5005728 Service Manual - French JOHNSON
J55WRLSRB
Service
Price: query
Rating:
Number on catalog scheme:
Compatible models:
J55WRLSRB
JOHNSON
BRP JOHNSON entire parts catalog list:
Information:
Introduction
Table 1
Revision History
Revision Summary of Changes
06 Added Effectivity
05 Added prefix, GK6, ME6, PF6, S7E, TE9, W6E, Z9E, BT9, K56, K57, K58, GZ8, GW8, GG8, GG9, GX8, GK8, GWT.
04 Added prefix K2D, HFB, D5T, LW5, PN5, RE5, TP5, WE5 The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is stated below.Problem
The machines that are listed above may experience one of the issues that are stated below.
No start situation
Engine ECM unavailable in Cat® Electronic Technician (ET)
Inability to flash the ECM using ERTECM failures are rare and these issues are typically due to the machine starting circuit, machine low-pressure fuel system, or improper flashing.Solution
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Table 2
Troubleshooting Test Steps Value Results
1. Determine the Diagnostic Code.
A. Establish communication between Cat® Electronic Technician (ET) and the ECM. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Check for active codes and check for logged codes on Cat ET.
C. Check Cat ET for any associated codes. Troubleshoot any active codes before continuing with this procedure.
Diagnostic code
Result: An associated code is active or logged.
Repair: Troubleshoot any associated codes before continuing with this procedure.
Result: An associated code is not active or logged.
Proceed to Test Step 2.
2. Check the Machine Electrical System.
A. Check that Cat ET can connect to the engine ECM with Key Switch ON.
Machine electrical system
Result: Cat ET can connect to the engine ECM, then the engine ECM is turned on.
Proceed to Test Step 3.
Result: Cat ET cannot connect to the engine ECM, and the machines starting circuit is not providing power to the engine ECM.
Repair: Go to Troubleshooting, "Electrical Power Supply - Test".
Check all grounds on the engine harness. This includes ground wires attached to the engine block, battery, and chassis ground studs. There have been known instances where ground wires were found loose, broken, or faulty through rust or paint.
For the 308E2, the engine ECM is typically being ordered, when PI32292 is being performed and the engine ECM did not flash. If the flashing procedure was not followed properly, it will appear that the engine ECM is dead since it cannot be seen by Cat ET. However, it can still be flashed by following Special Instruction, REHS9223, "Obtaining a DPK Flash File and Flashing Procedure with the Engine Reprogramming Tool" steps.
3. Check 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. Inspect the fuel system for external leaks. Ensure that there is no air in the clear bowl on the primary fuel filter.
D. Check that there are no external leaks, no air in the clear primary fuel filter. Change the primary fuel filter and the in-line filter for the fuel transfer pump.
E. Check fuel quality. Refer to Testing and Adjusting, "Fuel Quality - Test", for the proper procedure. Check the fuel tank for debris or foreign objects which may block the fuel supply.
F. Check for the proper operation of the fuel transfer pump. Replace the pre-filter if excessive contamination or if the maintenance interval is exceeded. Refer to Testing and Adjusting, "Fuel System", for test information.
Confirm fuel flow rate from transfer pump (dead head the pump for correct results):
SSL, MTL, CTL, and CWL - .5 gal per min @ 12 psi MHE - .09 gal per min @ 5 psi
Fuel Level
Result: The fuel system is OK.
Proceed to Test Step 4.
Result: The fuel system is not OK.
Repair: Replace the fuel filters. Clean the primary filter/water separator of debris. Refer to the Operation and Maintenance Manual for details.
4. Restrictions in the Air Inlet and Exhaust System.
A. Check for an air filter restriction indicator.
B. Check the air inlet and exhaust system for restrictions and/or leaks. To test the exhaust system, the DOC inlet temperature sensor can be removed to ensure the DOC/DPF are not plugged.
Air and exhaust system restrictions
Result: There are no system restrictions.
Proceed to Test Step 5.
Result: There are system restrictions.
Repair: Refer to Systems Operation, "Air Inlet and Exhaust System", for additional information on the air inlet and exhaust systems.
Replace plugged air filters. Refer to the Operation and Maintenance Manual for the correct procedure. If the DOC and/or DPF are plugged and not at the 3000 hour service interval, determine the root cause of premature plugging. Submit a DSN ticket if technical assistance is needed.
5. Swap Engine ECM with another similar machine.
A. Swapping an engine ECM is recommended to troubleshoot a true engine ECM failure before ordering a new engine ECM.
Engine ECMs can only be swapped with the same engine model.
Prefixes SSL, MTL, CTL, and CWL can be temporarily swapped. SSL, MTL, and CTL machines that are XHP can only be interchanged with each other.
MHE engine ECM cannot be swapped with other product families.
Note: Machine sales models that have the C3.3B engines that use the 436-0821 Monitoring Control are:
236D, 242D, 246D, 257D, 259D, 262D, 277D, 279D, 287D, 289D, 906M, 907M, 908M, 308E
Machine sales models that have the C3.8 engines that use the 392-4121 Electronic Control Gp are:
272D, 272D XHP, 299D, 229D XHP, 910K, 914K
Machine sales models that have the C3.8 Tier 4 Final engines that use the 458-9392 Electronic Control Gp are:
272D2, 272D2 XHP, 297D2, 297D2 XHP, 299D2, 299D2 XHP
Engine ECM
Result: The engine ECM from another machine resolves issue.
Repair: Verify that the problem is resolved, submit a DSN ticket with the completed troubleshooting results and PSR prior to ordering an engine ECM. This will help document any trends or potential issues to the product group.
