5032963 JOHNSON WASHER (17X23X1.4mm)

Operator Information
Obtain the following information from the operator:
The problem and the time of the occurrence
Determine the conditions for the occurrence. Refer to "Data Sheet".
Determine if there are any systems that were installed by the dealer or the customer that could cause the symptom.
Determine whether any other symptoms happened in addition to the problem.Note: If the problem only occurs under certain operating conditions (high idle, full load, engine operating temperature, etc), test the engine under those conditions.Other Symptoms
If other symptoms occurred in addition to the problem, determine whether the other symptoms are related to the problem. Determine whether the symptoms and the problem have a probable cause that is common.Report the Service Information
After you have successfully repaired the engine, it is important to provide good information about the repair. The following topics are recommended for your report:Complaint - Include a description of the customer's complaint in the report.Cause - Provide a specific description of the cause of the failure. Include the method that was used in order to diagnose the problem. For example, a visual inspection revealed abrasion of a wire in a harness. Be specific: testing of the engine produced power below specifications at 1800 rpm due to the loss of an ignition transformer.Repair - Explain your repair of the problem. For example, you may have installed a new wiring harness. You may have replaced the ignition transformer per instructions from the factory.Providing complete, accurate information will help Caterpillar provide better service to you and to the customer.Data Sheet
To help troubleshoot a gas engine, complete the information in Table 1. Be sure to include the units of measurement.
Table 1
Data Sheet for Troubleshooting
Customer and installation
Engine model and driven equipment
Engine serial number Application
Service hours Compression ratio Altitude Ignition timing
LHV of fuel Methane number of fuel Fuel rate Pressure to the regulator
Differential pressure of the regulator Brand of oil and type of oil
Engine rpm Percent load Throttle angle Detonation level Air restriction
Inlet manifold air pressure Inlet manifold air temperature Location of temperature probe
Turbocharger
boost pressure left Turbocharger exhaust
temperature left Exhaust stack
pressure
right right
Exhaust stack
temperature % O2 PPM of NOx PPM of CO Brand of exhaust analyzer
Cylinder exhaust
port temperatures (1) (3) (5) (7) (9) (11) (13) (15)
(2) (4) (6) (8) (10) (12) (14) (16)
Aftercooler water
temperature in Jacket water
temperature in Engine oil
temperature in
out out out
Comments
Problem with the CAT Digital Ignition System
For information on troubleshooting the CAT Digital Ignition System, refer to Special Instruction, REHS0880, "Installation of the CAT Digital Ignition System for G3406 Engines".The Engine Will Not Crank
Probable Causes
Batteries and/or battery cables
Low air pressure
Static load
Starting motor solenoid and/or starting circuit
Starter motor pinion or flywheel ring gear
Starting motor
Electrical circuit for the oil pressure switch
Internal mechanical problemRecommended Repairs
Batteries and/or Battery Cables
Inspect the main power switch, battery posts, and battery cables for loose connections and corrosion. If the battery cables are corroded, remove the battery cables and clean the battery cables. Tighten any loose connections.
Inspect the batteries. Make sure that the capacity of the batteries is sufficient.
Charge the batteries. Refer to Special Instruction, SEHS7633, "Battery Test Procedure".
Load test the batteries. Refer to Special Instruction, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8 and 12 Volt Lead Acid Batteries". Low Air Pressure
Determine the cause of the low air pressure. Inspect the air lines for leaks. Repair any leaks in the air lines.Static Load
Make sure that the driven equipment is not preventing the crankshaft from turning. Try to turn the crankshaft by hand. If necessary, disengage the driven equipment and test the engine.Starting Motor Solenoid or Starting Circuit
All of the wiring for the starting circuit must be adequately sized. Check the wiring to the starting motor solenoid. Test the operation of the starting motor solenoid. If the solenoid does not operate properly, install a new solenoid.Starter Motor Pinion or Flywheel Ring Gear
If the pinion engages the flywheel but the flywheel does not turn, there may be a problem with the starting motor. If the starting motor turns but the flywheel does not turn, inspect the gear teeth, the clutch jaws, or other parts.Inspect the pinion and the flywheel ring gear for damage. If the teeth of the pinion and/or the flywheel ring gear are worn or broken, replace the parts.If the pinion does not engage correctly with the flywheel, the pinion shaft may be stuck. Remove the pinion. Grease the splines of the drive shaft and the pinion.If the pinion does not engage the flywheel, the clutch jaws may be broken.Starting Motor
Inspect the starting motor for worn parts.Before you remove the starting motor, turn the crankshaft