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Northern Lights OM-C3 Operator's Manual

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OM-C3
For Models: M65C13 and M99C13
OPERATOR'S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators

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  • Page 1 OM-C3 For Models: M65C13 and M99C13 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 ©2013 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.: OM-C3 12/13...

  • 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 OM2-2 12/13...

  • Page 4: Introduction

    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. ® OM-C3 | 12/6 | 2...

  • 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 OM-C3 | 12/6 | 4...
  • Page 7 Sulfuric acid in battery electrolyte is poisonous and safety procedures and emergency response techniques strong enough to burn skin, eat holes into clothing and other materials, and cause blindness if splashed into eyes. OM-C3 | 12/6 | 5...
  • Page 8 Slowly loosen cap to relieve pressure before 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 OM-C3 | 12/6 | 9...

  • Page 12: Component Locations

    7. Belt Guard 12. Fuel Injection Lines 3. Fuel Filter 8. Starter 13. Exhaust Elbow 4. Lube Oil Fill 9. Lube Oil Dipstick 14. Thermostat Cover 5. Coolant Fill 10. Lube Oil Filter 15. Expansion Tank OM-C3 | 12/6 | 10...

  • Page 13: M99C13

    2. Air Cleaner 7. Lube Oil Fill 12. Thermostat Cover 3. Coolant Fill 8. Lube Oil Filter 13. Expansion Tank 4. Alternator 9. Fuel Filter 14. Exhaust Elbow 5. Belt Guard 10. Fuel Injection Lines 15. Turbocharger OM-C3 | 12/6 | 11...

  • Page 14: Engine & Generator Control Panels

    C) or drops below 140°F (60 C), 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. OM-C3 | 12/6 | 12...
  • Page 15 14. Press the "Menu" key to return to the main menu. Return To Main Menu OURGP11,00000B2 -19-03SEP03-13/14 15. Press the "Menu" key to exit the main menu and return to the engine parameter display. Select Remaining Parameters OURGP11,00000B2 -19-03SEP03-14/14 OM-C3 | 12/6 | 13...

  • Page 16: Engine Operation

    In these situations, an additional 100 hour break-in period is recommended using a new change of John Deere Engine Break-In Oil and a new John Deere oil filter. Continued on next page RG19661,00003BC -19-28FEB13-1/5 OM-C3 | 12/6 | 14...
  • Page 17 Unless temperature drops quickly, stop the engine and determine the cause before resuming operation. A—Coolant Temperature Gauge Coolant Temperature Gauge - Electronically Controlled Engine Continued on next page RG19661,00003BC -19-28FEB13-4/5 OM-C3 | 12/6 | 15...

  • Page 18: Auxiliary Gear Drive Limitations

    (with 50%—70% load) for 30 minutes every 2 weeks. DO NOT allow engine to run extended period of To assure that your engine will deliver efficient generator time with no load. operation when needed, start engine and run at rated RG,RG34710,5556 -19-20MAY96-1/1 OM-C3 | 12/6 | 16...

  • Page 19: Starting The Engine

    0:00 and the "Wait to Start" message is no with preheating options). The timer will display minutes longer displayed, you may start the engine. and seconds, counting down to zero. Once the timer Continued on next page RG19661,00003BD -19-23JAN13-1/2 OM-C3 | 12/6 | 17...
  • Page 20 If sea water does not flow within one minute after engine starts, stop engine and check sea cock, sea water strainer, and sea water pump for restrictions. A—Key Switch C—Oil Pressure Gauge B—Start Button D—Warning Light Start Engine - Electronically Controlled Engine RG19661,00003BD -19-23JAN13-2/2 OM-C3 | 12/6 | 18...

  • Page 21: Warming Engine

    These engines will idle at no Once an engine is warmed to normal operating load governed speed (high idle). temperatures, engine should be idled at slow idle speed. OUOD006,0000092 -19-19JUN07-1/1 OM-C3 | 12/6 | 19...

