclusion of careful gauge monitoring.

Watching your gauges can prevent damage to the unit

and dangerous power losses.

2. Do the following when your shutdown system is

activated:

a. Check the temperature gauge. If the temperature is

above 205°F (97°C), shut o the engine immediately.

b. Use the Trouble Shooting Guide on pages 22- 24 to isolate the cause of the overheat.

CAUTION: Do not remove the water ll cap of an overheated engine. Escaping high temperature steam can cause severe burns. Allow the engine to cool and then remove the cap slowly, using

protective clothing.

c. Make repairs and restart after the temperature gauge registers below 180°F (83°C).

d. Watch the temperature gauge regularly and turn

o the unit if the temperature rises above 200°F

(94°C). Repeat the troubleshooting process.

3. If the shutdown is activated and the temperature

gauge shows temperature within normal temperature

range:

a. Check the engine crankcase oil level. b.

If the oil level is low, ll with recommended lubricating

oil and restart. Watch the oil pressure gauge carefully

and shut o the engine if it does not show a normal

reading after a few seconds of operation. c. If the oil level was normal, DO NOT restart the engine. Call your Northern Lights or Lugger dealer for assistance.

OM3-80 9/15

Normal Engine Operation

Engine Operation

Observe engine coolant temperature and engine oil pressure.Temperatures and pressures will vary between engines and with changing operating conditions, temperatures, and loads.See GENERALENGINE

your engine.

If coolant temperaturerises abovethe maximum coolant

engine. Unless temperature drops quickly, stopengine and determine cause before resuming operation.

Operatethe engineunder a lighter load and at slowerthan

runengine at slow idle unless necessaryfor maneuvering out of dock and harbor.

Break-In Service

The engineis ready for normal operation. However, extra

more satisfactory long-term engineperformanceand life. DO NOT exceed 100 hoursof operation with break-in oil.See GENERALENGINE SPECIFICATIONSin

Stop engine immediatelyifthereare anysigns of part failure.Symptomsthatmay be early signs of engine problemsare:

Sudden drop in oilpressure

•

Abnormal coolant temperatures

•

High marine gear oil temperature

•

Unusualnoise or vibration

•

Sudden loss of power

•

Excessive black exhaust

•

Excessive fuel consumption

•

Excessive oil consumption

•

Fluid leaks

•

OUOD006,000008F -19-21JUN07-1/1

Northern Lights

Break-in Oil. Operate theengine at heavy loads with minimal idling during thebreak-in period.

idle, constant speeds, and/or light load usage,or

a longerbreak-in periodmay be required. In these situations,anadditional 100 hour break-in periodis recommended usinganew changeof Northern Lights

Northern Lights

CheckEngine Oil

A—Engine Oil Dipstick

Continued on next page RG19661,00003BC-19-28FEB13-1/5

OM3-80 9/15

B—Dipstick Tu be

RG22038—UN—28NOV12

Engine Operation (Continued)

RG19661,00003BC-19-28FEB13-2/5

RG19661,00003BC-19-28FEB13-3/5

Continued on next page RG19661,00003BC-19-28FEB13-4/5

IMPORTANT:DONOT add makeupoil untilthe oil

levelisBELOW the ADD markon dipstick. John Deere Engine Break-In Oil (TY22041) shouldbe usedtomake up anyoil consumed during thebreak-in period.

3. Check engine oil level more frequently during engine break-in period.Ifoil must be added duringthisperiod, John DeereEngine Break-InOil is preferred.See ENGINEBREAK-IN OIL,inFuels, Lubricants, and CoolantSection.

IMPORTANT:DONOT usePLUS-50® Engine Oil

during thebreak-in periodofanew engineor enginethathas hadamajor overhaul. PLUS-50 oil will not allowanewor overhauled engine to properly wearduring thisbreak-inperiod.

RG8028A—UN—15JAN99

CheckEngine Oil

A—Crosshatch Pattern On

Dipstick

theFULLmark, whichever is present. Oillevels anywherewithin thecrosshatchare considered in the acceptable operatingrange.

PLUS-50isatrademark of Deere&Company

ENGINE OIL ANDFILTERin Lubricationand Maintenance/250 HourSection.) Fill crankcase with seasonalviscosity grade oil. (See DIESEL ENGINE OIL,in Fuels,Lubricants, and CoolantSection.)

