5036162 JOHNSON SPRING

Probable Causes
Codes
Starting Aids (if applicable)
Load
Fuel Supply
Battery
Charging Circuit
StarterRecommended Actions
Table 2
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Establish communication between the Cat® Electronic Technician (ET) and the 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.
Codes
Result: An associated diagnostic trouble code is not active or logged.
Proceed to Test Step 2.
Result: An associated code is active or logged.
Repair: Troubleshoot the codes before continuing with this procedure. Refer to the appropriate procedure to troubleshoot the code.
2. Check the Operation of Starting Aids (if applicable)
A. If cold ambient conditions exist, check the operation of the starting aids.
Starting Aids
Result: The starting aid is operating correctly.
Proceed to Test Step 3.
Result: The starting aid is not operating correctly.
Repair: Refer to the appropriate circuit test to troubleshoot the starting aid.
3. Check for Excessive Loads
A. Check for an excessive load on the engine.
B. If necessary, disengage the driven equipment and test the engine.
Excessive Load
Result: The are excessive loads on the engine.
Repair: Reduce the load on the engine. Return the unit to service.
Result: The are not excessive loads on the engine.
Proceed to Test Step 4.
4. Inspect the Fuel Supply
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. Check the fuel quality.
Note: Make sure that the fuel meets the requirements of Special Publication, SEBU6250, "Caterpillar Machine Fluids Recommendations".
D. Inspect the fuel system.
Note: Refer to Systems Operation/Testing and Adjusting, "Fuel System" for additional information.
Fuel Level
Result: The fuel level is OK.
Proceed to Test Step 5.
Result: The fuel level is not OK.
Repair: Fill the tank.
If necessary, add fuel. If the engine has been run out of fuel, purge the air from the fuel system.
5. Check for a Worn Battery
A. Verify that the battery is no longer able to hold a charge. Refer to Systems Operation/Testing and Adjusting for the correct procedure.
Battery
Result: The battery will no longer hold a charge.
Repair: Replace the battery. Refer to Disassembly and Assembly for the correct procedure.
Result: The battery will hold a charge.
Proceed to Test Step 6.
6. Check for a Switched Battery Circuit
A. Inspect the battery cables, wiring, and connections in the charging circuit.
B. Verify that a switched battery circuit drained the battery by being left in the ON position.
C. Charge the battery. Verify that the battery is able to maintain a charge. Refer to Systems Operation/Testing and Adjusting for the correct procedure.
Battery Circuit
Result: The battery circuit is OK.
Proceed to Test Step 7.
Result: The battery circuit is not OK.
Repair: Clean all connections and tighten all connections. Replace any faulty parts, if necessary.
7. Inspect the Alternator
A. Inspect the condition of the alternator. Refer to Troubleshooting, "Alternator Problem" for the correct procedure.
Alternator
Result: The condition of the alternator is OK.
Proceed to Test Step 8.
Result: The condition of the alternator is not OK.
Repair: Replace or repair the alternator.
8. Inspect the Starter Engagement
A. Attempt to start the engine while you observe the status of the relay for the starting motor on Caterpillar Electronic Technician.
Starter Engagement
Result: The relay for the starting motor indicates that the engine should crank but no cranking occurs.
Repair: Troubleshoot the starting circuit.
Result: The relay for the starting motor indicates that the engine should crank and cranking occurs.
Proceed to Test Step 9.
9. Check the Crank Cycle
Note: A maximum of one crank cycle per overcrank is recommended.
A. Make sure that the engine can be cranked for enough time.
Crank Cycle
Result: The engine cannot be cranked for enough time.
Repair: Use Cat ET to check the "Cycle Crank Time" and the "Overcrank Time" parameters. Remember that the purge cycle is part of the total crank cycle. Reprogram the parameters, if necessary.
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).