9011J41 Mercury GEAR HOUSING ASSEMBLY, Complete (4.25 Inch/107.95 mm Torpedo Diameter)

Probable Causes
Connectors and wiring
Engine overload
Fuel system
Switches
Circuit protection
Speed/timing sensorsRecommended Actions
Table 1
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Wiring
A. Turn the main disconnect switch to the OFF position.
B. Check for the correct installation of the ECM J1/P1 and the J2/P2 connectors. Refer to Troubleshooting, "Electrical Power Supply - Test" for additional information.
C. Check for correct installation of the fuel injector connectors.
D. Check the power and ground connections to the ECM. Refer to Troubleshooting, "Electrical Power Supply - Test" for additional information.
Connectors and Wiring
Result: The connectors and wiring appear to be OK.
Proceed to Test Step 2.
Result: There is a problem with the connectors and/or wiring.
Repair: Repair or replace the connectors or wiring. Perform the following procedure:
1. Connect Cat® Electronic Technician (ET) to the service tool connector.
2. Use Cat ET to perform the following test:
- "Wiggle Test"
If the problem is not resolved, proceed to Test Step 2.
2. Check for Engine Overload
Note: When the load that is applied to the engine is too large, the engine will run in the lug condition. When the engine is running in the lug condition, engine rpm does not increase with an increase of fuel.
Load
Result: The engine is not being overloaded.
Proceed to Test Step 3.
Result: The engine is being overloaded.
Repair: Reduce engine load to an acceptable limit.
If the problem is not resolved, proceed to Test Step 3.
3. Inspect the Fuel System
Refer to Testing and Adjusting, "Fuel System Inspection" 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. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
Note: 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. Refer to Testing and Adjusting, "Fuel Quality - Test" for additional information. Check the fuel tank for debris or foreign objects which may block the fuel supply.
E. Check for fuel leaks.
Fuel System
Result: The fuel system is OK.
Proceed to Test Step 4.
Result: The fuel system is NOT OK.
Repair: Repair or replace damaged fuel system components.
If the problem is not resolved, proceed to Test Step 4.
4. Inspect the Switches
A. Check the keyswitch input to the ECM.
B. Check engine shutdown switches.
C. Connect Cat ET.
D. Use Cat ET to verify the status of the following parameters:
- Shutdown switches
Switches
Result: The switches are OK.
Proceed to Test Step 5.
Result: A switch is NOT OK.
Repair: Repair or replace damaged switch.
If the problem is not resolved, proceed to Test Step 5.
5. Check the Device for Circuit Protection
A. Inspect the wires and connectors to all circuit protection for the engine.
Circuit Protection
Result: The circuit protection device is not tripped.
Proceed to Test Step 6.
Result: The circuit protection device is tripped.
Repair: Reset the circuit breakers if the circuit breakers are tripped. If necessary, replace fuses (if equipped). Prior to returning the engine to service, determine the condition that caused the circuit breaker to trip. Make the necessary repairs.
If the problem is not resolved, proceed to Test Step 6.
6. Check the Engine Speed/Timing Sensors
A. Thoroughly inspect the connectors for the engine speed/timing sensors.
B. Crank the engine. If the engine starts and no speed timing codes are logged, the speed timing circuit is operating correctly.
Speed/Timeing Sensors
Result: The speed/timing sensors or wiring are NOT OK.
Repair: Repair or replace speed/timing sensors or wiring. Refer to Troubleshooting, "Speed/Timing - Test" for additional information.
Verify that the repair eliminated the problem.
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).