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OM3-80 12/21

Troubleshooting (Continued)

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Intermittent 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.
Possible 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.

Displaying Diagnostic Gauge Software

NOTE: The following steps can be used to display

the software version of the diagnostic gauge

if needed by your dealer for troubleshooting.

This is a read only function.

1. Starting at the single or four engine parameter display,

press the "Menu" key.

RG1315

9—

UN—26SEP0

Menu Key

2. The main menu will be displayed. Use the "Arrow" key

to scroll through the menu until "Utilities" is highlighted.

RG1323

4—

UN—22OCT03

Select Utilities

Содержание M150A13

Страница 1: ...OM3 80 For Models M80A13S M80A13 M99A13S M99A13 M150A13S M150A13 OPERATOR S MANUAL OPERATOR S MANUAL www northern lights com...

Страница 2: ...o the outside Do not modify or tamper with the exhaust system Do not idle the engine except as necessary For more information go to www P65warnings ca gov diesel CALIFORNIA Proposition 65 Warning Nort...

Страница 3: ...Control Units 18 Keeping Electronic Control Units Clean 18 SERVICE INTERVAL CHARTS Propulsion and Prime Power Units 20 Standby Generator Sets 21 LUBRICATION AND MAINTENANCE Daily Pre starting Checks...

Страница 4: ...ern Lights equipment by serial number please refer only to the number stamped on the Northern Lights serial number plate Serial Numberss Model Numberss 2 Northern Lights Tier III turbocharged marine d...

Страница 5: ...and clean condition Replace missing or damaged signs Be sure new equipment components and repair parts include the current safety signs For replacement signs proper placement of safety signs or clari...

Страница 6: ...parts have stopped before making any adjustments connections or performing any other type of service to the engine or other driven equipment Prevent accidental discharge of starting fluids by storing...

Страница 7: ...oisonous 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 appropr...

Страница 8: ...paint and solvent properly Service Cooling System Safely WARNING Opening a pressurized cooling system can release explosive fluids and causing serious burns Before opening any pressurized cooling sys...

Страница 9: ...ce components between the high pressure fuel pump and nozzles on engines with high pressure fuel systems ONLY AUTHORIZED TECHNICIANS CAN PERFORM REPAIRS ON AN HIGH PRESSURE FUEL INJECTION SYSTEMS Avoi...

Страница 10: ...annot 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 han...

Страница 11: ...OM3 80 12 21 Notes 9...

Страница 12: ...ll 4 Alternator 5 Belt Guard 6 Lube Oil Dipstick 7 Lube Oil Filter 8 Lube Oil Fill 9 Fuel Filter 10 DC Control Junction Box 11 Fuel Injection Lines 12 Starter 13 Thermostat Cover 14 Expansion Tank 15...

Страница 13: ...the switch and it will return to RUN position To stop the engine hold the switch in the STOP position 3 OIL PRESSURE GAUGE The oil pressure gauge shows the oil pressure in the engine lubricating syste...

Страница 14: ...s before adding load If the stand by generator set is loaded as soon as it reaches rated speed this procedure would not apply Operating 1 Check Gauges Often Oil pressure must be above 29 PSI if not ab...

Страница 15: ...the exclusion of careful gauge monitoring Watching your gauges can prevent damage to the unit and dangerous power losses 2 Do the following when your shutdown system is activated a Check the temperatu...

Страница 16: ...hours of operation with break in oil See GENERAL ENGINE SPECIFICATIONS in Break in Oil Operate the engine at heavy loads with minimal idling during the break in period idle constant speeds and or lig...

Страница 17: ...rops quickly stop the engine and determine the cause before resuming operation A Coolant Temperature Gauge RG13133 UN 07OCT03 Coolant Temperature Gauge Electronically Controlled Engine Generator Set P...

Страница 18: ...ment 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 Stop the engine and be sure PTO dr...

Страница 19: ...ttery ies for 24 volt electrical systems 1 Connect booster battery or batteries to produce the required system voltage for your engine application NOTE To avoid sparks DO NOT allow the free ends of ju...

Страница 20: ...welding reverse Steps 1 5 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 pe...

Страница 21: ...OM3 80 12 21 Notes 19...

Страница 22: ...se Ventilation Assembly Check Air Intake Hoses Connections System Replace Fuel Filter Elements Check Automatic Belt Tensioner and Belt Wear Check Cooling System Coolant Solution Analysis Add SCAs as r...

Страница 23: ...Check Engine Mounts Replace Crankcase Vent Filter If Equipped Clean Crankcase Ventilation Assembly Check Air Intake Hoses Connections System Replace Fuel Filter Elements Check Automatic Belt Tensioner...

