5036240 JOHNSON LEVER, CLUTCH NOTCH

Recommended Actions
Table 1
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Establish communication between Cat® Electronic Technician (ET) and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Warranty Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
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 2.
2. Check the Electrical Connections
A. Check for the correct installation of the ECM J1/P1 and the J2/P2 connectors. Check for correct installation of the fuel injector connectors.
Connectors
Result: There are suspect connectors.
Repair: Repair connectors that are suspect or replace connectors that are suspect.
Perform the "Wiggle Test" on Cat ET.
Result: There are no suspect connectors.
Proceed to Test Step 3.
3. Check the Fuel Injection
A. Perform the "Fuel Rail Pressure Test" in the "Diagnostic Tests" under the "Diagnostics" menu.
"Fuel Rail Pressure Test"
Result: The test was successful.
Proceed to Test Step 4.
Result: The test was not successful.
Repair: Diagnose the problem and then repair the problem. Reset all the codes. Verify that the repair eliminated the problem.
4. Check the Fuel Quality
A. Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel for the engine. If necessary, obtain a fuel analysis to confirm that the correct fuel is being used for the engine. Refer to Systems Operation/Testing and Adjusting, "Fuel System Quality Test" for the proper procedure.
Fuel quality
Result: The fuel quality is OK.
Proceed to Test Step 5.
Result: The fuel quality is not OK.
Repair: Replace the fuel. Verify that the repair eliminated the problem.
5. Inspect for Proper Lubrication
A. Check for proper lubrication of the valve components. Check for sufficient lubrication between the injector tappets and the rocker arms.
B. Check for blocked oil passages. Oil passages must be clean. Clean any oil passages that are questionable. Refer to the Disassembly and Assembly for additional information.
C. Inspect the engine oil filters for ferrous material.
D. Obtain an S-O-S oil analysis. The analysis will contribute to a better understanding of oil contamination and the origin of the contamination.
Lubrication
Result: The oil passages are not blocked and the engine has proper lubrication.
Proceed to Test Step 6.
Result: The oil passages are blocked or the engine does not have proper lubrication.
Repair: Make the necessary repairs, Verify that the repair eliminated the problem.
6. Isolate the Source of the Noise
A. If the source of the noise is the engine accessory, remove the suspect engine accessory. Inspect the suspect engine accessory.
Engine Accessory
Result An engine accessory is the source of the noise.
Repair: Repair the engine accessory and/or replace the engine accessory, if necessary.
Result An engine accessory is not the source of the noise.
Proceed to Test Step 7.
7. Inspect the Valve Train Components
A. Check the valve lash. Refer to Troubleshooting, "Valve Lash Is Excessive".
B. Check for damage to valve train components. Remove the valve cover from the suspect cylinders. Check the following items for damage:
- Camshaft
- Valve rotocoil
- Valve springs
- Camshaft followers
- Rocker shaft
- Bridges
- Pushrods
- Injectors
C. Check for valves that do not move freely. Remove the cylinder head and inspect the valves.
Note: Refer to the Disassembly and Assembly for additional information.
Valve Train
Result: The valve train components are not damaged.
Proceed to Test Step 8.
Result: The valve train components are damaged.
Repair: Make the necessary repairs, Verify that the repair eliminated the problem.
8. Inspect the Gear Train and Components of the Lower End
Gear Train
Result: The gear train or lower end components are damaged.
Repair: Replace any damaged parts.
Result: The gear train or lower end components are not damaged.
Proceed to Test Step 9.
9. Inspect the Crankshaft
A. Inspect the crankshaft and the related components. Look for worn thrust plates and wear on the crankshaft.
B. Inspect the connecting rod bearings and the bearing surfaces on the crankshaft. Make sure that the bearings are in the correct position.
C. Check the counterweight bolts.
Crankshaft
Result: The crankshaft or the related components are damaged or worn.
Repair: Repair or replace any damaged parts. Verify that the repair eliminated the problem.
If this procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solution Network (DSN).