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OM-C3 - Northern Lights

1. 17 18 Wartung Eng1li oto e Deren 19 Idling Engitie 19 Engaging amp Disengaging Front PTO If equipped 20 Cold Weather Operation sss 20 Stopping the Engin uu uuu 21 Using a Booster Battery or Charger 22 Welding Near Electronic Control Units 23 Welding Near Electronic Control Units Clean 23 LUBRICATION AND MAINTENANCE Observe Service 24 Use Correct Fuels Lubricants and Coolant 24 Lubrication amp Maintenance Service Interval Charts 19 26 Daily iine unaypa 27 29 250 Hour 6 Month 30 36 500 Hour 12 Month 37 49 2000 Hour 24 50 59 SERVICE AS REQUIRED M 60 70 TROUBLESHOOTING General Troubleshooting Information 71 72 Wiring Diagrams eee T3 97 Engine Troubleshooting 98 102 Electrical Troubleshooting 103 105 Diagnostic Trouble Codes 106 111 Intermittent Fault Diagnostics 112 Displaying Diagnostic Gauge Software112 113 Transition 8 114 STORAGE uu denter ads 115 117 SPECIFICATIONS 118 Proprietary Information This publi
2. 942 z 50357 1 2220 Throttle 1 Signal Out of Range High 91 04 12 2 Throttle 1 Signal Out of Range Low 91 09 Throttle 1 Communication Signal Erratic 94 01 58 Low Pressure Fuel Signal Extremely Low 94 03 2T 94 04 28 94 10 86 94 reete Low Pressure Fuel Out of Calibration 94 dE 85 High Pressure Fuel System Pressure Slightly Low 94 18 57 Fuel Supply Pressure Moderately Low 97 00 Water in Fuel Signal Continuously Detected 97 03 oce Water in Fuel Signal Out of Range High 97 04 Water in Fuel Signal Out of Range Low 97 16 Water in Fuel Detected 100 01 75 Engine Oil Pressure Signal Extremely Low 100 03 292 100 04 24i Low Pressure Fuel Signal Out of Range High Low Pressure Fuel Signal Out of Range Low Low Pressure Fuel Rate of Change Abnormal Engine Oil Pressure Signal Out of Range High Engine Oil Pressure Signal Out of Range Low Following is a list of SPNs Blink Codes and description of the diagnostic trouble codes that can occur in the various engine systems Not all of these codes will be present in all engine applications When trouble codes appear on the diagnostic gauge see your engine dealer for repairs as soon as
3. ec E 2 S 5 S 2 E 5 ce ek a 3 C05 1 OF Q Ow Q S o pr a Fes LA oM Ux J im TRANSMISSION SENSORS 5 SE SEI SEI ll 5050 z N a SE2 FOCUS 14 ECU 8 a Continued on next page RG19661 00003EB 19 21FEB13 1 2 OM C3 07 14 85 Troubleshooting A Focus 14 4 5 L 4 Valve Engine Control Unit ECU B Mating View of Rail Pressure Connector C05 Transmission Sensors C05 01 Transmission Pressure C05 02 Shaft Speed C05 03 Air Filter Restriction Fluid Temperature C05 04 Sensor Excitation 5 V J3 F1 Analog 15 C05 05 Sensor Return J3 F3 Return C05 06 Exhaust Temperature J3 G1 Excitation Voltage 1 D01 Water In Fuel Sensor J3 G2 Excitation Return 1 J3 A2 Excitation Voltage 5 J3 G3 Return J3 B2 Excitation Return J3 C1 Analog 6 J3 C4 Analog 3 P01 Manifold Air Pressure Sensor P05 Fuel Rail Pressure Sensor SE2 Focus 14 ECU T02 Manifold Air Temperature Sensor X01 Crankshaft Position Sensor X02 Camshaft Position Sensor Y5004 Low Pressure Fuel Pump RG19661 00003EB 19 21FEB13 2 2 OM C3 07 14 86 PRESSURE SENSOR CLEAN SIDE OIL FUEL PRESSURE SENSOR Troubleshooting FUEL TEMP COOLANT TEMP 4045 85 Marine Electronic Control System Wiring Diagram Cont d L833SL Nf1 0670008 5714 5412
4. 050 SPG RG15471 UN 04SEP07 SE3 Fly Bridge Panel Q From Wheelhouse Panel U Audible Alarm AB Diagnostic Gauge 412 ACC R Stop Button Momentary V External Alarm AC From Wheelhouse Panel 422 Starter Relay Solenoid S Start Button Momentary W Tachometer 002 Battery 432 Instrument Panel Power T Back Light Dimmer X Load 012 IGN 12V or 24V 904 CanH Y Voltmeter 020 CAN Shield 905 CanL Z Coolant Temp AA Oil Pressure OUOD006 00000BE 19 25JUL07 1 1 OM C3 07 14 76 Troubleshooting 4045TFM85 Marine Electronic Control System Wiring Diagram 4 5L Engine RAIL PRESSURE RAILPRESSURE CONNECTOR P05 e D co CAM SENSOR ENG ENG INCREASE oo PRESSURE RETURN RETURN 5 5 5 5 S e e ri a i 3 3 8 J B4 4 04 Jt A4 J1 E4 4 3 4 03 2 FOCUS 16 4 5L 4 VALVE ENGINE CONTROL UNIT ECU 32POSITION BLACK 42 48POSITION BROWN 43 32 POSITION BLUE J2 L2 JM3 J2M2 Jeli 2 J2 MI J24M 5050 5050 5022 E 5412 2 m LL wo SEI SEI 5050 550 2 1 x SE2 FOCUS 16 ECU c Continued on next page RG19661 00003EA 19 21FEB13 1 2 OM C3 07 14 77 Troubleshooting A Focus 16 4 5 L 4 Valve J1 D3 Excitation Voltage 1 J2 48 Position Brown X01 Crankshaft Position Engine Control Unit ECU
5. Visual Walkaround Inspection Drain Water From Fuel Filter Change Engine Oil And Replace Oil Filter Service Fire Extinguisher Service Battery Inspect and Replace Zinc Plugs Check Belt Tension and Wear Manual Tensioner Check Engine Mounts Replace Crankcase Vent Filter If Equipped Clean Crankcase Ventilation Assembly Check Air Intake Hoses Connections amp System Replace Fuel Filter Elements Check Automatic Belt Tensioner and Belt Wear Check Cooling System Coolant Solution Analysis Add SCAs as required Inspect and Clean Heat Exchanger Core and Aftercooler Core If Equipped Check Engine Speeds Check Engine Electrical Ground Check Crankshaft Vibration Damper 6 Cylinder Pressure Test Cooling System Inspect and Repair Sea Water Pump Check and Adjust Engine Valve Clearance Flush And Refill Cooling System Test Thermostats Add Coolant Replace Air Cleaner Element Service Dry Air Cleaner Element Replace Alternator Drive Belt Check Front PTO If Equipped Bleed Fuel System Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm 52 H2O or when reset button has popped up 6068SFM75 AFM75 only PChange the oil for the first time before 100 hours maximum of break in operation then every 250 hours thereafter If John De
6. RG22395 UN 05FEB13 Transition Harness RG19661 00003DD 19 11FEB13 1 1 OM C3 07 14 112 Storage Engine Storage Guidelines 1 John Deere engines can be stored outside for up to three 3 months with no long term preparation IF COVERED BY WATERPROOF COVERING No outside storage is recommended without a waterproof covering John Deere engines can be stored in a standard overseas shipping container for up to three 3 months with no long term preparation John Deere engines can be stored inside for up to six 6 months with no long term preparation John Deere engines expected to be stored more than six 6 months MUST have long term storage preparation See PREPARING ENGINE FOR LONG TERM STORAGE later in this section 5 Long term storage includes the use of a stabilized rust preventive oil to protect internal metal components of the engine This oil should be an SAE 10 oil with 1 4 percent morpholine or equivalent vapor corrosion inhibitor These rust preventive oils are available from area distributors IMPORTANT DO NOT USE BIODIESEL DURING MACHINE STORAGE When using biodiesel blends switch to petroleum diesel for long term storage Before storage operate engine on at least one complete tank of petroleum diesel fuel to purge the fuel system Follow normal storage procedures once the fuel system has been purged OUOD006 0000114 19 160 07 1 1 OM C3 07 14 113 St
7. Injector Power Supply Voltage Out of Range Low 12 5 Seien ECU EEPROM Error creme ECU Programming Error 19 34 ECU to Pump Communication Error 02 37 Fuel Shutoff EMON assiso inire 052 86 Fuel Shutoff Not Functioning 02 44 Engine Position Sensor Signal Unreliable 05 Camshaft Position Circuit Has High Resistance ce Camshaft Position Circuit Has Low Resistance 08 43 Engine Position Sensor Signal Missing 10 44 Engine Position Sensor Signal Rate of Change Abnormal 3944 5 Engine Timing Sensor Signal Unreliable 05 cum Crankshaft Position Circuit Has High Resistance 06 RR Crankshaft Position Circuit Has Low Resistance 07 seme Engine Timing and Position Signals Mismatch 08 38 Engine Timing Sensor Signal Missing 10 939 Engine Timing Signal Rate of Change T9 deeem CAN Bus 0224 Speed Input Erratic 0212 05 20 rennes Injector Number 1 Circuit Has High Resistance 05 Injector Number 1 Circuit Has High Resistance 02
8. Symptom Problem Entire electrical system does not function Sulfated or worn out batteries Blown main system fuse Faulty battery connection Solution Clean and tighten connections See your authorized servicing dealer or engine distributor Replace fuse DPSG OUODO007 335 19 04JAN02 2 2 Blink Code Method for Retrieving Diagnostic Trouble Codes NOTE If engine has an electronic instrument panel with diagnostic gauge refer to Instrument Panel Method for Retrieving Diagnostic Trouble Codes later in this section On marine applications that have a Fault Lamp the ECU has the ability to display DTCs using blinking sequence of the fault lamp To retrieve DTCs from the ECU using the blink code method NOTE The ECU blinks the codes in 2 digit codes only See LISTING OF DIAGNOSTIC TROUBLE CODES DTCS later in this Group 1 Turn the ignition switch ON 2 Press down Override Shutdown Switch if equipped for a few seconds 3 The Fault Lamp will begin to flash a code number For example flash three times short pause flash two times long pause This example is code 32 4 The ECU begins the flashing sequence by flashing a code 32 this indicates the start of blinking active codes If there are any active DTCs the ECU will flash it s 2 digit number If there is more than one active DTC the ECU will flash each code in numerical order If there are no active DTCs the Fau
9. f 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 e 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 Service Cooling System Safely Opening a pressurized cooling system can release explosive fluids and causing serious burns C Before opening any pressurized cooling system make sure the engine has been shut off Do not remove a filler cap unless it is cool enough to comfortably grip with bare hands Slowly loosen cap to relieve pressure before opening fully Avoid High Pressure Fluids Relieve pressure prior to disconnecting pressurized lines Escaping fluid under pressure can penetrate the skin causing serious injury Always relieve pressure before disconnecting hydraulic or other pressurized lines Tighten all connections firmly before re applying pressure If searching for leaks use a piece of cardboard Always protect your hands and other body parts from high pressure fluids 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 r
10. 2 gt Z NURL38 NOLWLIOXA ms gt 5412 5012 5911 5714 5050 RG19661 00003EF 19 21FEB13 1 2 Continued on next page OM C3 07 14 87 Troubleshooting A Focus 14 4 5 L 4 Valve Engine Control Unit ECU C08 Auxiliary Connector C08 A Sensor Excitation 5 V C08 B Switched Power C08 C Sensor Return C08 D Configurable Switch C08 E Configurable Switch C08 F Secondary Analog Throttle C08 G Stop Lamp Power C08 H Common Configurable Switch C08 J External Derate C08 K External Shutdown C08 L Configurable Switch C08 M Customer Loss of Coolant C08 N Configurable Output C08 O Configurable Switch C08 P Droop Isochronous Switch C08 Q External Derate Shut down Common C08 R PWM Throttle C08 S Frequency Input C08 T Throttle Station Two Lamp Wait To Start Lamp C08 U Throttle Station Three Lamp C08 V Engine Sync Lamp C08 W Throttle Station Two Lamp Stop Lamp C08 X Single Point Ground J1 32 Position Black J2 48 Position Brown J3 32 Position Blue J3 B1 Analog 2 J3 C2 Analog 5 J3 C3 Analog 4 J3 D3 Analog 8 J3 H3 Excitation Return 2 J3 H4 Excitation Voltage 2 P03 Fuel Rail Pressure Sensor P04 Engine Oil Pressure Sensor Clean Side SE2 Focus 16 ECU T04 Engine Coolant Temperature Sensor T05 Fuel Temperature Sensor RG19661 00003EF 19 21FEB13 2
11. 8 Flush the heat exchanger tubes with clean water making sure all tubes are cleared of debris Clean with brass rod and flush heat exchanger again if necessary to remove any remaining debris from tubes RG6066 UN 23JAN92 Clean Heat Exchanger If you suspect that your heat exchanger core is defective have your authorized servicing dealer or engine distributor pressure test for leaks Replace heat exchanger core as required 9 Remove and thoroughly clean water manifold heat exchanger housing if needed RG19661 000040B 19 10MAR13 2 2 Install Heat Exchanger Core Thoroughly inspect condition of end cap sealing O rings A Sealing O rings may be reused if not excessively worn or damaged during disassembly Replace sealing rings as necessary Lubricate front and rear end cap O rings with clean multi purpose grease 1 Install rear end cap install cap screws and evenly tighten until end cap B is about 6 4 mm 0 25 in from housing C Index end cap in same position as removed 2 Install heat exchanger core Make sure core is properly seated in rear end cap to avoid cutting O ring 3 Install front end cap with heat exchanger core properly seated in cap and cap properly indexed in same position as removed 4 Install and evenly tighten front end cap screws until cap contacts housing Evenly tighten rear end cap screws until cap contacts housing Tighten front and rear end cap screws to 24 N m 18
12. SE2 5020 5905 5904 FOCUS 14 4 5L 4 VALVE ENGINE CONTROL UNIT ECU SAE J1939 11 3 WAY DEUTSCH TERM 5904 5905 5020 SAE Jigagit C10 DEUTSCH CONN LOCATED NEAR ECU CANL J1 32 POSITION BLACK 48 POSITION BROWN 42 J 5020 J H G EYE 6 DAGNOSTCCONECITOR CH SE2 FOCUS 14 ECU Continued on next page J3 32 POSITION BLUE RG22432 UN 15FEB13 RG19661 00003F1 19 25FEB13 1 2 OM C3 07 14 91 Troubleshooting A Focus 14 4 5 L 4 Valve Engine Control Unit ECU C06 Wiring Supplied With JD Alternator C10 SAE J1939 11 Way Deutsch Connector Located Near ECU C11 Diagnostic Connector C16 Battery C12 Transient Voltage C17 Single Point Ground Protection 12 V or 24 V G1 Alternator 12 V C13 Starter Relay Coil Ground J1 32 Position Black C14 Starter Relay Coil Power J2 48 Position Brown C15 Remote On Off J3 32 Position Blue J2 A1 CAN High J2 B1 CAN Low J3 32 Position Blue M1 Start Motor 12 V SE1 Engine Start Components SE2 Focus 14 ECU RG19661 00003F1 19 25FEB13 2 2 OM C3 07 14 92 Troubleshooting 6068SFM85 AFM85 Marine Electronic Control System Wiring Diagram C19 6 8L Engine FUEL FILTER CONTROL DIAGNOSTIC PWR GND 06 01 02 03 N 3 8 2 2 z 2
13. a high pressure fuel pump while it is still warm To do so may cause seizure of pump parts Fuel Injection Pump A Fuel Injection Pump RG22161 UN O06DEC12 RG19661 00003C1 19 23JAN13 1 1 OM C3 07 14 60 Service as Required Adding Coolant Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely IMPORTANT Never pour cold liquid into a hot engine as it may crack cylinder head or block DO NOT operate engine without coolant for even a few minutes John Deere TY15161 Cooling System Sealer may be added to the cooling system to stop leaks DO NOT use any other stop leak additives in the cooling system Air must be expelled from cooling system when coolant is added 1 Loosen temperature sending unit fitting at rear of cylinder head or plug in side of thermostat housing to allow air to escape when filling system IMPORTANT When adding coolant to the system use the appropriate coolant solution See TS281 UN 23AUG88 High Pressure Fluids ENGINE COOLANT SPECIFICATIONS in Fuels Lubricants and Coolant Section for mixing of coolant ingredients before adding to cooling system Do not overfill cooling system A pressurized system needs space for heat expansion without ov
14. 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 off switch obtain a lock pad and or the appropriate colored tags and place the lock and tag through the shut off lever Retain the key until the repair is completed and the machine is safe to start Be certain the shut off 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 off 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 For servicing pneumatic and hydraulic equipment the following additional procedures must be implemented following completion of lock out tag out procedu
15. C09 B Fused Unswitched Power C09 C Sensor Return C09 D Start C09 E Ground C09 F CAN Shield C09 G Ignition C09 H Warning Lamp Config urable Output Kick Back Start C09 J Accessory C09 K Tachometer C09 L Throttle Station 1 C09 M Excitation Voltage 5 V C09 N Override Shutdown C09 P Override Shutdown Return C09 R Digital Throttle C09 S Sensor Return C09 T Resume Coast Bump Down C09 U Low C09 V CAN High C09 W Set Accelerator Bump Up C09 X Bump Enable J1 32 Position Black J1 C1 Cylinder 2 J1 D1 Cylinder 4 J1 E1 Cylinder 1 J1 F1 Cylinder 3 J1 H1 High Driver J1 H2 Low Driver J2 48 Position Brown J3 32 Position Blue SE2 Focus 14 ECU Y01 Pressure Control Valve 1 RG19661 00003F0 19 25FEB13 2 2 OM C3 07 14 90 Troubleshooting 4045 85 Marine Electronic Control System Wiring Diagram Cont d C16 BAT 5082 C AUX TERM i rE 5 m I EL pum 1 5 s ers fo START SINGLE 1 a POINT 2 GROUND 5 2 17 Ez 5050 SPG B B 15A 20 Fo2 A A 2 8 BLA X favor zy 12 E 12V OR 24V 8 8 SE SE2 SE2 SE1 ENGINE START COMPONENTS B Fo A 5032 5002 5032 C15 REMOTE ON OFF PLUG
16. Injector Number 1 Part Number Data Invalid o tasedi Injector Number 1 Circuit Has High Resistance 06 Injector Number 1 Circuit Has Low Resistance 07 Injector Number 1 Not Responding Injector Number 1 Part Number Calibration Fault 02 Injector Number 2 Part Number Data Invalid 05 Injector Number 2 Circuit Has High Resistance 06 Injector Number 2 Circuit Has Low Resistance Of uuu uum Injector Number 2 Not Responding Continued on next page Corrective Action Contact Servicing Dealer Add Fuel or Switch Fuel Tanks Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Add Fuel or Switch Fuel Tanks Contact Servicing Dealer Check Fault Codes or Contact Servicing Dealer Contact Servicing Dealer Reduce Engine Speed Contact Servicing Dealer Reduce Engine Speed Contact Servicing Dealer Check Wiring Check Wiring Check Wiring Check Wiring Contact Servicing Dealer Contact Service Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Service Dealer Contact Service Dealer Contact Service Dealer Contact Service Dealer Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Ch
17. Low oil pressure High oil consumption Engine emits white smoke Engine emits black or gray exhaust smoke Problem Leaking exhaust manifold gasket Defective aneroid control line Restricted fuel hose Low fast idle speed Damaged propeller Marine growth Low oil level Improper type of oil Crankcase oil too light Oil leaks Restricted crankcase vent tube Defective turbocharger if equipped Improper type of fuel Low engine temperature Defective thermostat Defective injection nozzles Engine out of time Improper type of fuel Clogged or dirty air cleaner Engine overloaded Continued on next page Solution See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Clean or replace fuel hose See your authorized servicing dealer or engine distributor Have propeller checked Clean hull Add oil Drain fill crankcase with oil of proper viscosity and quality Use proper viscosity oil Check for leaks in lines gaskets and drain plug Clean vent tube See your authorized servicing dealer or engine distributor Use proper fuel Warm up engine to normal operating temperature Remove and check thermostat See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Use proper fuel Service air cleaner Reduce load OUOD0
18. NOTE To avoid sparks DO NOT allow the free ends of jumper cables to touch the engine RG4678 UN 14DEC88 2 Connect one end of jumper cable to the POSITIVE post of the booster battery 3 Connect the other end of the jumper cable to the POSITIVE post of battery connected to starter 4 Connect one end of the other jumper cable to the NEGATIVE post of the booster battery 5 ALWAYS complete the hookup by making the last connection of the NEGATIVE cable to a good ground on the engine frame and away from the battery ies RG4698 UN 14DEC88 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 07 14 22 Engine Operation Welding Near Electronic Control Units IMPORTANT Do not jump start engines with arc welding equipment Currents and voltages are too high and may cause permanent damage 1 Disconnect the negative battery cable s 2 Disconnect the positive battery cable s 3 Connect the positive and negative cables together Do not attach to vehicle frame 4 Clear or move any wiring harness sections away from welding area 5 Connect welder ground close to welding point and away from control units TS953 UN 15MA
