5031567 JOHNSON HOLDER, SIDE COVER

Recommended Actions
Note: If the problem only occurs under certain conditions, test the engine under those conditions. Examples of certain conditions are high engine speed, full load and engine operating temperature. Troubleshooting the symptoms under other conditions can give misleading results.Diagnostic Codes and Event Codes
Certain diagnostic codes and/or event codes may cause poor performance. Connect Caterpillar Electronic Technician (ET) and check for active codes and/or for logged codes. Troubleshoot any codes that are present before continuing with this procedure.Cold Mode
Use Cat ET to verify that the engine has exited cold mode. Cold mode operation may cause the engine to run rough and engine power may be limited.
Observe the coolant temperature on the Cat ET status screen. Verify that the reading is valid.Decelerator Position Sensor
Monitor the signal for the decelerator position sensor on Cat ET. Verify that the signal for the sensor is stable at different set points between the low idle position and the high idle position.Electrical Connectors
Check for correct installation of the J1/P1 and J2/P2 Electronic Control Module (ECM) connectors and the unit injector connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect".Unit Injectors
Perform the "Injector Solenoid Test" on Cat ET in order to determine if all of the injector solenoids are being energized by the ECM.
Perform the "Cylinder Cutout Test" on Cat ET in order to identify any misfiring cylinder(s). Refer to Troubleshooting, "Injector Solenoids Circuit - Test" for more information.Intake Air Pressure Sensor (Boost)
Monitor the status of "Fuel Position", "Rated Fuel Limit", and "FRC Fuel Limit" on Cat ET while the engine is operating under full load. These parameters should reflect the information below.
Table 1
"Fuel Position" = "Rated Fuel Limit"    
and    
"Fuel Position" < "FRC Fuel Limit"    If "Fuel Position" equals "Rated Fuel Limit" and "Fuel Position" is less than "FRC Fuel Limit", the electronics are operating correctly. Otherwise, proceed with the next Step.
Monitor the status of "Intake Air Pressure (Boost)" and "Atmospheric Pressure" for normal operation on Cat ET. When the engine is not running, the correct value for "Intake Air Pressure (Boost)" is 0 kPa (0 psi).Air Inlet and Exhaust System
Observe the indicator lamps. Check for an air filter restriction indicator. Clean plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance Manual for additional information.
Check the air inlet and exhaust system for restrictions and/or for leaks. Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System".Parameters
If the ECM has been replaced, compare the values on the Engine Information Plate to following parameters from Cat ET:
FRC offset
Full Load Setting (FLS)
Full Torque Setting (FTS)Fuel Supply
Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines. If problems are found with the fuel lines, repair the lines and/or replace the lines.
Check the fuel tank for foreign objects which may block the fuel supply.
Check for air in the low pressure fuel supply system if any of the following procedures have been performed:
Replacement of the fuel filters
Service on the low pressure fuel supply circuit
Replacement of unit injectorsNote: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Refer to Systems Operation/Testing and Adjusting, "Air in Fuel - Test" for more information.
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
Purge air from the low pressure fuel supply circuit. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.
Cold weather adversely affects the characteristics of the fuel. Refer to Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold weather operation.
Check the fuel pressure during engine cranking. Check the fuel pressure after the fuel filter. Refer to Systems Operation/Testing and Adjusting, "Fuel System" for the correct pressure values. If the fuel pressure is low, replace the fuel filters. If the fuel pressure is still low, check the following items: fuel transfer pump, fuel transfer pump coupling and fuel pressure regulating valve.