880805A 1 Mercury GEAR KIT

Table 1
Troubleshooting Test Steps Values Results
1. Check the Machine Electrical System
A. Check that Cat ET can connect to the engine ECM with the keyswitch ON.
Machine Electrical System
Result: Cat ET can connect to the engine ECM, then the engine ECM is turned on.
Proceed to Test Step 2.
Result: Cat ET cannot connect to the engine ECM, and the machines starting circuit is not providing power to the engine ECM.
Repair: Refer to Troubleshooting, Electrical Power Supply - Test.
If the problem is not resolved, proceed to Test Step 2.
2. Inspection of the Fuel Supply
Refer to Systems Operation/Testing and Adjusting, "Fuel System" for additional information.
A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.
B. Ensure that the vent in the fuel cap is not filled with debris.
C. Inspect the fuel system for external leaks.
D. Check that there is no air in the clear primary fuel filter. Change the primary fuel filter and the in-line filter for the fuel transfer pump.
E. Check fuel quality. Refer to Systems Operation/Testing and Adjusting, "Fuel Quality - Test" for the proper procedure. Check the fuel tank for debris or foreign objects which may block the fuel supply.
F. Check for the proper operation of the fuel transfer pump. Replace the pre-filter if excessive contamination or if the maintenance interval is exceeded. Refer to Systems Operation/Testing and Adjusting, "Fuel System" for information.
Fuel level
Result: The fuel system is OK.
Proceed to Test Step 3.
Result: The fuel system is NOT OK.
Repair: Replace the fuel filters. Clean the primary filter/water separator of debris. Refer to the Operation and Maintenance Manual for details.
If the problem is not resolved, proceed to Test Step 3.
3. Restrictions in the Air Inlet and Exhaust System.
A. Check for an air filter restriction indicator.
B. Check the air inlet and exhaust system for restrictions and/or leaks. To test the exhaust system, the DOC inlet temperature sensor can be removed to ensure the DOC/DPF are not plugged.
Air and exhaust system restrictions
Result: There are no system restrictions.
Proceed to Test Step 4.
Result: There are system restrictions.
Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System" for additional information on the air inlet and exhaust systems.
Repair: Replace plugged air filters. Refer to Operation and Maintenance Manual for the correct procedure.
If the problem is not resolved, proceed to Test Step 4.
4. Starting Aids (If Applicable)
A. If cold ambient conditions exist, check the operation of the starting aids. Refer to the Machines Electronic Control System for details.
B. Verify that the starting aid is operating properly.
Starting aids
Result: The starting aids are OK.
Proceed to Test Step 5.
Result: The starting aids are NOT OK.
Repair: Make the necessary repairs.
If the problem is not resolved, proceed to Test Step 5.
5. Check the Combustion
A. Test the compression pressure.
B. Check the valve timing.
Refer to the System Operation/Testing and Adjusting.
Combustion
Result: The mechanical components are OK.
Proceed to Test Step 6.
Result: The mechanical components are NOT OK.
Repair: Make the necessary repairs.
If the problem is not resolved, proceed to Test Step 6.
6. Check the Fuel Injectors
Refer to the Systems Operation/Testing and Adjusting for more information.
Fuel injectors
Result: The injectors are OK.
STOP
Result: The injectors are NOT OK.
Repair: Replace the suspect injectors.
Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and Disassembly and Assembly, "Electronic Unit Injector - Remove" for the procedure to install the new injector QR codes within the engine ECM and on-line.
If two or more injectors are not working properly, this can indicate the following conditions: water in fuel, poor fuel quality, or contaminated fuel.
Contaminated fuel can occur by pre-filling the fuel filter or contamination during a previous repair of the fuel system. In order to prevent a future occurrence of contamination, the root cause must be determined.
If the problem is not resolved, contact the Technical Communicator (TC). For further assistance, the TC can contact the Dealer Solutions Network (DSN).