19. OPERATOR S MANUAL A 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 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 2 NORTHERN LIGHTS OPERATOR S MANUAL for Models 65 13 99 13 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 Incl ded doeet rtt 2 Model Numbers eee eee 2 Serial Numbets 22 22 2 nene es 2 WARRANTY cr TE 3 SAFETY RULES u u eet nes 3 7 Lockout Tag Out Procedures 8 COMPONENT LOCATIONS 10 99 1 inner ode EHE 11 a 12 13 ENGINE OPERATION Normal Engine Operation 14 Break In 14 15 Auxiliary Gear Drive Limitations 16 Generator Set Power Units 16 Starting the Engine
20. S s G S s 2 Z o Z ui 5 5 lt oj S u 2 E 2 els 5 5 38 2 x l a 8 8 BS 56 amp Sl S 5 5 2 kK I 5 8 e o 72 aD 5 rr lt gt co a p 4 4 b ef Sf ee 221 7 2 27 L 221 24 ES mE Ol ee 2 A D E F GH J K L M N O P Q R S T U V ay pusa q apama a aaa wa mi napsu Sa sce cee oes see C08 AUX CONNECTOR SE2 FOCUS 16 ECU Continued on next page INCREASE PRESSURE 5416 EXCITATION VOLTAGE 2 5050 5714 RG22435 UN 15FEB13 RG19661 00003EC 19 21FEB13 1 2 OM C3 07 14 79 Troubleshooting A Focus 16 4 5 L 4 Valve Engine Control Unit ECU C08 Auxiliary Connector C08 A Sensor Excitation 5 V C08 B Switched Power C08 C Sensor Return C08 D Configurable Switch C08 E Configurable Switch C08 F Secondary Analog Throttle C08 G Stop Lamp Power C08 H Common Configurable Switch C08 J External Derate C08 K External Shutdown C08 L Configurable Switch C08 M Customer Loss of Coolant C08 N Configurable Output C08 O Configurable Switch C08 P Droop Isochronous Switch C08 Q External Derate Shut down Common C08 R PWM Throttle C08 S Air Filter Restriction C08 V Configurable Output C08 W Stop Lamp C08 X Sing
21. When checking battery electrolyte level use a flashlight 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 16 C 60 F Always remove grounded battery clamp first and replace ground clamp last Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin eat holes into clothing and other materials and cause blindness if splashed into eyes 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 LY 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 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 handl
22. 110 00 63 110 03 18 110 04 19 8 1102 5 02 110 16 63 111 01 61 Engine Coolant Level Low 157 03 Fuel Rail Pressure Signal Out of Range High 157 04 Fuel Rail Pressure Signal Out of Range Low 157 10 Fuel Pressure Loss Detected Continued on next page Engine Coolant Temperature Signal Extremely High Engine Coolant Temperature Signal Slightly High Engine Coolant Temperature Signal Moderately High Contact Servicing Dealer Check Cooling System Reduce Power Engine Coolant Temperature Signal Out of Range High Check Sensor and Wiring Engine Coolant Temperature Signal Out of Range Low Check Sensor and Wiring MT Check Cooling System Reduce Power Check Cooling System Reduce Power Check Operator s Manual Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer OM C3 07 14 106 OURGP12 00001FC 19 08APR10 1 4 Troubleshooting SPN 158 174 174 174 174 174 174 189 189 190 190 190 190 611 611 620 620 627 627 627 629 629 629 632 632 636 636 636 636 636 637 637 637 637 637 637 639 644 651 651 651 651 651 651 651 652 652 652 652 FMI Blink Descriptio
23. 230 0 18 0 007 0 64 0 025 L16 HPCR Electronic 10 micron 2 micron 925 625 25 6 25 1 0 RG19661 00003E8 19 03MAR13 1 1 OM C3 07 14 116 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 NORTHERN LIGHTS 2013 All rights reserved Litho USA
24. 5012 INCREASE PRESSURE 2 30WIOANOUMIOKa sus 1 N0089 1NIOd TIONIS 5 9 m 8 dT dOLS ANYT INO NOLIVIS FILLOHHL i gt gt 9 gt j sors 9 aNV133BHLNOIINVIS 42 ges Da 90 6 9999 dT JAWS ONL NOIIVIS STLIOUHL 5 az o ss gt e A 1868 1869 3ILLOEHLINME c s 748 NONWOONG10HS3IVH30 DG a 1068 1 106 HOLIMS 2051 400801 s o amp eres 1 665 HOLIMS OI2NOO 1 ss gt E 5 996 119100 9100 3 e co L 8768 8763 17000 40 590183 01900 ss uj i 5 e ei 1468 1168 HOLIMS 9HN00 d uo gt b oues 1 L tr ea 5 1 lt gt SE 5 wes 1 5 gt as 6669 6869 3830 x m 5 cp lt 5 2108 NONNO2 OLINOD HOLINS a o Too 246 YIMOd 01 uo il 5 eies 6468 9OTYNY AUVCINOOSS 1 5 an ut 1565 a 963 HOIIMS ag e 1168 165 HOLIMS ONO eo 4 1 o Lo E mm PIS HOSNAS 1 1 1 ZOOTYNY 8208 DRE 2109 U3N0d 1 a8 lt 3 5 1168 465 NOLIVLIOY 805838 ecu 4 s9oww is gt lt Llu lu wm gt c
25. Grasp vibration damper with both hands and attempt to turn it in both directions If rotation is felt damper is defective and should be replaced IMPORTANT The vibration damper assembly is not repairable For all except 6068SFM75 AFM75 replace damper every 4500 hours or 60 months whichever occurs first Replace viscous damper on 6068SFM75 AFM75 engines every 8000 hours 3 Check vibration damper radial runout by positioning a dial indicator A so probe contacts damper outer diameter 4 With engine at operating temperature rotate crankshaft using either JDE83 or JDE81 1 Flywheel Turning Tool 5 Note dial indicator reading If runout exceeds specifications given below replace vibration damper Specification Vibration Damper Maximum Radial 1 50 mm 0 060 Check Runout RG8018 UN 15JAN99 RG7508 UN 23NOV97 OUOD006 0000096 19 09 9 1 1 Inspect and Repair Sea Water Pump 4045TFM85 Inspect pump housing for seal leakage 1 Inspect the sea water pump housing weep hole A if equipped for evidence of water or oil indicating seal leakage If water leakage is evident order a RE49490 Impeller Repair Kit and replace impeller and front housing shaft Seal If oil leakage is evident order a RE49491 Major Repair Kit and replace all internal components except shaft An arbor press and drivers are needed to install this kit Have an experienced technician ins
26. J1 D4 Return 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 RG19661 00003EA 19 21FEB13 2 2 OM C3 07 14 78 Troubleshooting 4045TFM85 Marine Electronic Control System Wiring Diagram Cont d OIL UEL MANIFOLD COOLANT F TEMP TEMP AIRTEMP PRESSURE SENSOR CLEAN SIDE T04 T05 T02 P04 EXCITATION RETURN 2 5428 ANALOG 2 5463 ANALOG 15 5467 ANALOG 4 5414 m Jt 1 02 FOCUS 164 5 4 VALVE ENGINE CONTROL UNIT ECU 32POSITION BLACK 42 48POSITION BROWN 43 32 POSITION BLUE J2 J J 2 P Jos G2 G J P B J K B G E H D 5954 e aN 5 5 B B uy 5 2 lt a 3 ml Sf e l S s 2 2 g 2 z 9 g s a um els g re g 2 5 5 Sls 5 8 15 5 Bl sic clo ule Blo d 5 5 Ed co E S El B gt 2 amp z Ble E e 2 z 2 s e e e e a eo gt S amp g E E 2 amp 2 E Sl 3 8 el 2 z 3 e Ss 9 2 s S sls E 5 E el 5 5 S 2 2 l 5 5 2 z 22 S
27. J2 J2 J2 2 J2 J2 J2 J2 J2 J2 J2 J2 C2 C3 K2 C1 01 A4 B4 F1 D4 E4 5474 Ti ELE piss EH 5439 ss se ss pi s 5955 Q es RESUME COAST BUMP DOWN 5936 EXCITATION VOLTAGE 5V 5616 CAN LOW 5905 FUSED UNSWITCHED PWR 5032 SENSOR RETURN 5814 START 5422 GND 5050 BUMP ENABLE 5923 IGN 5012 WARNING LAMP 5916 ACC 5412 OVERRIDE SHUTDOWN RETURN 5714 THROTTLE SWITCH 5947 OVERRIDE SHUTDOWN 5918 SENSOR RETURN 5714 WAIT TO START 5474 CAN SHIELD 5020 TACHOMETER 5439 ANALOG THROTTLE 5915 CAN HIGH 5904 SET ACCEL BUMP UP 5955 5 N N Cp NARS TUUN 1 5 ae UN C09 lt SE1SE1 5050 5 c 5012 IGN 5474 Wait to Start 5904 CAN High 5936 Resume Coast Bump 5020 CAN Shield 5616 Excitation Voltage 5V 5905 CAN Low Down 5032 Fused Unswitched Power 5714 Sensor Return Override 5915 Analog Throttle 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 07 14 96 Troubleshooting 24V 12V Y01 Y01 6 8L Engine PCV 1 PCV 1 C01 125 5 5419 DRIVER 5419 DRIVER 5424 DRIVER J1 G1 J1 E1 J1 B1 01 01 J1 A1 J1 F1 J1 C1 J1 G2 J1 D
28. OUOD006 0000080 19 22JUN07 1 1 OM C3 07 14 20 Engine Operation Stopping the Engine IMPORTANT Before stopping an engine that has been operating at working load idle engine at least 5 minutes at 1000 1200 rpm to cool hot engine parts Engines in generator set applications where the engine controller ECU is locked at a specified speed and no slow idle function is available run engine for at least 5 minutes at fast idle and no load 1 Remove load from engine or shift marine gear to NEUTRAL and run engine for at least 5 minutes at 1000 1200 rpm to allow coolant and oil to carry heat away from the combustion chamber turbocharger pistons and bearings 2 Turn key switch A to OFF position and remove key from ignition 3 If vessel will not be used for several days close fuel valves and sea cock 4 Turn main electrical power switch to OFF if equipped Fill the fuel tank to minimize possible water condensation problems Filling tanks at end of day drives out moisture laden air 6 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 Stopping The Engine Electronically Controlled Engines A Key Switch C Diagnos
29. Oil Pressure at Rated rpm 35 Oil Pressure at Low Idle 800 rpm Lubrication System Generator Applications Oil Pressure at Rated rpm 35 Cooling System Liquid pressurized with centrifugal pump Recommended Pressure Cap Coolant Temperature Operating Range Coolant Temperature Maximum Coolant Capacity Valve Actuation Valve Clearance Cold Intake Exhaust Fuel System ECU Description Fuel Injection Type Governor Type Primary Fuel Filter Secondary Fuel Filter Electrical System Battery Capacity Minimum 12 Volt System Battery Capacity Minimum 24 Volt System Air System Maximum Air Intake Restriction UNIT OF MEASURE mm in mm in L cu in mm in mm in mm in kg Ib kPa psi kPa psi kPa psi kPa psi C F C F L qt CCA CCA in H20 kPa psi ENGINE MODEL 4045TFM85 In line 4 cycle diesel Turbocharged 4 106 4 17 127 5 00 4 5 275 Direct Injection 16 0 1 715 28 1 912 35 9 1007 39 6 n a 290 42 110 16 82 94 180 202 110 230 0 18 0 007 0 64 0 025 L16 HPCR Electronic 10 micron 2 micron 625 500 25 6 25 1 0 ENGINE MODEL 4045AFM85 In line 4 cycle diesel Turbocharged and coolant after cooled 4 106 4 17 127 5 00 4 5 275 Direct Injection 16 7 1 770 30 3 964 31 0 1105 43 5 510 1125 436 63 213 31 378 55 110 16 82 94 180 202 110
30. RG12183 UN 25FEB02 Remove Front Cap Continued on next page RG19661 000040D 19 10MAR13 1 2 OM C3 07 14 47 Lubrication amp Maintenance 500 Hour 12 Month 8 Thoroughly clean all buildup from both end caps 9 Use a 4 76 mm 3 16 in diameter brass rod to clean out any buildup in each tube Run the rod the entire length of each tube to push debris out 10 Flush the tubes with clean water making sure all tubes are cleared of debris Clean with brass rod and flush aftercooler core again if necessary to remove any 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 RG12181 UN 25FEB02 Clean Aftercooler Core RG19661 000040D 19 10MAR13 2 2 OM C3 07 14 48 Lubrication amp Maintenance 500 Hour 12 Month Pressure Testing Cooling System AA ALTON Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely Test Coolant Filler Cap 1 Remove coolant filler cap and attach to an appropriate tester as shown 2 Pressurize cap to specifications Gauge should hold pressure for 10 seconds within the normal range if cap is acc
31. belt guard 4 Perform all appropriate prestarting checks See DAILY PRESTARTING CHECKS in Lubrication and Maintenance Daily Section 5 Open sea water valve and prime the sea water system 6 Open fuel valve fill fuel filter water separator with clean fuel and bleed the fuel system See BLEEDING THE FUEL SYSTEM in Service as Required Section IMPORTANT DO NOT operate starter more than 30 seconds at a time Wait at least 2 minutes for starter to cool before trying again 7 Crank engine for 20 seconds with starter do not allow the engine to start Wait 2 minutes and crank engine an additional 20 seconds to assure bearing surfaces are adequately lubricated 8 Start engine and run at low idle and no load for several minutes Warm up carefully and check all gauges before placing engine under load 9 On the first day of operation after storage check overall engine for leaks and check all gauges for correct operation NOTE If using BIODIESEL blends after long term storage frequency of fuel filter plugging may increase initially OUOD006 0000115 19 160 07 1 1 OM C3 07 14 115 Specifications General Marine Engine Specifications 4 5L ITEM General Data Engine Type Aspiration Number of Cylinders Bore Stroke Displacement Combustion System Compression Ratio Physical Dimensions Width Height Length Basic Dry Weight approximate Lubrication System Propulsion Applications
32. on tensioner mounting base 5 Install torque wrench C so that it is aligned with centers of pulley and tensioner Rotate the swing arm using a torque wrench until marks A and B are aligned 6 Record torque wrench measurement and compare with specification below Replace tensioner assembly as required Specification Spring Tension Torque 18 22 N m 13 16 Ib 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 gt 1 2 5 wo T 5 c S z Ed amp 2 1 D gt 7 S CN do O x Align Torque Wrench With Pulley and Tensioner gt 2 5 5 c Align Marks RG19661 00003E6 19 13FEB13 2 2 OM C3 07 14 41 Lubrication amp Maintenance 500 Hour 12 Month Checking Cooling System A CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely IMPORTANT Air must be expelled from cooling system when system is refilled Loosen temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to escape whe
33. 2 OM C3 07 14 88 Troubleshooting L833SL Nf1 LEPCCOH 5020 5905 5904 5050 x ias gt aa 2 206 ms Lu i apa gt 5 I 92 969 dN dN08 1309V 13S vos G i E 065 MOTNYO 5 S sc amp ges Ea NWOCdNnBlSOO3NnS3U a 2 I S ws Mua 1 2 1 2 I Merci eu N 1168 ues t 2 z m 39 ze 8165 816S NMOQIRS3QMUSO E uc 72 E 5 T o EE 9199 ems E ge me s 566 REESE 9468 SNONOUWLS x DET gt Sa o exe BLNO S e 1 2 as ov tS ul 25 c 089 169 OVE OUNOOINVIONNANM 5 i 5 o B gt a E uu e 28 5 05 ozs 5 2 2 1 2 ET 369 o wig lis Sy TT s ves 5 TT HOSNS i o as c 2 s a 1 2 m PAS MNISOLINM lt Los sas ut lt 179 gl 8 RG19661 00003F0 19 25FEB13 1 2 Continued on next page OM C3 07 14 89 Troubleshooting A Focus 14 4 5 L 4 Valve Engine Control Unit ECU C01 Fuel Injectors C09 A Wait To Start
34. 5 gt lt 5 1 ag 2s 5 008 0 asyo t C 3 anis 2 o 5 1 9 ves Nunua 1 gt 2009 GSHOUIMSNNGRsN4 lt 1 c dh E 77 PAS BAVISOLUMN lt 1 G e 1 4 cO LL 9 5 8 RG19661 00003ED 19 21FEB13 1 2 Continued on next page OM C3 07 14 81 Troubleshooting A Focus 16 4 5 L 4 Valve Engine Control Unit ECU C01 Fuel Injectors C09 A Wait To Start C09 B Fused Unswitched Power C09 C Sensor Return C09 D Start C09 E Ground C09 F CAN Shield C09 G Ignition C09 H Warning Lamp C09 J Accessory C09 K Tachometer C09 L Analog Throttle C09 M Excitation Voltage 5 V C09 N Override Shutdown C09 P Override Shutdown Return C09 R Digital Throttle C09 S Sensor Return C09 T Resume Coast Bump Down C09 U CAN Low C09 V CAN High C09 W Set Accelerator Bump Up C09 X Bump Enable J1 32 Position Black J1 C1 Cylinder 2 J1 D1 Cylinder 4 J1 E1 Cylinder 1 J1 F1 Cylinder 3 J1 H1 High Driver J1 H2 Low Driver J2 468 Position Brown J3 32 Position Blue SE2 Focus 16 ECU Y01 Pressure Control Valve 1 12 V 24 V RG19661 00003ED 19 21FEB13 2 2 OM C3 07 14 82 Troubleshooting 4045TFM85 Marine Ele
35. Inspecting Thermostats And Testing Opening Temperature following in this section RG8019A UN 19JUN00 7 Close all drain valves after coolant has drained Engine Block Drain Valve Aj E UON Do not run engine longer than 10 minutes Doing so may cause engine to overheat A Engine Block Drain Valve causing burns when cooling system is draining 8 Fillthe cooling system with clean water Run the engine about 10 minutes to stir up possible rust or sediment 9 Stop engine pull off lower cooling system hose and remove heat exchanger or top tank cap Immediately drain the water from system before rust and sediment settle 10 After draining water close drain valves Reinstall cap lower cooling system hose and clamp Fill the cooling System with clean water and a heavy duty cooling system cleaner such as Fleetguard RESTORE and RESTORE PLUS 11 After cleaning the cooling system drain cleaner and fill with water to flush the system Run the engine about 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 07 14 53 Lubrication amp Maintenance 2000 Hour 24 Month Remove Thermostats A o Explosive release of fluids from pressurized cooling system can cause serious burns Sh
36. John Deere COOL GARD is used the drain interval is 3000 hours or 36 months The drain interval may be extended to 5000 hours or 60 months of operation provided that the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive SCA If COOL GARD is not used the flushing interval is 2000 hours or 24 months of operation TS281 UN 23AUG88 Drain old coolant flush the entire cooling system test thermostats and fill with recommended clean coolant using the following procedure RG22040 UN 28NOV12 1 Pressure test entire cooling system and pressure cap if not previously done See PRESSURE TESTING COOLING SYSTEM in the Lubrication and Engin TOR Tank Maintenance 500 Hour 12 Month Section 2 Slowly open the cap on the top tank A or heat A Top Tank exchanger to relieve pressure and allow coolant to drain faster Continued on next page RG19661 00003D1 19 28JAN13 1 2 OM C3 07 14 52 Lubrication amp Maintenance 2000 Hour 24 Month 3 Open engine block drain valve A on left side of engine Drain all coolant from engine block 4 Open heat exchanger or top tank drain valve Drain all coolant from heat exchanger or top tank 5 Remove thermostats at this time if not previously done Install cover without thermostats using old gasket and tighten cap screws to 47 35 lb ft 6 Test thermostat opening temperature See
37. Mismatched Contact Servicing Dealer ECU Pump Timing Extremely Mismatched Contact Servicing Dealer Continued on next page OURGP12 00001FC 19 08APR10 3 4 OM C3 07 14 108 Troubleshooting SPN FMI Blink Description of Fault Corrective Action Code 03 21 Sensor Supply 1 Voltage High Check Wiring Ed 04 22 x Sensor Supply 1 Voltage Low Check Wiring 108 03 31 5 Sensor Supply 2 Voltage High Check Wiring I 108 04 32 Sensor Supply 2 Voltage Low Check Wiring E 31 2 Gee Engine Protection Shutdown Warning Check Fault Codes I tie eges Engine Protection Shutdown Check Fault Codes 13 00 ECU Temperature Signal Extremely High Contact Servicing Dealer 13 16 ECU Temperature Signal Moderately High Contact Servicing Dealer 4 134 05 TT High Pressure Fuel Pump Solenoid Number 1 Circuit Has High 2 Check Pump Wiring pou ces S ese Fuel Filer and lines 25 02 89 Pump Power Relay Contact Servicing Dealer 15 0252 corem Requested Torqu
38. Number 4 Circuit Has Low Resistance Check Injector Wiring or Injector Solenoid Injector Number 4 Not Responding Injector Failed or Flow Limiter Closed Injector Number 4 Part Number Calibration Fault Contact Servicing Dealer Injector Number 5 Part Number Data Invalid Contact Servicing Dealer Injector Number 5 Circuit Has High Resistance Check Injector Wiring or Injector Solenoid Injector Number 5 Circuit Has Low Resistance Check Injector Wiring or Injector Solenoid Injector Number 5 Not Responding Injector Failed or Flow Limiter Closed Injector Number 5 Part Number Calibration Fault Contact Servicing Dealer Injector Number 6 Part Number Data Invalid Contact Servicing Dealer Injector Number 6 Circuit Has High Resistance Check Injector Wiring or Injector Solenoid Injector Number 6 Circuit Has Low Resistance Check Injector Wiring or Injector Solenoid Injector Number 6 Part Number Calibration Fault Contact Servicing Dealer Injector Number 6 Not Responding Injector Failed or Flow Limiter Closed Glow Plug Signal Received When Not Expected Check Relay and Wiring Glow Plug Signal Not Received When Expected Check Relay and Wiring Inlet Air Heater Signal High Conta
