1. DL manuals
  2. Northern Lights
  3. Engine
  4. OM-C3
  5. Operator's Manual

Northern Lights OM-C3 Operator's Manual

Manual is about: Marine Engines

Summary of OM-C3

  • Page 2

    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. — california — proposition 65 warning: northern lights 4420 14th avenue n.W. Seattle, wa 98107 tel: (206) 789-3880 fax: (206) 782-5455 copyright ©201...

  • Page 3: Operator'S Manual

    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. Operator's manual #om-c3 for models: m65c13, and m99c13 introduction ....................................................2 models include...

  • Page 4

    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. Mar...

  • Page 5: Warning

    A warranty registration certificate is supplied with your set. The extent of coverage is described in the limited warranty statement. We recommend that you study the statement carefully. Note: if the warranty is to apply, the servicing instructions outlined in this manual must be followed. If furthe...

  • Page 6: Caution

    Safety rules (continued) operating equipment requires the full attention of the operator. Do not use radio or music headphones while operating machinery. Practice safe maintenance ! Caution understand all service procedures before starting work. Keep area clean and dry. Never lubricate, service, or ...

  • Page 7: Warning

    Safety rules (continued) install all safety guards ! Warning 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 drive...

  • Page 8: Caution

    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. W...

  • Page 9: Warning

    Safety rules (continued) material containing asbestos. Keep all bystanders away from any area where asbestos dust may be generated. Use proper lifting equipment and techniques ! Warning lifting heavy components incorrectly can cause severe injury or damage to machinery. Avoid unbalanced loads. Do no...

  • Page 10: Caution

    General policy to avoid dangerous or hazardous situations, refrain from any of the following: • removing or bypassing a guard or other safety device • placing any part of your body in a position where you could be caught by moving machinery. • cleaning or oiling machinery when in operation. • adjust...

  • Page 12

    Notes om-c3

  • Page 13

    1 2 3 4 5 6 7 8 9 10 14 13 12 11 15 component locations 1. Junction box 2. Air cleaner 3. Coolant fill 4. Alternator 5. Belt guard 6. Lube oil dipstick 7. Lube oil fill 8. Lube oil filter 9. Fuel filter 10. Fuel injection lines 11. Starter 12. Thermostat cover 13. Expansion tank 14. Exhaust elbow 15...

  • Page 14

    Northern lights control panels figure 7: series 3b generator control panel 1. Shutdown bypass switch this switch bypasses the safety shutdown feature during the starting process. 2. Engine control switch to start the engine, hold this switch in the start position until the engine is running. Note: e...

  • Page 15

    Instrument panels ourgp11,00000b2 -19-03sep03-12/14 ourgp11,00000b2 -19-03sep03-13/14 ourgp11,00000b2 -19-03sep03-14/14 12. The selected quadrant has now changed to the new selected parameter. Rg13153 —un—24sep03 4-up display 13. Repeat the parameter selection process until all spaces are as desired...

  • Page 16: Engine Operation

    Engine operation ouod006,000008f -19-21jun07-1/1 continued on next page rg19661,00003bc -19-28feb13-1/5 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 l...

  • Page 17

    Engine operation rg19661,00003bc -19-28feb13-2/5 rg19661,00003bc -19-28feb13-3/5 continued on next page rg19661,00003bc -19-28feb13-4/5 important: do not add makeup oil until the oil level is below the add mark on dipstick. John deere engine break-in oil (ty22041) should be used to make up any oil c...

  • Page 18

    Engine operation rg19661,00003bc -19-28feb13-5/5 rg,rg34710,5555 -19-03jan02-1/1 rg,rg34710,5556 -19-20may96-1/1 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...

  • Page 19

    Engine operation continued on next page rg19661,00003bd -19-23jan13-1/2 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 ...

  • Page 20

    Engine operation rg19661,00003bd -19-23jan13-2/2 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 tr...

