815026 1 Mercury COTTER PIN

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 the appropriate publication:
Special Instruction, REHS0880, "Installation of the CAT Digital Ignition System for G3406 Engines"
Special Instruction, REHS0476, "Installation Instructions for the CAT Digital Ignition System for G3408 and G3412 Engines"Problem with the Electronic Ignition System (EIS)
For information on troubleshooting the EIS, refer to Electronic Troubleshooting, SENR6535, " G3408C & G3412C 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.