39. Potentially harmful waste used in Northern Lights handling of these components is not dangerous equipment can include oil fuel coolant filters and as long as airborne dust containing asbestos is not batteries generated Avoid creating dust Never use compressed air for Use leakproof containers to drain fluid Do not cleaning Avoid brushing or grinding materials use food or beverage containers that may mislead containing asbestos When servicing wear an someone into drinking from them approved respirator A special vacuum cleaner is recommended to clean asbestos If this vacuum is Do not pour waste onto the ground down a drain or not available apply a mist of oil or water on the into any water source OM C3 07 14 7 Lock Out Tag Out Procedures Scone 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 Many serious accidents happen when someone thought the machine was turned off or all of its energy was safely blocked or released General Policy CAUTION 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
40. base making certain dust seal is in place on filter base Hand tighten ring about 1 3 turn until it snaps into the detent DO NOT overtighten retaining ring NOTE The proper installation is indicated when a click is heard and a release of the retaining ring is felt A plug is provided with the new element for plugging the used element 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 RG22097 UN 15FEB13 Fuel Filter Water Separator 4045 Engine RG22078 UN 03DEC12 Fuel Filter Water Separator C Filter Base D Filter Water Separator A Electrical Connector B Drain filters removed it will be necessary to bleed air from the system See BLEEDING THE FUEL SYSTEM in Service as Required Section RG19661 00003E5 19 13FEB13 1 1 OM C3 07 14 39 Lubrication amp Maintenance 500 Hour 12 Month Checking Belt Tensioner Spring Tension and Belt Wear Automatic Tensioner Belt drive systems equipped with automatic spring belt tensioners cannot be adjusted or repaired The automatic belt tensioner is designed to maintain proper belt tension over the life of the belt If tensioner spring tension is not within specification replace tensioner assembly Checking Belt Wear The belt tensioner is designed to operate within the limit of arm movement provided by the cast stops A and
41. nozzles Electronic fuel system problem Defective thermostat Defective temperature gauge or sender Engine overloaded Intake air restriction Clogged fuel filter Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Injector tip deposits Injection pump out of time Turbocharger not functioning Turbocharger engines only Continued on next page Solution See your authorized servicing dealer or engine distributor Remove and check thermostat See Engine Overheats Remove and check thermostat Replace fuel filter element Drain flush fill and bleed system Change to better quality fuel Have authorized servicing dealer or engine distributor check injectors See your authorized servicing dealer Remove and check thermostat Check gauge sender and connections Reduce load Service air cleaner Replace filter elements Use proper fuel See Engine Overheats Remove and check thermostat See your authorized servicing dealer or engine distributor Have authorized servicing dealer or engine distributor check injectors Use John Deere approved biodiesel fuel conditioners containing detergents See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor OUOD006 0000113 19 160 07 2 5 OM C3 07 14 99 Symptom
42. possible Corrective Action Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Check Switch and Wiring Check Switch and Wiring Check Sensor and Wiring Contact Servicing Dealer Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Check Sensor and Wiring Check Sensor and Wiring Stop and Drain Water Separator Check Oil Level Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Oil Level Check Air Cleaner Aftercooler or Room Temperature Check Sensor and Wiring Check Sensor and Wiring Check Air Cleaner Aftercooler or Room Temperature Check Air Cleaner Aftercooler or Room Temperature 100 16 Engine Pressure Signal Moderately High 100 18 74 Engine Oil Pressure Signal Moderately Low 105 00 Intake Manifold Air Temperature Signal Extremely High 105 03 Intake Manifold Air Temperature Signal Out of Range High 105 04 Intake Manifold Air Temperature Signal Out of Range Low 105 15 s s Manifold Air Temperature Slightly High 105 16 Intake Manifold Air Temperature Signal Moderately High 107 00 Air Filter Pressure Differential Extremely High
43. referencing Northern Lights equipment by serial number please refer only to the number stamped on the Northern Lights serial number plate Serial No Model No Northern Lights 4420 14th Ave NW Seattle WA 98107 NORTHERN LIGHTS Northern Lights 4420 14th Ave N W 98107 2 Generator Set Data Set Serial No M I No Set Model No OM C3 07 14 2 Warranty A warranty registration certificate is supplied NOTE If the warranty is to apply the servicing with your set The extent of coverage is described instructions outlined in this manual must be in the Limited Warranty Statement We recommend followed If further information is needed please that you study the statement carefully contact an authorized dealer or the factory Safety Rules A 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 on parts and components from outside suppliers Electromagnetic equipment including generator sets that is not reproduced in this manual Consult the and their accessories can cause bodily harm and suppliers for additional safety information life threatening injuries when improperly installed operated or maintained To prevent accidents be aware Learn how to operate the machine and ho
44. turning before trying again This will prevent possible damage to the starter and or flywheel NOTE Key switch A on main standard instrument panel must be in ON position to start engine using fly bridge optional instrument panel 6 Press start button B to crank the engine When the engine starts release the button 7 After the engine starts observe the oil pressure gauge C until it reads at least the slow idle pressure specified for your engine in the Specifications Section RG13291 UN 06NOV03 8 Warm up the engine at or below 1200 rpm with no load for 1 2 minutes See following guidelines 9 Check all gauges for normal engine operation If operation is not normal stop the engine and determine the cause 10 Check sea water outlet for water flow Check exhaust pipe for water flow on engines with wet exhaust systems 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 RG13134 UN 070CT03 B Start Button D Warning Light OM C3 07 14 18 Start Engine Electronically Controlled Engine RG19661 00003BD 19 23JAN13 2 2 Engine Operation Warming Engine IMPORTANT To assure proper lubrication operate engine at or below 1200 rpm with no load for 1 2 minutes Extend this period 2 4 minute
45. 0 seconds without permitting engine to start This will help insure adequate lubrication to engine components before engine starts NOTE Crankcase oil capacity may vary slightly ALWAYS fill crankcase within crosshatch marks A Rocker Arm Cover Oil Filler on dipstick DO NOT overfill 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 OM C3 07 14 32 Lubrication amp Maintenance 250 Hour 6 Month Servicing Battery Zh on Battery gas can explode Keep sparks and flames away from batteries Use a flashlight to check battery electrolyte level Never check battery charge by placing a metal object across the posts Use a voltmeter or hydrometer Always remove grounded NEGATIVE battery clamp first and replace it last WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling 1 On regular batteries check electrolyte level Fill each cell to bottom of filler neck with distilled water NOTE Low maintenance or maintenance free batteries should require little additional service However electrolyte level can be checked by cutting the center section of decal on dash line and removing cell plugs If necessar
46. 06 0000113 19 16OCT07 3 5 Troubleshooting Symptom Engine overheats High fuel consumption Problem Fuel injectors dirty Engine out of time Turbocharger not functioning Electronic fuel system problem Engine overloaded Low coolant level Faulty coolant tank cap Stretched poly vee belt or defective belt tensioner Faulty sea raw water pump Low engine oil level Cooling system needs flushing Defective thermostat Defective temperature gauge or sender Electronic fuel system problem Incorrect grade of fuel Plugged heat exchanger Plugged keel cooler Trash or debris in engine compartment Improper type of fuel Clogged or dirty air cleaner Continued on next page Solution Use John Deere approved biodiesel or diesel fuel conditioners containing detergents If no improvement is seen see your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer Reduce load Fill coolant tank to proper level check coolant tank and hoses for loose connections or leaks Have serviceman check Check automatic belt tensioner and check belts for stretching Replace as required Check replace impeller pump Check oil level Add oil as required Flush cooling system Remove and check thermostat Check water temperatur
47. 137 UN 06DEC12 RG22048 UN 29NOV12 Inspect Zinc Plugs 6 Cylinder RG19661 00003D5 19 29JAN13 1 2 3 Measure zinc plugs A to determine the amount of erosion on length B and outer diameter C If length is less than 15 9 mm 0 63 in or outer diameter is less than 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 RG6007 UN 27JAN92 Zinc Plug Erosion RG19661 00003D5 19 29JAN13 2 2 OM C3 07 14 35 Lubrication amp Maintenance 250 Hour 6 Month Checking Belt Wear 1 Remove belt guard A 2 Swing tensioner arm C to remove all belt slack 3 Remove and inspect belt for cracks fraying or stretched out areas Replace if necessary NOTE While belt is removed inspect pulleys and bearings Rotate and feel for hard turning or any unusual sounds If pulleys or bearings need replacement see your John Deere dealer 4 f tensioner has been removed tighten tensioner mounting cap screw B to 70 N m 52 lb ft 5 Install belt guard A Belt Guard C Tensioner Arm B Mounting Cap Screw RG22049 UN 29NOV12 s 1 1 Check Belt Wear RG19661 00003D6 19 09MAR13 1 1 Checking Engine Mounts Engine mounting is the responsibility of the vessel or g
48. 3 F 57 PSI OIL TEMP OIL PRES Return To Main Menu RG13154 UN 24SEP03 OURGP11 00000B2 19 03SEP03 13 14 15 Press the Menu key to exit the main menu and return GO TO 1 UP DISPLAY 125 to the engine parameter display CHIONE CODES dee 1000 RPM SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY uet ADJUST BACKLIGHT TEMP OIL PRES Select Remaining Parameters RG13155 UN 07OCT03 OURGP11 00000B2 19 03SEP03 14 14 OM C3 07 14 13 Engine Operation Normal 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 GENERAL ENGINE SPECIFICATIONS in Specifications Section near end of manual for temperature and pressure specifications for your engine If coolant temperature rises above the maximum coolant temperature see Specifications Section reduce load on engine Unless temperature drops quickly stop engine and determine cause before resuming operation Operate the engine under a lighter load and at slower than normal speed for first 15 minutes after start up DO NOT run engine at slow idle unless necessary for maneuvering out of dock and harbor Stop engine immediately if there are any signs of part failure Symptoms that may be early signs of engine problems are Sudden drop in oil pressure Abnormal coolant t
49. 3 J1 H2 J1 H2 J1 H1 CANL CANH J2 J2 J2 B2 B1 1 5012 5905 s TWISTED SAE J1939 11 3 WAY SHIELDED DEUTSCH TERM 1 5904 A una 5020 5020 gt SAE J1939 11 3 WAY C1 0 DEUTSCH CONN LOCATED NEAR ECU 5020 5905 5904 C11 DIAGNOSTIC CONNECTOR 5050 5050 RG15323A UN 27JAN11 C10 Deutsch Conn Located C11 Diagnostic Connector 5419 Driver Low Near ECU 5424 Driver High RG19661 00003E1 19 11FEB13 2 2 OM C3 07 14 97 Troubleshooting Engine Troubleshooting NOTE If using BIODIESEL blends above B20 the possibility of some of the symptoms listed below such as power loss could increase Symptom Engine cranks but will not start Engine hard to start or will not start Engine knocks NOTE Before troubleshooting the engine first retrieve any fault codes on the diagnostic gauge display and perform the corrective actions See information later in this section If any problems remain use the following charts to solve engine problems Problem Incorrect starting procedure No fuel Exhaust restricted Fuel filter plugged or full of water Injection pump not getting fuel or air in fuel system Faulty injection pump or nozzles Engine starting under load Improper starting procedure No fuel Air in fuel line Cold weather Slow starter speed Crankcase oil too heavy Improper type of fuel
50. B when correct belt length and geometry is used Visually inspect cast stops A and B on belt tensioner assembly If the tensioner cast stop A on swing arm is hitting either fixed cast stop 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 RG22080 UN 03DEC12 Cast Stops Tensioner Arm A Tensioner Cast Stops Continued on next page B Fixed Cast Stops RG19661 00003E6 19 13FEB13 1 2 OM C3 07 14 40 Lubrication amp Maintenance 500 Hour 12 Month Checking Tensioner Spring Tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used Measure tensioner spring tension using a torque wrench and procedure outlined below 1 Release tension on belt using a long handled 1 2 inch drive tool in square hole in tensioner arm Earlier tensioner arms have bolt in place of square hole and require breaker bar with socket Remove belt from pulleys NOTE While belt is removed inspect pulleys and bearings Rotate and feel for hard turning or any unusual sounds If pulleys or bearings need replacement see your John Deere dealer 2 Release tension on tension arm and remove drive tool Put a mark A on swing arm of tensioner as shown 4 Measure 21 mm 0 83 in from A and put a mark B
51. H This switch bypasses the safety shutdown feature during the starting process 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 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 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 COOLANT TEMPERATURE GAUGE Water temperature gauge shows the temperature of the cooling water If the gauge registers over 200 F 93 3 C or drops below 140 F 60 C stop the engine and investigate HOUR METER Keeps track of the engine running time DC VOLTMETER When the engine is running it indicates the voltage output of the alternator OM C3 07 14 12 Instrument Panels 12 The selected quadrant has now changed to the new selected parameter 125 F 1000 RPM COOL TEMP ENG RPM 143 F 57 PSI OIL TEMP OIL PRES 4 Up Display RG13153 UN 24SEP03 OURGP11 00000B2 19 03SEP03 12 14 13 Repeat the parameter selection process until all spaces are as desired 125 1000 RPM 14 Press the Menu key to return to the main menu COOL TEMP ENG RPM 14
52. Month Inspecting Thermostats and Testing Opening Temperature 1 Remove thermostats See REMOVING THERMOSTATS earlier in this section Visually inspect thermostats for corrosion or damage Replace thermostats as a matched set as necessary Inspect thermostat with wiggle wire in vent notch If wire movement is restricted replace thermostat if cleaning does not free movement CAUTION DO NOT allow thermostat or thermometer to rest against the side or bottom of container when heating water Either may rupture if overheated Suspend thermostats and a thermometer in a container of water Stir the water as it heats Observe opening action of thermostat and compare temperatures with specifications See GENERAL ENGINE SPECIFICATIONS in Specification Section NOTE Due to varying tolerances of different supplies initial opening and full open temperatures may 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 7 RG5971 UN 23NOV97 Thermostat And Thermometer In Water If any one thermostat is defective replace both thermostats OUOD006 0000095 19 19JUNO07 1 1 OM C3 07 14 55 Lubrication amp Maintenance 2000 Hour 24 Month Checking Crankshaft Vibration Damper 6 Cylinder Engine Only 1 Remove belts shown removed 2
53. N13 2 4 IMPORTANT A restricted or clogged sea water strainer will result in hotter than normal 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 RG5993 UN 27JAN92 Sea Water Strainer Continued on next page RG19661 00003D3 19 29JAN13 3 4 OM C3 07 14 28 Lubrication amp Maintenance Daily 4 If equipped with air intake restriction indicator gauge A check gauge to determine if air cleaner needs to be serviced The reset button will pop up when air cleaner needs to be serviced IMPORTANT Maximum air intake restriction is 625 mm 25 in H gt O A clogged air cleaner element will cause excessive intake restriction and a reduced air supply to the engine 5 Make a thorough inspection of the engine compartment Look for oil or coolant leaks worn drive belts loose connections and trash build up Remove trash buildup and have repairs made as needed if leaks are found NOTE Wipe all fittings caps and plugs before performing any maintenance to reduce the chance of system contamination Inspect Engine shields and guards for trash build up Air intake system hoses and connections for cracks and loose clamps Alternator drive belt for cracks breaks other damage Water pump for coolant leaks Coolant system for leaks NOTE It is
54. OLIVLIOX3 Ht NYNLAY NOIIVLIOX3 Hf HOVEIOA NOLIVLIOX3 9 SOWNV di A31 VET3O NYNLJY NOLIVLIOX3 SL c ADVLIOA NOLIVLIOX3 9178 1975 696 8279 L9rS 775 21079 9765 3 75 7478 9575 J3 H4 J3 C3 J3 D3 J3 B1 J3 C2 J3 D2 FOCUS 14 6 8L 4 VALVE ENGINE CONTROL UNIT ECU J3 H3 J3 G1 J3 G2 J3 C1 J3 B2 J3 F1 EM iw es N HE B euo iesu MANN Se T L LAZA J2 G2 6 VIZESLOMH 5050 LNIOd 319NIS 6 74 dNV1dOLS LEtS LNdNI AONANDAYSA 1865 JILLOHHL INMd 7145 NOWINOO 1 HS alVvuadq 1X3 4664 AOD JOSI 765 351099 957 HOLIMS NOLLOIHLIS3H YALA 8764 INV IOOO dO 5501 HAWOLSNO 4166 3SInHO 310W3H 1769 NMOGLNHS TIVNH3 LX3 6565 3l1VHdQ IVNH3LX3 0108 NONINOO 351099 10 dNV1dO1S 6169 31LlOHH1 5 vs6S 1469 AWNSAY ONVO 351099 78 NYN1AY HOSN3S 105 H3MOd Q3HOLIMS 1168 9 NOLIVLIOX3 HOSN3S P gt L QRS TU J K B C DE C08 AUX CONNECTOR ie 5050 RG19661 00003E0 19 15FEB13 1 2 Continued on next page OM C3 07 14 94 Troubleshooting C08 Aux Connector D01 Water in Fuel P03 Fuel Pressure Sensor P04 Oil Pressure Sensor Clean Side P05 Rail Pressure T02 Manifold Air Temp T04 Coolant Temp T05 Fue
55. SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES Select Utilities RG13237 UN 220CT03 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 JD X XX Software Version RG13236 UN 130CT03 OURGP11 00000E3 19 29SEP03 4 4 OM C3 07 14 111 Troubleshooting Transition Harness The marine transition harness connects the engine wiring harness and the main instrument panel The engine end of the transition harness contains connections for the 21 and 23 pin connectors the starter cutout relay an external shutdown connection station select and an auxiliary analog throttle input The instrument panel end of the harness contains connectors for station select engine sync engine sync in and out power and starting circuit wiring for the instrument panel wheelhouse analog throttle and CAN bus connection A Wheelhouse Station Speed Input B Wheelhouse Throttle Input C CAN Connector to marine instrument panel D Battery Ground E Engine Sync Input F Engine Sync Output G External Shutdown Conector H Starter Cutout Relay I Auxiliary Throttle Input J Auxiliary Station Select Input K 23 Pin Connector engine wiring harness L 21 Pin Connector engine wiring harness