Страница 24: ...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 the dipstick Oil levels anywhere within crosshat...

Страница 25: ...3AUG88 High Pressure Fluids RG22040 UN 28NOV12 Engine Top Tank IMPORTANT A restricted or clogged sea water strainer will result in hotter than normal or overheated engine coolant and marine gear oil t...

Страница 26: ...essive coolant leakage may indicate the need to replace the water pump seal Contact your engine distributor or servicing dealer for repairs 6 Move switch to ON position and check instruments for prope...

Страница 27: ...0 hours thereafter If John Deere PLUS 50 or ACEA E7 E6 E5 E4 engine change interval may be extended by 50 percent or to 375 hours IMPORTANT If using BIODIESEL blends greater than B20 shorten oil chang...

Страница 28: ...ling Surface On Header F Dust Seal RG22045 UN 29NOV12 Oil Filter RG11617 UN 24OCT01 Oil Filter Seals RG22046 UN 29NOV12 OIl Filter Mounting Header Northern Lights RG19661 00003D4 19 28FEB13 3 3 9 Fill...

Страница 29: ...ee 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 necessary add clean soft w...

Страница 30: ...your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 10 15 minutes Get medical attention immediately If acid is swallowed 1 Drink large amounts...

Страница 31: ...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 apart when tapped install a new zinc plug A Zinc Plugs B End Cap RG221...

Страница 32: ...gs need replacement see your John Deere dealer 4 If tensioner has been removed tighten tensioner mounting cap screw B to 70 N m 52 lb ft 5 Install belt guard A Belt Guard B Mounting Cap Screw C Tensio...

Страница 33: ...nt Filter Checking Closed Crankcase Vent System 1 Inspect hoses A B C and oil drain line D for kinks blockage or other damage sure it is not plugged 3 Verify that the crankcase vent system bypass port...

Страница 34: ...s from entering fuel system 3 Loosen drain plug and air vent screw Drain fuel into a suitable container clockwise 1 4 turn when viewed from the top to remove from base required be indexed properly wit...

Страница 35: ...bottom of fuel tank not illustrated keep debris from entering fuel system 3 Disconnect water in fuel sensor 4 Drain fuel into a suitable container E required be indexed properly with slots in mountin...

Страница 36: ...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...

Страница 37: ...serious burns cool enough to touch with bare hands Slowly before removing completely IMPORTANT Air must be expelled from cooling of cylinder head or plug in thermostat the air has been expelled 1 Chec...

Страница 38: ...ps 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 IMPOR...

Страница 39: ...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 COOLS...

Страница 40: ...ks Replace heat exchanger core as required 9 Remove and thoroughly clean water manifold heat exchanger housing if needed Install Heat Exchanger Core Thoroughly inspect condition of end cap sealing O r...

Страница 41: ...ank 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 Tighte...

Страница 42: ...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 7 Remove aftercooler core from the rear of the engine A Clamp B Clamps C Mounting Bolt...

Страница 43: ...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 Cooling System Pres sure 110kPa 16 psi 4 W...

Страница 44: ...and O ring 5 Remove clamps E and remove hoses from front cap 6 Remove four cap screws F front cap and O ring 7 Remove aftercooler core from the rear of the engine A Clamp B Clamps C Mounting Bolt D Ca...

Страница 45: ...can cause serious burns cool enough to touch with bare hands Slowly before removing completely NOTE When John Deere COOL GARD is used the drain interval is 3000 hours or 36 months The drain interval...

Страница 46: ...oing so may cause engine to overheat causing burns when cooling system is draining 8 Fill the cooling system with clean water Run the engine about 10 minutes to stir up possible rust or sediment 9 Sto...

Страница 47: ...xhaust manifold 4 Remove cap screws F attaching thermostat housing to the exhaust manifold 5 Remove thermostat housing with gasket I Remove and disgard all gasket material Clean all sealing surfaces 6...

Страница 48: ...DO NOT allow thermostat or thermometer to rest against the side or bottom of container when heating water Either may rupture if overheated 4 Suspend thermostats and a thermometer in a container of wa...

Страница 49: ...Remove cam screw B holding cam plate to impeller housing bore RG9853 UN 05JAN99 Remove Cover Plate RG6243 UN 23MAR92 Inspect Sea Water Pump Impeller A Cover Plate B Cam Screw 6 Thoroughly clean impel...

Страница 50: ...aligned Apply LOCTITE 242 to cam screw B install and tighten The cam plate should be inspected to insure that none of damage The cam screw should also be inspected to insure that it does not protrude...