  • Page 21

    Engine operation ouod006,0000091 -19-21jun07-1/1 ouod006,0000092 -19-19jun07-1/1 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 minutes when operating at temperatures below freezing. Engines used in gen...

  • Page 22

    Engine operation ourgp11,0000144 -19-08dec03-1/1 ouod006,0000080 -19-22jun07-1/1 engaging and disengaging front pto (if equipped) 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...

  • Page 23

    Engine operation rg19661,00003be -19-23jan13-1/1 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 lock...

  • Page 24

    Engine operation rg,rg34710,5564 -19-03jan02-1/1 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. Caution: gas given off by battery is explosive. Keep sparks a...

  • Page 25

    Engine operation dx,ww,ecu02 -19-14aug09-1/1 dx,ww,ecu04 -19-11jun09-1/1 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. Disco...

  • Page 26

    Lubrication and maintenance rg19661,00003bf -19-23jan13-1/1 dpsg,ouoe003,20 -19-19jun07-1/1 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 ...

  • Page 27

    Lubrication and maintenance ouod006,0000081 -19-18aug11-1/1 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 chec...

  • Page 28

    Lubrication and maintenance ouod006,0000082 -19-27oct11-1/1 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...

  • Page 29

    Lubrication & maintenance/daily continued on next page rg19661,00003d3 -19-29jan13-1/4 daily prestarting checks do the following before starting the engine for the first time each day: important: do not add makeup oil until the oil level is below the add mark. Depending on application, oil dipstick ...

  • Page 30

    Lubrication & maintenance/daily rg19661,00003d3 -19-29jan13-2/4 continued on next page rg19661,00003d3 -19-29jan13-3/4 a—engine top tank ts281 —un—23aug88 high-pressure fluids rg22040 —un—28nov12 engine top tank important: a restricted or clogged sea water strainer will result in hotter than normal ...

  • Page 31

    Lubrication & maintenance/daily rg19661,00003d3 -19-29jan13-4/4 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 ...

  • Page 32

    Lubrication & maintenance/250 hour/6 month continued on next page rg19661,00003d4 -19-28feb13-1/3 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-...

  • Page 33

    Lubrication & maintenance/250 hour/6 month continued on next page rg19661,00003d4 -19-28feb13-2/3 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- ...

  • Page 34

    Lubrication & maintenance/250 hour/6 month rg19661,00003d4 -19-28feb13-3/3 ourgp11,000015d -19-28jan04-1/1 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...

  • Page 35

    Lubrication & maintenance/250 hour/6 month continued on next page rg,rg34710,5568 -19-20may96-1/2 servicing battery caution: 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 ...

  • Page 36

    Lubrication & maintenance/250 hour/6 month rg,rg34710,5568 -19-20may96-2/2 caution: 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 ar...

  • Page 37

    Lubrication & maintenance/250 hour/6 month rg19661,00003d5 -19-29jan13-1/2 rg19661,00003d5 -19-29jan13-2/2 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 w...

  • Page 38

    Lubrication & maintenance/250 hour/6 month rg19661,00003d6 -19-09mar13-1/1 rg19661,00003d7 -19-29jan13-1/1 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. N...

  • Page 39

    Lubrication & maintenance/500 hour/12 month rg19661,00003d8 -19-13feb13-1/1 rg19661,00003d9 -19-13feb13-1/1 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...

  • Page 40

    Lubrication & maintenance/500 hour/12 month rg19661,00003da -19-26feb13-1/1 checking air intake system important: the air intake system must not leak. Any leak, no matter how small, may result in engine failure due to abrasive dirt and dust entering the intake system. 1. Inspect all intake hoses (pi...

  • Page 41

    Lubrication & maintenance/500 hour/12 month rg19661,00003e4 -19-13feb13-1/1 replace fuel filter caution: 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 hand...

  • Page 42

    Lubrication & maintenance/500 hour/12 month rg19661,00003e5 -19-13feb13-1/1 replacing fuel filter/water separator caution: escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel or other lines. Tighten all connections before applying p...

