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Northern Lights OM3-80 Operator's Manual

Marine generators for models: m80a13
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OM3-80
For Models: M80A13
OPERATOR'S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators

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Summary of Contents for Northern Lights OM3-80

  • Page 1 OM3-80 For Models: M80A13 OPERATOR’S MANUAL Marine Generators | Marine Diesel Engines | Land-Based Generators...
  • Page 2 4420 14th Avenue N.W. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455 Copyright ©2015 Northern Lights, Inc. All rights reserved. Northern Lights™, and the Northern Lights logo are trademarks of Northern Lights, Inc. Printed in U.S.A. PART NO.: OM3-80 9/15...

  • Page 3: Table Of Contents

    This publication is the property of Northern Lights, Inc. It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc. © Northern Lights, Inc. All rights reserved. Litho U.S.A. Publication number OM3-80 9/15...

  • Page 4: Introduction

    M80A13 Powertech Tier III 6068 engine block and an electronically controlled fuel system. 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...

  • Page 5: Warranty

    For replacement signs, ALWAYS STOP ENGINE proper placement of safety signs or clarification on any BEFORE FUELING safety issue, consult your Northern Lights dealer or the MACHINE. Always fill factory. portable fuel tank outdoors. There can be additional safety information contained Never fuel a hot engine.
  • Page 6 Wear suitable authorized moving parts have stopped hearing protection, such before making any adjustments, as earmuffs or plugs to connections, or performing protect against loud noises. any other type of service to the engine or other driven equipment. OM3-80 9/15...
  • Page 7 Among the potentially hazardous with a metal object. Use a volt-meter or hydrometer. chemicals that may be used with Northern Lights Frozen batteries may explode if charged. Never products are lubricants, charge a battery that has not been allowed to warm to at least 16 o C (60 o F).
  • Page 8 Slowly loosen cap to relieve pressure before and use appropriate equipment exactly as recommended. opening fully. Contact your Northern Lights dealer or Northern Lights factory for MSDS’s used on Northern Lights products. Avoid High Pressure Fluids WARNING...
  • Page 9 Exhaust parts and streams can reach high Follow all recommended removal and installation temperatures during operation, leading to burns or procedures in this and associated Northern Lights other serious injury. manuals. Cleaning exhaust filters can also lead to exposure to...

  • Page 10: Lockout / Tag Out Procedures

    Scope During maintenance, repairs or retooling of a Northern Lights generator set, simply turning the machine off or unplugging it while it is being worked on does not give enough protection to others who are not performing the maintenance or repair.
  • Page 11 Notes OM3-80 9/15...

  • Page 12: Component Locations

    2. Air Cleaner 7. Lube Oil Filter 12. Starter 3. Coolant Fill 8. Lube Oil Fill 13. Thermostat Cover 4. Alternator 9. Fuel Filter 14. Expansion Tank 5. Belt Guard 10. DC/Control Junction Box 15. Exhaust Elbow 16. Turbocharger OM3-80 9/15...

  • Page 13: Control Panels Series 3B

    Northern Lights Control Panels 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 muffler systems can cause engine damage.

  • Page 14: Operating Procedures

    3. If the engine fails to start the first time, be sure the starter has stopped before re-engaging. Wait 2 NOTE: Do not turn the battery switch to OFF while minutes before starting engine again. the engine is running. OM3-80 9/15...

  • Page 15: Shutdowns And Alarms

    If the oil level was normal, DO NOT restart the engine. Call your Northern Lights or Lugger dealer for assistance. OM3-80 9/15...

  • Page 16: Engine Operation

    A—Engine Oil Dipstick B—Dipstick Tube a longer break-in period may be required. In these situations, an additional 100 hour break-in period is recommended using a new change of Northern Lights Northern Lights Continued on next page RG19661,00003BC -19-28FEB13-1/5 OM3-80 9/15...
  • Page 17 Check sea (raw) water strainer for plugging on heat exchanger engines. Unless temperature drops quickly, stop the engine and determine the cause before resuming operation. A—Coolant Temperature Coolant Temperature Gauge - Electronically Controlled Engine Gauge Continued on next page RG19661,00003BC -19-28FEB13-4/5 OM3-80 9/15...