  • Page 22: Engaging & Disengaging Front Pto (If Equipped)

    CAUTION: Starting fluid is highly flammable. DO NOT use starting fluid on engines equipped with air intake heaters. DO NOT use starting fluid near fire, sparks, or flames. DO NOT incinerate or puncture a starting fluid container. OUOD006,0000080 -19-22JUN07-1/1 OM-C3 | 12/6 | 20...

  • Page 23: Stopping The Engine

    The sea water pump will require priming before starting the engine. RG19661,00003BE -19-23JAN13-1/1 OM-C3 | 12/6 | 21...

  • Page 24: Using A Booster Battery Or Charger

    6. Start the engine. Disconnect jumper cables 24-Volt System immediately after engine starts. Disconnect NEGATIVE (–) cable first. A—12-Volt Machine Battery C—Booster Cable (ies) D—Cable to Starting Motor B—12-Volt Booster Battery (ies) RG,RG34710,5564 -19-03JAN02-1/1 OM-C3 | 12/6 | 22...

  • Page 25: Welding Near Electronic Control Units

    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 OM-C3 | 12/6 | 23...

  • Page 26: Lubrication And Maintenance

    John Deere Parts Network for recommended fuels, lubricants, and coolant. Also available are necessary additives for use when operating engines in tropical arctic, or any other adverse conditions. Parts Network DPSG,OUOE003,20 -19-19JUN07-1/1 OM-C3 | 12/6 | 24...

  • Page 27: Daily

    AND additives are replenished as needed by adding a supplemental coolant additive, the flushing interval may be extended to 5000 hours or 60 months, whichever occurs first. OUOD006,0000081 -19-18AUG11-1/1 OM-C3 | 12/6 | 25...
  • Page 28 AND additives are replenished as needed by adding a supplemental coolant additive, the flushing interval may be extended to 5000 hours or 60 months, whichever occurs first. OUOD006,0000082 -19-27OCT11-1/1 OM-C3 | 12/6 | 26...

  • Page 29: Daily Prestarting Checks

    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 OM-C3 | 12/6 | 27...
  • Page 30 (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 OM-C3 | 12/6 | 28...
  • Page 31 Water pump for coolant leaks. • generator set daily service recommendations. Coolant system for leaks. NOTE: It is normal for a small amount of leakage to occur as the engine cools down and parts contract. RG19661,00003D3 -19-29JAN13-4/4 OM-C3 | 12/6 | 29...

  • Page 32: 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 OM-C3 | 12/6 | 30...
  • Page 33 Oil Pan Drain Plug With O-Ring—Torque............. 50 N·m (37 lb-ft) A—Oil Filter Element D—Sealing Surface On Header B—Inner Seal E—Sealing Surface On Header C—Outer Seal F— Dust Seal OIl Filter Mounting Header Continued on next page RG19661,00003D4 -19-28FEB13-2/3 OM-C3 | 12/6 | 31...

  • Page 34: Servicing Fire Extinguisher

    250 hours of engine operation or every 6 months. Once extinguisher is operated, no matter how long, it must be recharged. Keep record of inspections on the tag which comes with the extinguisher instruction booklet. Fire Extinguisher OURGP11,000015D -19-28JAN04-1/1 OM-C3 | 12/6 | 32...

  • Page 35: Servicing Battery

    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 OM-C3 | 12/6 | 33...
  • Page 36 24 Volt Standard Duty -18°C (0°F): Starter—Cold Cranking Amps....................570 Specification 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 OM-C3 | 12/6 | 34...
  • Page 37 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 OM-C3 | 12/6 | 35...

  • Page 38: Hour/6 Month

    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 OM-C3 | 12/6 | 36...
  • Page 39 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 OM-C3 | 12/6 | 37...