Страница 51: ...r 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 coole...

Страница 52: ...ot 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 regulations or othe...

Страница 53: ...en 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 coola...

Страница 54: ...n 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 cleanings See following blocks l...

Страница 55: ...t room temperature being oiled with oil provided in kit RE504585 motor oil diesel fuel or any type light weight spray lubricant These products will damage NOTE Red dye is added to oil to show areas of...

Страница 56: ...or reset button A and release to reset indicator RG9927 UN 18NOV99 Air Restriction Indicator Reset Button Replacing Air Cleaner Filter Element IMPORTANT Replace the element after 10 cleanings RG9926 U...

Страница 57: ...pulleys or bearings need replacement see your John Deere dealer 1 Remove cap screws A and carefully remove belt guard from engine 2 Release tension on belt using a breaker bar and socket on tension a...

Страница 58: ...ers 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 T...

Страница 59: ...leaks with a piece of cardboard Protect hands and If an accident occurs see a doctor immediately removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury may call...

Страница 60: ...Inspect gear teeth for damage Install new gear D by aligning key C to the pump shaft keyway insure key is properly in place 6 Tighten hex nut to 68 N m 50 lb ft 7 Install sea water pump with new gaske...

Страница 61: ...rly If the ECU detects a problem with the electronic control 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 i...

Страница 62: ...ponents 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 T...

Страница 63: ...Connector 10 Camshaft Position Sensor Connector 11 Low Pressure Fuel Pump Connector 12 Oil Pressure Sensor Connector 13 Fuel Pressure Sensor Connector 14 Water in Fuel Sensor Connector 15 Fuel Rail P...

Страница 64: ...N BLUE RETURN RETURN 5022 J2 M1 5050 J2 L3 5050 J2 L2 4 5LEngine 5022 J2 M4 A B C02 C 5412 SE2 FOCUS16 ECU SE1 A B C07 C 5412 5412 1 3 2 MATINGVIEW OF RAIL PRESSURE CONNECTOR 5050 5050 SE1 FOCUS164 5L...

Страница 65: ...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 Ret...

Страница 66: ...5943 AUX CONNECTOR P Q R S T U V W X EXTERNAL SHUTDOWN 5941 5941 EXTERNAL DERATE 5939 5939 CONFIG SWITCH 5917 5917 C08 PWM THROTTLE 5981 5981 DROOP ISOC SWITCH 5937 5937 5050 5050 SENSOR EXCITATION 5...

Страница 67: ...s of Coolant C08 P Droop Isochronous Switch C08 Q External Derate Shut down Common C08 R PWM Throttle C08 S Air Filter Restriction C08 W Stop Lamp C08 X Single Point Ground D01 Water In Fuel Sensor J1...

Страница 68: ...E1 START 5422 D SE1 SENSOR RETURN 5814 C SENSOR RETURN 5714 S GND 5050 E CAN SHIELD 5020 F IGN 5012 G ACC 5412 J C09 L ANALOG THROTTLE 5915 M EXCITATION VOLTAGE 5V 5616 OVERRIDE SHUTDOWN RETURN 5714 P...

Страница 69: ...y 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...

Страница 70: ...J2 B1 J2 A1 B A B A C15 REMOTEON OFF PLUG SE1 ENGINESTARTCOMPONENTS 5002 5032 5032 C17 C12 12VOR24V G1 M1 C14 ALT 12V START MOTOR 12V STARTER RELAY 12VOR24V BAT S IGN 5050 SPG TVP 5082 BAT 5050 5412...

Страница 71: ...ocated Near ECU C11 Diagnostic Connector C12 Transient Voltage Protection 12 V or 24 V C13 Starter Relay Coil Ground C14 Starter Relay Coil Power C15 Remote On Off C16 Battery C17 Single Point Ground...

Страница 72: ...022 J2 M1 5050 J2 L3 5050 J2 L2 5050 4 5LEngine 5022 J2 M4 A B C02 C 5412 SE2 FOCUS14 ECU SE1 A B C07 C 5412 5412 1 3 2 MATINGVIEW OF RAIL PRESSURE CONNECTOR 5050 5050 5052 5052 INCREASE PRESSURE 01 0...

Страница 73: ...5 04 Sensor Excitation 5 V C05 05 Sensor Return C05 06 Exhaust Temperature D01 Water In Fuel Sensor J3 A2 Excitation Voltage 5 J3 B2 Excitation Return J3 C1 Analog 6 J3 C4 Analog 3 J3 F1 Analog 15 J3...

