0433226 JOHNSON MOTOR & CABLE AY

Recommended Actions
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.
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Diagnostic Codes
A. Download the Histograms before performing any troubleshooting or clearing any diagnostic codes.
Note: The downloaded information will be required by the Dealer Solutions Network (DSN) if troubleshooting assistance is needed.
B. Use the electronic service tool to check for active or logged codes.
Diagnostic codes
Result: A diagnostic code is present.
Repair: Troubleshoot the code and then reset the histogram. Refer to Troubleshooting, Diagnostic Trouble Codes or Troubleshooting, Event Codes.
Result: A diagnostic code is not present.
Proceed to Test Step 2.
2. Visible Faults
A. Check that the fuel supply valve (if equipped) is in the OPEN position.
B. Check for the correct level of fuel, oil, and coolant.
C. Check for water in the primary fuel filter/water separator.
D. If the ambient temperature is below 0 °C (32 °F), check the specification of engine oil and oil for the machine.
E. Visually inspect the engine for the following faults:
Missing components
Damaged components
Damaged electrical cables or loose electrical cables
Oil leaks
Fuel leaks
All fuel filters are correctly installed.
F. Check that the battery voltage is correct.
G. Use the electronic service tool to check the average cranking speed of the engine.
Visible faults
Result: The fuel supply valve (if equipped) is not in the OPEN position.
Repair: Move the fuel supply valve to the OPEN position.
Result: The level of fuel, oil, or coolant is not correct.
Repair: Replenish any fluids with an incorrect level.
Result: Water is present in the primary fuel filter/water separator.
Repair: Drain any water from the primary fuel filter/water separator.
Result: The correct specification of engine oil and oil for the machine is not in use.
Repair: Replenish the system with oil of the correct specification for the ambient conditions.
Result: Battery voltage is low.
Repair: Check the batteries. Refer to Troubleshooting, "Battery Problem".
Result: The cranking speed is less than 150 rpm.
Repair: Investigate the cause of the low cranking speed and rectify, as necessary.
Note: If the DPF frequently collects excessive soot prior to this fault, there may be a faulty cylinder in the engine. Proceed to Test Step 12.
Result: All checks are OK.
Proceed to Test Step 3.
3. Check the "Engine Starting" Screen on the Electronic Service Tool
A. Use the electronic service tool to check the "Engine Starting" screen while cranking the engine.
B. Check that the battery voltage is greater than 9 V for a 12 V system or 18 V for a 24 V system.
C. Check that the engine speed is greater than 150 rpm.
D. Check that the "Injector Disable" parameter is set to "Off".
E. Check that the "Fuel Rail Pressure" is greater than 25 MPa (3625 psi).
F. Check that the "Primary Engine Speed Sensor Timing Pattern Status" and "Secondary Engine Speed Sensor Timing Pattern Status" indicate "Detected".
"Engine Starting" screen
Result: The battery voltage is low.
Repair: Refer to Troubleshooting, Electrical Power Supply - Test.
Result: The engine cranking speed is less than 150 rpm.
Repair: Refer to Troubleshooting, Engine Does not Crank.
Result: The "Injector Disable" parameter is not set to "Off".
Repair: Proceed to Test Step 11.
Result: The "Fuel Rail Pressure" is less than 25 MPa (3625 psi).
Proceed to Test Step 6.
Result: The "Primary Engine Speed Sensor Timing Pattern Status" or "Secondary Engine Speed Sensor Timing Pattern Status" does not indicate "Detected".
Proceed to Test Step 5.
Result: All parameters on the "Engine Starting" screen are OK.
Proceed to Test Step 4.
4. Air Intake and Exhaust System
A. Check the air filter restriction indicator, if equipped.
B. Check the air intake and exhaust systems for the following defects:
Blockages
Restrictions
Damage to lines or hoses
Air and Exhaust System restrictions
Result: The air filter is restricted.
Repair: Replace the air filter.
Result: There are system restrictions.
Refer to Systems Operation, Testing and Adjusting, "Air Inlet and Exhaust System" for additional information on the air inlet and exhaust systems.
Result: The air intake and exhaust system are OK.
Proceed to Test Step 5.
5. Speed/Timing Sensors
A. Crank the engine and observe the engine speed on the electronic service tool status screen.
Note: 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.
Speed/timing sensor
Result: The speed/timing sensors are not operating correctly.
Repair: Test the speed/timing sensors. Refer to Troubleshooting, "Speed/Timing - Test".
Result: The speed/timing sensors are operating correctly.
Proceed to Test Step 6.
6. Starting Aids
A. Check the operation of the glow plugs. Refer to Troubleshooting, "Glow Plug Starting Aid - Test".
B. If equipped, check the operation of the ether starting aid. Refer to Troubleshooting, "Ether Starting Aid - Test".
Starting aids
Result: One or more of the glow plugs are faulty.
Repair: Replace any faulty glow plugs. Refer to Disassembly and Assembly, "Glow Plug - Remove and Install".
Check that the engine starts normally.
If the engine will not start, proceed to Test Step 7.
Result: The ether starting aid is faulty.
Repair: Diagnose the ether system. Refer to Troubleshooting, "Ether Starting Aid - Test".
Check that the engine starts normally.
If the engine will not start, proceed to Test Step 7.
7. Low-Pressure Fuel System
A. Visually check the fuel tank for fuel.
Note: The fuel gauge may be faulty.
B. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
C. Check the primary filter/water separator for water in the fuel.
D. Check for fuel supply lines that are restricted or not correctly installed.
E. Check that the electric fuel priming pump is operating correctly.
F. Check for air in the fuel system and that the fuel system is primed.
G. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".
Low-pressure fuel system
Result: The fuel tank level is low.
Repair: Fill the fuel tank.
Result: The fuel contains solidified wax.
Repair: Replace the fuel with fuel of the correct specification for the ambient conditions.
Replace any filters and/or screens in the fuel system. Refer to Operation and Maintenance Manual for further information.
Result: There are fuel supply lines that are restricted or not correctly installed.
Repair: Install the fuel lines correctly. Replace