  • Page 40: Checking Air Intake System

    Also A—Clamps B—Air Restriction Indicator replace element if it is torn, or visibly dirty.is torn or visibly dirty. Service as necessary. (See REPLACING AIR CLEANER in Service As Required Section.) RG19661,00003DA -19-26FEB13-1/1 OM-C3 | 12/6 | 38...
  • Page 41 (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 OM-C3 | 12/6 | 39...
  • Page 42 (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 OM-C3 | 12/6 | 40...
  • Page 43 (B), check mounting brackets (alternator, belt tensioner, idler pulley, etc.) and the belt length. Replace belt as needed (see REPLACING FAN AND ALTERNATOR BELTS in Service As Required Section). Continued on next page RG19661,00003E6 -19-13FEB13-1/2 OM-C3 | 12/6 | 41...
  • Page 44 Replace tensioner assembly as required. Specification 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 OM-C3 | 12/6 | 42...
  • Page 45 2. Thoroughly inspect all cooling system hoses. Replace system. Retighten fitting or plug when all hoses when hard, flimsy, or cracked. the air has been expelled. 1. Check entire cooling system for leaks. Tighten all clamps securely. RG,RG34710,5580 -19-20MAY96-1/1 OM-C3 | 12/6 | 43...
  • Page 46 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 OM-C3 | 12/6 | 44...

  • Page 47: Testing Diesel Engine Coolant

    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 OM-C3 | 12/6 | 45...
  • Page 48 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 OM-C3 | 12/6 | 46...
  • Page 49 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 OM-C3 | 12/6 | 47...
  • Page 50 6. Remove four cap screws (F), front cap and O-ring. 7. Remove aftercooler core from the rear of the engine. Remove Rear Cap A—Clamp D—Cap Screws B—Clamps E—Clamps C—Mounting Bolt F— Cap Screws Remove Front Cap Continued on next page RG19661,000040D -19-10MAR13-1/2 OM-C3 | 12/6 | 48...
  • Page 51 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 OM-C3 | 12/6 | 49...

  • Page 52: Pressure Testing Cooling System

    This will verify that the first measurement was immediately. accurate. Test Cooling System NOTE: Engine should be warmed up to test overall cooling system. RG19661,0000409 -19-08MAR13-1/1 OM-C3 | 12/6 | 50...
  • Page 53 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 OM-C3 | 12/6 | 51...
  • Page 54 Rocker Arm Adjusting Adjusting Valves Screw Jam Nut—Torque..........27 N·m (20 lb-ft) 5. Install rocker arm cover and crankcase ventilator tube. A—Adjusting Screw Jam Nut B—Feeler Gauge 6. Reconnect battery terminal. Continued on next page RG19661,00003D0 -19-29JAN13-2/4 OM-C3 | 12/6 | 52...
  • Page 55 Turn crankshaft 360°. Lock No. 6 piston at TDC compression stroke (C). Adjust valve clearance on No. 2, 4 and 6 exhaust valves and No. 3, 5, and 6 intake valves. 6-cylinder Engine Valve Adjustment RG19661,00003D0 -19-29JAN13-4/4 OM-C3 | 12/6 | 53...
  • Page 56 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 OM-C3 | 12/6 | 54...
  • Page 57 10 minutes, remove heat exchanger or top tank cap and pull off lower cooling system hose to drain out flushing water. 12. Close all drain valves. Reinstall hoses and tighten clamps securely. Install thermostats using a new gasket. RG19661,00003D1 -19-28JAN13-2/2 OM-C3 | 12/6 | 55...
  • Page 58 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 finger-tight. RG19661,0000405 -19-08MAR13-1/1 OM-C3 | 12/6 | 56...
  • Page 59 7. If any one thermostat is defective, replace both thermostats. vary slightly from specified temperatures. 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 OM-C3 | 12/6 | 57...