  • Page 43

    Lubrication & maintenance/500 hour/12 month continued on next page rg19661,00003e6 -19-13feb13-1/2 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 tension...

  • Page 44

    Lubrication & maintenance/500 hour/12 month rg19661,00003e6 -19-13feb13-2/2 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 outli...

  • Page 45

    Lubrication & maintenance/500 hour/12 month rg,rg34710,5580 -19-20may96-1/1 checking cooling system 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 fi...

  • Page 46

    Lubrication & maintenance/500 hour/12 month dpsg,ouod002,1921 -19-23nov01-1/1 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 ...

  • Page 47

    Lubrication & maintenance/500 hour/12 month ouod002,0000175 -19-23nov01-1/1 continued on next page rg19661,000040b -19-10mar13-1/2 testing diesel engine coolant maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system ...

  • Page 48

    Lubrication & maintenance/500 hour/12 month rg19661,000040b -19-10mar13-2/2 continued on next page rg19661,000040f -19-10mar13-1/2 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 cl...

  • Page 49

    Lubrication & maintenance/500 hour/12 month rg19661,000040f -19-10mar13-2/2 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...

  • Page 50

    Lubrication & maintenance/500 hour/12 month continued on next page rg19661,000040d -19-10mar13-1/2 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 eve...

  • Page 51

    Lubrication & maintenance/500 hour/12 month rg19661,000040d -19-10mar13-2/2 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 wit...

  • Page 52

    Lubrication & maintenance/500 hour/12 month rg19661,0000409 -19-08mar13-1/1 pressure testing cooling system rg6557 —un—20jan93 rg9850 —un—06jan99 caution: explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to ...

  • Page 53

    Lubrication & maintenance/500 hour/12 month ourgp11,00000c5 -19-08sep03-1/1 ouod002,0000169 -19-23nov01-1/1 checking and adjusting engine speeds observe tachometer reading (a) on the instrument panel to verify engine speeds. (refer to fuel system specifications in specifications section later in thi...

  • Page 54

    Lubrication&maintenance/2000 hour/24 month rg19661,00003d0 -19-29jan13-1/4 continued on next page rg19661,00003d0 -19-29jan13-2/4 checking and adjusting engine valve clearance caution: to prevent accidental starting of engine while performing valve adjustments, always disconnect negative (—) battery...

  • Page 55

    Lubrication&maintenance/2000 hour/24 month rg19661,00003d0 -19-29jan13-3/4 rg19661,00003d0 -19-29jan13-4/4 4-cylinder engine note: firing 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 flyw...

  • Page 56

    Lubrication&maintenance/2000 hour/24 month continued on next page rg19661,00003d1 -19-28jan13-1/2 flushing and refilling cooling system 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...

  • Page 57

    Lubrication&maintenance/2000 hour/24 month rg19661,00003d1 -19-28jan13-2/2 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 thi...

  • Page 58

    Lubrication&maintenance/2000 hour/24 month rg19661,0000405 -19-08mar13-1/1 remove thermostats 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 st...

  • Page 59

    Lubrication&maintenance/2000 hour/24 month ouod006,0000095 -19-19jun07-1/1 inspecting thermostats and testing opening temperature 1. Remove thermostats. (see removing thermostats earlier in this section.) 2. Visually inspect thermostats for corrosion or damage. Replace thermostats as a matched set a...

  • Page 60

    Lubrication&maintenance/2000 hour/24 month ouod006,0000096 -19-09dec09-1/1 continued on next page rg19661,0000401 -19-06mar13-1/3 checking crankshaft vibration damper (6-cylinder engine only) 1. Remove belts (shown removed). 2. Grasp vibration damper with both hands and attempt to turn it in both di...

  • Page 61

    Lubrication&maintenance/2000 hour/24 month continued on next page rg19661,0000401 -19-06mar13-2/3 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...