Страница 74: ...917 5917 C08 PWM THROTTLE 5981 5981 DROOP ISOC SWITCH 5937 5937 5050 5050 SENSOR EXCITATION 5V 5911 SWITCHED POWER 5012 SENSOR RETURN 5714 5050 STOP LAMP POWER 5012 SWITCH CONFIG COMMON 5012 EXT DERAT...

Страница 75: ...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 S...

Страница 76: ...ED PWR 5032 B SE1 START 5422 D SE1 SENSOR RETURN 5814 C SENSOR RETURN 5714 S GND 5050 E CAN SHIELD 5020 F IGN 5012 G ACC 5412 J C09 L THROTTLE STATION ONE 5915 M EXCITATION VOLTAGE 5V 5616 OVERRIDE SH...

Страница 77: ...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 B...

Страница 78: ...B A B A C15 REMOTEON OFF PLUG SE1 ENGINESTARTCOMPONENTS 5002 5032 5032 C17 C12 12VOR24V G1 M1 C14 ALT 12V START MOTOR 12V STARTER RELAY 12VOR24V BAT S IGN 5050 SPG TVP 5082 BAT 5050 5412 BAT A WIRING...

Страница 79: ...ocated Near ECU C11 Diagnostic Connector C12 Transient Voltage Protection 12 V or 24 V C13 Starter Relay Coil Ground C14 Starter Relay Coil Power C15 Remote On Off C16 Battery C17 Single Point Ground...

Страница 80: ...ting fuel or air in fuel system bleed fuel system Faulty injection pump or nozzles Consult authorized diesel repair station for repair or replacement Engine hard to start or will not start Engine star...

Страница 81: ...ature Defective thermostat Remove and check thermostat Defective temperature gauge or sender Check gauge sender and connections Lack of power Engine overloaded Reduce load Intake air restriction Servi...

Страница 82: ...igh oil consumption Crankcase oil too light Use proper viscosity oil Oil leaks Check for leaks in lines gaskets and drain plug Restricted crankcase vent tube Clean vent tube Defective turbocharger if...

Страница 83: ...olant tank cap Have serviceman check Stretched poly vee belt or defective belt tensioner Check automatic belt tensioner and check belts for stretching Replace as required Faulty sea raw water pump Che...

Страница 84: ...e distributor Injection nozzles dirty See your authorized servicing dealer or engine distributor Injector tip deposits Use John Deere approved biodiesel fuel conditioners containing detergents Engine...

Страница 85: ...y vee belt or defective belt tensioner Adjust belt tension or replace belt Starter will not crank PTO engaged if equipped Disengage PTO Marine gear control engaged Disengage marine gear Loose or corro...

Страница 86: ...icing Dealer 97 00 Water in Fuel Signal Continuously Detected Contact Servicing Dealer 97 03 Water in Fuel Signal Out of Range High Check Sensor and Wiring 97 04 Water in Fuel Signal Out of Range Low...

Страница 87: ...rvice Dealer 636 02 44 Engine Position Sensor Signal Unreliable Check Sensor and Wiring 636 05 Camshaft Position Circuit Has High Resistance Check Sensor and Wiring 636 06 Camshaft Position Circuit Ha...

Страница 88: ...istance Check Injector Wiring or Injector Solenoid 656 06 Injector Number 6 Circuit Has Low Resistance Check Injector Wiring or Injector Solenoid 656 13 Injector Number 6 Part Number Calibration Fault...

Страница 89: ...ealer 156 8 02 Requested Torque Curve Signal Unreliable Contact Servicing Dealer 156 9 31 47 Engine in Derate Condition Check Fault Codes 200 0 13 Security Violation Contact Servicing Dealer 350 9 03...

Страница 90: ...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...

Страница 91: ...three 3 months with no long term preparation 3 John Deere engines can be stored inside for up to six 6 months with no long term preparation 4 John Deere engines expected to be stored more than six 6 m...

Страница 92: ...g appropriate coolant See RECOMMENDED ENGINE COOLANT in Fuels Lubricants and Coolant Section and ADDING COOLANT in Service As Required Section 5 Prepare a tank with a solution of diesel fuel and rust...

Страница 93: ...tion Install 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 cle...

Страница 94: ...Idle 800 rpm kPa psi 213 31 Lubrication System Generator Applications Oil Pressure at Rated rpm 35 kPa psi 378 55 Cooling System Liquid pressurized with centrifugal pump Recommended Pressure Cap kPa p...

Страница 95: ......

Страница 96: ...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 2021 All rights reserved Litho USA...

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