  • Page 60: Checking Crankshaft Vibration Damper

    Kit and replace all internal components except shaft. An Inspect Sea Water Pump arbor press and drivers are needed to install this kit. Have an experienced technician install this kit. A—Weep Hole (Earlier Engines Only) Continued on next page RG19661,0000401 -19-06MAR13-1/3 OM-C3 | 12/6 | 58...
  • Page 61 6. Thoroughly clean impeller housing bore and cam plate cooled by raw water should be thoroughly (if cam plate is reused). cleaned and flushed. 5. Remove cam screw (B) holding cam plate to impeller housing bore. Continued on next page RG19661,0000401 -19-06MAR13-2/3 OM-C3 | 12/6 | 59...
  • Page 62 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 OM-C3 | 12/6 | 60...
  • Page 63 13. Open sea cocks, start engine and check pump operation. 10. Install sea water 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 OM-C3 | 12/6 | 61...

  • Page 64: Service As Required

    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 OM-C3 | 12/6 | 62...

  • Page 65: Adding Coolant

    Replace Air Filter Element possible engine damage. A—Air Filter Assembly Clamps B—Air Filter Element 2. Install new air filter element (B), install cover and engage clamps. RG19661,00003F5 -19-22FEB13-1/1 OM-C3 | 12/6 | 63...
  • Page 66 Remove Filter Element OUOD006,0000098 -19-10DEC09-1/5 Spray air filter cleaner (B) (from kit RE504585) liberally onto entire element. Let soak into filter media for 10 minutes. Spray Filter with Cleaner Continued on next page OUOD006,0000098 -19-10DEC09-2/5 OM-C3 | 12/6 | 64...
  • Page 67 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. 8. Install filter and tighten clamp. Apply Oil To Filter Continued on next page OUOD006,0000098 -19-10DEC09-4/5 OM-C3 | 12/6 | 65...
  • Page 68 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 OM-C3 | 12/6 | 66...
  • Page 69 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 OM-C3 | 12/6 | 67...
  • Page 70 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 OM-C3 | 12/6 | 68...
  • Page 71 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 OM-C3 | 12/6 | 69...
  • Page 72 47 N•m (35 lb-ft). 3. Connect water piping and tighten clamps. Install Sea Water Pump 4. Open sea cock, start engine, and check for leaks. A—Outlet Tube C—Splined Shaft B—Mounting Screws D—Drive Gear Splined ID RG19661,00003FE -19-02MAR13-1/1 OM-C3 | 12/6 | 70...
  • Page 73 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 OM-C3 | 12/6 | 71...
  • Page 74 (B) to 12 N·m (9 lb.-ft.). 8. Connect sea water pump inlet. A—Aftercooler Inlet E—Nuts 9. Open sea cock, start engine and check for leaks. B—Constant Tension Clamps F— Studs C—Formed Hose G—O-ring D—Cap Screws H—Sea Water Pump RG19661,0000404 -19-07MAR13-1/1 OM-C3 | 12/6 | 72...