56. Water dirt or air in fuel system Clogged fuel filter Dirty or faulty injection nozzles Electronic fuel system problem Injection pump shut off not reset Low engine oil level Continued on next page Solution Verify correct starting procedure Check fuel in tank and manual shut off valve Check and correct exhaust restriction Replace fuel filter or drain water from filter Check fuel flow at supply pump or bleed fuel system Consult authorized diesel repair station for repair or replacement Disengage PTO if equipped Review starting procedure Check fuel tank Bleed fuel line Use cold weather starting aids See Starter Cranks Slowly Use oil of proper viscosity Consult fuel supplier use proper type fuel for operating conditions Drain flush fill and bleed system Replace filter element Have authorized servicing dealer or engine distributor check injectors See your authorized servicing dealer Turn key switch to OFF then to ON Add oil to engine crankcase OUOD006 0000113 19 160 07 1 5 OM C3 07 14 98 Troubleshooting Symptom Engine runs irregularly or stalls frequently Below normal engine temperature Lack of power Problem Injection pump out of time Low coolant temperature Engine overheating Low coolant temperature Clogged fuel filter Water dirt or air in fuel system Poor quality fuel Dirty or faulty injection
57. Water Pump 1 Close sea cock and drain sea water system 2 Remove sea water pump inlet connection Loosen constant tension clamps B on formed hose C that is attached to the aftercooler inlet A 3 Remove sea water pump bracket cap screws D Remove pump mounting nuts E and remove sea water pump H 4 Clean sealing surfaces and inspect for defects Replace O ring G if necessary 5 Install sea water pump with O ring on studs F Install nuts E finger tight evenly on both studs and tighten to 60 N m 44 Ib ft 6 Install bracket cap screws D and tighten to 35 N m 26 Ib ft 7 Install formed hose C and tighten constant tension clamps B to 12 N m 9 Ib ft 8 Connect sea water pump inlet 9 Open sea cock start engine and check for leaks A Aftercooler Inlet B Constant Tension Clamps C Formed Hose D Cap Screws RG22484 UN 07MAR13 RG22483 UN 07MAR13 E Nuts F Studs G O ring H Sea Water Pump RG19661 0000404 19 07 13 1 1 OM C3 07 14 70 Troubleshooting General Troubleshooting Information Troubleshooting engine problems can be difficult Engine wiring diagrams are provided in this section to help isolate electrical problems on engines using John Deere wiring harness and instrument gauge panel Later in this section is a list of possible engine problems that may be encountered accompanied by possible causes and correction
58. Y90 After welding reverse Steps 1 5 DX WW ECU02 19 14AUG09 1 1 Keep Electronic Control Unit Connectors Clean IMPORTANT Do not open control unit and do not clean with a high pressure spray Moisture dirt and other contaminants may cause permanent damage 1 Keep terminals clean and free of foreign debris Moisture dirt and other contaminants may cause the terminals to erode over time and not make a good electrical connection If a connector is not in use put on the proper dust cap appropriate seal to protect it from foreign debris and moisture 3 Control units are not repairable 4 Since control units are the components LEAST likely to fail isolate failure before replacing by completing a diagnostic procedure See your John Deere dealer The wiring harness terminals and connectors for electronic control units are repairable DX WW ECU04 19 11JUN09 1 1 OM C3 07 14 23 Lubrication and Maintenance Observe Service Intervals IMPORTANT Recommended service intervals are for normal operating conditions Service MORE OFTEN if engine is operated under adverse conditions Neglecting maintenance can result in failures or permanent damage to the engine Using diagnostic gauge hour meter A as a guide perform all services at the hourly intervals indicated on following pages At each scheduled maintenance interval perform all previous maintenance op
59. a Water Pump Impeller repair kit IMPORTANT If impeller has chunks of material klate B Cam Screw missing the heat exchanger marine gear oil cooler and any other circuit that are cooled by raw water should be thoroughly 6 Thoroughly clean impeller housing bore and cam plate cleaned and flushed if cam plate is reused RG6243 UN 23MAR92 5 Remove cam screw B holding cam plate to impeller housing bore Continued on next page RG19661 0000401 19 06MAR13 2 3 OM C3 07 14 57 Lubrication amp Maintenance 2000 Hour 24 Month Install Impeller 1 Apply LOCTITE 242 Deere Part No TY9370 to curved side of cam plate near threaded hole and install cam plate into impeller housing bore be sure holes in cam plate and housing are aligned Apply LOCTITE 242 to cam screw B install and tighten The cam plate should be inspected to insure that none of the cam fingers are protruding which could cause impeller damage The cam screw should also be inspected to insure that it does not protrude below the cam plate Replace cam plate and cam screw or grind screw flush as needed IMPORTANT Petroleum based lubricants can cause the impeller to swell and are not recommended to lubricate the impeller before installation 2 Lubricate impeller blades with a non petroleum based lubricant such as silicone or soapy water Install impeller using a twisting motion and be sure the impeller blades are bent the sam
60. a machine or on equipment that has been locked out Restarting Procedures CAUTION 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 OM C3 07 14 8 Notes OM C3 07 14 9 Figures 1 amp 2 M65C13 1 Junction Box 2 Air Cleaner 3 Fuel Filter 4 Lube Oil Fill 5 Coolant Fill Component Locations 6 Alternator 7 Belt Guard 8 Starter 9 Lube Oil Dipstick 10 Lube Oil Filter OM C3 07 14 10 11 Turbocharger 12 Fuel Injection Lines 13 Exhaust Elbow 14 Thermostat Cover 15 Expansion Tank 16 Stop Start Panel Component Locations Shown with optional PTO Figure 3 amp 4 99 1 Junction Box 6 Lube Oil Dipstick 11 Starter 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 16 Stop Start Panel OM C3 07 14 11 Northern Lights Control Panels Figure 7 Series 3B Generator Control Panel SHUTDOWN BYPASS SWITC
61. additive the flushing interval may be extended to 5000 hours or 60 months whichever occurs first OUOD006 0000082 19 270CT11 1 1 OM C3 07 14 26 Lubrication amp Maintenance Daily Daily Prestarting Checks j 4 Do the following BEFORE STARTING THE ENGINE for 2 the first time each day IMPORTANT DO NOT add makeup oil until the oil 9 2 level is BELOW the add mark Depending on application oil dipstick A and oil filler cap B may be located on either the left or the right side of engine In addition oil may be added at rocker arm filler cap C RG9837 UN 12JAN99 1 Check engine oil level on dipstick A Add as required using seasonal viscosity grade oil See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section for oil specifications IMPORTANT DO NOT fill above the top mark on the dipstick Oil levels anywhere within crosshatch D are considered in the acceptable operating range A Dipstick C Rocker Arm Filler Cap B Left Side Oil Filler Cap D Crosshatch On Oil Dipstick RG22038 UN 28NOV12 RG22037 UN 28NOV12 Rocker Arm Cover Filler Cap RG22039 UN 08JAN13 Oil Fill Level on Dipstick Continued on next page RG19661 00003D3 19 29JAN13 1 4 OM C3 07 14 27 Lubrication amp Maintenance Daily TS281 UN 23AUG88 A Engine Top Tank RG22040 UN 28NOV12 Engine Top Tank RG19661 00003D3 19 29JA
62. air cleaner See REPLACING AIR CLEANER FILTER ELEMENTS in Service As Required Section 4 Draining and flushing of cooling system is not necessary if engine is to be stored only for several months However for extended storage periods of a year or longer it is recommended that the cooling system be drained flushed and refilled Refill with appropriate coolant See RECOMMENDED ENGINE COOLANT in Fuels Lubricants and Coolant Section and ADDING COOLANT in Service As Required Section e Prepare a tank with a solution of diesel fuel and rust preventive oil at ten 10 ounces of rust preventive oil per gallon of diesel fuel 6 Remove existing lines plugs as required and run a temporary line from the tank to the engine fuel intake and another temporary line from the fuel return manifold to the tank so rust preventive oil solution is circulated through the injection system during cranking 7 Crank the engine several revolutions with starter do not allow the engine to start This will allow rust preventive oil solution to circulate Remove temporary lines installed in Step 6 above and replace any lines plugs previously removed NOTE One gallon of fuel oil solution can be used to treat 100 engines two gallons to treat 200 engines etc The oil could then be replenished by adding an additional five 5 ounces of rust preventive oil per gallon of solution However starting over with a new solution is recommended to
63. all engine mechanical and other systems NS not related to the electronic control system are operating properly RG13140 UN 070CT03 Diagnostic Gauge 2 Read and record diagnostic trouble codes DTCs displayed on the diagnostic gauge A To access trouble codes on diagnostic gauge A see Section 15 of this manual A Diagnostic Gauge 3 Go to the LISTING OF DIAGNOSTIC TROUBLE 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 19 055 03 1 1 OM C3 07 14 105 Troubleshooting Listing Of Diagnostic Trouble Codes DTC The Diagnostic Trouble Codes DTCs are output on the diagnostic gauge according to the J1939 standard as a two part code The first part is a two to four digit Suspect Parameter Number SPN followed by a one or two digit Failure Mode Identifier FMI code Listing Of Diagnostic Trouble Codes Continued SPN FMI Blink Description of Fault Code 28527034 03 Throttle 3 Signal Out of Range High 28 04 14 Throttle 3 Signal Out of Range Low 29 03 15 Throttle 2 Signal Out of Range High 29 04 16 Throttle 2 Signal Out of Range Low 84 02 Vehicle Speed
64. am to help you monitor machine performance and identify potential problems before they cause serious damage OILSCAN or OILSCAN PLUS kits are available from your John Deere dealer Oil samples should be taken prior to the oil change Refer to instructions provided with kit To change engine oil and oil filter 1 Run engine approximately 5 minutes to warm up oil Shut engine off PLUS 50 is a trademark of Deere amp Company OILSCAN is a trademark of Deere amp Company OILSCAN PLUS is a trademark of Deere amp Company Oil Pan Drain Plug RG22041 UN 07JAN13 2 Remove oil pan drain plug arrow 3 Drain crankcase oil from engine while warm NOTE Drain plug location may vary depending on the application Continued on next page RG19661 00003D4 19 28FEB13 1 3 OM C3 07 14 30 Lubrication amp Maintenance 250 Hour 6 Month 4 Turn filter element A using a suitable filter wrench to remove Discard oil filter element NOTE Depending on engine application oil filter may be located on either side of the engine in a high or low mount location IMPORTANT Filtration of oils is critical to proper lubrication Always change filter regularly Use filter meeting John Deere performance specifications 5 Apply clean engine oil to the new filter at the inner B and outer C seals and to filter threads 6 Wipe both sealing surfaces of the header D E with a clean rag Ensure t
65. and inspect the engine heat exchanger core at 250 hour or three month service interval on a new engine Then remove and clean at every 500 hour or 12 month interval thereafter 1 Close sea cocks and drain the sea water system 2 Open drain cock on cylinder block and drain approximately two gallons of engine coolant into a clean container Close drain cock 3 Loosen hose clamp A and remove hose from rear end cap B 4 Remove two end cap mounting cap screws and remove end cap C with heat exchanger core D from rear of engine C End Cap D Heat Exchanger Core A Clamp B End Cap Continued on next page gt RG6063 UN 23JAN92 RG19661 000040B 19 10MAR13 1 2 OM C3 07 14 44 Lubrication amp Maintenance 500 Hour 12 Month On All Engines NOTE The heat exchanger core may be removed from housing when either end cap is removed It is strongly recommended that both end caps be removed for cleaning when cleaning the heat exchanger core 5 Remove remaining end cap from water manifold heat exchanger housing Remove end cap from heat exchanger core 6 Thoroughly clean all buildup from both end caps and inspect zinc plug in each Replace plugs as needed See INSPECT AND REPLACE ZINC PLUGS in 250 Hour Section 7 Use a 4 76 mm 3 16 in diameter brass rod to clean out any buildup in each heat exchanger tube Run the rod the entire length of each tube to push debris out
66. ausing serious injury Relieve pressure before disconnecting fuel or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard or paper to search for leaks Do not use your hand If any fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result Doctors unfamiliar with this type of injury may call the Deere amp Company Medical Department in Moline Illinois or other knowledgeable medical source 1 Close fuel shut off valve at bottom of fuel tank not illustrated 2 Clean entire area surrounding fuel filter assembly to keep debris from entering fuel system 3 Disconnect water in fuel sensor 4 Drain fuel into a suitable container 5 Firmly grasp the filter or filter housing and rotate it counterclockwise 1 4 turn Remove ring with filter element E 6 Inspect filter mounting base for cleanliness Clean as required NOTE Raised locators on fuel filter canisters must be indexed properly with slots in mounting base for correct installation 7 Install new filter element onto mounting base Be sure element is properly indexed and firmly seated on base It may be necessary to rotate filter for correct alignment 8 Align keys on filter element with slots in filter base 9 Install retaining ring onto mounting
67. cal System Layout 1 Engine Control Unit ECU 2 Auxiliary Power Connector 9 Fuel Temperature Sensor Connector 3 Coolant Temperature Sensor 10 Camshaft Position Sensor Connector Connector 4 Fuel Injection Harness 11 Low Pressure Fuel Pump Connector Connector 5 Alternator Connector 12 Oil Pressure Sensor 6 Manifold Air Pressure Sensor Connector Connector 13 Fuel Pressure Sensor 7 Manifold Air Temperature Connector Sensor Connector 14 Water in Fuel Sensor 8 Suction Control Valve Sensor Connector Connector 15 Fuel Rail Pressure Sensor Connector 16 Crankshaft Position Sensor Connector 17 Control Panel Connector 18 Auxiliary Connector 19 Diagnostic Connector 20 CAN Terminator Connector 21 Remote On Off Connector 22 Unterminated Ground Battery 23 Unterminated Power Battery 24 Low Pressure Fuel Pump Fuse 15 Amp RG22346 UN 05FEB13 25 ECU Fuse 20 Amp 26 Transient Voltage Protection Connector 27 System Fuse 30 Amp 28 Starter Relay Coil Connector Power 29 Starter Relay Coil Connector Ground RG19661 00003DE 19 15FEB13 1 1 OM C3 07 14 73 Troubleshooting Wiring Diagram for John Deere Main Station Wheel House Instrument Panel Electronically Controlled Engine 432 Instrument Panel Pwr 020 Can Shield 904 Can H 905 Can L 012 IGN 12V OR 24V T LL R
68. cation 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 7 14 OM C3 07 14 1 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 Failures begin with minor problems that are overlooked and become amplified 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 Model Numbers M65C 13 65 kW Northern Lights commercial marine generator set with a John Deere Powertech Tier 6068 engine block and an electronically controlled fuel System M99C13 99 kW Northern Lights commercial marine generator with a John Deere Powertech Tier 6068 engine block and an electronically controlled fuel system Serial Numbers When
69. ct Servicing Dealer Inlet Air Heater Signal Low Contact Servicing Dealer Calculated Vehicle Speed Input Noise Contact Servicing Dealer Vehicle Speed or Torque Message Not Valid Contact Servicing Dealer Auxiliary Engine Shutdown Switch Signal Invalid Contact Servicing Dealer External Shutdown Non Engine Fault Check Other Shutdown Devices External Fuel Derate Switch Non Engine Fault Check Other Shutdown Devices Low Pressure Fuel Pump Circuit Has High Resistance Check Pump and Wiring Low Pressure Fuel Pump Circuit Has Low Resistance Check Pump and Wiring Low Pressure Fuel Pump Status Error Check Pump and Wiring Injection Pump Detected Defect Contact Servicing Dealer Attempting to Fuel Without Command Contact Servicing Dealer Pump Supply Voltage Out Contact Servicing Dealer Pump Self Test Erotic n era Io engen Contact Servicing Dealer Pump Detected Communication Error Contact Servicing Dealer Pump Initiated Engine Protection Contact Servicing Dealer ECU Pump Timing Moderately Mismatched Contact Servicing Dealer ECU Pump Speed
70. ction or a wire intermittently shorting to ground To access DTC s with the diagnostic gauge A see section 15 of this manual If a sensor or wiring fails and a DTC is active for the sensor the ECU will use a substitute limp home value in its calculations to continue engine operation A list of DTCs is given later in this section with a description of each Contact your engine servicing dealer to correct any DTCs which are displayed on the instrument panel OUOD006 00000F8 19 255 07 1 1 OM C3 07 14 71 Troubleshooting Precautions for Welding Remove paint before welding or heating see Safety Section in this manual for more information on paint removal and high pressure lines Bee Avoid potentially toxic fumes and dust Hazardous fumes can be generated when paint is heated by welding soldering or using a torch Do all work outside or in a well ventilated area Dispose of paint and solvent properly If you sand or grind paint avoid breathing the dust by wearing an approved respirator If you use solvent or paint stripper remove with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area before welding Allow fumes to disperse at least 15 minutes before welding or heating IMPORTANT Welding on the engine is NOT ALLOWED If welding must be performed on the machine follow these precautions IMPORTANT High currents or electrostatic di
71. ctronic Control System Wiring Diagram Cont d C16 BAT 5082 2 AUX TERM E m IEE I EL I ion ES ioe 5 s Ji s N81 START SINGLE 1 POINT X GROUND C17 Ez 5050 SPG B 204 F02 A 5022 5002 STARTER RELAY 12V OR 24 C12 12V OR 24V 5022 5002 SE2 SE SE1 ENGINE START COMPONENTS B Fo A 5032 5002 5032 C15 REMOTE ON OFF PLUG SE2 5020 5905 5904 FOCUS 16 4 5L 4 VALVE ENGINE CONTROL UNIT ECU SAE J1939 11 3 WAY DEUTSCH TERM 5904 5905 5020 SAE Jigagit C10 DEUTSCH CONN LOCATED NEAR ECU CANL ead J1 32 POSITION BLACK 48 POSITION BROWN 42 J 5020 lt lt lt lt i m DIAGNOSTIC CONNECTOR C11 SE2 FOCUS 16 ECU Continued on next page J3 32 POSITION BLUE RG22437 UN 21FEB13 RG19661 00003EE 19 25FEB13 1 2 OM C3 07 14 83 Troubleshooting A Focus 16 4 5 L 4 Valve Engine Control Unit ECU C06 Wiring Supplied With JD Alternator C10 SAE J1939 11 Way Deutsch Connector Located Near ECU C11 Diagnostic Connector C16 Battery C12 Transient Voltage C17 Single Point Ground Protection 12 V or 24 V G1 Alternator 12 V C13 Starter Relay Coil Ground J1 32 Pos
72. d strap starter or alternator Defective battery Defective alternator Cracked battery case Defective battery Battery charging rate too high Loose or corroded connections Sulfated or worn out batteries Stretched poly vee belt or defective belt tensioner PTO engaged if equipped Marine gear control engaged Loose or corroded connections Low battery output voltage Faulty start circuit relay Blown main system fuse Low battery output Crankcase oil too heavy Loose or corroded connections Blown fuse on magnetic switch Continued on next page Solution Remove accessories or install higher output alternator Increase engine rpm when heavy electrical load is used Inspect and clean as necessary Test battery Test charging system Check for moisture and replace as necessary Test battery Test charging system Clean and tighten connections See your authorized servicing dealer or engine distributor Adjust belt tension or replace belt Disengage PTO Disengage marine gear Clean and tighten loose connections See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Replace fuse See your authorized servicing dealer or engine distributor Use proper viscosity oil Clean and tighten loose connections Replace fuse DPSG OUOD007 335 19 04JANO02 1 2 OM C3 07 14 103 Troubleshooting