  • Page 18: Engaging & Disengaging Front Pto (If Equipped)

    If equipped, follow steps 1- 3 as listed under STARTING THE ENGINE, earlier in this section. in arctic conditions. Starting Fluid is Flammable with air intake heaters. OUOD006,0000080 -19-22JUN07-1/1 OM3-80 9/15...

  • Page 19: Using A Booster Battery Or Charger

    6. Start the engine. Disconnect jumper cables 24-Volt System immediately after engine starts. Disconnect A—12-Volt Machine Battery C—Booster Cable (ies) D—Cable to Starting Mot B—12-Volt Booster Battery (ies) RG,RG34710,5564 -19- OM3-80 9/15...

  • Page 20: Welding Near Electronic Control Units

    (See your John Deere dealer.) Moisture, dirt, and other contaminants may cause the 5. The wiring harness terminals and connectors for terminals to erode over time and not make a good electronic control units are repairable. electrical connection. DX,WW,ECU04 -19-11JUN09-1/1 OM3-80 9/15...
  • Page 21 Notes OM3-80 9/15...

  • Page 22: Propulsion And Prime Power Units

    Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (52 in.) H2O, or when reset button has popped up (6068SFM75 / AFM75 only). is used and the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive, the OUOD006,0000081 -19-18AUG11-1/1 OM3-80 9/15...

  • Page 23: Standby Generator Sets

    Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (52 in.)H2O. is used and the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive, the OUOD006,0000082 -19-27OCT11-1/1 OM3-80 9/15...

  • Page 24: Daily Prestarting Checks

    A—Dipstick C—Rocker Arm Filler Cap B—Left Side Oil Filler Cap D—Crosshatch On Oil Dipstick Left Side Oil Filler and Dipstick Location Rocker Arm Cover Filler Cap Oil Fill Level on Dipstick Continued on next page RG19661,00003D3 -19-29JAN13-1/4 OM3-80 9/15...
  • Page 25 (or overheated) engine coolant and marine gear oil temperatures. 3. The sea water strainer should be checked daily and cleaned as required, depending upon the operating environment. Sea Water Strainer Continued on next page RG19661,00003D3 -19-29JAN13-3/4 OM3-80 9/15...
  • Page 26 OILSCAN™ or OILSCAN PLUS™ kits are available from your John Deere dealer. Oil samples should be taken prior to the oil change. Refer OM3-80 9/15 to instructions provided with kit.

  • Page 27: Hour/6 Month

    1. Run engine approximately 5 minutes to warm up oil. Shut engine off. PLUS-50 is a trademark of Deere & Company. OILSCAN is a trademark of Deere & Company. OILSCAN PLUS is a trademark of Deere & Company. Continued on next page RG19661,00003D4 -19-28FEB13-1/3 OM3-80 9/15...
  • Page 28 NOTE: Crankcase oil capacity may vary slightly. A—Rocker Arm Cover Oil Filler Opening 10. Start engine and run to check for possible leaks. 11. Stop engine and check oil level after 10 minutes. Oil level reading should be within crosshatch on dipstick. RG19661,00003D4 -19-28FEB13-3/3 OM3-80 9/15...
  • Page 29 POSITIVE (+) battery charger lead to POSITIVE (+) 2. Keep batteries clean by wiping them with a damp battery post. Then attach NEGATIVE (–) battery cloth. Keep all connections clean and tight. Remove charger lead to a good ground. Continued on next page RG,RG34710,5568 -19-20MAY96-1/2 OM3-80 9/15...
  • Page 30 If necessary to replace battery(ies), replacements must meet or exceed the following recommended capacities at 24 Volt Standard Duty -18°C (0°F): Starter—Cold Cranking Amps....................570 12 Volt Standard Duty Starter—Cold Cranking Amps....................640 12 Volt Heavy Duty Starter—Cold Cranking Amps....................800 RG,RG34710,5568 -19-20MAY96-2/2 OM3-80 9/15...
  • Page 31 4.8 mm (0.19 in.) on either plug, replace all zinc plugs. NOTE: Zinc plug new part dimensions are 31.8 mm (1.25 in.) long and 9.5 mm (0.38 in.) outer diameter. A—Measure Zinc Plugs C—Measure Diameter B—Measure Length Zinc Plug Erosion RG19661,00003D5 -19-29JAN13-2/2 OM3-80 9/15...
  • Page 32 1. Check the engine mounting bolts on support frame and engine block for tightness. Tighten as necessary. 2. Inspect overall condition of vibration isolators, if equipped. Replace isolators, as necessary, if rubber has deteriorated or mounts have collapsed. Check Mounting Holes RG19661,00003D7 -19-29JAN13-1/1 OM3-80 9/15...