  • Page 75: 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 OM-C3 | 12/6 | 73...
  • Page 76 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 OM-C3 | 12/6 | 74...
  • Page 77 23— Unterminated Power 7— Manifold Air Temperature Connector Sensor Connector 14— Water-in-Fuel Sensor (Battery) Connector 24— Low-Pressure Fuel Pump 8— Suction Control Valve Sensor Connector 15— Fuel Rail Pressure Sensor Fuse (15 Amp) Connector RG19661,00003DE -19-15FEB13-1/1 OM-C3 | 12/6 | 75...
  • Page 78 X9— Single Point Ground 904— Can H F— Extension to Fly Bridge Panel KST— Starter Relay X10— CAN Terminator 905— Can L L— Coolant Temp 002— Battery M—Oil Pressure M1—Start Motor N—Diagnostic Gauge OUOD006,00000BC -19-25JUL07-1/1 OM-C3 | 12/6 | 76...
  • Page 79 X9— Single Point Ground 904— Can H F— Extension to Fly Bridge Panel KST— Starter Relay X10— CAN Terminator 905— Can L L— Coolant Temp 002— Battery M—Oil Pressure M1—Start Motor N—Diagnostic Gauge OUOD006,00000BD -19-27SEP07-1/1 OM-C3 | 12/6 | 77...
  • Page 80 W—Tachometer 002— Battery 432— Instrument Panel Power T— Back Light Dimmer X—% Load 012— IGN +12V or +24V 904— Can H Y—Voltmeter 020— CAN Shield 905— Can L Z— Coolant Temp AA—Oil Pressure OUOD006,00000BE -19-25JUL07-1/1 OM-C3 | 12/6 | 78...
  • Page 81 FOCUS 16 4.5L 4 VALVE ENGINE CONTROL UNIT (ECU) 32 POSITION - BLACK 48 POSITION - BROWN 32 POSITION - BLUE J2-L2 J2-L3 J2-M2 J2-L1 J2-L4 J2-M1 J2-M4 5412 5412 5050 5050 - FOCUS 16 (ECU) Continued on next page RG19661,00003EA -19-21FEB13-1/2 OM-C3 | 12/6 | 79...
  • Page 82 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 RG19661,00003EA -19-21FEB13-2/2 OM-C3 | 12/6 | 80...
  • Page 83 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 OM-C3 | 12/6 | 81...
  • Page 84 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 OM-C3 | 12/6 | 82...
  • Page 85 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 OM-C3 | 12/6 | 83...
  • Page 86 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 OM-C3 | 12/6 | 84...
  • Page 87 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 OM-C3 | 12/6 | 85...
  • Page 88 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 OM-C3 | 12/6 | 86...
  • Page 89 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 OM-C3 | 12/6 | 87...
  • Page 90 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 OM-C3 | 12/6 | 88...
  • Page 91 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 OM-C3 | 12/6 | 89...
  • Page 92 Common J3-C2— Analog 5 C08-H— Common Configurable 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 OM-C3 | 12/6 | 90...
  • Page 93 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 OM-C3 | 12/6 | 91...
  • Page 94 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 OM-C3 | 12/6 | 92...
  • Page 95 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 OM-C3 | 12/6 | 93...
  • Page 96 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 OM-C3 | 12/6 | 94...
  • Page 97 5443— Return 5486— Driver 6 Diagnostic/Pwr/Gnd 5042— Unswitched Power 5448— Return X01— Engine Crank Sensor 5050— Ground 5457— Xfer Pump Speed 5434— Xfer Pump Status Input Command (+5V) 5458— Xfer Pump Motor Current RG19661,00003DF -19-15FEB13-1/1 OM-C3 | 12/6 | 95...
  • Page 98 INCREASE PRESSURE t˚ J3-F1 J3-B2 J3-C1 J3-G1 J3-G2 J3-H3 J3-D2 J3-D3 J3-B1 J3-C2 J3-C3 J3-H4 FOCUS 14 6.8L 4 VALVE ENGINE CONTROL UNIT (ECU) 5050 AUX CONNECTOR 5050 Continued on next page RG19661,00003E0 -19-15FEB13-1/2 OM-C3 | 12/6 | 96...
  • Page 99 5971— Cruise Canc. Resume T05— Fuel Temp 5456— Analog 15 5913— Secondary Analog 5981— Pwr Throttle 5012— Switched Power/Stop 5461— Analog 8 Throttle Lamp Power/Cruise 5467— Analog 4 5917— Remote Cruise Common 5937— Isoc. Gov RG19661,00003E0 -19-15FEB13-2/2 OM-C3 | 12/6 | 97...
  • Page 100 5947— Throttle Switch 5050— Ground Shutdown Return 5916— Warning Lamp 5955— Set Accel/Bump Up 5412— ACC 5814— Sensor Return 5918— Override Shutdown 5422— Start 5923— Bump Enable 5439— Tachometer Continued on next page RG19661,00003E1 -19-11FEB13-1/2 OM-C3 | 12/6 | 98...
  • Page 101 DEUTSCH TERM 5904 5904 5905 5905 5020 5020 SAE J1939/11 3-WAY DEUTSCH CONN LOCATED NEAR ECU DIAGNOSTIC CONNECTOR 5050 C10— Deutsch Conn. Located C11— Diagnostic Connector 5419— Driver Low Near ECU 5424— Driver High RG19661,00003E1 -19-11FEB13-2/2 OM-C3 | 12/6 | 99...

