5035199 JOHNSON PLUG, SIDE COVER

Probable Causes
Parameters
Driven equipment
Software
Inlet air restriction
Exhaust restriction
Turbocharger
Fuel system
Fuel injectorsRecommended Actions
Table 1
Troubleshooting Test Steps Values Results
1. Check for Incorrect Configuration Parameters
A. Connect Cat® Electronic Technician (ET) to the service tool connector.
B. Use Cat ET to verify that the correct parameters are being used.
Parameters
Result: The parameters are correct.
Proceed to Test Step 2.
Result: The parameters are not correct.
Repair: Input the correct parameters. Refer to Troubleshooting, "Configuration Parameters" for additional information.
If the problem is not resolved, proceed to Test Step 2.
2. Inspect the Driven Equipment
Driven Equipment
Result: The driven equipment is OK.
Proceed to Test Step 3.
Result: The driven equipment is NOT OK.
Repair: Repair or replace damaged driven equipment.
If the problem is not resolved, proceed to Test Step 3.
3. Ensure that the latest Flash File Software is Installed in the ECM
A. Connect Cat ET.
B. Use Cat ET to verify that the correct flash file is being used.
Flash File
Result: The latest flash file is installed.
Proceed to Test Step 4.
Result: The latest flash file is not installed.
Repair: Perform the following procedure:
1. Download the latest flash file from SIS web.
2. Install the software into the ECM.
Refer to Troubleshooting, "ECM Software - Install" for additional information.
If the problem is not resolved, proceed to Test Step 4.
4. Check for a Restriction in the Inlet Air System
A. Check the air filter restriction indicator, if equipped. Refer to the Operation and Maintenance Manual for additional information.
B. Measure the inlet air restriction for each turbocharger. Refer to Troubleshooting, "Inlet Air Is Restricted" for additional information.
Restriction
Result: The inlet air restriction is OK.
Proceed to Test Step 5.
Result: The inlet air restriction is NOT OK. An imbalance in the system is discovered.
Repair: Repair or replace damaged inlet air system components. Equalize the inlet air restriction for each of the turbochargers.
If the problem is not resolved, proceed to Test Step 5.
5. Check for a Restriction in the Exhaust System
A. Visually inspect the exhaust for signs of restrictions.
B. Visually inspect the Diesel Oxidation Catalyst (DOC) for restrictions.
Restriction
Result: There are no exhaust restrictions.
Proceed to Test Step 6.
Result: There are exhaust restrictions.
Repair: Repair or replace damaged exhaust system components.
If the problem is not resolved, proceed to Test Step 6.
6. Check for Proper Operation of the Turbocharger
A. Check for any oil that may be leaking into the inlet air.
Turbocharger
Result: The turbocharger is not leaking oil into the inlet air.
Proceed to Test Step 7.
Result: The turbocharger is leaking oil into the inlet air.
Repair: Repair or replace damaged turbocharger.
If the problem is not resolved, proceed to Test Step 7.
7. Inspect 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 vent in the fuel cap is not filled with debris.
C. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
Note: 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.
D. Check fuel quality. Check the fuel tank for debris or foreign objects which may block the fuel supply.
E. Check for fuel leaks.
F. Check for air in the fuel. Refer to Testing and Adjusting, "Air in Fuel - Test" for additional information.
Fuel System
Result: The fuel system is OK.
Proceed to Test Step 8.
Result: The fuel system is NOT OK.
Repair: Repair or replace damaged fuel system components.
If the problem is not resolved, proceed to Test Step 8.
8. Test the Fuel Injectors
A. Connect Cat ET.
B. Use Cat ET to perform the following fuel injector tests:
- "Injector Solenoid Test"
- "Cylinder Cutout Test"
Refer to Troubleshooting, "Cat ET Service Features" for additional information.
Fuel Injectors
Result: The tests were not successful.
Repair: Diagnose the problem. Repair or replace damaged components.
Verify that the repair eliminated the problem.
If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).