NOTE:Someincreasein oil consumptionmay be

expectedwhen low viscosity oilsare used. Check oil levelsmorefrequently.

If air temperatureis below -10°C (14°F), use an engine block heater.

RG22045 —UN—29NOV12

RemoveOil Filter

A—Oil Filter

6. Watch coolanttemperature gauge (A) closely. If coolant temperaturerises above maximum coolant temperature (seeGENERAL ENGINE

loadonengine. Check sea (raw) water strainer for pluggingon heat exchanger engines. Unless temperature drops quickly, stop theengine and determinethe causebeforeresumingoperation.

A—Coolant Temperature

Gauge

RG13133—UN—07OCT03

CoolantTemperature Gauge -ElectronicallyControlledEngine

GeneratorSet Power Units

operation when needed, start engine and runatrated speed (with 50%—70%load) for30 minutes every2 weeks.DONOT allow engine to run extended periodof time with no load.

OM3-80 9/15

Engine Operation (Continued)

7. Check poly-vee beltfor proper alignment and seating in pulley grooves.

Two zincplugs (A) are installedinthe seawater cooling systemto help neutralizethe corrosive action of salt wateron internal cavitiesofmarine engine components.The reactionofthe zinc, when exposed to the saltwater, causes the plugstodeteriorate instead of criticalengine components.

operation, remove zinc plug fromeachheat exchanger end cap (B) and inspectfor corrosion to getanidea of rateof deteriorationinsea water.

If rate of corrosion is slightat50—100hoursor 2—4 weeks initialinspection, zinc plugs shouldbe inspectedat 250 hour intervals thereafter. (See INSPECTAND REPLACE ZINCPLUGS in Lubrication &Maintenance/250Hour Section)

EngagingAnd Disengaging FrontPTO (If Equipped)

CAUTION: Entanglementinrotatingdriveline

can cause serious injuryordeath.Keep shield on PTO driveshaftbetween clutch housingand the engine driven equipment at alltimes during

A—Zinc Plugs

B—End Cap

Stopthe engine andbe surePTO drivelineis stoppedbeforemaking adjustments.

CAUTION:Metal surfaces of PTO housing may be

hottothe touch during operationorat shutdown.

The optional front power take-off (PTO) transfersenginepowertoauxiliaryequipment or moving components.

ThePTO clutchiselectric and engaged by aswitch. Engage Gen-Setengines at no loadrpm.

ColdWeather Operation

Additional information on cold weatheroperation is available from your engine distributoror authorized servicing dealer.

Some engines are equippedwithan air intake heater whichwillmake startingthe engine easier in cold weather. If equipped, follow steps1-3as listed underSTA RTING THEENGINE, earlierin this section.

in arctic conditions.

TS198 —UN—23AUG88

AvoidEntanglement

If thepowertake-off does not work properly,contactyour authorized servicing dealeror engine distributor.

OURGP11,0000144-19-08DEC03-1/1

TS1356—UN—18MAR92

Starting FluidisFlammable

with air intake heaters.

OUOD006,0000080-19-22JUN07-1/1

OM3-80 9/15

Engine Operation (Continued)

RG,RG34710,5564 -19-03JAN02-1/1

UsingaBoosterBattery or Charger

A12-volt booster batterycan be connectedin parallel with battery(ies)onthe unittoaid in cold weather starting. ALWAYS use heavyduty jumper cables.

CAUTION:Gas given offbybattery is explosive.

Before connectingor disconnectingabattery charger,turn chargeroff. Make lastconnection

battery. Always connectNEGATIVE(–) cable

IMPORTANT:Besurepolarity is correct before making

connections. Reversed polarity willdamage electrical system.Always connectpositiveto positive andnegativetoground. Always use 12-volt booster battery for 12-volt electrical systems and24-volt boosterbattery(ies)for 24-volt electricalsystems.

1. Connect booster battery or batteriestoproduce the required system voltagefor your engine application.

NOTE:Toavoid sparks,DONOT allowthe free ends

of jumper cablesto touchthe engine.

2. Connect one end of jumper cabletothe POSITIVE (+) postofthe boosterbattery.

3. Connectthe other end of the jumper cable to the POSITIVE (+) post of battery connectedto starter.

4. Connect one end of the other jumper cableto the NEGATIVE(–) postofthe booster battery.

5. ALWAYS completethe hookup by making the last connectionofthe NEGATIVE(–) cabletoagood ground on theengine frame and away from the battery(ies).

