11338A88 Mercury GASKET SET, Engine Overhaul

Recommended Actions
Table 1
Troubleshooting Test Steps Values Results
1. Check the Engine Shutdown Switches (If Applicable)
A. The engine shutdown switches should be in the OFF position. Ensure that the shutdown switches are in the correct position by verifying with Caterpillar Electronic Technician (ET).
B. When a shutdown occurs, the Electronic Control Module (ECM) must be powered down for at least 15 seconds prior to attempting to start the engine.
If Cat ET will not communicate with the Electronic Control Module (ECM), the problem is most likely with the electrical power supply to the ECM. Refer to the diagnostic functional test Troubleshooting, "Electrical Power Supply Circuit - Test".
Shutdown Switches
Result: The shutdown switches are OK.
Proceed to Test Step 2.
Result: The shutdown switch is NOT OK.
Repair: Perform the necessary repairs and return to service.
2. Check the Circuit Breakers
A. Check the state of each of the circuit breakers.
Circuit Breaker
Result: The circuit breaker has not tripped and is in good working condition.
Proceed to Test Step 2.
Result: The circuit breaker has tripped and/or is not in good working condition.
Repair: Reset the circuit breakers if the circuit breakers are tripped. Prior to returning the engine to service, determine the condition that caused the circuit breaker to trip. Perform the necessary repairs and return to service.
3. Inspect the Battery Cables and/or Batteries
A. Inspect the battery disconnect switch, bus bars, battery posts, and battery cables for loose connections and corrosion.
B. Inspect the batteries.
C. Charge the batteries, if necessary. Refer to Special Instruction , REHS7633, "Battery Test Procedure".
D. Load test the batteries. Refer to Special Instruction, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8, and 12 V Lead Acid Batteries."
Battery
Result: The batteries, battery disconnect switch, bus bars, battery posts, and battery cables are corrosion free and working properly.
Proceed to Test Step 3.
Result: The batteries, battery disconnect switch, bus bars, battery posts, and battery cables have corrosion and are not working properly.
Repair: Perform the necessary repairs and return to service.
4. Check the Starting Circuit
A. Test the operation of the starting motor and associated circuit components.
Starting Circuit
Result: The operation of the starting motor and associated circuit components are functionally correctly.
Proceed to Test Step 5.
Result: The operation of the starting motor and associated circuit components are not functionally correctly.
Repair: Perform the necessary repairs and return to service. Refer to the Systems Operation and Testing and Adjusting manual.
5. Check the Driven Equipment and/or Engine Accessories
A. Ensure free movement of the driveline.
B. Ensure that timing pin was not left in the flywheel housing.
C. Remove any engine accessories that may lock up the engine.
D. Inspect the condition of the accessories. The following list illustrates examples of engine accessories that may lock up the engine:
- Fuel transfer pump
- Air compressor
- Engine oil pump
Driven Equipment and/or Engine Accessories
Result: The driven equipment and/or engine accessories are properly working.
Proceed to Test Step 6.
Result: The driven equipment and/or engine accessories are not properly working.
Repair: Perform the necessary repairs and return to service.
If the problem is not resolved, proceed to the nest step.
6. Check for Hydraulic Cylinder Lock
A. Check for fluid in the cylinders (hydraulic cylinder lock) by removing the individual unit injectors. Be sure to drain the fuel from the cylinder head prior to removing the injectors. Fuel will flow from the cylinder head into the cylinders when the unit injector is removed.
Hydraulic Cylinder Lock
Result: The engine does not have a hydraulic cylinder lock.
Proceed to Test Step 7.
Result: The engine does have a hydraulic cylinder lock.
Repair: Perform the necessary repairs and return to service.
7. Check for an Internal Engine Problem
A. If a mechanical problem is suspected, disassemble the engine. Refer to the Disassembly and Assembly manual.
B. Inspect the internal components for the following conditions:
- Seizure
- Broken Components
- Bent Components
Mechanical Problem
Result: There is no internal engine problem.
Result: The engine has an internal engine problem.
Repair: Repair or replace any worn parts. Refer to the Disassembly and Assembly manual.