0396396 JOHNSON LEAF PLATE ASSY.

Probable Causes
Fuel
Active diagnostic codes
Automatic purge cycle
Engine shutdown switches (if applicable)
Starting aids (if applicable)
Air inlet and exhaust system
Theft deterrent system (if applicable)
Engine speed/timing
Fuel system
Injectors
Cylinder compression
CombustionRecommended Actions
Use Cat® Electronic Technician (ET) to view the "No Start Parameters" group to view parameters related to engine starting.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 Fuel System
A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
Fuel
Result: The fuel level is OK.
Proceed to Test Step 2.
Result:The fuel level is NOT OK.
Repair: Fill the tank.
If the problem is not resolved, proceed to Test Step 2.
2. Check for Active Diagnostic Codes
A. Establish communication between Cat ET and the Electronic Control Module (ECM).
B. Monitor the diagnostic codes on Cat ET. Check for active diagnostic codes. Specifically check for codes related to the fuel system, the engine speed/timing sensors, and the fuel injectors.
Note: Wait at least 30 seconds in order for diagnostic codes to become active.
Active Diagnostic Codes
Result: There are active codes.
Repair: Troubleshoot any active codes before continuing with this procedure.
Result: There are no active codes.
Proceed to Test Step 3.
3. Check for Engine E-Stop or Unexpected Shutdown
A. Verify that the engine E-Stop is not active.
B. Check the engine for an unexpected shutdown.
E-Stop or Unexpected Shutdown
Result: The E-Stop not is on.
Continue with Test Step 3.
Result: The E-Stop is on.
Repair: Turn the E-Stop in the off position. The engine will complete an automatic purge cycle.
Result: There was not an unexpected shutdown.
Proceed to Test Step 4.
Result: There was an unexpected shutdown.
Repair: Make the necessary repairs. The engine will complete an automatic purge cycle.
If the problem is not resolved, proceed to Test Step 4.
4. Check the Engine Shutdown Switches (if applicable)
A. The engine shutdown switches must be in the OFF position.
Switches are in the OFF Position
Result: The switches are in the OFF position.
Proceed to Test Step 5.
Result: The switches are not in the OFF position.
Repair: Turn the switches to the OFF position. STOP.
If the problem is not resolved, proceed to Test Step 5.
5. Check the Starting Aids (if applicable)
A. If cold ambient conditions exist, check the operation of the starting aids.
Starting Aids are Operational
Result: The starting aid is operating correctly.
Proceed to Test Step 6.
Result: The starting aid is not operating correctly.
Repair: Refer to the appropriate diagnostic test in order to troubleshoot the starting aid.
If the problem is not resolved, proceed to Test Step 6.
6. Restrictions in the Air Inlet and Exhaust System
A. Check for an air filter restriction indicator (if applicable).
B. Check the air inlet and exhaust system for restrictions and/or leaks.
Air and Exhaust System Restrictions
Result: There are no system restrictions.
Proceed to Test Step 7.
Result: There are system restrictions.
Repair: Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System" for additional information on the air inlet and exhaust systems.
Replace plugged air filters. Refer to the Operation and Maintenance Manual for the correct procedure.
If the problem is not resolved, proceed to Test Step 7.
7. Check the Theft Deterrent System (if applicable)
A. Verify that the theft deterrent system is not active.
Theft System is Inactive.
Result: The theft deterrent system is not active.
Proceed to Test Step 8.
Result: The theft deterrent system is active.
Repair: Turn the theft deterrent system OFF.
If the problem is not resolved, proceed to Test Step 8.
8. Engine Speed/Timing
A. Crank the engine and observe the engine speed on the Cat ET status screen. Refer to Troubleshooting, "Speed/Timing - Test" for additional information.
B. Upon initial cranking, the status for engine speed may indicate that the engine speed signal is abnormal. This message will be replaced with an engine speed once the ECM is able to calculate a speed from the signal.
Timing Signal
Result: The timing sensor is OK.
Proceed to Test Step 9.
Result: The timing sensor is NOT OK.
Repair: Refer to Troubleshooting, "Speed/Timing - Test" for troubleshooting information.
If the problem is not resolved, proceed to Test Step 9.
9. Fuel System
A. Inspect the fuel system. Refer to Systems Operation/Testing and Adjusting, "Fuel System" for additional information.
B. Cold weather adversely affects the characteristics of the fuel. Refer to the engines Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold-weather operation.
C. Check fuel quality. Refer to Systems Operation/Testing and Adjusting, "Fuel System" for the proper procedure. Check the fuel tank for debris or foreign objects which may block the fuel supply.
D. Check the filtered fuel pressure while the engine is being cranked. Refer to Systems Operation/Testing and Adjusting, "Fuel System" for the test procedure and for the correct pressure values.
If the fuel pressure is low, replace the fuel filters. Clean the primary filter/water separator of debris. Refer to the Operation and Maintenance Manual for details.
E. Check for the proper operation of the fuel transfer pump. Refer to Systems Operation/Testing and Adjusting, "Fuel System" for test information.
Fuel System
Result: The fuel system is OK.
Proceed to Test Step 10.
Result: The fuel system is NOT OK.
Repair: Make the necessary repairs.
If the problem is not resolved, proceed to Test Step 10.
10. Check the Fuel Injectors
A. Use Cat ET to perform the "Injector Solenoid Test" to identify electrical problems in the fuel injection system.
Injector Solenoids
Result: Cat ET reports that all injector solenoids are OK.
Proceed to Test Step 11.
Result: Cat ET reports "Short" or "Open" for one or more injector solenoids.
Repair: Refer to Troubleshooting, "Injector Solenoid - Test" for troubleshooting information.
If the problem is not resolved, proceed to Test Step 11.
11. Low Cylinder Compression
A. Perform a compression test on each cylinder.
Cylinder Compression
Result: At least one cylinder is NOT OK.
Repair: Identify the cause of the low compression. Possible causes of low compression include the following:
- Faulty piston
- Faulty piston rings
- Worn cylinder bores
- Worn valves
- Faulty cylinder head gasket
- Damaged cylinder head
Perform the necessary repairs.
Verify that the repair eliminated the problem.
Result: The compression for each cylinder is OK.
Proceed to Test Step 12.
12. Combustion Problems
A. Check for mechanical problems that may contribute to poor combustion.
Cylinder Combustion
Result: Problems that contribute to