6. Startthe engine. Disconnect jumper cables immediately after engine starts. Disconnect

TS204—UN—23AUG88

Exploding Battery

RG4678 —UN—14DEC88

12-Volt System

RG4698 —UN—14DEC88

24-Volt System

A—12-VoltMachine Battery

(ies)

B—12-VoltBoosterBattery

(ies)

C—Booster Cable D—Cableto StartingMotor

OM3-80 9/15

Engine Operation (Continued)

WeldingNear ElectronicControl Units

IMPORTANT:Do not jump-start engines witharc

welding equipment. Currents andvoltages are too highand may causepermanent damage.

1. Disconnect thenegative(-) battery cable(s).

2. Disconnect the positive (+) battery cable(s).

3. Connectthe positive and negative cables together. Do not attach to vehicle frame.

4. Clear or move any wiring harness sections awayfrom weldingarea.

5. Connect welder ground closeto welding point and away from control units.

TS953—UN—15MAY90

6. After welding,reverse Steps 1—5.

DX,WW,ECU02-19-14AUG09-1/1

Keep ElectronicControl Unit Connectors Clean

IMPORTANT:Donot opencontrol unit anddonot

clean withahigh-pressure spray.Moisture, dirt, andother contaminants may cause permanent damage.

1. Keep terminals clean and free of foreign debris. Moisture, dirt, and other contaminantsmay cause the terminals to erodeovertime and notmakeagood electrical connection.

2. If a connector is not in use, put on theproper dust cap or an appropriate sealtoprotectitfromforeign debris and moisture.

3. Control units are not repairable.

4. Since controlunitsare the componentsLEASTlikely to fail,isolate failure before replacing by completing a diagnosticprocedure. (See your John Deeredealer.)

5. Thewiring harnessterminals and connectorsfor electronic control units arerepairable.

DX,WW,ECU04-19-11JUN09-1/1

OM3-80 9/15

Notes

OM3-80 9/15

Lubrication and Maintenance

OUOD006,0000081 -19-18AUG11-1/1

Lubricationand MaintenanceService Interval Chart—Propulsion andPrime PowerUnits

Lubricationand Maintenance ServiceIntervals

Item

Daily/Before

Every Startup

250Hour/6

Month

500Hour/12

Month

2000Hour/24

Month

Service As

Required

Check EngineOil Leveland Coolant Level

•

CheckSea Water Strainer

•

CheckAir CleanerDustUnloader Valve&Restriction Indicator Gauge

•

VisualWalkaround Inspection

•

Drain WaterFromFuel Filter

••

Change EngineOil AndReplace OilFilter

•

Service Fire Extinguisher

•

Service Battery

•

Inspect and Replace Zinc Plugs

•

Check BeltTension and Wear (Manual Tensioner)

•

Check EngineMounts

•

Replace Crankcase Ve nt Filter (If Equipped)

•

CleanCrankcase Ventilation Assembly

•

CheckAir Intake Hoses,Connections, & System

•

Replace Fuel Filter Elements

•

CheckAutomatic Belt Tensioner and BeltWear

•

CheckCooling System

•

Coolant Solution Analysis-AddSCAs as required

•

Inspectand CleanHeat ExchangerCoreand Aftercooler Core (If Equipped)

•

Check Engine Speeds

•

Check Engine ElectricalGround

•

CheckCrankshaftVibration Damper (6-Cylinder)

•

Pressure Te st Cooling System

•

Inspectand RepairSea Water Pump

•

Checkand Adjust EngineValveClearance

•

Test Thermostats

•

AddCoolant

•

Replace AirCleaner Element

•

Service DryAir CleanerElement

•

Replace Alternator DriveBelt

•

CheckFront PTO(If Equipped)

•

BleedFuel System

•

Replace primary air cleaner elementwhenrestriction indicatorshows avacuum of 625mm (52 in.) H2O,orwhen

reset button has poppedup(6068SFM75 /AFM75 only).

is used and the coolantis tested annuallyAND additives arereplenished as neededby addingasupplementalcoolant additive, the

OM3-80 9/15

Lubrication and Maintenance (Continued)

OUOD006,0000082 -19-27OCT11 -1/1

Lubricationand MaintenanceService Interval Chart—Standby GeneratorSets

Lubricationand Maintenance ServiceIntervals

Item

Daily/Before

Every Startup

250Hour/6

Month

500Hour/12

Month

2000Hour/24

Month

Service As

Required

Operate EngineatRated Speed and 50%—70% Loadfor a Minimum of 30 Minutes.Perform every 2weeks.