  • Page 33: Hour/12 Month

    4. Inspect turbocharger compressor coupling for cracks, blockage or other damage. A—Hose, Compressor to Filter D—Oil Drain Line Housing E—Crankcase Vent System B—Hose, Rocker Arm Cover to Fitting Filter Housing C—Hose, Oil Drain Crankcase Vent System Fitting RG19661,00003D9 -19-13FEB13-1/1 OM3-80 9/15...
  • Page 34 (lines disconnected or is heard and a release of the retaining ring is felt. system. (See BLEEDING THE FUEL SYSTEM in Service A plug is provided with the new element for as Required Section.) plugging the used element. RG19661,00003E4 -19-13FEB13-1/1 OM3-80 9/15...
  • Page 35 (See BLEEDING THE FUEL SYSTEM in Service as Required Section.) 10. Connect water in fuel sensor. 11. Open fuel shut-off valve. Whenever the fuel system has been opened up for service (lines disconnected or RG19661,00003E5 -19-13FEB13-1/1 OM3-80 9/15...
  • Page 36 6. Record torque wrench measurement and compare as required. Spring Tension—Torque........18-22 N·m (13-16 lb-ft) NOTE: Threads on belt tensioner roller cap screw are LEFT-HAND threads A—Mark On Swing Arm C—Torque Wrench B—Mark On Tensioner Mounting Base Align Marks RG19661,00003E6 -19-13FEB13-2/2 OM3-80 9/15...
  • Page 37 IMPORTANT: Air must be expelled from cooling High-Pressure Fluids of cylinder head or plug in thermostat 2. Thoroughly inspect all cooling system hoses. Replace the air has been expelled. 1. Check entire cooling system for leaks. Tighten all clamps securely. RG,RG34710,5580 -19-20MAY96-1/1 OM3-80 9/15...
  • Page 38 COOL-GARD is a registered trademark of Deere & Company COOLSCAN is a registered trademark of Deere & Company COOLSCAN PLUS is a registered trademark of Deere & Company COOLSCAN PLUS is a registered trademark of Deere & Company DPSG,OUOD002,1921 -19-23NOV01-1/1 OM3-80 9/15...
  • Page 39 (B). 4. Remove two end cap mounting cap screws and remove end cap (C) with heat exchanger core (D) from rear of engine. A—Clamp C—End Cap B—End Cap D—Heat Exchanger Core Continued on next page RG19661,000040B -19-10MAR13-1/2 OM3-80 9/15...
  • Page 40 5. Connect all water piping and tighten hose clamps securely. Fill cooling system with the proper amount and concentration of ethylene-glycol base antifreeze. 6. Open sea cock, start engine and check for leaks. Install Heat Exchanger A—O-Rings C—Housing B—End Cap Continued on next page RG19661,000040F -19-10MAR13-1/2 OM3-80 9/15...
  • Page 41 7. Connect all water piping and tighten hose clamps securely. Fill cooling system with the proper amount and concentration of ethylene-glycol base antifreeze. 8. Open sea cock, start engine and check for leaks. A—Rear End Cap B—Front End Cap Install Front End Cap RG19661,000040F -19-10MAR13-2/2 OM3-80 9/15...
  • Page 42 Clean (with brass rod) and remaining debris from tubes. If you suspect that your aftercooler core is defective, have your authorized servicing dealer or engine distributor pressure test for leaks. Replace aftercooler core as required. Clean Aftercooler Core RG19661,000040D -19-10MAR13-2/2 OM3-80 9/15...
  • Page 43 RG19661,0000409 -19-08MAR13-1/1 Checking Engine Electrical Ground Also see precautions in Troubleshooting Section when Connections welding on engine or machine. Keep all engine ground connections clean and tight to prevent electrical arcing which can damage electronic components. OUOD002,0000169 -19-23NOV01-1/1 OM3-80 9/15...