Result: The ECM swap does not resolve issue.
STOP 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).
Table 1
Revision History
Revision Summary of Changes
06 Added Effectivity
05 Added prefix, GK6, ME6, PF6, S7E, TE9, W6E, Z9E, BT9, K56, K57, K58, GZ8, GW8, GG8, GG9, GX8, GK8, GWT.
04 Added prefix K2D, HFB, D5T, LW5, PN5, RE5, TP5, WE5 The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is stated below.Problem
The machines that are listed above may experience one of the issues that are stated below.
No start situation
Engine ECM unavailable in Cat® Electronic Technician (ET)
Inability to flash the ECM using ERTECM failures are rare and these issues are typically due to the machine starting circuit, machine low-pressure fuel system, or improper flashing.Solution
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Table 2
Troubleshooting Test Steps Value Results
1. Determine the Diagnostic Code.
A. Establish communication between Cat® Electronic Technician (ET) and the ECM. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Check for active codes and check for logged codes on Cat ET.
C. Check Cat ET for any associated codes. Troubleshoot any active codes before continuing with this procedure.
Diagnostic code
Result: An associated code is active or logged.
Repair: Troubleshoot any associated codes before continuing with this procedure.
Result: An associated code is not active or logged.
Proceed to Test Step 2.
2. Check the Machine Electrical System.
A. Check that Cat ET can connect to the engine ECM with Key Switch ON.
Machine electrical system
Result: Cat ET can connect to the engine ECM, then the engine ECM is turned on.
Proceed to Test Step 3.
Result: Cat ET cannot connect to the engine ECM, and the machines starting circuit is not providing power to the engine ECM.
Repair: Go to Troubleshooting, "Electrical Power Supply - Test".
Check all grounds on the engine harness. This includes ground wires attached to the engine block, battery, and chassis ground studs. There have been known instances where ground wires were found loose, broken, or faulty through rust or paint.
For the 308E2, the engine ECM is typically being ordered, when PI32292 is being performed and the engine ECM did not flash. If the flashing procedure was not followed properly, it will appear that the engine ECM is dead since it cannot be seen by Cat ET. However, it can still be flashed by following Special Instruction, REHS9223, "Obtaining a DPK Flash File and Flashing Procedure with the Engine Reprogramming Tool" steps.
3. Check 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. Inspect the fuel system for external leaks. Ensure that there is no air in the clear bowl on the primary fuel filter.
D. Check that there are no external leaks, no air in the clear primary fuel filter. Change the primary fuel filter and the in-line filter for the fuel transfer pump.
E. Check fuel quality. Refer to Testing and Adjusting, "Fuel Quality - Test", for the proper procedure. Check the fuel tank for debris or foreign objects which may block the fuel supply.
F. Check for the proper operation of the fuel transfer pump. Replace the pre-filter if excessive contamination or if the maintenance interval is exceeded. Refer to Testing and Adjusting, "Fuel System", for test information.
Confirm fuel flow rate from transfer pump (dead head the pump for correct results):
SSL, MTL, CTL, and CWL - .5 gal per min @ 12 psi MHE - .09 gal per min @ 5 psi
Fuel Level
Result: The fuel system is OK.
Proceed to Test Step 4.
Result: The fuel system is not OK.
Repair: Replace the fuel filters. Clean the primary filter/water separator of debris. Refer to the Operation and Maintenance Manual for details.
4. Restrictions in the Air Inlet and Exhaust System.
A. Check for an air filter restriction indicator.
B. Check the air inlet and exhaust system for restrictions and/or leaks. To test the exhaust system, the DOC inlet temperature sensor can be removed to ensure the DOC/DPF are not plugged.
Air and exhaust system restrictions
Result: There are no system restrictions.
Proceed to Test Step 5.
Result: There are system restrictions.
Repair: Refer to Systems Operation, "Air Inlet and Exhaust System", for additional information on the air inlet and exhaust systems.
Replace plugged air filters. Refer to the Operation and Maintenance Manual for the correct procedure. If the DOC and/or DPF are plugged and not at the 3000 hour service interval, determine the root cause of premature plugging. Submit a DSN ticket if technical assistance is needed.
5. Swap Engine ECM with another similar machine.
A. Swapping an engine ECM is recommended to troubleshoot a true engine ECM failure before ordering a new engine ECM.
Engine ECMs can only be swapped with the same engine model.
Prefixes SSL, MTL, CTL, and CWL can be temporarily swapped. SSL, MTL, and CTL machines that are XHP can only be interchanged with each other.
MHE engine ECM cannot be swapped with other product families.
Note: Machine sales models that have the C3.3B engines that use the 436-0821 Monitoring Control are:
236D, 242D, 246D, 257D, 259D, 262D, 277D, 279D, 287D, 289D, 906M, 907M, 908M, 308E
Machine sales models that have the C3.8 engines that use the 392-4121 Electronic Control Gp are:
272D, 272D XHP, 299D, 229D XHP, 910K, 914K
Machine sales models that have the C3.8 Tier 4 Final engines that use the 458-9392 Electronic Control Gp are:
272D2, 272D2 XHP, 297D2, 297D2 XHP, 299D2, 299D2 XHP
Engine ECM
Result: The engine ECM from another machine resolves issue.
Repair: Verify that the problem is resolved, submit a DSN ticket with the completed troubleshooting results and PSR prior to ordering an engine ECM. This will help document any trends or potential issues to the product group.
Result: The ECM swap does not resolve issue.
STOP 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).
Parts service JOHNSON:
5005646