Check EngineOil Leveland Coolant Level

•

CheckSea Water Strainer

•

CheckAir CleanerDustUnloader Valve&Restriction Indicator Gauge

•

VisualWalkaround Inspection

•

Drain WaterFromFuel Filter

••

Change EngineOil AndReplace OilFilter

•

Service Fire Extinguisher

•

Service Battery

•

Inspect and Replace Zinc Plugs

•

Check BeltTension and Wear (Manual Tensioner)

•

Check EngineMounts

•

Replace Crankcase Ve nt Filter (If Equipped)

•

CleanCrankcase Ventilation Assembly

•

CheckAir Intake Hoses,Connections, & System

•

Replace Fuel Filter Elements

•

CheckAutomatic Belt Tensioner and BeltWear

•

CheckCooling System

•

Coolant Solution Analysis-AddSCAs as required

•

Inspectand CleanHeat ExchangerCoreand Aftercooler Core (If Equipped)

•

Check Engine Speeds

•

Check Engine ElectricalGround

•

CheckCrankshaftVibration Damper (6-Cylinder)

•

Pressure Te st Cooling System

•

Inspectand RepairSea Water Pump

•

Checkand Adjust EngineValveClearance

•

Test Thermostats

•

AddCoolant

•

Replace AirCleaner Element

•

Service DryAir CleanerElement

•

Replace Alternator DriveBelt

•

CheckFront PTO(If Equipped)

•

BleedFuel System

•

Replace primaryair cleaner elementwhenrestriction indicator showsavacuum of 625mm(52 in.)H2O.

is used and the coolantis tested annuallyAND additives arereplenished as neededby addingasupplementalcoolant additive, the

OM3-80 9/15

Lubrication & Maintenance/Daily

Continued on next page RG19661,00003D3 -19-29JAN13-1/4

DailyPrestartingChecks

Do the following BEFORESTARTINGTHE ENGINEfor

IMPORTANT:DONOT add makeupoil untilthe oil

levelisBELOW theadd mark.

cap (B) maybe locatedon eitherthe left or the right side of engine.In addition,oil maybeadded at rocker arm

1. Check engine oil levelondipstick (A). Addas required, using seasonal viscositygrade oil. (See DIESEL ENGINE OIL in Fuels, Lubricants, and CoolantSection

the dipstick. Oil levelsanywhere within crosshatch (D)are considered in the acceptable operatingrange.

A—Dipstick B—Left Side Oil FillerCap

C—Rocker ArmFillerCap D—CrosshatchOnOil Dipstick

RG9837 —UN—12JAN99

Left SideDipstick -4CylinderOnly

RG22038—UN—28NOV12

Left Side OilFillerand Dipstick Location

RG22037 —UN—28NOV12

Rocker Arm CoverFiller Cap

RG22039—UN—08JAN13

OilFill Level on Dipstick

OM3-80 9/15

Lubrication & Maintenance/Daily (Continued)

RG19661,00003D3-19-29JAN13-2/4

Continued on next page RG19661,00003D3 -19-29JAN13-3/4

A—Engine To pTank

TS281—UN—23AUG88

High-Pressure Fluids

RG22040—UN—28NOV12

Engine To pTank

IMPORTANT:Arestrictedorclogged sea waterstrainer

willresult in hotter than normal (or overheated) engine coolantand marinegear oil temperatures.

3. Thesea water strainershouldbe checked dailyand cleanedas required, depending uponthe operating environment.

RG5993 —UN—27JAN92

Sea Wa terStrainer

OM3-80 9/15

Lubrication & Maintenance/Daily (Continued)

RG19661,00003D3-19-29JAN13-4/4

4. If equipped withair intake restriction indicator gauge (A), check gauge to determineifair cleaner needsto be serviced. The reset button will pop up when air cleanerneeds to be serviced.

IMPORTANT: Maximum air intake restriction is 625

mm (25 in. H

O).Acloggedair cleaner element willcause excessive intake restriction anda reduced air supplytothe engine.

