0435616 JOHNSON DECAL SET

Operator Information
* What happened, and when?* Under what conditions? Was the engine rpm (speed) high or low?Was the engine under load?* Are there any customer or dealer installed systems that could cause this symptom?* What else occurred?* When did the symptoms begin (and what else happened at that time)?LOGGED Diagnostic Codes
* Do they correlate to probable causes?* Did they occur at the same time as the symptoms?* Are some codes Logged repeatedly?Other Symptoms
* Are they related to this symptom?* Do they have common probable causes?Finally, test each probable cause using the tests suggested by the procedure. Be sure to check connectors, especially on intermittent problems! Refer to Section 5: P-501: Inspecting Electrical Connectors for details.P-301: Engine Will Not Crank
This is NOT an electronic system problem. Refer to the Systems Operation, Testing & Adjusting Manual for additional information on the following tests. Probable root causes:* Battery Cables/Batteries* Starting motor solenoid or circuit problem (in system wiring)* Starting motor/flywheel ring gear* Transmission or Power Take-Off (PTO) problem* Engine accessory* Hydraulic cylinder lock* Internal engine problem Perform the following tests in order:1. Check Main Disconnect Switch, battery posts and battery/starter cables for loose connections and corrosion. Remove and clean cables and connections if corroded. Load test batteries, refer to Special Instruction, SEHS9249 Use Of 4C4911 Battery Load Tester. If necessary, charge the batteries. Refer to Special Instruction, SEHS7633 Battery Test Procedure.2. Test starting motor solenoid operation. Check system wiring to starting motor solenoid.3. Test starting motor operation. Refer to Systems Operation, Testing & Adjusting Manual. Inspect starting motor pinion and ring gear for damage.4. Ensure free movement of driveline. If not free, refer to the machine Systems Operation, Testing & Adjusting Manual.5. Verify timing pin was not left in the flywheel housing after setting valve lash. Use the 9S9082 Engine Turning Tool and attempt to manually turn the engine. If unable to turn the engine, remove and inspect engine accessories that can lock up the engine (air compressor, oil pump, etc). Repair or replace as necessary. Refer to the engine System Operation Testing & Adjusting Manual.6. Remove injectors and check for fluid in the cylinders.7. Disassemble engine to inspect for internal components that may be seized, broken, bent, out of alignment, etc. Refer to the Disassembly & Assembly Manual.P-302: Engine Cranks But Will Not Start
Probable root causes:* Low Fuel or Oil Level* Starting aids/fuel gel (cold temperature operation)* Emergency Stop Switch setting* An engine shutdown is Active* Machine/Engine wiring* Personality Module or ECM* Speed/Timing signal; injection timing, incorrect speed/timing wheel orientation assembly.* Injection actuation pressure* Electrical connections to the unit injector solenoids* Fuel supply: poor fuel quality or unit injector priming problem, low supply pressure, air in low pressure fuel supply circuit* Combustion problem Perform the following tests in order:1. Visually check fuel level (do not rely on fuel gauge only). Check the engine oil level. Engine oil supplies the high pressure injection actuation pump and is required for fuel injection.2. If cold ambient conditions exist, check operation of any installed starting aids. Check for presence of congealed fuel (wax).3. Make sure all Emergency Stop Switches are in the RUN position. Connect an Electronic Service Tool and verify the Ground Level Shutdown input status. If Electronic Service Tool does not operate, Refer to P-307: Electronic Service Tool Will Not Communicate With ECM. If a shutdown occurs, the keyswitch must be turned to the OFF position for at least 15 seconds, then to the ON position before the engine will start. Refer to P-507: Ground Level Shutdown Switch (Relay).4. Use an Electronic Service Tool to verify a Shutdown is not Active. If a Shutdown is Active, determine the reason for the shutdown. After correcting the problem, cycle the keyswitch to the OFF position for at least 15 seconds before trying to restart the engine. Aftermarket engine protection devices usually interrupt power to the ECM and prevent communications with the Electronic Service Tool. Check for correct installation and operation of aftermarket engine protection devices. Aftermarket devices may need to be bypassed to continue.5. Check for correct installation of the ECM connectors J1/P1 and J2/P2, Speed/Timing Sensor connectors J20/P20 and J44/P44, and Unit Injector connectors J52/P52 through J57/P57.
Exercise caution to avoid being sprayed or splashed by oil from any excessively leaking unit injector(s). Always use a board or cardboard protector when performing this test. Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury or possible death. If fluid is injected into your skin, it must be treated by a doctor familiar with this type of injury immediately!
Refer to P-501: Inspecting Electrical Connectors. If the problem occurs only after the engine is warmed up, the circuit breakers may be exceeding the trip point because of overheating. Check the circuit breakers on the machine, reset if required.6. Verify there is not an Active 253-02 Diagnostic Code. If the diagnostic code is present, refer to Section 2: Programming Parameters.7. Observe engine rpm on an Electronic Service Tool Status screen while cranking the engine. If the Electronic Service Tool displays 0 rpm while cranking the engine, there is a problem in the Speed/Timing Sensor circuit. Refer to P-514: Speed/Timing Sensor. If engine rpm is present (50 rpm or more while cranking) the Speed/Timing circuitry appears to be operating correctly. Verify that the timing reference gear is installed correctly and keyed to the camshaft by means of the locating dowel. If the gear was installed backwards or flipped over during assembly, the engine will not start. Check for proper orientation between crankshaft and camshaft drive gears, repair as required. Refer to procedure in Disassembly & Assembly Manual.8. Check for Injection Actuation Pressure System Diagnostic Codes. Crank the engine while observing the injection actuation pressure reading on the Electronic Service Tool Status Screen. If the injection actuation pressure is reaching at least 5000 kPa (725 psi), the problem is not in the Injection Actuation Pressure System. Check injection