0583387 JOHNSON SENSOR ASSY.

Probable Causes
Active codes and logged codes
Incorrect parameters
Accessory and/or parasitic loads
Incorrect flash file
Restriction in the air inlet and exhaust system
Proper operation of the turbocharger
Low-pressure fuel system
Fuel injectorsRecommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.Note: Engines rated for constant speed use are allowed to complete a starting sequence, an operation at a single constant speed, and a shutdown sequence. Every time the engine is run, each of these operations should occur only once. The starting sequence and shutdown sequence can include a short period of operation at the low idle speed for purposes of warming up and cooling down the engine or driven equipment. The emissions type approval is not valid for operation of a constant speed in a manner different from that described above.
Table 1
Troubleshooting Test Steps Values Results
1. Active Codes and Logged 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.
Troubleshoot any active codes before continuing with this procedure.
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. Incorrect Parameters
A. Use Cat ET to verify that the correct engine parameters are being used. Refer to Troubleshooting, "Configuration Parameters" for additional information.
B. Verify that all of the parameters for parasitic loads are correct.
Parameters
Result: The parameters are configured correctly.
Proceed to Test Step 3.
Result: The parameters are not configured correctly.
Repair: Correctly configure the parameters.
Verify that the repair eliminated the problem.
3. Accessory and/or Parasitic Loads
A. Check all accessory equipment for problems that may create excessive load on the engine.
B. Check for any excess parasitic load on the engine.
Parasitic loads
Result: There is not an excessive load on the engine.
Proceed to Test Step 4.
Result: There is an excessive load on the engine.
Repair: Diagnose the problem and then repair the problem.
Verify that the repair eliminated the problem.
4. Incorrect Flash File
A. Verify that the latest flash file is installed in the Electronic Control Module (ECM). Refer to Troubleshooting, "ECM Software - Install" for the proper procedure.
Flash file
Result: The latest flash file is installed in the ECM.
Proceed to Test Step 5.
Result: The latest flash file is not installed in the ECM.
Repair: Install the latest flash file. Verify that the repair eliminated the problem.
5. Restriction in the Air Inlet and Exhaust System
A. Check the air filter restriction indicator, if equipped. Clean plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance Manual.
B. Check the air inlet and exhaust system for restrictions and/or leaks.
Restrictions
Result: There are restrictions in the air inlet or exhaust system.
Repair: Make the necessary repairs, Verify that the repair eliminated the problem.
Result: There are no restrictions in the air inlet or exhaust system.
Proceed to Test Step 6.
6. Proper Operation of the Turbocharger
A. Check for proper operation of the turbocharger.
Turbocharger
Result: The turbocharger is operating properly.
Proceed to Test Step 7.
Result: The turbocharger is not operating properly.
Repair: Repair or replace the turbocharger. Verify that the repair eliminated the problem.
7. Low Pressure Fuel System
A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
C. Inspect the fuel system. Refer to Systems Operation/Testing and Adjusting, "Fuel System - Inspect" for additional information.
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 the filtered fuel pressure while the engine is being cranked. Refer to Troubleshooting, "Fuel Pressure Is Low" for the proper testing procedure.
Fuel system
Result: The fuel system is operating properly.
Proceed to Test Step 8.
Result: The fuel system is not operating properly.
Repair: Make the necessary repairs. Verify that the repair eliminates the problem.
8. Fuel Injectors
If service has been performed on the engine fuel system recently, verify that the injector trim files are correct. Use Cat ET to check that the injector trim files are correct for the injectors that are installed on the engine.
A. Use Cat ET to ensure that there are not any active diagnostic codes for the injector solenoids. Perform the "Cylinder Cutout Test" in order to check for a misfiring cylinder. Refer to Troubleshooting, "Injector Solenoid - Test" for information that is related to the test.
Use Cat ET to perform the "Fuel System Verification Test" in order to check the mechanical condition of the fuel injectors. Refer to Troubleshooting, "Injector Solenoid - Test" for information that is related to the test.
Injector Solenoid Test or Fuel System Verification Test
Result: The test was successful.
Return the unit to service.
Result: The test was not successful.
Repair: Diagnose the problem and then repair the problem.
Reset all active codes and clear all logged codes.
Verify that the repair eliminated the problem.