  • Page 62

    Lubrication&maintenance/2000 hour/24 month rg19661,0000401 -19-06mar13-3/3 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...

  • Page 63

    Lubrication&maintenance/2000 hour/24 month rg19661,0000402 -19-09mar13-1/1 inspect and repair sea water pump (4045afm85/6068afm85) 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. Remo...

  • Page 64: Service As Required

    Service as required rg,rg34710,5591 -19-20may96-1/1 rg19661,00003c1 -19-23jan13-1/1 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 d...

  • Page 65

    Service as required rg,rg34710,5593 -19-04jan02-1/1 rg19661,00003f5 -19-22feb13-1/1 adding coolant 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 fir...

  • Page 66

    Service as required ouod006,0000098 -19-10dec09-1/5 continued on next page ouod006,0000098 -19-10dec09-2/5 servicing air cleaner filter element important: always service primary air cleaner element when air restriction indicator shows a vacuum of 625 mm (25 in.) h 2 o, or when reset button has poppe...

  • Page 67

    Service as required ouod006,0000098 -19-10dec09-3/5 continued on next page ouod006,0000098 -19-10dec09-4/5 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 ...

  • Page 68

    Service as required ouod006,0000098 -19-10dec09-5/5 dpsg,ouod007,2908 -19-24dec02-1/2 dpsg,ouod007,2908 -19-24dec02-2/2 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, fu...

  • Page 69

    Service as required rg19661,00003f4 -19-20feb13-1/1 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. Caution: belt guard should...

  • Page 70

    Service as required ourgp11,0000145 -19-09dec03-1/1 ouod006,0000083 -19-16oct07-1/1 check front power take-off (pto) 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...

  • Page 71

    Service as required rg19661,00003fd -19-01mar13-1/1 bleeding fuel system caution: high-pressure fluid remaining in 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 ...

  • Page 72

    Service as required rg19661,00003fe -19-02mar13-1/1 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 previous...

  • Page 73

    Service as required rg19661,00003ff -19-02mar13-1/1 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 sur...

  • Page 74

    Service as required rg19661,0000404 -19-07mar13-1/1 remove and install sea water pump (6068sfm85) rg22485 —un—04mar13 remove and install sea water pump rg22484 —un—07mar13 1. Close sea cock and drain sea water system. 2. Remove sea water pump inlet connection. Loosen constant tension clamps (b) on f...

  • Page 75: Troubleshooting

    Troubleshooting ouod006,00000f8 -19-25sep07-1/1 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...

  • Page 76

    Troubleshooting dx,welding,precautions -19-06dec10-1/1 dpsg,ouod007,2898 -19-04nov99-1/1 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). Caution: avoid potentially toxic fumes and dust. ...

  • Page 77

    Troubleshooting rg19661,00003de -19-15feb13-1/1 electronically controlled engine electrical system layout rg22346 —un—05feb13 1— engine control unit (ecu) 2— auxiliary power connector 3— coolant temperature sensor connector 4— fuel injection harness connector 5— alternator connector 6— manifold air ...

  • Page 78

    Troubleshooting ouod006,00000bc -19-25jul07-1/1 wiring diagram for john deere main station (wheel house) instrument panel - electronically controlled engine rg15473 —un—27sep07 a—vehicle harness connector b—key switch c—start button- momentary d—to fly bridge panel e—in absence of fly bridge panel f...

  • Page 79

    Troubleshooting ouod006,00000bd -19-27sep07-1/1 wiring diagram for john deere main station (wheel house) instrument panel - electronically controlled engine - cont'd rg15470 —un—04sep07 a—vehicle harness connector b—key switch c—start button- momentary d—to fly bridge panel e—in absence of fly bridg...

  • Page 80

    Troubleshooting ouod006,00000be -19-25jul07-1/1 wiring diagram for john deere optional fly bridge instrument panel - electronically controlled engine rg15471 —un—04sep07 q—from wheelhouse panel r—stop button- momentary s—start button- momentary t— back light dimmer u—audible alarm v—external alarm w...