5. Makeathorough inspectionofthe engine compartment. Lookfor oilor coolant leaks, worndrive belts, loose connections and trash build-up. Remove trash buildup and haverepairs madeasneededif leaksare found.

performing any maintenanceto reduce the chanceof system contamination.

Inspect:

•

Engine shields and guardsfor trash build-up.

•

Airintake system hoses and connectionsfor cracks

and loose clamps.

•

Alternator drivebelt for cracks, breaksorother damage.

•

Waterpumpfor coolant leaks.

•

Coolant system for leaks.

NOTE:Itisnormalforasmall amount of leakage to

occurasthe engine coolsdown and parts contract.

RG9874 —UN—12FEB99

AirIntakeRestriction Gauge

A—Air IntakeRestriction

Gauge

Excessive coolant leakage may indicatethe needto replacethe waterpump seal. Contact yourengine distributor or servicing dealer forrepairs.

6. Move switch to “ON” position and checkinstruments forproper operation. Turn key switch “OFF”.

7. Refertomanufacturer'sliteraturefor generator set daily service recommendations.

OM3-80 9/15

RG19661,00003D3-19-29JAN13-4/4

IMPORTANT: Maximum air intake restriction is 625

mm (25 in. H

O).Acloggedair cleaner element willcause excessive intake restriction anda reduced air supplytothe engine.

performing any maintenanceto reduce the chanceof system contamination.

Inspect:

•

Engine shields and guardsfor trash build-up.

•

Airintake system hoses and connectionsfor cracks

and loose clamps.

•

Alternator drivebelt for cracks, breaksorother damage.

•

Waterpumpfor coolant leaks.

•

Coolant system for leaks.

NOTE:Itisnormalforasmall amount of leakage to

occurasthe engine coolsdown and parts contract.

RG9874 —UN—12FEB99

AirIntakeRestriction Gauge

A—Air IntakeRestriction

Gauge

Excessive coolant leakage may indicatethe needto replacethe waterpump seal. Contact yourengine distributor or servicing dealer forrepairs.

6. Move switch to “ON” position and checkinstruments forproper operation. Turn key switch “OFF”.

7. Refertomanufacturer'sliteraturefor generator set daily service recommendations.

Continued on next page RG19661,00003D4 -19-28FEB13-1/3

Changing Engine Oil and Replacing Oil Filter

before 100 hoursmaximum of operation, then every250 hoursthereafter.

If John DeerePLUS-50™ or ACEA-E7/E6/E5/E4engine

change intervalmay be extended by 50 percentorto375 hours.

IMPORTANT:Ifusing BIODIESEL blends greater

than B20,shorten oil change intervaltohalf therecommendedservice interval or monitor engine oil using OILSCAN to ensure thatfuel dilution doesnot exceed 5%.

NOTE:OnGen Setengines usedasstandby units,

hours. No is allowed beyond 350 hours.

OILSCAN™ or OILSCANPLUS™ is a John Deere samplingprogram to help you monitormachine performanceand identify potential problemsbefore they cause serious damage. OILSCAN™ or OILSCAN PLUS™ kits are available from your John Deere dealer. Oil samples should be takenprior to the oil change. Refer to instructions provided with kit.

1. Run engine approximately5minutestowarmup oil. Shut engineoff.

RG22041—UN—07JAN13

OilPan DrainPlug

2. Remove oilpan drainplug(arrow).

3. Drain crankcase oilfrom engine while warm.

NOTE:Drain plug location may vary, depending

on theapplication.

PLUS-50isatrademark of Deere&Company. OILSCAN is atrademarkofDeere &Company. OILSCAN PLUS is atrademarkofDeere&Company.

Lubrication & Maintenance/250 Hour/6 Month

OM3-80 9/15

Lubrication & Maintenance/250 Hour/6 Month (Continued)

Continued on next page RG19661,00003D4 -19-28FEB13-2/3

maybe locatedon either sideofthe engine in a high-orlow-mount location.

