5032231 JOHNSON PISTON

Probable Causes
Engine operation
Diagnostic codes, event codes and derates
Fuel quality
Fuel injection
Engine speed/timing
Air inlet and exhaust system
Check for damaged accessory equipmentRecommended Actions
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Note: Fuel consumption may also be affected by environmental conditions such as wind and snow.
Table 1
Troubleshooting Test Steps Values Results
1. Engine Operation
Use Cat® Electronic Technician (ET) to check the "Current Totals" for excessive idle time and/or for a high load factor. Excessive idle time and/or for a high load factor would be indicative of poor operating habits.
Operation
Result: Excessive idling is not indicated.
Proceed to Test Step 2.
Result: Excessive idling is indicated.
Repair: Make the necessary changes. Ensure that the problem is resolved.
2. Check for Codes and Derates
A. Connect Cat ET and download the "Warranty Report" from the engine Electronic Control Module (ECM) before performing any troubleshooting or clearing diagnostic trouble codes.
B. Wait at least 30 seconds in order for any codes to become active.
Codes and Derates
Result: No codes are active.
Proceed to Test Step 3.
Result: Codes are active.
Repair: Troubleshoot the codes that are present.
Proceed to Test Step 3.
3. Check the Fuel Quality
Note: Cold weather adversely affects the characteristics of the fuel.
Poor Fuel Quality
Result: Fuel quality is desirable.
Proceed to Test Step 4.
Result: Fuel quality is undesirable.
Repair: Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold-weather operation. Ensure that the problem is resolved.
4. Check the Fuel Injection
A. Perform the "Fuel Rail Pressure Test" in Cat ET. Refer to Troubleshooting, "Injector Solenoid - Test".
"Fuel Rail Pressure Test"
Result The "Fuel Rail Pressure Test" completed successfully.
Proceed to Test Step 5.
Result The "Fuel Rail Pressure Test" failed.
Repair: Diagnose the problem and then repair the problem. Clear all logged diagnostic codes. Verify that the repair eliminated the problem.
5. Check the Engine Speed/Timing
A. Perform a speed/timing sensor calibration. Refer to the calibration procedure Troubleshooting, "Timing - Calibrate".
Engine Speed/Timing
Result The speed/timing sensor calibration completed successfully.
Proceed to Test Step 6.
Result The speed/timing sensor calibration failed.
Repair: Resolve the issue. Ensure that the problem is resolved.
6. Inspect the Air Inlet and Exhaust System
A. Inspect the air filter for a restriction. If the air filter shows signs of plugging, clean the air filter or replace the air filter.
B. Check the air inlet and exhaust system for restrictions and/or for leaks. Refer to Systems Operation/Testing and Adjusting.
C. Check the turbocharger and exhaust balance valve. Refer to Troubleshooting, "Exhaust Balance Valve - Test".
Air inlet and Exhaust System
Result The air inlet and exhaust system is functioning correctly.
Proceed to Test Step 7.
Result The air inlet and exhaust system is not functioning correctly.
Repair: Make the proper repairs. Ensure that the problem is resolved.
7. Check for Damaged Accessory Equipment
A. Check all accessory equipment for problems that may create excessive load on the engine.
Damaged Accessory Equipment
Result Problems have been found with the accessory equipment.
Repair: Repair any damaged components or replace any damaged components.
Result No problems have been found with the accessory equipment.
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).