  • Page 81

    Troubleshooting continued on next page rg19661,00003ea -19-21feb13-1/2 4045tfm85 marine electronic control system wiring diagram 5445 5447 eng cam sensor eng crank sen so r b a b a 5448 5443 5050 505 0 502 2 502 2 j2-m2 j2-l1 j2-l4 j1-b4 j1-d4 x01 x02 j1-a4 j1-e4 5946 excit ation vol ta ge # 1 5475 ...

  • Page 82

    Troubleshooting rg19661,00003ea -19-21feb13-2/2 a— focus 16, 4.5 l, 4 valve, engine control unit (ecu) b— mating view of rail pressure connector j1— 32 position - black j1-d3— excitation voltage #1 j1-d4— return j1-e2— excitation return #1 j1-e3— analog 6 j1-e4— return j2— 48 position - brown j3— 32...

  • Page 83

    Troubleshooting continued on next page rg19661,00003ec -19-21feb13-1/2 4045tfm85 marine electronic control system wiring diagram - cont-d 5416 excit ation vol ta ge # 2 5467 analog 4 5428 analog 2 5461 analog 8 t t t coolant temp fuel temp 5414 5414 a b 01 02 increase pressure oil pressure sensor (c...

  • Page 84

    Troubleshooting rg19661,00003ec -19-21feb13-2/2 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— sto...

  • Page 85

    Troubleshooting continued on next page rg19661,00003ed -19-21feb13-1/2 4045tfm85 marine electronic control system wiring diagram - cont-d 5419 driver j1-h2 5424 driver j1-h1 01 02 y01 pcv 1 lo w hig h j1-f2 se2 - focus 16 (ecu) 5050 5050 5904 5905 5020 digit al thr ottle 5947 bump enable 5923 resume...

  • Page 86

    Troubleshooting rg19661,00003ed -19-21feb13-2/2 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— ...

  • Page 87

    Troubleshooting continued on next page rg19661,00003ee -19-25feb13-1/2 4045tfm85 marine electronic control system wiring diagram - cont-d se2 - focus 16 (ecu) c10 sae j1939/11 3-way deutsch term sae j1939/11 3-way deutsch conn 5905 5904 c b a located near ecu 5020 5905 5904 b c f g h j diagnostic co...

  • Page 88

    Troubleshooting rg19661,00003ee -19-25feb13-2/2 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 c12— transient voltage protection (12 v or 24 v) c13— starter relay coil...

  • Page 89

    Troubleshooting continued on next page rg19661,00003eb -19-21feb13-1/2 4045afm85 marine electronic control system wiring diagram 5445 5447 eng cam sensor eng crank sen so r b a b a 5448 5443 5050 505 0 502 2 502 2 j2-m2 j2-l1 j2-l4 j3-f4 j3-f3 x01 x02 j3-g4 j3-g3 5474 excit ation return j3-b2 5946 e...

  • Page 90

    Troubleshooting rg19661,00003eb -19-21feb13-2/2 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 ...

  • Page 91

    Troubleshooting continued on next page rg19661,00003ef -19-21feb13-1/2 4045afm85 marine electronic control system wiring diagram - cont’d 5416 excit ation vol ta ge # 2 5467 analog 4 5428 analog 2 5461 analog 8 t t coolant temp fuel temp 5414 5414 a b 01 02 increase pressure oil pressure sensor (cle...

  • Page 92

    Troubleshooting rg19661,00003ef -19-21feb13-2/2 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— sto...

  • Page 93

    Troubleshooting continued on next page rg19661,00003f0 -19-25feb13-1/2 4045afm85 marine electronic control system wiring diagram - cont’d 5419 driver j1-h2 5424 driver j1-h1 01 02 y01 pcv 1 lo w hig h j1-d3 se2 - focus 14 (ecu) 5050 5050 5904 5905 5020 digit al thr ottle 5947 bump enable 5923 resume...

