61402-93821-02M Suzuki Cover Set, Engine

Troubleshooting When The Starter Is Not Operating
Table 1
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Establish communication between Cat® Electronic Technician (ET) and the Electronic Control Module (ECM).
B. Download the "Product Status Report" from the engine ECM before troubleshooting or clearing diagnostic trouble codes.
Codes
Result: Cat ET cannot connect to the engine ECM, then the machines starting circuit is not providing power to the engine ECM.
Repair: Refer to Systems Operation, Electrical System, and the section on "Starting System Circuit" for how the Engine ECM is powered on by the Machine.
Make the necessary repairs.
Result: A diagnostic trouble code is not active or logged.
Proceed to Test Step 2.
Result: A diagnostic trouble code is active or logged.
Repair: Troubleshoot the active or logged codes.
If the problem is not resolved, proceed to Test Step 2.
2. Inspection of the Batteries and Battery Cables
A. Inspect the main power switch, battery posts, and battery cables for loose connections and for corrosion. If the battery cables are corroded, remove the battery cables and clean the battery cables. Tighten any loose connections.
B. Check the resistance of the Battery+ cable to the starter.
If the resistance is less than 1Ω, that cable is OK.
C. Inspect the batteries, refer to Battery - Test.
Batteries
Result: The batteries and cables are OK.
Proceed to Test Step 3.
Result: The batteries and cables are NOT OK.
Repair: Make the necessary repairs.
If the problem is not resolved, proceed to Test Step 3.
3. Check the Starter for Proper Operation
A. Check that the starter supply voltage is 12 V.
B. Check the starter for a good ground.
C. Check the starter solenoid supply from the relay is 12 V during the cranking cycle.
For Skid Steer Loaders, Multi-Terrain Loaders, and Compact Track Loaders, the belt guard must be installed. Take necessary precautions to ensure that there is no contact with the belt.
Starter
Result: The results are OK.
Repair: Replace the starter.
Result: The results are NOT OK.
Repair: Repeat Test Step 3 to make the necessary repairs.
4. Check the Machine Starting Circuit
A. Check the starter relay for proper operation.
Refer to Systems Operation, Electrical System - Starter Operation for details on how the starter relay receives ground from the engine ECM.
Refer to the machine Electrical Schematic for how the starter relay receives 12 V supply from the machine ECM.
Machine starting circuit
Result: The machine starting circuit is OK.
Proceed to Test Step 4.
Result: The machine starting circuit is NOT OK.
Repair: Refer to the machine Electrical Schematic to troubleshoot the circuit.
If the problem is not resolved, proceed to Test Step 4.
If the problem is not resolved, contact the dealer Technical Communicator (TC). For further assistance, the TC can contact the Dealer Solution Network (DSN).Troubleshooting When The Starter Is Operating
Table 2
Troubleshooting Test Steps Values Results
1. Inspect the Starter Pinion and Flywheel Ring Gear
A. Test the operation of the starting motor.
B. Check the pinion clearance. Inspect the pinion and the flywheel ring gear for damage. Refer to Systems Operation/Testing and Adjusting, "Electrical System" for additional information.
Starter pinion and flywheel ring gear are OK
Result: The starter pinion and flywheel ring gear are OK.
Proceed to Test Step 2.
Result: The starter pinion and flywheel ring gear is not OK.
Repair: Make the necessary repairs.
If the problem is not resolved, proceed to Test Step 2.
2. Hydraulic Cylinder Lock
A. If an injector has been replaced, evacuate any fluids from the cylinder and attempt to start the engine. Fuel will flow from the cylinder head into the cylinders when a unit injector is removed.
B. If the engine will not start, check for fluid in the cylinders (hydraulic cylinder lock) by removing the individual unit injectors. Check for damaged seals. Determine the type of fluid that locked up the cylinder.
C. If there was excessive fuel in the cylinder, replace the seals and reinstall the injector. Drain any excess fuel from the cylinder head.
D. If a mechanical problem is suspected, disassemble the engine. Refer to the Disassembly and Assembly manual. Inspect the internal components for the following conditions:
1. Seizure
2. Broken components
3. Bent components
Hydraulic cylinder lock
Result: The engine has hydraulic cylinder lock.
Repair: Make the necessary repairs.
If the problem is not resolved, contact the dealer Technical Communicator (TC). For further assistance, the TC can contact the Dealer Solution Network (DSN).