0350302 JOHNSON DECAL, "Johnson" - Front

Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in the order of the listed test steps.
Table 1
Troubleshooting Test Steps Values Results
1. Check the Engine Shutdown Switches
A. The engine shutdown switches should be in the RUN position. Ensure that the shutdown switches are in the proper positions. Use Caterpillar Electronic Technician (ET) to verify the status of the "EMCP" and the "Remote E-Stop Switch" parameters.
B. When a shutdown occurs, the Electronic Control Module (ECM) must be powered down for at least 15 seconds prior to attempting to start the engine.
Shutdown Switches
Results: The shutdown switches are OK.
Repair: Proceed to the next Step
Results: The shutdown switch is NOT OK.
Repair: Perform the necessary repairs.
If the problem is not resolved, proceed to the next step.
2. Check the Batteries
A. Inspect the batteries.
B. Charge the batteries, if necessary. Refer to Special Instruction, SEHS7633, "Battery Test Procedure".
C. Load test the batteries. Refer to Special Instruction, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8 V and 12 V Lead Acid Batteries"
Batteries
Results: The batteries are OK.
Repair: Proceed to the next Step
Results: The batteries are NOT OK.
Repair: Perform the necessary repairs.
If the problem is not resolved, proceed to the next step.
3. Check the Electric Starting System (if applicable)
A. If the application is equipped with an electric starting system, perform the following procedure:
a. Check the wiring to the starting motor solenoid. Refer to the electrical schematic.
b. Check the engine start switch and the engine start relay for electrical power.
c. Check the starting motor cables. If the starting motor cables are corroded, remove the starting motor cables and clean the starting motor cables.
d. Test the operation of the starting motors.
Starter
Results: The electric starter is OK.
Repair: Proceed to Test Step 7
Proceed to Test Step
Results: The electric starter is NOT OK.
Repair: Perform the necessary repairs.
If the problem is not resolved, proceed to the next step.
4. Check the Air Starting System (if applicable)
A. If the application is equipped with an air start system, perform the following procedure:
a. Verify that the air start system has an adequate supply pressure for starting.
b. Check the wiring to the air start relay that is for the air starting motors. Refer to the applications electrical schematic.
c. Check the engine start switch for electrical power.
d. Check the air start supply lines. If the supply lines are leaking or damaged, repair the lines.
e. Test the operation of the air start motors.
Starter
Results: The air starter is OK.
Repair: Proceed to Test Step 7
Proceed to Test Step
Results: The air starter is NOT OK.
Repair: Perform the necessary repairs.
If the problem is not resolved, proceed to the next step.
5. Check the Hydraulic Starting System (if applicable)
A. If the application is equipped with a hydraulic starting system, perform the following procedure:
a. Verify that the hydraulic starting system has an adequate supply pressure for starting.
b. Check the wiring to the start relay that is for the starting motors. Refer to the applications electrical schematic.
c. Check the engine start switch for electrical power.
d. Check the hydraulic starting lines. If the supply lines are leaking or damaged, repair the lines.
e. Test the operation of the hydraulic starting motors.
Starter
Results: The hydraulic starter is OK.
Repair: Proceed to Test Step 7
Results: The hydraulic starter is NOT OK.
Repair: Perform the necessary repairs.
If the problem is not resolved, proceed to the next step.
6. Inspect the Flywheel Ring Gear
A. Inspect the flywheel ring gear for damage.
Ring Gear
Results: The flywheel ring gear is OK.
Repair: Proceed to the next Step.
Results: The flywheel ring gear is NOT OK.
Repair: Perform the necessary repairs.
If the problem is not resolved, proceed to the next step.
7. Inspect the Transmission
A. Inspect the transmission for damage.
B. Verify that the driveline moves freely.
Transmission
Results: The transmission is OK.
Repair: Proceed to the next Step.
Results: The transmission is NOT OK.
Repair: Perform the necessary repairs.
If the problem is not resolved, proceed to the next step.
8. Inspect the PTO
A. Inspect the PTO for damage.
B. Ensure that the PTO system is operating correctly.
PTO
Results: The PTO is OK.
Repair: Proceed to the next Step.
Results: The PTO is NOT OK.
Repair: Perform the necessary repairs.
If the problem is not resolved, proceed to the next step.
9. Check the Engine Accessories
A. Remove engine accessories that may prevent the engine cranking and inspect the accessories.
B. The following accessories may prevent the engine cranking:
- Engine oil pump
- High-pressure fuel pump
Engine accessories
Result The engine accessories are OK.
Result: Proceed to the next Step
Result The engine accessories and transmission are not OK.
Repair: Perform the necessary repairs.
If the problem is not resolved, proceed to the next step.
10. Check for Hydraulic Cylinder Lock
A. If an injector has been replaced, evacuate any fluids from the cylinder and attempt to start the engine. Fuel will flow from the cylinder head into the cylinders when a unit injector is removed.
B. If the engine will not start, check for fluid in the cylinders (hydraulic cylinder lock) by removing the individual unit injectors. Check for damaged seals. Determine the type of fluid that locked up the cylinder.
C. If there was a coolant leak, determine the cause of the leak.
D. If there was excessive fuel in the cylinder, replace the seals and reinstall the injector. Drain any excess fuel from the cylinder head.
Hydraulic cylinder lock
Result: The engine does not have a hydraulic cylinder lock.
Repair: Proceed to the next Step.
Result: The engine has a hydraulic cylinder lock.
Repair: Perform the necessary repairs.
If the problem is not resolved, proceed to the next step.
11. Check for an Internal Engine Problem
A. If a mechanical problem is suspected, disassemble the engine. Refer to the Disassembly and Assembly manual. Inspect the internal components for the following conditions:
- Seizure
- Broken components
- Bent components
Mechanical problem
Result: No mechanical problem
Result: The engine has mechanical problems.
Repair: Repair or replace any worn parts. Refer to the Disassembly and Assembly manual.