  • Page 94

    Troubleshooting rg19661,00003f0 -19-25feb13-2/2 a— focus 14, 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/config- urable output/ki...

  • Page 95

    Troubleshooting continued on next page rg19661,00003f1 -19-25feb13-1/2 4045afm85 marine electronic control system wiring diagram - cont’d se2 - focus 14 (ecu) c10 sae j1939/11 3-way deutsch term sae j1939/11 3-way deutsch conn 5905 5904 c b a located near ecu 5020 5905 5904 b c f g h j diagnostic co...

  • Page 96

    Troubleshooting rg19661,00003f1 -19-25feb13-2/2 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 c12— transient voltage protection (12 v or 24 v) c13— starter relay coil...

  • Page 97

    Troubleshooting rg19661,00003df -19-15feb13-1/1 6068sfm85 / afm85 marine electronic control system wiring diagram 05 a se1 se1 se1 fuel filter control / diagnostic / pwr / gnd eng crank sensor 6.8l engine c19 x01 c02 c07 5042 unswitched po wer 06 5050 5042 5042 5050 5412 5412 5050 5412 gr ound 01 j1...

  • Page 98

    Troubleshooting continued on next page rg19661,00003e0 -19-15feb13-1/2 6068sfm85 / afm85 marine electronic control system wiring diagram - continued t02 manifold air temp mating view of rail pressure connector focus 14 6.8l 4 valve engine control unit (ecu) j3-f1 5456 analog 15 j3-c1 5475 analog 6 j...

  • Page 99

    Troubleshooting rg19661,00003e0 -19-15feb13-2/2 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— fuel temp 5012— switched power/stop lamp power/cruise common 5050— single point groun...

  • Page 100

    Troubleshooting continued on next page rg19661,00003e1 -19-11feb13-1/2 6068sfm85 / afm85 marine electronic control system wiring diagram - continued a j2- c2 w ait t o st ar t 5474 c09 j3 c01 dt06-6s-ce05 j1 j2 c j2- c3 sensor return 5814 5814 5474 5491 5491 d st ar t 5422 e gnd 5050 f j2- k2 can sh...

  • Page 101

    Troubleshooting rg19661,00003e1 -19-11feb13-2/2 c01 dt06-12sa-ce05 c11 diagnostic connector sae j1939/11 3-way deutsch conn located near ecu sae j1939/11 3-way deutsch term c10 j2- b1 can l 5905 j2- a1 can h 5904 j2- b2 5012 6.8l engine 01 02 5050 5410 j g 5904 f e d a c h b 5493 cyl #1 j1-e1 5494 c...

  • Page 102

    Troubleshooting continued on next page ouod006,0000113 -19-16oct07-1/5 engine troubleshooting note: if using biodiesel blends above b20, the possibility of some of the symptoms listed below, such as power loss, could increase. Note: before troubleshooting the engine, first retrieve any fault codes o...

  • Page 103

    Troubleshooting continued on next page ouod006,0000113 -19-16oct07-2/5 symptom problem solution injection pump out of time. See your authorized servicing dealer or engine distributor. Low coolant temperature. Remove and check thermostat. Engine overheating. See “engine overheats”. Engine runs irregu...

  • Page 104

    Troubleshooting continued on next page ouod006,0000113 -19-16oct07-3/5 symptom problem solution leaking exhaust manifold gasket. See your authorized servicing dealer or engine distributor. Defective aneroid control line. See your authorized servicing dealer or engine distributor. Restricted fuel hos...

  • Page 105

    Troubleshooting continued on next page ouod006,0000113 -19-16oct07-4/5 symptom problem solution fuel injectors dirty. Use john deere approved biodiesel or diesel fuel conditioners containing detergents. If no improvement is seen, see your authorized servicing dealer or engine distributor. Engine out...