73. dispose of any water or other impurities 9 Loosen or remove and store fan alternator poly vee belt 10 Remove and clean batteries Store them in a cool dry place and keep them fully charged 11 Disengage the clutch for any driveline 12 Clean the exterior of the engine with salt free water and touch up any scratched or chipped painted surfaces with a good quality paint 13 Coat all exposed machined metal surfaces with grease or corrosion inhibitor if not feasible to paint 14 Seal all openings on engine with plastic bags and tape 15 Store the engine in a dry protected place If engine must be stored outside cover it with a waterproof canvas or other suitable protective material and use a strong waterproof tape OUOD006 00000FC 19 26FEB10 1 1 OM C3 07 14 114 Removing Engine from Long Term Storage Refer to the appropriate section for detailed services listed below or have your authorized servicing dealer or engine distributor perform services that you may not be familiar with 1 Remove all protective coverings from engine Unseal all openings in engine and remove covering from electrical systems 2 Remove the batteries from storage Install batteries fully charged and connect the terminals 3 Install alternator poly vee belt if removed Adjust belt tension See CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR in Lubrication and Maintenance 500 Hour 12 Month Section Install
74. e Curve Signal Unreliable Contact Servicing Dealer E ades 47 Engine in Derate Condition Check Fault Codes 19 cre Security Violatio esc sc uxo eue datae don Contact Servicing Dealer 350 0 Sensor Supply Number 1 Voltage Out of Range High Contact Servicing Dealer 350 04 Sensor Supply Number 1 Voltage Out of Range Low Contact Servicing Dealer EJ 0 ce Sensor Supply Number 2 Voltage Out of Range High Contact Servicing Dealer E 04 Sensor Supply Number 2 Voltage Out of Range Low Contact Servicing Dealer 351 03 Sensor Supply Number 3 Voltage Out of Range High Contact Servicing Dealer i 351 04 Sensor Supply Number 3 Voltage Out of Range Low Contact Servicing Dealer EJ 03 Gem Sensor Supply Number 4 Voltage Out of Range High Contact Servicing Dealer E 04 Sensor Supply Number 4 Voltage Out of Range Low Contact Servicing Dealer oot 03 Sensor Supply Number 5 Voltage Out of Range High Contact Servicing Dealer EJ 04 vue 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 07 14 109 Troubleshooting Intermitt
75. e direction as they were upon removal Be sure impeller is installed in same direction as removed if reusing existing impeller 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 RG9853 UN O5JAN99 A Cover Plate B Cam Screw 4 Using a new O ring install cover plate A onto impeller housing Install six screws with washers Tighten screws evenly 5 Reconnect all water piping if disconnected 6 Open sea cock and prime sea water pump with water Start engine and check for leaks RG19661 0000401 19 06MAR13 3 3 OM C3 07 14 58 Lubrication amp Maintenance 2000 Hour 24 Month Inspect And Repair Sea Water Pump 4045 85 6068 85 NOTE Sea water pump with shaft key is illustrated Sea water pumps with a splined shaft follow the same procedure 1 Close sea cocks and drain sea water system 2 Remove cover plate A from sea water pump NOTE Special impeller puller tool is provided with minor and major sea water pump rebuild kits If tool is not available the impeller can normally be removed by using two pair of pliers to grip impeller vanes on opposite sides of impeller Rotating the pump shaft by hand may help free the impeller Petroleum based lubricants can cause the impeller to swell and are not recommended to free a stuck impeller 3 Remove impeller B and
76. e with thermometer and replace if necessary See your authorized servicing dealer Use correct grade of fuel Clean heat exchanger and core Flush and clean keel cooler Check for marine growth on O D of keel cooler tubes Clean engine compartment Use proper type of fuel Service air cleaner OUOD006 0000113 19 160 07 4 5 OM C3 07 14 101 Troubleshooting Symptom Problem Engine overloaded Improper valve clearance Injection nozzles dirty Injector tip deposits Engine out of time Defective turbocharger Low engine temperature Solution Reduce load See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Use John Deere approved biodiesel fuel conditioners containing detergents See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Check thermostat OUOD006 0000113 19 160 07 5 5 OM C3 07 14 102 Troubleshooting Electrical Troubleshooting Symptom Undercharged electrical system Battery uses too much water Batteries will not charge Starter will not crank Starter cranks slowly Starter and hour meter functions rest of electrical system does not function Problem Excessive electrical load from added accessories Excessive engine idling Poor electrical connections on battery groun
77. eck Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Contact Servicing Dealer Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Contact Servicing Dealer Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Contact Servicing Dealer Contact Servicing Dealer Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed OURGP12 00001FC 19 08APR10 2 4 OM C3 07 14 107 Troubleshooting Blink Description of Fault Corrective Action Injector Number 2 Part Number Calibration Fault Contact Servicing Dealer Injector Number 3 Part Number Data Invalid Contact Servicing Dealer Injector Number 3 Circuit Has High Resistance Check Injector Wiring or Injector Solenoid Injector Number Circuit Has Low Resistance Check Injector Wiring or Injector Solenoid Injector Number Not Responding Injector Failed or Flow Limiter Closed Injector Number 3 Part Number Calibration Fault Contact Servicing Dealer Injector Number 4 Part Number Data Invalid Contact Servicing Dealer Injector Number 4 Circuit Has High Resistance Check Injector Wiring or Injector Solenoid Injector
78. elay Solenoid Audible Alarm Tachometer Wiring Supplied With JD Alternator In Absence Of Fly Bridge Pane L OR 8 wO re Fly Bridge Panel SE3 12v or 24v 3 x 5 n D N 5 8 ii ingle z Ground SE4 050 SPG A 050 SE1 Engine Start Components SE2 Wheel House Panel Continued Next Page A Vehicle Harness Connector G Audible Alarm N1 Transient Voltage Protection 012 IGN 12V or 24V B Key Switch G1 Alternator O Back Light Dimmer 020 CAN Shield C Start Button Momentary H External Alarm P To Fly Bridge Panel 412 ACC D To Fly Bridge Panel I Tachometer X7 Alternator Harness 422 Starter Relay Solenoid E In Absence of Fly Bridge J Load Connector 432 Instrument Panel Power Panel K Voltmeter X9 Single Point Ground 904 CanH F Extension to Fly Bridge Panel KST Starter Relay X10 CAN Terminator 905 CanL L Coolant Temp 002 Battery M Oil Pressure M1 Start Motor N Diagnostic Gauge OUOD006 00000BC 19 25JUL07 1 1 OM C3 07 14 74 Troubleshooting Wiring Diagram for John Deere Main Station Wheel House Instrument Panel Controlled Engine Cont d 432 Instrument Panel Pwr 020 Can Shield 904 CanH 905 Can L b 012 IGN 12V OR 24V ILE E n 412 ACC IE Ei i 422 Starter Relay Solenoid ls Is masi 002 Battery Can H 904 905 Voltmeter Diagnostic Co
79. element IMPORTANT Replace filter element after 10 cleanings See following blocks 2 Tap end of filter GENTLY on hard surface to dislodge loose dirt 3 Brush dirt side of filter GENTLY with soft bristle brush IMPORTANT Use kit RE504585 to service filter element DO NOT clean element with gasoline solvents parts cleaners strong detergents or caustic cleaning solutions DO NOT steam clean or use high pressure washers to clean element These processes will damage filter media and or rubber base or end cap RG12749 UN 24DEC02 RG9926 UN 18NOV99 NN Remove Filter Element OUOD006 0000098 19 10DEC09 1 5 4 Spray air filter cleaner B from kit RE504585 liberally onto entire element Let soak into filter media for 10 minutes Continued on next page RG9943 UN 17NOV99 Spray Filter with Cleaner OUOD006 0000098 19 10DEC09 2 5 OM C3 07 14 62 Service as Required 5 Rinse filter with low pressure water flushing opposite the direction of air flow from clean side to dirty side IMPORTANT Let element dry at room temperature Compressed air will damage filter media Heat will shrink filter media and may damage rubber base or end cap 6 Shake off excess water and let the element dry at room temperature IMPORTANT Never put filter in service without oiling it The filter will not function properly without being oiled with oil provided in kit RE504585 D
80. emperatures High marine gear oil temperature Unusual noise or vibration Sudden loss of power Excessive black exhaust Excessive fuel consumption Excessive oil consumption Fluid leaks OUOD006 000008F 19 21JUNO07 1 1 Break In Service The engine is ready for normal operation However extra care during the first 100 hours of operation will result in more satisfactory long term engine performance and life DO NOT exceed 100 hours of operation with break in oil See GENERAL ENGINE SPECIFICATIONS in Specifications Section near end of manual for oil pressure and coolant temperature specifications for your engine 1 This engine is factory filled with John Deere Engine Break in Oil Operate the engine at heavy loads with minimal idling during the break in period 2 If the engine has significant operating time at idle constant speeds and or light load usage or makeup oil is required in the first 100 hour period 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 John Deere Engine Break In Oil and a new John Deere oil filter Continued on next page RG22038 UN 28NOV12 Check Engine Oil A Engine Oil Dipstick B Dipstick Tube RG19661 00003BC 19 28FEB13 1 5 OM C3 07 14 14 Engine Operation IMPORTANT DO NOT add makeup oil until the oil level is BELOW the ADD mark on dipstick John Dee
81. enerator manufacturer Follow manufacturer s guidelines for mounting specifications Front engine mounts A only are available from John Deere IMPORTANT Use only SAE Grade 8 or higher grade of hardware for engine mounting 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 RG22051 UN 29NOV12 Check Mounting Holes RG19661 00003D7 19 29JAN13 1 1 OM C3 07 14 36 Lubrication amp Maintenance 500 Hour 12 Month Replace Crankcase Vent Filter 1 Remove screws A and remove the crankcase vent lid 2 Remove old filter and discard 3 Install new filter into crankcase vent housing and snap into place 4 Install lid and lock down screws 1 2 A Screws 2 1 lt Replace Crankcase Vent Filter RG19661 00003D8 19 13FEB13 1 1 Checking Closed Crankcase Vent System 1 Inspect hoses A B C and oil drain line D for kinks blockage or other damage 2 Inspect crankcase fitting E for damage and make sure it is not plugged 3 Verify that the crankcase vent system bypass port E is not plugged 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 A
82. ent Fault Diagnostics Intermittent faults are problems that periodically go away A problem such as a terminal that intermittently doesn t make contact can cause an intermittent fault Other intermittent faults may be set only under certain operating conditions such as heavy load extended idle etc When diagnosing intermittent faults take special note of the condition of wiring and connectors since a high percentage of intermittent problems originate here Check for loose dirty or disconnected connectors Inspect the wiring routing looking for possible shorts caused by contact with external parts for example rubbing against sharp sheet metal edges Inspect the connector vicinity looking for wires that have pulled out of connector terminals damaged connectors poorly positioned terminals and corroded or damaged terminals Look for broken wires damaged splices and wire to wire shorts Use good judgement if component replacement is thought to be required NOTE The Engine Control Unit ECU is the component LEAST likely to fail Suggestions for diagnosing intermittent faults If the problem is intermittent try to reproduce the operating conditions that were present when the Diagnostic Trouble Code DTC set If a faulty connection or wire is suspected to be the cause of the intermittent problem clear DTCs then check the connection or wire by wiggling it while watching the diagnostic gauge to see if the fault resets Poss
83. eptable If gauge does not hold pressure replace pressure cap Specification Radiator Cap Pressure 110kPa 1 1 bar 16 psi 3 Remove the cap from gauge turn it 180 and retest cap This will verify that the first measurement was accurate Test Cooling System NOTE Engine should be warmed up to test overall cooling system RG6557 UN 20JAN93 RG9850 UN 06JAN99 1 Allow engine to cool then carefully remove coolant filler cap 2 Fill tank with coolant to the normal operating level IMPORTANT DO NOT apply excessive pressure to cooling system doing so may damage coolant tank and hoses 3 Connect gauge and adapter to filler neck Pressurize cooling system to specifications Specification Cooling System Pres 110kPa 16 psi 4 With pressure applied check all cooling system hose connections coolant tank and overall engine for leaks If leakage is detected correct as necessary and pressure test system again If no leakage is detected but the gauge indicated a drop in pressure coolant may be leaking internally within the system or at the block to head gasket Have your servicing dealer or distributor correct this problem immediately RG19661 0000409 19 08MAR13 1 1 Checking Engine Electrical Ground Connections Keep all engine ground connections clean and tight to prevent electrical arcing which can damage electronic compone
84. erations in addition to the ones specified Keep a record of hourly intervals and START DIMMER NS services performed using charts provided in Lubrication 6 JOHNDEERE 2 and Maintenance Records Section Hour Meter Electronically Controlled Engines RG13137 UN 070CT03 A Diagnostic Gauge Hour Meter RG19661 00003BF 19 23JAN13 1 1 Use Correct Fuels Lubricants and Coolant IMPORTANT Use only fuels lubricants and coolants meeting specifications outlined in Fuels Lubricants and Coolant Section when servicing your John Deere Engine Consult your John Deere engine distributor servicing dealer or your nearest 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 TS100 UN 23AUG88 Parts Network DPSG OUOE003 20 19 19JUN07 1 1 OM C3 07 14 24 Lubrication and Maintenance Lubrication and Maintenance Service Interval Chart Propulsion and Prime Power Units Lubrication and Maintenance Service Intervals Item Daily Before Every Startup 250 Hour 6 Month 500 Hour 12 Month 2000 Hour 24 Month Service As Required Check Engine Oil Level and Coolant Level Check Sea Water Strainer Check Air Cleaner Dust Unloader Valve amp Restriction Indicator Gauge
85. ere PLUS 50 or ACEA E7 6 ACEA E5 or 4 oil is used along with the specified John Deere oil filter the oil change interval may be extended by 50 percent to 375 hours If John Deere COOL GARD is used the flushing interval may be extended to 3000 hours or 36 months If John Deere COOL GARD is used and the coolant is tested annually 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 07 14 25 Lubrication and Maintenance Lubrication and Maintenance Service Interval Chart Standby Generator Sets Lubrication and Maintenance Service Intervals Item Daily Before Every Startup 250 Hour 6 Month 500 Hour 12 Month 2000 Hour 24 Month Service As Required Operate Engine at Rated Speed and 50 70 Load for a Minimum of 30 Minutes Perform every 2 weeks Check Engine Oil Level and Coolant Level Check Sea Water Strainer Check Air Cleaner Dust Unloader Valve amp Restriction Indicator Gauge Visual Walkaround Inspection Drain Water From Fuel Filter Change Engine Oil And Replace Oil Filter b Service Fire Extinguisher Service Battery Inspect and Replace Zinc Plugs Check Belt Tension and Wear Manual Tensioner Check Engine Mounts Replace Crankcase Vent Filter I
86. erflowing at top of coolant tank Fill until coolant level touches bottom of coolant tank filler neck Tighten plugs and fittings when air has been expelled from system RG RG34710 5593 19 04JANO2 1 1 Replacing Dry Air Cleaner Element IMPORTANT ALWAYS REPLACE primary air cleaner element when air restriction indicator A shows vacuum of 625 mm 25 H20 or when reset button has popped up if equipped Also replace element if it is torn or visibly dirty 1 Release air filter assembly clamps A and remove COVer IMPORTANT Insure all air intake connections are secure to prevent ingestion of abrasive dirt and dust into the system causing possible engine damage 2 Install new air filter element B install cover and engage clamps RG22155 UN 21FEB13 Replace Air Filter Element A Air Filter Assembly Clamps B Air Filter Element RG19661 00003F5 19 22FEB13 1 1 OM C3 07 14 61 Service as Required Servicing Air Cleaner Filter Element IMPORTANT Always service primary air cleaner element when air restriction indicator shows a vacuum of 625 mm 25 2 or when reset button has popped up 6068SFM75 AFM75 only Also replace element if it is torn or visibly dirty NOTE This procedure applies to John Deere air cleaner kits Refer to manufacturers instructions for servicing air cleaners not supplied by John Deere 1 Loosen clamp A and remove filter
87. ernator T Tensioner CSP Crankshaft Pulley CP Coolant Pump RG12077 UN 26FEB02 Belt Routing RG19661 00003F4 19 20FEB13 1 1 OM C3 07 14 65 Service as Required Check Front Power Take Off PTO Entanglement in rotating driveline can cause serious injury or death Keep shield on PTO driveshaft between clutch housing and the engine driven equipment at all times during engine operation Wear close fitting clothing Stop the engine and be sure PTO driveline is stopped before making adjustments 7 CA Metal surfaces of PTO housing may be hot to the touch during operation or at shutdown The optional front power take off PTO from John Deere transfers engine power to auxiliary equipment or moving components Proper performance of the power take off unit will be related to the care it is given Periodically check for any oil leaks that may occur Oy lt TS1644 UN 22AUG95 Rotating Drivelines If the power take off does not work properly contact your authorized servicing dealer or engine distributor OURGP11 0000145 19 09DECO3 1 Drain Water From Fuel Filter IMPORTANT When using BIODIESEL blends monitor water quantity more closely in the fuel filter element Water in the filter separator may need to be drained more frequently If instrument panel provides a water in fuel warning drain water or debris from filter using the following steps 1 Loo
88. erviced ALWAYS fully depress the air restriction indicator reset button if equipped to assure accurate readings 3 If equipped fully depress air restriction indicator reset button A and release to reset indicator RG9927 UN 18NOV99 Air Restriction Indicator Reset Button DPSG OUOD007 2908 19 24DEC02 2 2 OM C3 07 14 64 Service as Required Replacing Alternator Belt With Automatic Tensioner Refer to CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR in Lubrication and Maintenance 500 Hour 12 Month Section for additional information on the belt tensioner Belt guard should be in place at all times when engine is running NOTE While belt is removed inspect pulleys and bearings Rotate and feel for hard turning or any unusual sounds If pulleys or bearings need replacement see your John Deere dealer RG22162 UN 06DEC12 1 Remove cap screws A and carefully remove belt guard from engine Remove Belt Guard 2 Release tension on belt using a breaker bar and socket on tension arm and remove poly vee belt from pulleys 3 Inspect belts for cracks fraying or stretched out areas Replace if necessary 4 Install new belt making sure belt is correctly seated in all pulley grooves 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 Alt
