816856A 1 Mercury FUEL CONNECTOR

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Customer Specified Parameters
Connect the Caterpillar Electronic Technician (Cat ET) to the data link connector.
Check the "Engine Monitoring Mode" parameter.
Verify that the "Engine Monitoring Mode" parameter is programmed to the desired option:
"Warning"
"Derate"
"Shutdown"
Check the following parameters:
"Rating Number"
"Top Engine Limit"
"Vehicle Speed Limit"
"Lower Gears Engine RPM Limit"
"Intermediate Gears Engine RPM Limit"
"Gear Down Protection Engine RPM Limit"
Set each parameter to the maximum value one at a time and determine whether the problem is corrected.Cold Mode
Note: Cold mode is normal operation if the problem occurs only after start-up in cold weather.
Monitor the status screen on Cat ET in order to verify that the engine has progressed from cold mode.An active cold mode is indicated in the upper corner of any status screen.Torque Limit Switch
Check the setting for the "Torque Limit" parameter.If the "Torque Limit" is programmed below 2712 N m (2000 lb ft), check the status screen for the torque limit switch. Ensure that the status screen indicates that the torque limit switch is off. If the status of the torque limit switch is on and a "Torque Limit" is programmed, the system is operating correctly. If the switch that is connected to this signal input is not switching on and switching off, refer to Troubleshooting, "PTO Switch Circuit - Test".Electronic System
Monitor the Fuel Position, the Rated Fuel Limit and the Fuel Limit for the Fuel Ratio Control (FRC).While the vehicle is operating under full load, the parameters should meet the following conditions:
The fuel position is equal to the rated fuel limit.
The fuel position is less than the FRC limit.If the fuel position is equal to the rated fuel limit and the fuel position is less than the FRC limit, the electronics are operating correctly. Proceed to "Vehicle Speed Signal".
If the fuel position is not equal to the rated fuel limit and/or the fuel position is not less than the FRC limit, perform the following tests in order:
When the engine is off, turn the ignition key switch to the ON position. Check the boost pressure on the status screen.When the engine is off, the correct boost pressure is 0 kPa (0 psi).Accelerator Pedal Position
Monitor the status of the accelerator pedal position sensor. Operate the engine at high idle with the vehicle in neutral.If the engine cannot reach the programmed top engine limit, check the duty cycle of the accelerator pedal position sensor. Ensure that the duty cycle of the accelerator pedal position sensor is within calibration (75 to 90 percent at high idle).If the accelerator pedal position is unstable, check the duty cycle of the accelerator pedal position sensor. Slowly operate the accelerator pedal in order to verify that the accelerator pedal position sensor is within calibration. The accelerator pedal position sensor is within calibration when both of the following conditions are met:
10 to 22 percent at low idle
75 to 90 percent at high idleAlso, ensure that the duty cycle changes as the pedal position changes. If a problem with the accelerator pedal position sensor is suspected, refer to Troubleshooting, "Accelerator Pedal (Throttle) Position Sensor Circuit - Test".Vehicle Speed Signal
Monitor the vehicle speed signal. Ensure the accuracy of the vehicle speed signal by comparing the vehicle speed signal to the actual vehicle speed.If the vehicle speed is greater than the "VSL", the power is limited. If a problem is discovered, refer to Troubleshooting, "Vehicle Speed Circuit - Test".Power Train Data Link
Check the power train data link. Ensure that the power train data link is not limiting the power.
Monitor the "Powertrain Data Link" status screen while the vehicle is experiencing problems.If the "Powertrain Data Link" status screen indicates that the data link is limiting the power or the rpm, verify that the limit is not normal operation. If the limit is not normal operation, refer to the vehicle OEM for repairs.Fuel Supply
Monitor the exhaust for smoke while the engine is being cranked.If no smoke is present, there may be a problem with the fuel quality or there may be a problem with the fuel supply.
Check the fuel quality.
Check the fuel pressure. Refer to Testing and Adjusting, "Fuel System Pressure - Test".
Ensure that the fuel system has been primed. Refer to Testing and Adjusting, "Fuel System - Prime".
Check for fuel supply lines that are restricted.
Check the fuel filters.
If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
Check for air in the fuel system. Refer to Testing and Adjusting, "Air in Fuel - Test".Air Inlet and Exhaust System
Check for leakage in the air-to-air aftercooler core . Refer to Testing and Adjusting, "Aftercooler - Test".
Check the air inlet system for restrictions or for leakage. Check the exhaust system for restrictions or for leakage. Refer to Testing and Adjusting, "Air Inlet and Exhaust System - Inspect".Individual Cylinder Problem
Ensure that the J300/P300 electronic unit injector connector is fully connected and ensure that the electronic unit injector connector is free of corrosion.
Ensure that the J2/P2 ECM connector is fully connected and ensure that the ECM connector is free of corrosion.
Perform the "Cylinder Cutout Test". Access the "Cylinder Cutout Test" by selecting the "Diagnostic Menu" and the "Diagnostics Test Menu". Run the "Cylinder Cutout Test" in order to disable each cylinder. Disabling each cylinder allows the technician to isolate the misfiring cylinders.If the misfiring cylinder can be isolated to a specific cylinder, refer to Troubleshooting, "Injector Solenoid Circuit - Test".
Perform a Performance Analysis Report (PAR).Low Injection Actuation Pressure
Check the engine oil level. Engine oil is used to activate the high pressure hydraulic pump.
Ensure that the engine oil meets the recommendations of the engine manufacturer. Refer to the Operation and Maintenance Manual for further details.
Refer to Troubleshooting, "Injection Actuation Pressure -Test".