  • Page 106

    Troubleshooting ouod006,0000113 -19-16oct07-5/5 symptom problem solution engine overloaded. Reduce load. Improper valve clearance. See your authorized servicing dealer or engine distributor. Injection nozzles dirty. See your authorized servicing dealer or engine distributor. Injector tip deposits us...

  • Page 107

    Troubleshooting continued on next page dpsg,ouod007,335 -19-04jan02-1/2 electrical troubleshooting symptom problem solution undercharged electrical system excessive electrical load from added accessories. Remove accessories or install higher output alternator. Excessive engine idling. Increase engin...

  • Page 108

    Troubleshooting dpsg,ouod007,335 -19-04jan02-2/2 rg19661,000040a -19-10mar13-1/1 symptom problem solution entire electrical system does not function faulty battery connection. Clean and tighten connections. Sulfated or worn-out batteries. See your authorized servicing dealer or engine distributor. B...

  • Page 109

    Troubleshooting ourgp11,00000bb -19-05sep03-1/1 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 o...

  • Page 110

    Troubleshooting continued on next page ourgp12,00001fc -19-08apr10-1/4 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 (...

  • Page 111

    Troubleshooting continued on next page ourgp12,00001fc -19-08apr10-2/4 spn fmi blink code description of fault corrective action 158 ... 17 ..... 54 ..... Ecu power down error (internal ecu problem) ............. Contact servicing dealer 174 ... 00 ..... 67 ..... Fuel temperature signal extremely hi...

  • Page 112

    Troubleshooting continued on next page ourgp12,00001fc -19-08apr10-3/4 spn fmi blink code description of fault corrective action 652 ... 13 ..... ........ Injector number 2 part number calibration fault ............ Contact servicing dealer 653 ... 02 ..... ........ Injector number 3 part number dat...

  • Page 113

    Troubleshooting ourgp12,00001fc -19-08apr10-4/4 spn fmi blink code description of fault corrective action 107 9 ...... 03 ..... 21 ..... Sensor supply 1 voltage high .................................... Check wiring 107 9 ...... 04 ..... 22 ..... Sensor supply 1 voltage low ............................

  • Page 114

    Troubleshooting ourgp11,0000206 -19-07oct03-1/1 ourgp11,00000e3 -19-29sep03-1/4 continued on next page ourgp11,00000e3 -19-29sep03-2/4 intermittent fault diagnostics intermittent faults are problems that periodically “go away”. A problem such as a terminal that intermittently doesn't make contact ca...

  • Page 115

    Troubleshooting ourgp11,00000e3 -19-29sep03-3/4 ourgp11,00000e3 -19-29sep03-4/4 3. Once "utilities" is highlighted, press "enter" to activate the utilities function. Rg13237 —un—22oct03 select utilities 4. Scroll to the "software version". Press "enter" to view the software version. Press the menu b...

  • Page 116

    Troubleshooting rg19661,00003dd -19-11feb13-1/1 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 sh...

  • Page 117: Storage

    Storage ouod006,0000114 -19-16oct07-1/1 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. 2. John deere engines can be stor...

  • Page 118

    Storage ouod006,00000fc -19-26feb10-1/1 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 w...

  • Page 119

    Ouod006,0000115 -19-16oct07-1/1 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...

  • Page 120: Specifications

    Specifications rg19661,00003e8 -19-03mar13-1/1 general marine engine specifications - 4.5l item unit of measure engine model 4045tfm85 engine model 4045afm85 general data engine type in-line, 4 cycle diesel in-line, 4 cycle diesel aspiration turbocharged turbocharged and coolant after cooled number ...

  • Page 122

    4420 14th ave. Nw., seattle wa 98107 tel: (206) 789-3880 • 1-800-762-0165 • www.Northern-lights.Com northern lights and lugger are registered trademarks of northern lights, inc. © 2013 all rights reserved. Litho usa..