89. ery ground cable before making any adjustments or service work Stay Clear of Rotating Drivelines 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 fitting 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 OM C3 07 14 4 Safety Rules Continued Install all Safety Guards _ WARNING OA 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 fitting 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 Prevent Battery Explosions Battery gas is highly flammable Battery explosions can cause severe injury or death To help prevent battery explosions keep sparks lighted matches and open flame away from the top of battery
90. f Equipped Clean Crankcase Ventilation Assembly Check Air Intake Hoses Connections amp System Replace Fuel Filter Elements Check Automatic Belt Tensioner and Belt Wear Check Cooling System Coolant Solution Analysis Add SCAs as required Inspect and Clean Heat Exchanger Core and Aftercooler Core If Equipped Check Engine Speeds Check Engine Electrical Ground Check Crankshaft Vibration Damper 6 Cylinder Pressure Test Cooling System Inspect and Repair Sea Water Pump Check and Adjust Engine Valve Clearance Flush And Refill Cooling System Test Thermostats Add Coolant Replace Air Cleaner Element Service Dry Air Cleaner Element Replace Alternator Drive Belt Check Front PTO If Equipped Bleed Fuel System Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm 52 20 During engine break in change the oil and filter for the first time before 100 hours of operation Extended oil change interval of 375 hours can be used if John Deere PLUS 50 or ACEA E7 ACEA E6 ACEA E5 or ACEA E4 oil is used along with the specified John Deere oil filter If John Deere COOL GARD is used the flushing interval may be extended to 3000 hours or 36 months If John Deere COOL GARD is used and the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant
91. g adjustments 2 USE Metal surfaces of PTO housing may be hot to the touch during operation or at shutdown The optional front power take off PTO from John Deere transfers engine power to auxiliary equipment or moving components The PTO clutch is electric and engaged by a switch Engage the clutch on propulsion engines at engine speeds below 1200 rpm Engage Gen Set engines at no load rpm A TS198 UN 23AUG88 Avoid Entanglement If the power take off does not work properly contact your authorized servicing dealer or engine distributor OURGP11 0000144 19 08DEC03 1 Cold Weather Operation Additional information on cold weather operation is available from your engine distributor or authorized servicing dealer Some engines are equipped with an air intake heater which will make starting the engine easier in cold weather If equipped follow steps 1 4 as listed under STARTING THE ENGINE earlier in this section Switch on the air intake heater for 30 seconds and then proceed to operate the starter Follow remaining steps 5 11 Synthetic oils improve flow at low temperatures especially in arctic conditions Ao 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 TS1356 UN 18MAR92 E Starting Fluid is Flammable
92. g order is 1 3 4 2 Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves Rotate flywheel 360 Lock No 4 piston at TDC compression stroke C Adjust valve clearance on No 2 and 4 exhaust valves and No 3 and 4 intake valves A Front of Engine E Exhaust Valve B No 1 Piston at TDC I Intake Valve Compression Stroke C No 4 Piston at TDC Compression Stroke RG22378 UN 28JAN13 t 4 Cylinder Engine Valve Adjustment RG19661 00003D0 19 29JAN13 3 4 6 Cylinder Engine NOTE Firing order is 1 5 3 6 2 4 Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 3 and 5 exhaust valves and No 1 2 and 4 intake valves 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 RG22377 UN 28JAN13 t t 6 cylinder Engine Valve Adjustment RG19661 00003D0 19 29JAN13 4 4 OM C3 07 14 51 Lubrication amp Maintenance 2000 Hour 24 Month Flushing And Refilling Cooling System A UO Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely NOTE When
93. hat the notches in dust seal F are properly installed in the slots of the housing Replace if damaged IMPORTANT When installing filter element HAND TIGHTEN only A filter wrench may be used for REMOVAL ONLY 7 Install and tighten oil filter by hand until firmly against dust seal F DO NOT apply an extra 3 4 to 1 1 4 turn after gasket contact as done with standard filters 8 Tighten drain plug to specifications Specification Oil Pan Drain Plug With Copper Washer Torque nennen 70 N m 52 Ib ft Oil Pan Drain Plug With O Ring Torque eese nennen 50 N m 37 Ib ft A Oil Filter Element D Sealing Surface On Header B Inner Seal E Sealing Surface On Header C Outer Seal F Dust Seal Continued on next page RG22045 UN 29NOV12 RG11617 UN 240CT01 Oil Filter Seals RG22046 UN 29NOV12 Oll Filter Mounting Header RG19661 00003D4 19 28FEB13 2 3 OM C3 07 14 31 Lubrication amp Maintenance 250 Hour 6 Month 9 Fill engine crankcase with correct John Deere engine oil through rocker arm cover opening A See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section for determining correct engine oil To determine the correct oil fill quantity for your engine see ENGINE CRANKCASE OIL FILL QUANTITIES in the Specifications Section of this manual IMPORTANT Immediately after completing any oil change crank engine for 3
94. hers and tighten cap screws to 47 Nem 35 Ib ft RG9864 UN O6JAN99 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 07 14 68 Service as Required Remove And Install Sea Water Pump 4045AFM85 6068AFM85 1 Close sea cock and drain sea water system 2 Remove sea water outlet connection A remove sea water pump cap screws B and remove pump 3 Clean all gasket material from both mating surfaces 4 Inspect gear teeth for damage Install new gear D by aligning key C to the pump shaft keyway 5 Install lock washer E and hex nut F finger tight and insure key is properly in place 6 Tighten hex nut to 68 N m 50 Ib ft Install sea water pump with new gasket to front plate and tighten cap screws B to 140 N m 103 Ib ft 8 Connect sea water inlet and outlet RG22172 UN 10DEC12 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 RG22173 UN 10DEC12 274 Sea Water Pump Drive Gear RG19661 00003FF 19 02MAR13 1 1 OM C3 07 14 69 Service as Required Remove and Install Sea Water Pump 6068SFM85 RG22485 UN 04MAR13 Remove and Install Sea
95. ible Causes of Intermittent Faults 1 Faulty connection between sensor or actuator and harness 2 Faulty contact between terminals in connector 3 Faulty terminal wire connection Electromagnetic interference EMI from an improperly installed 2 way radio etc can cause faulty signals to be sent to the ECU NOTE Refer to wiring diagram foldouts earlier in this section as a guide to connections and wires OURGP11 0000206 19 070 03 1 1 Displaying Diagnostic Gauge Software 98 LOAD RPM 1000 RPM NOTE The following steps can be used to display 4800 RPM the software version of the diagnostic gauge 14 2 57 PSI p if needed by your dealer for troubleshooting EXE Sero me 1 This is a read only function 5 Q 1 Starting at the single or four engine parameter display 5 press the 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 STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES 8 1 po Continued on next page Select Utilities OURGP11 00000E3 19 29SEP03 2 4 OM C3 07 14 110 Troubleshooting 3 Once Utilities is highlighted press Enter to activate the utilities function STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY
96. ing Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injur 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 specific details on chemical products including physical hazards safety procedures and emergency response techniques OM C3 07 14 5 Safety Rules Continued 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 CAUTION 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 affected by heat
97. isk of gangrene or other infection Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns and bodily injury Pressurized lines can rupture when heat goes beyond the immediate flame area Do not weld solder or use a torch or open flame near pressurized lines or other flammable fluids Do Not Open High Pressure Fuel System Many Northern Lights engines use high pressure fuel injection High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt any repair of fuel lines sensors or other OM C3 07 14 6 Safety Rules Continued components between the high pressure fuel pump material containing asbestos Keep all bystanders and nozzles on engines with high pressure fuel away from any area where asbestos dust may be systems generated ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH Use Proper Lifting Equipment and Techniques PRESSURE FUEL INJECTION SYSTEMS WARNING Avoid Hot Exhaust Lifting heavy components incorrectly can cause severe injury or damage WARNING to machinery Avoid unbalanced loads Do not use lifting eyes Lift the NA Avoid exposure to and physical generator set using lifting bars inserted contact with hot exhaust through the lifting holes on the skid gases Exhaust parts and streams can reach high Follow all recommended removal and i
98. ition Black C14 Starter Relay Coil Power J2 48 Position Brown C15 Remote On Off J3 32 Position Blue J2 A1 CAN High J2 B1 CAN Low J3 32 Position Blue M1 Start Motor 12 V SE1 Engine Start Components SE2 Focus 16 ECU RG19661 00003EE 19 25FEB13 2 2 OM C3 07 14 84 Troubleshooting 4045 85 Marine Electronic Control System Wiring Diagram Y5004 TRANSFER PUMP 4 5L Engine MANIFOLD MANIFOLD AIR PRESSURE AIR TEMP SENSOR 02 amp RAIL PRESSURE INCREASE oi PRESSURE RAILPRESSURE CONNECTOR 2 5 05 2 amp B z a e EE n WO INCREASE oo PRESSURE 5 gt 5456 ANALOG 15 5474 EXCITATION RETURN 5468 ANALOG 3 5446 EXCITATION VOLTAGE 5 5475 ANALOG 6 5946 EXCITATION VOLTAGE 1 5427 EXCITATION RETURN 1 548 5445 5443 3 0804 3903 4382 43 04 J3 A2 J3 C1 J3 G1 13 02 a FOCUS 14 4 5 4 VALVE ENGINE CONTROL UNIT ECU 32POSITION BLACK 42 48POSITION BROWN J3 32 POSITION BLUE J Ho J Ee cue J2 M DM B H D Gt 5050 5050 5050 5022 5022 5022 5476 5494 5437 5433 5431 5436 MIS SM SUP RTL DISP 1 1 007 Lo teur aera L Sut 5M2 ll 5012 5911 5714 ks EA EY i WATER a ep IN FUEL 8 30 5 5012 5 2 5 s e E 83 E 2 z 2 8 2 8 S
99. ive in John Deere engines DO NOT mix one brand of SCA with a different brand Test the coolant solution at 500 hours or 12 months of operation using either John Deere coolant test strips or a COOLSCAN or COOLSCAN PLUS analysis If a COOLSCAN or COOLSCAN PLUS analysis is not available recharge the system per instructions printed on label of John Deere Liquid Coolant Conditioner IMPORTANT ALWAYS maintain coolant at correct level and concentration DO NOT operate engine without coolant even for a few minutes If frequent coolant makeup is required the glycol concentration should be checked with JT07298 Coolant Battery Tester to ensure that the desired freeze point is maintained Follow manufacturer s instructions provided with Coolant Battery Tester Add the manufacturer s recommended concentration of supplemental coolant additive DO NOT add more than the recommended amount The use of non recommended supplemental coolant additives may result in additive drop out and gelation of the coolant COOL GARD is a registered trademark of Deere amp Company COOLSCAN is a registered trademark of Deere amp Company COOLSCAN PLUS is a registered trademark of Deere amp Company COOLSCAN PLUS is a registered trademark of Deere amp Company RG6261 UN 08DEC97 RG6241 Coolant Check RG6262 UN O5DEC97 RG6262 JT07298 Coolant Battery Tester If other coolants are used consult the coolant supplier and follow
100. l Temp 5012 Switched Power Stop Lamp Power Cruise Common 5050 Single Point Ground 5414 Excitation Return 2 5416 Excitation Voltage 2 5427 Excitation Return 1 5428 Analog 2 5431 Frequency Input 5436 Air Filter Restriction Switch 5456 Analog 15 5461 Analog 8 5467 Analog 4 5469 5473 5474 5475 5714 5911 5913 5917 5937 Analog 5 Stop Lamp Excitation Return Delta Temp Analog 6 Sensor Return Ext Derate Shut Dn Common Sensor Excitation 5V Secondary Analog Throttle Remote Cruise Isoc Gov 5939 5941 5943 5946 5948 5954 5971 5981 External Derate External Shutdown Cruise Brake Excitation Voltage 1 Customer Loss of Coolant Cruise On Cruise Canc Resume Pwr Throttle RG19661 00003E0 19 15FEB13 2 2 OM C3 07 14 95 Troubleshooting 6068SFM85 AFM85 Marine Electronic Control System Wiring Diagram Continued 4 5L Engine C01 J1 G1 J1 E1 J1 C1 J1 G2 J1 F1 J1 D1 J1 D3 J 3 32 POSITION BLUE LEFT HAND CAM CINCH 580 04 00 006 JD 57M8523 J 1 32 POSITION BLACK LEFT HAND CAM CINCH 580 04 00 001 JD 57M8518 32 POSITION BLUE RIGHT HAND CAM CINCH 580 04 00 008 JD 57M8525 32 POSITION BLACK RIGHT HAND CAM CINCH 580 04 00 002 JD 57M8519 J 2 48 POSITION BROWN LEFT HAND CAM CINCH 580 04 00 013 JD 57M8526 48 POSITION BROWN RIGHT HAND CAM CINCH 580 04 00 014 JD 57M8527
101. lb ft 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 A O Rings C Housing B End Cap RG6067 UN 23JAN92 o Install Heat Exchanger RG9848 UN O6JAN99 Continued on next page RG19661 000040F 19 10MAR13 1 2 OM C3 07 14 45 Lubrication amp Maintenance 500 Hour 12 Month 1 Insert two O rings into front and rear end caps 2 Lubricate ends of tube bundle lightly with clean multi purpose grease NOTE For proper orientation of the tube bundle the core divider plate must be in line with inlet end cap divider slot with arrow pointing in the correct direction 3 Install rear end cap A over tube bundle with core divider plate in slot on cap 4 Guide heat exchanger core into heat exchanger tank Align core divider vertically with stamped note indicating This side up Core shown separated from cap for illustration purposes 5 Fasten rear end cap and core to tank with bolts and washers Tighten bolts to 24 3 N m 18 2 lb ft 6 Install front end cap B over core and bolt to tank Ensure core holes are aligned with heat exchanger tank holes Tighten bolts to 24 3 N m 18 2 lb ft 7 Connect all water piping and tighten hose clamps securely Fill cooling sys
102. le Point Ground D01 Water In Fuel Sensor J1 32 Position Black J1 A3 Analog 4 J1 C2 Analog 15 J1 C4 Analog 8 J1 D2 Excitation Return 2 J1 F3 Excitation Voltage 2 J1 F4 Analog 2 J2 48 Position Brown J3 32 Position Blue P04 Engine Oil Pressure Sensor Clean Side SE2 Focus 16 ECU T02 Manifold Air Temperature Sensor T04 Engine Coolant Temperature Sensor T05 Fuel Temperature Sensor RG19661 00003EC 19 21FEB13 2 2 OM C3 07 14 80 Troubleshooting 19335 98794 5020 5905 5904 5050 I 2 aa a 209 amp gt m I 3 amp gt c s gt 5 s mmm lt 98 T sses dN 8118719007155 1 1 B 068 HOHNYO gt a os mov 601 5 gt ges 906 NWOCdNnBlSOO3NnS3U 1 a EE IIT 1 2 5 lt gt 1168 ues t 2 gt 2 c 95 PUS lt o 8 m am gt eT s il zt 8168 NMOGLNHS ul ag pp os 3 9198 9 lt a I sles SOT MATE I2 6009 lt t 5 puro g P 3 am 004 1 2 s 9168 2
103. lt Lamp will flash a code 88 5 Following the active codes the Fault Lamp will flash a code 33 This indicates the start of blinking stored codes If there are any stored DTCs the Fault Lamp will flash its 2 digit number If there is more than one stored DTC the ECU will flash each code in numerical order If there are no stored DTCs the Fault Lamp will flash a code 88 6 Once complete this sequence will repeat 7 When complete turn ignition OFF As an example if an engine had an active DTC 18 and stored DTC 53 the flashing sequence would be flash three times short pause flash two times long pause flash one time short pause flash eight times long pause flash three times short pause flash three times long pause flash five times short pause flash three times RG19661 000040A 19 10MAR13 1 1 OM C3 07 14 104 Troubleshooting Instrument Panel Method for Retrieving Diagnostic Trouble Codes IMPORTANT Care should be used during diagnostic procedures to avoid damaging the terminals of connectors sensors and actuators Probes should not be poked into or around the terminals or damage will result Probes should only be touched against the terminals to make measurements Diagnosis of the electronic control system should be performed according to the following procedure START DIMMER 1 sure
104. maged signs Be sure new equipment components and repair parts include the current safety signs For replacement signs ALWAYS STOP ENGINE S proper placement of safety signs or clarification any BEFORE FUELING Handle Fuel Safely Avoid Flames Diesel is highly flammable and should be treated with care at all times Do do not refuel while smoking or when near sparks or open flame 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 OM C3 07 14 3 Safety Rules Continued Prevent accidental discharge of starting fluids by storing all cans in a cool safe place away from sparks or open flame Store with cap securely on container Never incinerate or puncture a fuel container Prevent fires 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 fire starts Keep a first aid kit and fire extinguisher handy Keep emergency contact numbers for fire 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 machi
105. n ically Controlled Engines RG13135 UN 070CT03 OUOD006 0000091 19 21JUN07 1 1 Idiing Engine Avoid excessive engine idling Prolonged idling may cause the engine coolant temperature to fall below its normal range This in turn causes crankcase oil dilution due to incomplete fuel combustion and permits formation of gummy deposits on valves pistons and piston rings It also promotes rapid accumulation of engine sludge and unburned fuel in the exhaust system Once an engine is warmed to normal operating temperatures engine should be idled at slow idle speed Slow idle speed for this engine is set at factory See Specifications Section near end of manual for slow idle speed for your engine If an engine will be idling for more than 5 minutes stop and restart later NOTE Generator set applications where the governor is locked at a specified speed may not have a slow idle function These engines will idle at no load governed speed high idle OUOD006 0000092 19 19JUN07 1 1 OM C3 07 14 19 Engine Operation Engaging And Disengaging Front PTO If Equipped A CAUTION Entanglement in rotating driveline can cause serious injury or death Keep shield on PTO driveshaft between clutch housing and the engine driven equipment at all times during engine operation Wear close fitting clothing Stop the engine and be sure PTO driveline is stopped before makin
106. n filling system Retighten fitting or plug when all the air has been expelled 1 Check entire cooling system for leaks Tighten all clamps securely TS281 UN 23AUG88 High Pressure Fluids 2 Thoroughly inspect all cooling system hoses Replace hoses when hard flimsy or cracked RG RG34710 5580 19 20MAY96 1 1 OM C3 07 14 42 Lubrication amp Maintenance 500 Hour 12 Month Replenishing Supplemental Coolant Additives SCAs Between Coolant Changes IMPORTANT Do not add supplemental coolant additives when the cooling system is drained and refilled with John Deere COOL GARD NOTE If system is to be filled with coolant that does not contain SCAs the coolant must be precharged Determine the total system capacity and premix with 3 John Deere Coolant Conditioner Through time and use the concentration of coolant additives is gradually depleted during engine operation Periodic replenishment of inhibitors is required even when John Deere COOL GARD is used The cooling system must be recharged with additional supplemental coolant additives available in the form of liquid coolant conditioner Maintaining the correct coolant conditioner concentration SCAs and freeze point is essential in your cooling system to protect against rust liner pitting and corrosion and freeze ups due to incorrect coolant dilution John Deere LIQUID COOLANT CONDITIONER is recommended as a supplemental coolant addit