  • Page 102: Engine Troubleshooting

    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 OM-C3 | 12/6 | 100...
  • Page 103 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 OM-C3 | 12/6 | 101...
  • Page 104 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 OM-C3 | 12/6 | 102...
  • Page 105 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 OM-C3 | 12/6 | 103...
  • Page 106 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 OM-C3 | 12/6 | 104...

  • Page 107: Electrical Troubleshooting

    Use proper viscosity oil. Loose or corroded connections. Clean and tighten loose connections. Starter and hour meter functions; Blown fuse on magnetic switch. Replace fuse. rest of electrical system does not function Continued on next page DPSG,OUOD007,335 -19-04JAN02-1/2 OM-C3 | 12/6 | 105...
  • Page 108 This example is code 32. times...long pause...flash three times...short pause...flash 4. The ECU begins the flashing sequence by flashing three times...long pause...flash five times...short a code 32, this indicates the start of blinking active pause...flash three times. RG19661,000040A -19-10MAR13-1/1 OM-C3 | 12/6 | 106...

  • Page 109: Diagnostic Trouble Codes

    4. Contact your nearest engine distributor or servicing CODES (DTCs) later in this section, to interpret the dealer with a list of DTC codes that are displayed so DTCs present. necessary repairs can be made. OURGP11,00000BB -19-05SEP03-1/1 OM-C3 | 12/6 | 107...
  • Page 110 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 OM-C3 | 12/6 | 108...
  • Page 111 ....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 OM-C3 | 12/6 | 109...
  • Page 112 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 OM-C3 | 12/6 | 110...
  • Page 113 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 OM-C3 | 12/6 | 111...

  • Page 114: Intermittent Fault Diagnostics

    "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 OM-C3 | 12/6 | 112...
  • Page 115 Select Utilities OURGP11,00000E3 -19-29SEP03-3/4 4. Scroll to the "Software Version". Press "Enter" to view the software version. Press the menu button twice to return to the main menu. Software Version OURGP11,00000E3 -19-29SEP03-4/4 OM-C3 | 12/6 | 113...

  • Page 116: Transition Harness

    J— Auxiliary Station Select D— Battery (+), Ground (—) Input E— Engine Sync Input K— 23-Pin Connector (engine F— Engine Sync Output wiring harness) L— 21-Pin Connector (engine wiring harness) Transition Harness RG19661,00003DD -19-11FEB13-1/1 OM-C3 | 12/6 | 114...

  • Page 117: 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 OM-C3 | 12/6 | 115...
  • Page 118 Refill with a strong waterproof tape. appropriate coolant. (See RECOMMENDED ENGINE COOLANT in Fuels, Lubricants, and Coolant Section and ADDING COOLANT in Service As Required Section.) OUOD006,00000FC -19-26FEB10-1/1 OM-C3 | 12/6 | 116...
  • Page 119 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. frequency of fuel filter plugging may increase initially. OUOD006,0000115 -19-16OCT07-1/1 OM-C3 | 12/6 | 117...

  • Page 120: Specifications

    Secondary Fuel Filter 2 micron 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) (6.25) (psi) (1.0) (1.0) RG19661,00003E8 -19-03MAR13-1/1 OM-C3 | 12/6 | 118...
  • Page 122 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. © 2013 All rights reserved. Litho USA.

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