  • Page 44: 2000 Hour/24 Month

    Clean (with brass rod) and remaining debris from tubes. If you suspect that your aftercooler core is defective, have your authorized servicing dealer or engine distributor pressure test for leaks. Replace aftercooler core as required. Clean Aftercooler Core RG19661,000040D -19-10MAR13-2/2 OM3-80 9/15...
  • Page 45 TESTING COOLING SYSTEM, in the Lubrication and Maintenance/500 Hour/12 Month Section.) A—Top Tank Cap 2. Slowly open the cap on the top tank (A) or heat exchanger to relieve pressure and allow coolant to drain faster. Continued on next page RG19661,00003D1 -19-28JAN13-1/2 OM3-80 9/15...
  • Page 46 10 minutes, remove heat exchanger or top tank cap and pull off lower cooling system hose to drain out 12. Close all drain valves. Reinstall hoses and tighten clamps securely. Install thermostats using a new gasket. RG19661,00003D1 -19-28JAN13-2/2 OM3-80 9/15...
  • Page 47 Install thermostat cover with O-ring, cap screws, washer and nut. Tighten nut and all cap 7. Install thermostats with a new gasket and pilot housing screws to 35 N·m (25 lb.-ft.) on stud (J). Install thermostat housing cap screws RG19661,0000405 -19-08MAR13-1/1 OM3-80 9/15...
  • Page 48 7. If any one thermostat is defective, replace both initial opening and full open temperatures may thermostats. 6. Remove thermostat and observe its closing action as it cools. In ambient air the thermostat should close completely. Closing action should be smooth and slow. OUOD006,0000095 -19-19JUN07-1/1 OM3-80 9/15...
  • Page 49 6. Open sea cock and prime sea water pump with water. Start engine and check for leaks. 3. Rotate impeller to align keyway and slide the key in place. Install impeller end cap in end of impeller bore. LOCTITE is a registered trademark of Loctite Corp. RG19661,0000401 -19-06MAR13-3/3 OM3-80 9/15...
  • Page 50 6. Open sea cock and prime sea water pump with water. Start engine and check for leaks. 3. Rotate impeller to align keyway and slide the key in place. Install impeller end cap in end of impeller bore. LOCTITE is a registered trademark of Loctite Corp. RG19661,0000401 -19-06MAR13-3/3 OM3-80 9/15...
  • Page 51 13. Open sea cocks, start engine and check pump operation. 10. Install pump and tighten cap screws to 73 N·m (54 lb-ft). 11. Connect sea water inlet and outlet tubes. Tighten mounting cap screws evenly until secure. RG19661,0000402 -19-09MAR13-1/1 OM3-80 9/15...