107. n of Fault Code eee 54 ECU Power Down Error Internal ECU Problem 00 67 Fuel Temperature Signal Extremely High esses Fuel Temperature Signal Out of Range High 04 Fuel Temperature Signal Out of Range Low 15 33 5 Fuel Temperature Slightly High Suis 16 T4 Fuel Temperature Signal Moderately High STi 98 Fuel Temperature Sensor Faulty 00 oem Engine Speed Derate Condition Exists 1 225 48 Engine Speed Derate 00 42 Engine Speed Extremely High OT cue Engine Speed Extremely Low 16 42 Engine Speed Moderately High 18 Engine Speed Moderately Low 03 Injector Shorted to Power 04 Injector Shorted to Ground 03 Sensor Supply Voltage High 04 Sensor Supply Voltage Low All Injector Circuits Have High Resistance 04 ECU Unswitched Power 18
108. nery severe injury or death could result ec G Check for any loose electrical connections or faulty wiring Look completely around engine to make sure that everything is clear before starting Wear Protective Clothing To prevent catching anything in moving machinery always wear close fitting 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 4 ay ow E as earmuffs or plugs to protect against loud noises 38 4 Operating equipment requires the full attention of the operator Do not use radio or music headphones while operating machinery Practice Safe Maintenance CAUTION d 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 power driven 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 specifically 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 batt
109. normal for a small amount of leakage to occur as the engine cools down and parts contract RG9874 UN 12FEB99 Air Intake Restriction Gauge A Air Intake Restriction Gauge Excessive coolant leakage may indicate the need to replace the water pump seal Contact your engine distributor or servicing dealer for repairs 6 Turn key switch to ON position and check instruments for proper operation Turn key switch OFF Refer to manufacturer s literature for marine gear and generator set daily service recommendations RG19661 00003D3 19 29JAN13 4 4 OM C3 07 14 29 Lubrication amp Maintenance 250 Hour 6 Month Changing Engine Oil and Replacing Oil Filter NOTE Change engine oil and filter for the first time before 100 hours maximum of operation then every 250 hours thereafter If John Deere PLUS 50 or ACEA E7 E6 E5 E4 engine oil and a John Deere oil filter are used the oil and filter change interval may be extended by 50 percent or to 375 hours IMPORTANT If using BIODIESEL blends greater than B20 shorten oil change interval to half the recommended service interval or monitor engine oil using OILSCAN to ensure that fuel dilution does not exceed 5 NOTE On Gen Set engines used as standby units oil and filter change can be extended to 350 hours No extended interval for oil filter change is allowed beyond 350 hours OILSCAN or OILSCAN PLUS is a John Deere sampling progr
110. nstallation 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 hot exhaust gas and the injury risk associated with Use Proper Tools it Avoid exposure to and physical contact with hot exhaust gases when cleaning exhaust filters A C AUTION During auto or manual stationary exhaust filter Makeshift tools and procedures cleaning operations engine will run at can create safety hazards elevated temperatures for an extended period of Always use appropriate tools for time Exhaust parts and streams can reach high the job temperatures during operation leading to burns or other serious injury Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware always use the correct sized tools Avoid Harmful Asbestos Dust Inhaling asbestos fibers may cause lung cancer Avoid breathing any dust that may be generated when Dispose of Waste Properly handling components containing asbestos fibers including some gaskets A CAUTION Disposing of waste improperly can threaten the Do not use US measurement tools on metric fasteners or vice versa Use only service parts that meet Northern Lights specifications The asbestos used in these components is usually environment and lead to unsafe working conditions found in a resin or otherwise sealed Normal
111. nts Also see precautions in Troubleshooting Section when welding on engine or machine OUOD002 0000169 19 23NOV01 1 1 OM C3 07 14 49 Lubrication amp Maintenance 2000 Hour 24 Month Checking and Adjusting Engine Valve Clearance 7 prevent accidental starting of engine while performing valve adjustments always disconnect NEGATIVE battery terminal IMPORTANT Valve clearance MUST BE checked and adjusted with engine COLD 1 Remove rocker arm cover and crankcase ventilator tube IMPORTANT Visually inspect contact surfaces of valve tips bridges and rocker arm wear pads Check all parts for excessive wear breakage or cracks Replace parts that show visible damage Rocker arms that exhibit excessive valve clearance should be inspected more thoroughly to identify damaged parts 2 Remove plastic plugs or cover plate from engine timing rotation hole A and timing pin hole B NOTE Some engines are equipped with flywheel housings which do not allow use of an engine flywheel rotation tool These engines with straight nose crankshafts may be rotated from front nose of engine using JDG966 Crankshaft Front Rear Rotation Adapter 3 Using JDE83 JDG820 Flywheel Turning Tool rotate engine flywheel in running direction clockwise Flywheel Housing Timing Holes A Timing Rotation Hole B Timing Pin Hole viewed from front until No 1 front cylinder is at TDC compression st
112. o E Ot oz z 2 E zu z lt I 5 iv E 9 gt g E z o 23 z z gt o a z x 5 5 o 7 n n n n z z z D z 2h m gt 5 LL H tc Lu a tr n oo lt wo 41 02 J1 C3 1 41 04 43 24 43 23 43 64 43 63 4242 4243 2 2 241 4244 J2 M1 2 4 S S S S 8 wo lO wo N 3 8 Ir to N 3 8 1 8 C07 A Bl lt 3 5412 E 3 wo z 1 lt x SE1 SE1 SE1 5050 S C19 Fuel Filter Control X02 Engine Cam Sensor 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 07 14 93 Troubleshooting 6068SFM85 AFM85 Marine Electronic Control System Wiring Diagram Continued gt 0 2 E W 50 NO ow uz Cz 20 ao lt c LL 520 a2 Quiz 2909 a Q 5E no JN LLI LLI Z Dow Low En Rik 5 a FSF rod u W Ok Sz INCREASE PRESSURE INCREASE PRESSURE INCREASE PRESSURE PRESSURE P05 RAIL T02 MANIFOLD AIR TEMP Y SOWNV S 9OTVNV 2 DOWNY 8 eit NYNLAY N
113. o not use automatic transmission fluid motor oil diesel fuel or any type light weight spray lubricant These products will damage filter or degrade its performance NOTE Red dye is added to oil to show areas of oil application RG9944 UN 17NOV99 Rinse Filter OUOD006 0000098 19 10DEC09 3 5 7 Spray air filter oil from squeeze bottle C in kit from distance of 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 RG9945 UN 17NOV99 Apply Oil To Filter Continued on next page OUOD006 0000098 19 10DEC09 4 5 OM C3 07 14 63 Service as Required IMPORTANT Whenever the air cleaner has been serviced ALWAYS fully depress the air restriction indicator reset button if equipped to assure accurate readings 9 If equipped fully depress air restriction indicator reset button A and release to reset indicator RG9927 UN 18NOV99 Air Restriction Indicator Reset Button OUOD006 0000098 19 10DEC09 5 5 Replacing Air Cleaner Filter Element IMPORTANT Replace the element after 10 cleanings 1 Loosen clamp A and remove filter element 2 Install new filter element and tighten clamp RG9926 UN 18NOV99 Remove Filter Element DPSG OUOD007 2908 19 24DEC02 1 2 IMPORTANT Whenever the air cleaner has been s
114. olant Oil Pressure Can Shield Electronically B B 13458 1336 1346 1356 d th i ii 1 Dataj SPG Back Light Dimmer 1 2 To Fly Bridge Panel SPG T 3 i 1 050 SPG e SE2 Wheel House Panel Continued 4 A Vehicle Harness Connector B Key Switch C Start Button Momentary D To Fly Bridge Panel Absence of Fly Bridge Panel F Extension to Fly Bridge Panel G Audible Alarm G1 Alternator H External Alarm I Tachometer J Load K Voltmeter KST Starter Relay L Coolant Temp M Oil Pressure M1 Start Motor N Diagnostic Gauge N1 Transient Voltage Protection 012 IGN 12V or 24V O Back Light Dimmer P To Fly Bridge Panel X7 Alternator Harness Connector X9 Single Point Ground X10 CAN Terminator 002 Battery 020 CAN Shield 412 ACC 422 Starter Relay Solenoid 432 Instrument Panel Power 904 CanH 905 CanL OUOD006 00000BD 19 275 07 1 1 OM C3 07 14 75 Troubleshooting Wiring Diagram for John Deere Optional Fly Bridge Instrument Panel Electronically Controlled Engine 432 Instrument Panel Pwr 020 CAN Shield 904 CAN H 905 CAN L 012 Ign 12v or 24v 412 ACC 422 Starter Relay Solenoid 002 Battery Diagnostic Gauge B A Coolant es Oil Pressure B 1346 1346 Wal i HI TE i omu 5 dh s Panel From Panel
115. orage Preparing Engine for Long Term Storage The following storage preparations are used for long term engine storage up to one year After that the engine should be started warmed up and retreated for an extended storage period IMPORTANT Any time your engine will not be used for over six 6 months the following recommendations for storing it and removing it from storage will help to minimize corrosion and deterioration IMPORTANT DO NOT USE BIODIESEL DURING MACHINE STORAGE When using biodiesel blends switch to petroleum diesel for long term storage Before storage operate engine on at least one complete tank of petroleum diesel fuel to purge the fuel system Follow normal storage procedures once the fuel system has been purged 1 Change engine oil and replace filter See CHANGE ENGINE OIL AND FILTER in Lubrication and Maintenance 500 Hour Section Used oil will not give adequate protection Add one 1 ounce of rust preventive oil to the engine crankcase for every quart of oil This rust preventive oil should be an SAE 10 oil with 1 4 percent morpholine or equivalent vapor corrosion inhibitor 2 Ensure the machine fuel tank is filled with high quality petroleum diesel fuel Filling the tank completely will ensure that water does not build up due to condensation For storage of more than one year use John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent at the specified concentration 3 Service
116. r temperature is below 10 C 14 F use an engine block heater RG22045 UN 29NOV12 Remove Oil Filter A Oil Filter RG19661 00003BC 19 28FEB13 3 5 6 Watch coolant temperature gauge A closely If coolant temperature rises above maximum coolant temperature see GENERAL ENGINE SPECIFICATIONS in Specifications Section reduce load on engine 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 Gauge RG13133 UN 070CT03 Coolant Temperature Gauge Electronically Controlled Engine Continued on next page RG19661 00003BC 19 28FEB13 4 5 OM C3 07 14 15 Engine Operation 7 Check poly vee belt for proper alignment and seating in pulley grooves Two zinc plugs A are installed in the sea water cooling system to help neutralize the corrosive action of salt water on internal cavities of marine engine components The reaction of the zinc when exposed to the salt water causes the plugs to deteriorate instead of critical engine components 8 After the first 50 100 hours 2 4 weeks of operation remove zinc plug from each heat exchanger end cap B and inspect for corrosion to get an idea of rate of deterioration in sea water If rate of corrosion is slight at 50 100 hours or 2 4 weeks initial inspection zinc plugs sho
117. re Engine Break In Oil TY22041 should be used to make up any oil consumed during the break in period 3 Check engine oil level more frequently during engine break in period If oil must be added during this period John Deere Engine Break In Oil is preferred See ENGINE BREAK IN OIL in Fuels Lubricants and Coolant Section IMPORTANT DO NOT use PLUS 50 Engine Oil during the break in period of a new engine or engine that has had a major overhaul PLUS 50 oil will not allow a new or overhauled engine to properly wear during this break in period PLUS 50 is a trademark of Deere amp Company RG8028A UN 15JAN99 Check Engine Oil A Crosshatch Pattern On Dipstick DO NOT fill above the crosshatch pattern A or the FULL mark whichever is present Oil levels anywhere within the crosshatch are considered in the acceptable operating range RG19661 00003BC 19 28FEB13 2 5 During the first 20 hours avoid prolonged periods of engine idling If engine will idle longer than 5 minutes stop engine After the first 100 hours maximum change engine oil and replace engine oil filter A See CHANGE ENGINE OIL AND FILTER in Lubrication and Maintenance 250 Hour Section Fill crankcase with seasonal viscosity grade oil See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section NOTE Some increase in oil consumption may be expected when low viscosity oils are used Check oil levels more frequently If ai
118. res for the unit to be serviced Shut off air water or supply valves at the equipment to be serviced Check the local bleed off point for completed release of pressurized air water or oil If shutting off of air water or other material cannot be achieved at the local supply valve shut off valves further back in the system and re check the bleed off point until complete shut off is achieved Affix a DO NOT OPERATE tag to each valve handle that requires shut off 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 fitting must be shutdown and unplugged Excess air must be bled prior to removing the air hose prior to any maintenance or repair activities Affix a DO NOT OPERATE tag to the air hose near the detachable fitting 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 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 Verification of Isolation CAUTION Verify the machinery or equipment is actually isolated and de energized prior to beginning work on
119. rm Cover to Fitting Filter Housing C Hose Oil Drain 1 z 1 Crankcase Vent System Fitting RG19661 00003D9 19 13FEB13 1 1 OM C3 07 14 37 Lubrication amp Maintenance 500 Hour 12 Month Replace Fuel Filter r9 Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before disconnecting fuel or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard or paper to search for leaks Do not use your hand If any fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result Doctors unfamiliar with this type of injury may call the Deere amp Company Medical Department in Moline Illinois or other knowledgeable medical source 1 Close fuel shut off valve at bottom of fuel tank not illustrated 2 Clean entire area surrounding fuel filter assembly to keep debris from entering fuel system 3 Loosen drain plug and air vent screw Drain fuel into a suitable container 4 Firmly grasp the filter or filer housing and rotate it clockwise 1 4 turn when viewed from the top to remove from base 5 Inspect filter mounting base for cleanliness Clean as required NOTE Raised locators on fuel filter canister must be indexed properly with slots in mo
120. roke Insert JDG1571 or JDE81 4 Timing Pin in flywheel If No 1 cylinder rocker arms are loose the engine is at No 1 TDC compression If No 1 cylinder rocker arms are not loose rotate engine one full revolution 360 to No 1 TDC compression RG19661 00003D0 19 29JAN13 RG13749 UN 11NOV04 1 4 4 Adjust valves to specifications below using the valve clearance adjustment procedure in the following blocks Loosen the jam nut A on rocker arm adjusting screw Turn adjusting screw until feeler gauge B slips with a slight drag Hold the adjusting screw from turning with screwdriver and tighten jam nut to specifications Recheck clearance again after tightening jam nut Readjust clearance as necessary Specification Intake Valve Clearance Adjustment Rocker Arm to Bridge Engine Cold Clearance seen 0 36 mm 0 014 in Exhaust Valve Clearance Adjustment Rocker Arm to Bridge Engine Cold Clearance eere 0 46 mm 0 018 in Rocker Arm Adjusting Screw Jam Nut Torque eene 27 N m 20 Ib ft 5 Install rocker arm cover and crankcase ventilator tube 6 Reconnect battery terminal Continued on next page Adjusting Valves A Adjusting Screw Jam Nut B Feeler Gauge RG19661 00003D0 19 29JAN13 RG13809 UN 07DEC04 2 4 OM C3 07 14 50 Lubrication amp Maintenance 2000 Hour 24 Month 4 Cylinder Engine NOTE Firin
121. s The illustrated diagrams and troubleshooting information are of a general nature final design of the overall system for your engine application may be different See your engine distributor or servicing dealer if you are in doubt For Electronically Controlled Engines The Engine Control Unit ECU has the ability to detect problems internally and in the electronic control system This includes determining if any of the sensor input voltages are too high or too low if the camshaft and crankshaft position sensor inputs are valid and if the unit injector solenoids are responding properly If the ECU detects a problem with the electronic control system a Diagnostic Trouble Code DTC specific to the failed system will be stored in the ECU s memory There are two types of DTCs Active Inactive Stored Active DTCs indicate that the failure is occurring These type of failures are sometimes called hard failures They can be accessed on the diagnostic gauge A on the instrument panel Inactive or stored DTCs indicate that a failure has occurred in the past but is not currently occurring This type of stored DTC can be caused by an intermittent failure KEY ON START DIMMER Jormbecre RG13140 UN 070CT03 Diagnostic Gauge A Diagnostic Gauge Electronically Controlled Engine These could be problems such as a bad conne
122. s when operating at temperatures below freezing Engines used in generator set applications where the governor is locked at a specified speed may not have a slow idle function Operate these engines at high idle for 1 to 2 minutes before applying the load This procedure does not apply to standby generator sets where the engine is loaded immediately upon reaching rated speed 1 Check oil pressure gauge A as soon as engine starts If gauge needle does not rise above minimum oil pressure specification within 5 seconds stop the engine and determine the cause See GENERAL ENGINE SPECIFICATIONS and ENGINE POWER AND SPEED SPECIFICATIONS in Specifications Section for all oil pressure engine speed and coolant temperature specifications NOTE On certain engines the oil pressure and coolant temperature gauges are replaced by indicator warning lights The lights must be OFF when engine is running 2 Watch coolant temperature gauge B Do not place engine under full load until it is properly warmed up See Specifications Section for the normal engine coolant temperature range specification NOTE It is a good practice to operate the engine under a lighter load and at lower speeds than normal for the first few minutes after start up A Oil Pressure Gauge B Coolant Temperature Gauge Moe start EY ON START DIMME 52 96 w AE D Oil Pressure And Coolant Temperature Gauges Electro
