5035108 JOHNSON LEAD WIRE

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. 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.
5. Check for Hydraulic Cylinder Lock
A. If the engine will not start, check for fluid in the cylinders (hydraulic cylinder lock) by removing the individual spark plugs. Check for damaged seals. Determine the type of fluid that locked up the cylinder.
B. If there was a coolant leak, determine the cause of the leak.
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.
6. 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.