  • Page 52: Service As Required

    (See your authorized servicing dealer or engine distributor.) A—Fuel Injection Pump IMPORTANT: Never steam clean or pour cold water on a high-pressure fuel pump while it is still warm. To do so may cause seizure of pump parts. RG19661,00003C1 -19-23JAN13-1/1 OM3-80 9/15...
  • Page 53 IMPORTANT: Insure all air intake connections are secure to prevent ingestion of abrasive dirt and dust into the system, causing Replace Air Filter Element possible engine damage. B—Air Filter Element A—Air Filter Assembly Clamps engage clamps. RG19661,00003F5 -19-22FEB13-1/1 OM3-80 9/15...
  • Page 54 DO NOT steam clean or use high-pressure washers to clean media and/or rubber base or end cap. Remove Filter Element OUOD006,0000098 -19-10DEC09-1/5 for 10 minutes. Spray Filter with Cleaner Continued on next page OUOD006,0000098 -19-10DEC09-2/5 OM3-80 9/15...
  • Page 55 25 cm (10 in.) onto a group of pleats until the pleats become reddish in color. Respray any areas that are still white 10 minutes after initial application. Apply Oil To Filter Continued on next page OUOD006,0000098 -19-10DEC09-4/5 OM3-80 9/15...
  • Page 56 ALWAYS fully depress the air restriction indicator reset button (if equipped) to assure accurate readings. If equipped, fully depress air restriction indicator reset button (A) and release to reset indicator. Air Restriction Indicator Reset Button DPSG,OUOD007,2908 -19-24DEC02-2/2 OM3-80 9/15...
  • Page 57 Refer to belt routing at right. 5. Apply tension to belt with tensioner. Remove socket. 6. Start engine and check belt alignment. A—Cap Screws I— Idler Pulley ALT— Alternator T— Tensioner CSP—Crankshaft Pulley CP—Coolant Pump Belt Routing RG19661,00003F4 -19-20FEB13-1/1 OM3-80 9/15...
  • Page 58 1. Loosen thumb screw (A) and drain water and debris into a suitable container. Tighten thumb screw. 2. Dispose of water and debris in an environmentally safe manner. Drain Primary Fuel Filter - 6068SFM50 Shown A—Thumb Screw OUOD006,0000083 -19-16OCT07-1/1 OM3-80 9/15...
  • Page 59 NOTE: Normally the fuel system on these engines is necessary to turn the key off and on again to reprime the self-priming and self-bleeding, and does not require system before starting. a bleeding procedure by the operator. RG19661,00003FD -19-01MAR13-1/1 OM3-80 9/15...
  • Page 60 (B) to 140 N·m (103 lb.-ft.). 8. Connect sea water inlet and outlet. 9. Open sea cock, start engine and check for leaks. A—Sea Water Outlet D—Gear B—Cap Screws E—Lock Wasker C—Key F— Hex Nut Sea Water Pump Drive Gear RG19661,00003FF -19-02MAR13-1/1 OM3-80 9/15...

  • Page 61: Troubleshooting

    Inactive or stored DTCs indicate that a failure has occurred any DTCs which are displayed on the instrument panel. in the past, but is not currently occurring. This type of “stored” DTC can be caused by an “intermittent” failure. OUOD006,00000F8 -19-25SEP07-1/1 OM3-80 9/15...

  • Page 62: Precautions For Welding

    1. Remove the ground connection for the engine control system-to-vessel frame. Welding Precautions 2. Disconnect the connectors from the ECU. 3. Connect the welder ground close to the welding point and be sure ECU or other electronic components are not in the ground path. DPSG,OUOD007,2898 -19-04NOV99-1/1 OM3-80 9/15...

  • Page 63: Ec Engine Electrical System Layout

    13 — Fuel Pressure Sensor (Battery) 7— Manifold Air Temperature Connector 23— Unterminated Power Sensor Connector 14— Water-in-Fuel Sensor (Battery) 8— Suction Control Valve Sensor Connector 24— Low-Pressure Fuel Pump Connector 15— Fuel Rail Pressure Sensor Fuse (15 Amp) Connector RG19661,00003DE -19-15FEB13-1/1 OM3-80 9/15...

  • Page 64: Wiring Diagrams

    J3— 32 Position - Blue Sensor B— Mating View of Rail Pressure J1-E2— Excitation Return #1 P05— Fuel Rail Pressure Sensor X02— Camshaft Position Sensor Connector J1-E3— Analog 6 SE2— Focus 16 (ECU) J1— 32 Position - Black J1-E4— Return OM3-80 9/15 RG19661,00003EA -19-21FEB13-2/2...
  • Page 65 J3— 32 Position - Blue Sensor B— Mating View of Rail Pressure P05— Fuel Rail Pressure Sensor J1-E2— Excitation Return #1 X02— Camshaft Position Sensor Connector J1-E3— Analog 6 SE2— Focus 16 (ECU) J1— 32 Position - Black J1-E4— Return RG19661,00003EA -19-21FEB13-2/2 OM3-80 9/15...
  • Page 66 FOCUS 16 4.5L 4 VALVE ENGINE CONTROL UNIT (ECU) 32 POSITION - BLACK 48 POSITION - BROWN 32 POSITION - BLUE 5714 5412 5412 5012 5050 AUX CONNECTOR 5050 5050 5050 - FOCUS 16 (ECU) Continued on next page RG19661,00003EC -19-21FEB13-1/2 OM3-80 9/15...
  • Page 67 J1-C2— Analog 15 T04— Engine Coolant Throttle C08-P— Droop Isochronous J1-C4— Analog 8 Temperature Sensor C08-G— Stop Lamp Power Switch J1-D2— Excitation Return #2 T05— Fuel Temperature Sensor C08-Q— External Derate/Shut- J1-F3— Excitation Voltage #2 down Common RG19661,00003EC -19-21FEB13-2/2 OM3-80 9/15...
  • Page 68 FOCUS 16 4.5L 4 VALVE ENGINE CONTROL UNIT (ECU) 32 POSITION - BLACK 48 POSITION - BROWN 32 POSITION - BLUE 5714 5020 5412 5905 5012 5904 5050 5050 5050 - FOCUS 16 (ECU) Continued on next page RG19661,00003ED -19-21FEB13-1/2 OM3-80 9/15...
  • Page 69 (12 V/ 24 V) C09-D— Start Return J1— 32 Position - Black C09-E— Ground C09-R— Digital Throttle J1-C1— Cylinder 2 C09-F— CAN Shield C09-S— Sensor Return J1-D1— Cylinder 4 C09-G— Ignition J1-E1— Cylinder 1 J1-F1— Cylinder 3 RG19661,00003ED -19-21FEB13-2/2 OM3-80 9/15...
  • Page 70 CAN H 5020 5905 5904 SAE J1939/11 3-WAY DEUTSCH TERM 5904 5904 5905 5905 5020 5020 SAE J1939/11 3-WAY DEUTSCH CONN LOCATED NEAR ECU DIAGNOSTIC CONNECTOR 5050 5050 5050 - FOCUS 16 (ECU) Continued on next page RG19661,00003EE -19-25FEB13-1/2 OM3-80 9/15...
  • Page 71 SE1— Engine Start Components C10— SAE J1939/ 11 Way C14— Starter Relay Coil Power J2— 48 Position - Brown SE2— Focus 16 (ECU) Deutsch Connector, C15— Remote On/Off J3— 32 Position - Blue Located Near ECU J2-A1— CAN High RG19661,00003EE -19-25FEB13-2/2 OM3-80 9/15...
  • Page 72 48 POSITION - BROWN 32 POSITION - BLUE J2-L2 J2-L3 J2-M2 J2-L1 J2-L4 J2-M1 J2-M4 5412 5412 5012 5911 5714 WATER IN FUEL 5012 TRANSMISSION SENSORS 5050 5050 - FOCUS 14 (ECU) Continued on next page RG19661,00003EB -19-21FEB13-1/2 OM3-80 9/15...
  • Page 73 J3-B2— Excitation Return P01— Manifold Air Pressure Y5004— Low-Pressure Fuel C05-02— Shaft Speed J3-C1— Analog 6 Sensor Pump C05-03— Air Filter Restriction J3-C4— Analog 3 P05— Fuel Rail Pressure Sensor Fluid Temperature SE2— Focus 14 (ECU) RG19661,00003EB -19-21FEB13-2/2 OM3-80 9/15...
  • Page 74 FOCUS 14 4.5L 4 VALVE ENGINE CONTROL UNIT (ECU) 32 POSITION - BLACK 48 POSITION - BROWN 32 POSITION - BLUE 5714 5412 5412 5012 5012 5911 5714 5050 AUX CONNECTOR 5050 5050 5050 - FOCUS 14 (ECU) Continued on next page RG19661,00003EF -19-21FEB13-1/2 OM3-80 9/15...
  • Page 75 J3-B1— Analog 2 C08-G— Stop Lamp Power down Common J3-C2— Analog 5 C08-R— PWM Throttle J3-C3— Analog 4 Switch C08-S— Frequency Input J3-D3— Analog 8 C08-T— Throttle Station Two J3-H3— Excitation Return #2 Lamp/Wait To Start Lamp RG19661,00003EF -19-21FEB13-2/2 OM3-80 9/15...
  • Page 76 FOCUS 14 4.5L 4 VALVE ENGINE CONTROL UNIT (ECU) 32 POSITION - BLACK 48 POSITION - BROWN 32 POSITION - BLUE 5714 5020 5412 5905 5012 5904 5050 5050 5050 - FOCUS 14 (ECU) Continued on next page RG19661,00003F0 -19-25FEB13-1/2 OM3-80 9/15...
  • Page 77 SE2— Focus 14 (ECU) C09-D— Start C09-N— Override Shutdown Y01— Pressure Control Valve 1 C09-E— Ground C09-P— Override Shutdown C09-X— Bump Enable C09-F— CAN Shield Return J1— 32 Position - Black C09-G— Ignition J1-C1— Cylinder 2 J1-D1— Cylinder 4 RG19661,00003F0 -19-25FEB13-2/2 OM3-80 9/15...
  • Page 78 CAN H 5020 5905 5904 SAE J1939/11 3-WAY DEUTSCH TERM 5904 5904 5905 5905 5020 5020 SAE J1939/11 3-WAY DEUTSCH CONN LOCATED NEAR ECU DIAGNOSTIC CONNECTOR 5050 5050 5050 - FOCUS 14 (ECU) Continued on next page RG19661,00003F1 -19-25FEB13-1/2 OM3-80 9/15...
  • Page 79 SE1— Engine Start Components C10— SAE J1939/ 11 Way C14— Starter Relay Coil Power J2— 48 Position - Brown SE2— Focus 14 (ECU) Deutsch Connector, C15— Remote On/Off J3— 32 Position - Blue Located Near ECU J2-A1— CAN High RG19661,00003F1 -19-25FEB13-2/2 OM3-80 9/15...

  • Page 80: Engine Troubleshooting

    Electronic fuel system problem See your authorized servicing dealer Injection pump shut-off not reset. Turn key switch to “OFF” then to “ON”. Engine knocks Low engine oil level. Add oil to engine crankcase. Continued on next page OUOD006,0000113 -19-16OCT07-1/5 OM3-80 9/15...
  • Page 81 Use John Deere approved biodiesel fuel conditioners containing detergents. Injection pump out of time. See your authorized servicing dealer or engine distributor. Turbocharger not functioning. See your authorized servicing dealer (Turbocharger engines only.) or engine distributor. Continued on next page OUOD006,0000113 -19-16OCT07-2/5 OM3-80 9/15...
  • Page 82 See your authorized servicing dealer or engine distributor. Engine emits black or gray exhaust Improper type of fuel. Use proper fuel. smoke Clogged or dirty air cleaner. Service air cleaner. Engine overloaded. Reduce load. Continued on next page OUOD006,0000113 -19-16OCT07-3/5 OM3-80 9/15...
  • Page 83 O.D. of keel cooler tubes. Trash or debris in engine Clean engine compartment. compartment. High fuel consumption Improper type of fuel. Use proper type of fuel. Clogged or dirty air cleaner. Service air cleaner. Continued on next page OUOD006,0000113 -19-16OCT07-4/5 OM3-80 9/15...
  • Page 84 Use John Deere approved biodiesel fuel conditioners containing detergents. Engine out of time. See your authorized servicing dealer or engine distributor. Defective turbocharger. See your authorized servicing dealer or engine distributor. Low engine temperature. Check thermostat. OUOD006,0000113 -19-16OCT07-5/5 OM3-80 9/15...