IMPORTANT: Filtrationof oilsiscriticalto

6. Wipe both sealing surfacesofthe header(D, E) witha clean rag.Ensure thatthe notchesin dust seal(F) are properly installedinthe slotsofthe housing. Replace if damaged.

usedfor REMOVALONLY.

dustseal (F).DONOT apply an extra 3/4to 1-1/4 turn

OilPan Drain PlugWithCopper

Washer—Torque.............................................................70 N·m (52 lb-ft)

OilPan Drain PlugWith

O-Ring—Torque............................................................. 50 N·m (37 lb-ft)

A—Oil Filter Element B—Inner Seal C—OuterSeal

D—SealingSurface On Header E—SealingSurface On Header F— Dust Seal

RG22045 —UN—29NOV12

OilFilter

RG11617—UN—24OCT01

OilFilter Seals

RG22046—UN—29NOV12

OIlFilter Mounting Header

Northern Lights

RG19661,00003D4 -19-28FEB13-3/3

9. Fillengine crankcase with correct John Deere engine oil through rockerarm cover opening (A). (See DIESEL ENGINEOIL in Fuels, Lubricants, and CoolantSection for determining correctengine oil.)

seeENGINE CRANKCASE OIL FILLQUANTITIESin

IMPORTANT: Immediately after completing any

oil change, crank enginefor 30 seconds without permitting engineto start. This will help insure adequate lubrication to engine components beforeengine starts.

NOTE: Crankcaseoil capacitymay vary slightly.

10. Start engine and runto check forpossible leaks.

11.Stop engineand checkoil level after 10 minutes. Oil levelreading should be within crosshatch on dipstick.

A—Rocker ArmCover Oil Filler

Opening

OM3-80 9/15

Lubrication & Maintenance/250 Hour/6 Month (Continued)

Continued on next page RG,RG34710,5568 -19-20MAY96-1/2

Servicing Battery

CAUTION:Battery gas can explode. Keepsparks

to check battery electrolyte level.

Nevercheck battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Always removegroundedNEGATIVE(–) battery

WARNING: Battery posts, terminals, and related

accessoriescontain lead and lead compounds, chemicals knowntothe Stateof Californiato cause cancer and reproductive harm. Wash hands after handling.

1. On regular batteries, check electrolyte level. Filleach

NOTE:Low-maintenanceor maintenance-freebatteries

shouldrequire littleadditional service.However, electrolyte levelcan be checkedbycutting the center sectionofdecal on dash-line, andremoving cell plugs.If necessary, add clean, soft water

2. Keep batteries cleanby wiping them withadamp cloth.Keep all connections clean and tight. Remove

TS204—UN—23AUG88

Exploding Battery

any corrosion, and washterminalswithasolution of 1 part baking soda and4parts water.Tighten all connections securely.

NOTE:Coat battery terminals and connectors

with a mixture of petroleum jelly and baking sodatoretard corrosion.

3. Keep battery fully charged, especially during cold weather.Ifabatterycharger is used,turn charger off before connecting charger to battery(ies). Attach POSITIVE (+) battery charger lead to POSITIVE (+) battery post. ThenattachNEGATIVE (–)battery charger lead toagoodground.

OM3-80 9/15

Lubrication & Maintenance/250 Hour/6 Month (Continued)

RG,RG34710,5568 -19-20MAY96-2/2

CAUTION:Sulfuric acid in battery electrolyte is

poisonous.Itisstrong enough to burnskin, eat holesin clothing,and cause blindness if splashed into eyes.

Avoid thehazard by:

1. Fillingbatteries in a well-ventilated area.

2. Wearing eyeprotection andrubber gloves.

3. Avoidingbreathing fumes when electrolyte is added.

4. Avoidingspilling or dripping electrolyte.

5. Use proper jump startprocedure.

If youspill acidonyourself:

1. Flushyour skin with water.

2. Apply baking sodaor limeto help neutralizethe acid.

3. Flushyour eyes with waterfor 10–15 minutes. Getmedical attentionimmediately.

If acid is swallowed:

1. Drinklarge amountsof waterormilk.

2. Thendrink milk of magnesia, beaten eggs, or vegetable oil.

3. Get medical attention immediately.

In freezing weather,run engineat least30 minutesto assure thorough mixing after adding waterto battery.

If necessar yto replace battery(ies), replacements must meetor exceedthe followingrecommended capacitiesat

-18°C (0°F):

12 Volt StandardDuty Starter—ColdCranking

Amps.................................................................................................. 640

12 Volt HeavyDuty Starter—ColdCranking

Amps.................................................................................................. 800

TS203—UN—23AUG88

Sulfuric Acid

24 Volt StandardDuty Starter—Cold Cranking

Amps.................................................................................................. 570

OM3-80 9/15

+ 67 hidden pages

Northern Lights OM3-80 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual