825003A 1 Mercury CABLE ASSEMBLY, DDT

Probable Causes
Active codes and logged codes
Parameters
Accessory and/or parasitic loads
Flash file
Air inlet and exhaust system
Turbocharger
Fuel system
Fuel injectors
Derate or high altitude operationRecommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in the order of the listed test steps.
Table 1
Troubleshooting Test Steps    Values    Results    
1. Active Codes and Logged Codes
A. Establish communication between Cat® Electronic Technician (Cat®ET) and the Electronic Control Module (ECM).
B. Monitor the diagnostic codes on Cat ET. Certain diagnostic codes and/or event codes may cause poor performance.
Note: Wait at least 30 seconds in order for diagnostic codes to become active.
   
Codes
   
Result: There are active codes.
Repair: Troubleshoot any codes before continuing with this procedure.
Verify that the repair eliminated the problem.
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. 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. Perform the "Injector Solenoid Test" on Cat ET in order to determine if all of the injector solenoids are being energized by the ECM.
B. Access the "Cylinder Cutout Test" in the "Diagnostic Tests" under the "Diagnostics" menu.
C. Perform the "Automatic Cylinder Cutout Test" on Cat ET.
   
Injector Solenoid 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.
   
9. Check Derate or High Altitude Operation
A. Connect Caterpillar Electronic Technician (ET) and check for logged events that derate engine power. An engine derate indicator will appear on Cat ET if an active engine derate is occurring.
B. Determine the operating conditions of the engine. Interview the operator, when possible. Determine if an excessive load was placed on the engine during the low-power complaint. Determine if the engine is operating at a high altitude.
   
Derate or Altitude
   
Result: The engine is not operating at a high altitude.
Proceed to the next step.
Result: The engine is operating at a high altitude.
Repair: Make sure that the settings for the engine are correct for the altitude.
   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).