5036241 JOHNSON PLATE, 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 codes.
Codes
Result: There are no codes present.
Proceed to Test Step 2.
Result: There are active codes.
Repair: Troubleshoot any active codes before continuing with this procedure.
2. 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 Quality - Test" for the proper procedure.
Fuel
Result: The fuel quality is OK.
Proceed to Test Step 3.
Result: The fuel quality is not OK.
Repair: Replace the fuel. Verify that the repair eliminated the problem.
3. Check the Fuel Injectors
A. Use Cat ET to ensure that there are not any active codes for the injector solenoids. Perform the "Cylinder Cutout Test" to check for a misfiring cylinder.
Note: Refer to Troubleshooting, "Injector Solenoid - Test" for information that is related to the test.
Use Cat ET to perform the "Fuel Rail Pressure Test" to check the mechanical condition of the fuel injectors. Refer to Troubleshooting, "Injector Solenoid - Test" for information that is related to the test.
"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 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 5.
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.
5. 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 6.
Result: The valve train components are damaged.
Repair: Make the necessary repairs. Verify that the repair eliminated the problem.
6. 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.
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).