123. scharge into electronic components from welding may cause permanent damage 1 Remove paint from the area to be welded and ground cable clamp location 2 Disconnect the negative battery cable s or open battery switch if equipped TS953 UN 15MAY90 Disconnect the positive battery cable s or open battery switch if equipped Clear or move any wiring harness sections away from the welding area 5 Welding on engine components is not allowed Never connect the welder ground to any engine component or engine driven components that may be connected to the engine After welding reverse steps 2 3 DX WELDING PRECAUTIONS 19 06DEC10 1 1 Precautions For Welding On Vessels Equipped With Electronic Engine Control Unit ECU IMPORTANT ALWAYS disconnect Electronic Control Unit ECU connectors and engine control system to vessel ground before welding High currents or electro static discharge in electronic components from welding may cause permanent damage 1 Remove the ground connection for the engine control system to vessel frame 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 TS953 UN 15MAY90 Welding Precautions DPSG OUOD007 2898 19 04NOV99 1 1 OM C3 07 14 72 Troubleshooting Electronically Controlled Engine Electri
124. sen 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 A Thumb Screw RG13253 UN 08DEC03 Drain Primary Fuel Filter 6 068SFM50 Shown OUOD006 0000083 19 160 07 1 1 OM C3 07 14 66 Service as Required Bleeding Fuel System High pressure fluid remaining fuel lines can cause serious injury Do not disconnect or attempt repair of fuel lines sensors or any other components between the high pressure fuel pump and nozzles on engines with High Pressure Common Rail HPCR fuel system Only technicians familiar with this type of system can perform repairs See your John Deere dealer Escaping fluid under pressure can penetrate the skin causing serious injury Avoid hazards by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury may call the Deere amp Company Medical Department in Moline Illinois or other knowledgeable medical source IMPORTANT Four valve cylinder head engines are especially sensitive to fuel contamina
125. shaft key C if equipped from pump housing 4 Remove O ring D Inspect cam plate E for evidence of heavy pitting or wear Replace as needed 6 Inspect impeller for damages such as tears stress cracks excess abrasions on vane ends or chunks of material missing Impellers that are run dry will overheat and fail the impeller blades at the root Impellers that swell and stick fail the impeller in the middle of the blade If impeller replacement is necessary order an impeller repair kit IMPORTANT If impeller has chunks of material missing the heat exchanger aftercooler marine gear oil cooler and any other circuit that are cooled by raw water should be thoroughly cleaned and flushed 7 Install shaft key C if equipped on shaft IMPORTANT Petroleum based lubricants can cause the impeller to swell and are not recommended to lubricate the impeller before installation 8 Lubricate new impeller blades with a non petroleum based lubricant such as silicone or soapy water Install impeller using a twisting motion and be sure the impeller blades are bent in the same direction as they were upon removal to prevent damage at startup Rotate impeller on shaft to align keyways splines and slide the impeller onto the shaft 9 Using a new O ring D install cover plate and tighten cap screws with washers securely 10 Install sea water pump and tighten cap screws to 73 N m 54 Ib ft 11 Connect sea water inlet and ou
126. tall this kit Continued on next page Inspect Sea Water Pump A Weep Hole Earlier Engines Only RG9852 UN 05JAN99 RG19661 0000401 19 06MAR13 1 3 OM C3 07 14 56 Lubrication amp Maintenance 2000 Hour 24 Month Remove and Inspect Impeller 1 Close sea cock and drain sea water system if not previously done 2 Remove six cover plate cap screws with washers and remove cover plate A with O ring Remove impeller end cap from end of impeller bore NOTE Normally the impeller can be removed by using two pair of pliers to grip impeller vanes on opposite sides of impeller Rotating the pump shaft by hand may help free the impeller Petroleum based lubricants can cause the impeller to swell and are not recommended to free a stuck impeller RG9853 UN O5JAN99 3 Carefully remove impeller with cam plate Be careful not to damage impeller if in reusable condition Remove key from shaft keyway The impeller must be installed in the same direction as removed Mark the impeller to ensure installation in proper direction of rotation if impeller is reused 4 Inspect impeller for damages such as tears stress cracks excess abrasions on vane ends or chunks of material missing Impellers that are run dry will overheat and fail the impeller blades at the root Impellers that swell and stick fail the impeller in the middle of the blade If impeller replacement is necessary order an impeller Inspect Se
127. tem 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 RG15325 UN 19JULO7 Install Core and Rear End Cap RG15326 UN 19JULO7 Install Front End Cap RG19661 000040F 19 10MAR13 2 2 OM C3 07 14 46 Lubrication amp Maintenance 500 Hour 12 Month QUE Remove Inspect and Clean Engine Aftercooler Core IMPORTANT Initially remove and inspect the aftercooler core at 250 hour or three month service interval on a new engine Then remove and clean at every 500 hour or 12 month interval thereafter IMPORTANT Ensure Service Kit RE18060 is readily available before removing aftercooler core Air side seals will be destroyed during core removal and RE18060 kit includes required replacement seals as well as end cap O rings RG12190 UN 25FEB02 1 Close sea cocks and drain the sea water system 2 Loosen clamp A and remove air filter 3 Loosen clamps B remove mounting bolt C and remove water line from rear of aftercooler 4 Remove four cap screws D and remove rear cap and O ring 5 Remove clamps E and remove hoses from front cap 6 Remove four cap screws F front cap and O ring RG12182 UN 25FEBO2 7 Remove aftercooler core from the rear of the engine A Clamp D Cap Screws B Clamps E Clamps C Mounting Bolt F Cap Screws
128. the manufacturer s recommendation for use of supplemental coolant additives See DIESEL ENGINE COOLANTS AND SUPPLEMENTAL ADDITIVE INFORMATION for proper mixing of coolant ingredients before adding to the cooling system DPSG OUODO002 1921 19 23 01 1 1 OM C3 07 14 43 Lubrication amp Maintenance 500 Hour 12 Month Testing Diesel Engine Coolant Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing corrosion and cylinder liner erosion and pitting Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating Coolant Test Strips Coolant test strips are available from your John Deere dealer These test strips provide a simple effective method to check the freeze point and additive levels of your engine coolant Compare the results to the supplemental coolant additive SCA chart to determine the amount of inhibiting additives in your coolant and whether more John Deere COOLANT CONDITIONER should be added COOLSCAN Or COOLSCAN PLUS For a more thorough evaluation of your coolant perform a COOLSCAN or COOLSCAN PLUS analysis See your John Deere dealer for information about COOLSCAN or COOLSCAN PLUS OUOD002 0000175 19 23 01 1 1 Remove Inspect and Clean Engine Heat Exchanger Core IMPORTANT Initially remove
129. tic Gauge Hour B Stop Button Mechanically Meter Controlled Engines Observe the hour meter reading on diagnostic gauge hour meter C to determine if periodic maintenance is necessary Make appropriate entries in maintenance logs See LUBRICATION AND MAINTENANCE RECORDS Section Perform required periodic maintenance on all other equipment as recommended by the equipment manufacturers RG13290 UN 06NOV03 RG19661 00003BE 19 23JAN13 1 1 OM C3 07 14 21 Engine Operation Using a Booster Battery or Charger A 12 volt booster battery can be connected in parallel with battery ies on the unit to aid in cold weather starting ALWAYS use heavy duty jumper cables Zh CC DON Gas given off by battery is explosive Keep sparks and flames away from battery Before connecting or disconnecting a battery charger turn charger off Make last connection and first disconnection at a point away from battery Always connect NEGATIVE cable last and disconnect this cable first TS204 UN 23AUG88 IMPORTANT Be sure polarity is correct before making connections Reversed polarity will damage electrical system Always connect positive to positive and negative to ground Always use 12 volt booster battery for 12 volt electrical systems and 24 volt booster battery ies for 24 volt electrical systems 1 Connect booster battery or batteries to produce the required system voltage for your engine application
130. tion Do not crack any fuel lines to bleed the fuel system NOTE Normally the fuel system on these engines is self priming and self bleeding and does not require a bleeding procedure by the operator TS1343 UN 18MAR92 High Pressure Fuel Lines X9811 UN 23AUG88 High Pressure Fluids If engine will not start after filter changes turn ignition key ON for 60 seconds to prime the fuel system It may be necessary to turn the key off and on again to reprime the system before starting RG19661 00003FD 19 01MAR13 1 1 OM C3 07 14 67 Service as Required Remove and Install Sea Water Pump 4045TFM85 NOTE Sea water pump may have two more mounting cap screws than illustrated Remove install procedure is unchanged Remove Sea Water Pump 1 Close sea cock and drain sea water system if not previously done RG9861 UN O6JAN99 2 Remove water inlet tube shown removed and outlet tube A from sea water pump 3 Remove two cap screws B attaching sea water pump to gear housing Withdraw pump from housing until splined shaft C is free from splined drive gear ID D 4 Clean all gasket material from both mating surfaces Install Sea Water Pump 1 Position a new gasket on water pump mounting flange Install splined pump shaft in splined ID of drive gear 2 Align mounting holes in water pump flange and gasket with threaded holes in gear housing Install cap screws with was
131. tlet tubes Tighten mounting cap screws evenly until secure RG14949 UN 20JUNO7 RG12189 UN 25FEB02 RG6243 UN 23MAR92 Inspect Sea Water Pump Impeller A Cover Plate D O Ring B Impeller E Cam Plate C Shaft Key 12 Replace O rings on oil tubes and install oil filter housing and oil tubes Tighten mounting cap screws to 35 N m 26 lb ft 13 Open sea cocks start engine and check pump operation RG19661 0000402 19 09MAR13 1 1 OM C3 07 14 59 Service as Required Additional Service Information This is not a detailed service manual If you want more detailed service information use the form in the back of this manual to order a component technical manual RG4624 UN 15DEC88 RG RG34710 5591 19 20MAY96 1 1 Do Not Modify Fuel System IMPORTANT Modification or alteration of the injection pump arrow the injection pump timing or the fuel injectors in ways not recommended by the manufacturer will terminate the warranty obligation to the purchaser In addition tampering with fuel system which alters emission related equipment on engines may result in fines or other penalties per EPA regulations or other local emission laws Do not attempt to service injection pump or fuel injectors yourself Special training and special tools are required See your authorized servicing dealer or engine distributor IMPORTANT Never steam clean or pour cold water on
132. uld be inspected at 250 hour intervals thereafter See INSPECT AND REPLACE ZINC PLUGS in Lubrication amp Maintenance 250 Hour Section A Zinc Plugs B End Cap RG19661 00003BC 19 28FEB13 5 5 Auxiliary Gear Drive Limitations IMPORTANT When attaching a sea water pump or other accessory to be driven by the auxiliary gear drive A engine timing gear train at front of engine power requirements of the accessory must be limited to values listed below 30 kW 40 hp Continuous Operation 37 kW 50 hp Intermittent Operation Gear Drive RG7634A UN 22JAN99 Auxiliary Gear Drive RG RG34710 5555 19 03 2 1 1 Generator Set Power Units speed 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 07 14 16 Engine Operation Starting the Engine The following instructions apply to the optional controls and instruments available through the John Deere Parts Distribution Network The controls and instruments for your engine may be different from those shown here always follow manufacturer s instructions 3 P Waaa Before starting engine in a confined 5 engine room install proper outlet exhaust i ventilation equipment Al
133. unting base for correct installation 6 Install new filter element onto mounting base Be sure element is properly indexed and firmly seated on base It may be necessary to rotate filter for correct alignment If equipped with a water separator bowl remove separator bowl from filter element Drain and clean separator bowl Dry with compressed air Install bowl onto new filter element Tighten securely 7 Align keys on filter element with slots in filter base 8 Install retaining ring onto mounting base making certain dust seal is in place on filter base Hand tighten ring about 1 3 turn until it snaps into the detent DO NOT overtighten retaining ring NOTE The proper installation is indicated when a click is heard and a release of the retaining ring is felt A plug is provided with the new element for plugging the used element RG22096 UN 05DEC12 RG22079 UN 15FEB13 Fuel Filter 6068 Engines A Drain B Filter Filter Housing C Filter Base 9 Open fuel shut off valve Whenever the fuel system has been opened up for service lines disconnected or filters removed it will be necessary to bleed air from the system See BLEEDING THE FUEL SYSTEM in Service as Required Section RG19661 00003E4 19 13FEB13 1 1 OM C3 07 14 38 Lubrication amp Maintenance 500 Hour 12 Month Replacing Fuel Filter Water Separator Escaping fluid under pressure can penetrate the skin c
134. ut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely DO NOT drain coolant until it has reached ambient temperature 1 Visually inspect area around thermostat housing and cover for leaks 2 Remove coolant tank pressure cap and partially drain coolant system 3 Remove cap screws A nut B and washer C attaching coolant cover D with sealing O ring E to the thermostat housing G and exhaust manifold 4 Remove cap screws F attaching thermostat housing to the exhaust manifold 5 Remove thermostat housing with gasket 1 Remove and disgard all gasket material Clean all sealing surfaces 6 Inspect and test thermostats for proper opening temperature 7 Install thermostats with a new gasket and pilot housing on stud J Install thermostat housing cap screws finger tight 8 Remove and Install Thermostats A Cap Screws Thermostat F Cap Screws Thermostat Cover Housing B Nut G Thermostat Housing C Washer H Thermostats D Thermostat Cover I Gasket E O ring J Stud Inspect thermostat cover sealing O ring and replace if necessary Install thermostat cover with O ring cap screws washer and nut Tighten nut and all cap screws to 35 N m 25 lb ft RG22482 UN 04MAR13 RG19661 0000405 19 08MAR13 1 1 OM C3 07 14 54 Lubrication amp Maintenance 2000 Hour 24
135. w to use of potential dangers and act safely the controls properly Only trained personnel should operate machines or work on or around them READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL Keep you machine in proper working condition PRIOR TO THE INSTALLATION UNAUTHORIZED MODIFICATIONS TO THE OF ANY GENERATOR SET OR MACHINERY MAY IMPAIR ITS FUNCTION ACCESSORY KEEP THESE AND SAFETY PARAMETERS INSTRUCTIONS FOR FUTURE REFERENCE Prevent Bypass and Accidental Starting Recognize Safety Symbols and Instructions In addition to the information found in this section this WARNING operator s manual uses three different signal words to outline potential dangers of a specific nature Do not start engine by shorting 2 across start terminal Engine will indicates a hazardous situation which if start if normal circuitry is bypassed 4 not avoided will result in death or serious injury creating a hazard by runaway WARNING indicates a hazardous situation which if machinery not avoided could result in death or serious injury CAUTION indicates a hazardous situation which Start en ine onl from operator 5 station A AUTION if not avoided could result in minor or moderate 5 y p injury 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 da
136. ways use safety 1 approved fuel storage and piping 5 NOTE If temperature is below 0 32 F it be Use Proper Ventilation necessary to use cold weather starting aids See COLD WEATHER OPERATION later in this section 1 Perform all prestarting checks outlined in Lubrication TO START ate gad PREHEATING amp Maintenance Daily Section later in this manual Open the fuel supply shut off valve 0 30 5 Set marine gear control lever in the NEUTRAL 1 position on propulsion units 1 4 Move the throttle control lever approximately 1 3 of the 8 way off the idle position 5 Turn the key switch to the ON position The Wait To Wait To Screen Start Preheating message will be displayed when ambient temperatures require preheating for engines has reach 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 07 14 17 Engine Operation IMPORTANT Do not operate the starter for more than 30 seconds at a time To do so may overheat the starter If the engine does not start the first time wait at least 2 minutes before trying again If engine does not start after four attempts see Troubleshooting Section If the start switch button is released before the engine starts wait until the starter and the engine stop
137. y add clean soft water to bring level to bottom of filler neck 2 Keep batteries clean by wiping them with a damp cloth Keep all connections clean and tight Remove Continued on next page TS204 UN 23AUG88 Exploding Battery any corrosion and wash terminals with a solution of 1 part baking soda and 4 parts water Tighten all connections securely NOTE Coat battery terminals and connectors with a mixture of petroleum jelly and baking soda to retard corrosion Keep battery fully charged especially during cold weather If a battery charger is used turn charger off before connecting charger to battery ies Attach POSITIVE battery charger lead to POSITIVE battery post Then attach NEGATIVE battery charger lead to a good ground RG RG347 10 5568 19 20 96 1 2 OM C3 07 14 33 Lubrication amp Maintenance 250 Hour 6 Month Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed into eyes Avoid the hazard by 1 Filling batteries in a well ventilated area 2 Wearing eye protection and rubber gloves 3 Avoiding breathing fumes when electrolyte is added 4 Avoiding spilling or dripping electrolyte 5 Use proper jump start procedure If you spill acid on yourself Flush your skin with water Apply baking soda or lime to help neutralize the acid 3 Flush
138. your eyes with water for 10 15 minutes Get medical attention immediately Na If acid is swallowed 1 Drink large amounts of water or milk 2 Then drink milk of magnesia beaten eggs or vegetable oil 3 Get medical attention immediately TS203 UN 23AUG88 In freezing weather run engine at least 30 minutes to assure thorough mixing after adding water to battery Sulfuric Acid If necessary to replace battery ies replacements must meet or exceed the following recommended capacities at 24 Volt Standard Duty 18 C 0 Starter Cold Cranking Specification 12 Volt Standard Duty Starter Cold Cranking 12 Volt Heavy Duty Starter Cold Cranking RG RG34710 5568 19 20MAY96 2 2 OM C3 07 14 34 Lubrication amp Maintenance 250 Hour 6 Month Inspect and Replacing Zinc Plugs Two zinc plugs A are installed in the sea water cooling system to help reduce the corrosive action of salt in the sea water The reaction of the zinc to sea water causes the plugs to deteriorate instead of the more critical cooling system parts Therefore the zinc plugs MUST BE inspected every 250 Hours NOTE Zinc plugs are located in each heat exchanger end cap and are mounted on hex head pipe plug 1 Remove zinc rod from each end cap B and observe condition of each 2 Tap the zinc rods lightly with a hammer If rod flakes apart when tapped install a new zinc plug A 2Zinc Plugs B End Cap RG22

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