  • Page 85: Electrical Troubleshooting

    DPSG,OUOD007,335 -19-04JAN02-1/2 Symptom Problem Solution Entire electrical system does not Faulty battery connection. Clean and tighten connections. function Sulfated or worn-out batteries. See your authorized servicing dealer or engine distributor. Blown main system fuse. Replace fuse. DPSG,OUOD007,335 -19-04JAN02-2/2 OM3-80 9/15...

  • Page 86: Diagnostic Trouble Codes

    Fuel Rail Pressure Signal Out of Range High Check Sensor and Wiring ..... Fuel Rail Pressure Signal Out of Range Low Check Sensor and Wiring ..... Fuel Rail Pressure Loss Detected Contact Servicing Dealer Continued on next page OURGP12,00001FC -19-08APR10-1/4 OM3-80 9/15...
  • Page 87 Check Injector Wiring or Injector Solenoid ......Injector Number 2 Circuit Has Low Resistance Check Injector Wiring or Injector Solenoid ........... Injector Number 2 Not Responding Injector Failed or Flow Limiter Closed Continued on next page OURGP12,00001FC -19-08APR10-2/4 OM3-80 9/15...
  • Page 88 ......ECU/Pump Timing Moderately Mismatched Contact Servicing Dealer ..........ECU/Pump Speed Mismatched Contact Servicing Dealer ........ECU/Pump Timing Extremely Mismatched Contact Servicing Dealer ..Continued on next page OURGP12,00001FC -19-08APR10-3/4 OM3-80 9/15...
  • Page 89 ..Sensor Supply Number 5 Voltage Out of Range Low Contact Servicing Dealer ..NOTE: Diagnostic gauge on instrument panel may also display text for communication faults, such as “CAN BUS FAILURE”. Contact you servicing dealer. OURGP12,00001FC -19-08APR10-4/4 OM3-80 9/15...

  • Page 90: Intermittent Fault Diagnostics

    1. Starting at the single or four engine parameter display, press the "Menu" key. Menu Key OURGP11,00000E3 -19-29SEP03-1/4 2. The main menu will be displayed. Use the "Arrow" key to scroll through the menu until "Utilities" is highlighted. Select Utilities Continued on next page OURGP11,00000E3 -19-29SEP03-2/4 OM3-80 9/15...

  • Page 91: Storage

    Follow than six (6) months MUST have long term storage normal storage procedures once the fuel preparation. ( See PREPARING ENGINE FOR LONG system has been purged. TERM STORAGE, later in this section.) OUOD006,0000114 -19-16OCT07-1/1 OM3-80 9/15...
  • Page 92 (See RECOMMENDED ENGINE COOLANT in Fuels, Lubricants, and Coolant Section and ADDING COOLANT in Service As Required Section.) OUOD006,00000FC -19-26FEB10-1/1 OM3-80 9/15...
  • Page 93 DAILY PRESTARTING CHECKS in Lubrication and correct operation. Maintenance/Daily Section.) NOTE: If using BIODIESEL blends after long term storage, 5. Open sea water valve and prime the sea water system. OUOD006,0000115 -19-16OCT07-1/1 OM3-80 9/15...

  • Page 94: Specifications

    Governor Type Electronic Primary Fuel Filter 10 micron Secondary Fuel Filter 2 micron Electrical System Battery Capacity (Minimum)- 12 Volt System Battery Capacity (Minimum)- 24 Volt System Air System in. H Maximum Air Intake Restriction (kPa) (6.25) (psi) (1.0) OM3-80 9/15...
  • Page 97 4420 14th Ave. NW., Seattle WA 98107 Tel: (206) 789-3880 • 1-800-762-0165 • www.northern-lights.com Northern Lights and Lugger are registered trademarks of Northern Lights, Inc. © 2015 All rights reserved. Litho USA.

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