892267523 Mercury INSULTOR

Table 1
J1939 Code and Description CDL Code and Description Comments
157–15
Engine Injector Metering Rail #1 Pressure : High - least severe (1) E396 (1)
Engine Injector Metering Rail #1 Pressure : High - least severe (1) The fuel rail pressure is above an acceptable level.
The code is logged. Engine power is derated.
157-16
Engine Injector Metering Rail #1 Pressure: High - moderate severity (2) E396 (2)
Engine Injector Metering Rail #1 Pressure: High - moderate severity (2) The fuel rail pressure is above an acceptable level.
The code is logged. Engine power is derated.
157–17
Engine Injector Metering Rail #1 Pressure : Low - least severe (1) E398 (1)
Engine Injector Metering Rail #1 Pressure : Low - least severe (1) The fuel rail pressure is below an acceptable level.
The code is logged. Engine power is derated.
157-18
Engine Injector Metering Rail #1 Pressure: Low - moderate severity (2) E398 (2)
Engine Injector Metering Rail #1 Pressure: Low - moderate severity (2) The fuel rail pressure is below an acceptable level.
The code is logged. Engine power is derated.
5571-12
High Pressure Common Rail Fuel Pressure Relief Valve : Failure 5355-12
High Pressure Common Rail Fuel Pressure Relief Valve : Failure The pressure relief valve (PRV) in the fuel rail is open. This code is a calculated parameter.
The code is logged. Probable Causes
Diagnostic codes
Electrical connectors
Fuel rail pressure sensor
Return fuel lines
Fuel Rail Pressure Relief Valve (PRV)Recommended Actions
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Table 2
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Connect the electronic service tool to Cat® Electronic Technician (ET). Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Warranty Report" and the "Product Status Report" with Histograms before performing any troubleshooting or clearing any diagnostic codes.
Note: The downloaded information will be required by the Dealer Solutions Network (DSN) if troubleshooting assistance is needed.
C. Determine if a diagnostic is active or recently logged.
Codes
Result: A code other than the codes in Table 1 is present.
Repair: Troubleshoot the code. Refer to the applicable troubleshooting procedure.
Result: One of the codes in Table 1 is present.
Proceed to Test Step 2.
2. Inspect the Fuel System
A. Inspect the fuel system and return lines. Refer to Systems Operation/Testing and Adjusting, "Fuel System - Inspect" for inspection of the high-pressure fuel lines and the fuel rail.
B. Make sure that the fuel return line is not blocked or kinked.
Fuel System Problems
Result: Problems were found with the fuel system.
Repair: Repair the components or replace the components that are damaged. Verify that the problem is resolved.
Result: Problems were not found with the fuel system.
Proceed to Test Step 3.
3. Check the Status of the Fuel Rail Pressure Sensor
A. Make sure that the engine has been shut down for at least 10 minutes. Use Cat ET to check the status of the "Fuel Rail Pressure".
Fuel Rail Pressure Sensor
Result: The "Fuel Rail Pressure (absolute)" is more than 2000 kPa (290 psi).
Repair: Replace the fuel rail pressure sensor.
Proceed to Test Step 4.
Result: The "Fuel Rail Pressure (absolute)" is less than 2000 kPa (290 psi).
Proceed to Test Step 4.
4. Perform the "Fuel Rail Pressure Relief Valve Test"
A. Perform the "Fuel Rail Pressure Relief Valve Test" using Cat ET.
Note: The Fuel Rail Pressure Relief Valve (PRV) has a limited life based on the number of "valve open occurrences". The Number of "Fuel Rail Pressure Relief Valve Open Occurrences" is displayed in the "Totals" status screen as "Fuel Rail Pressure Relief Valve Open Occurrences". A high occurrence count is normally caused by improper operator engine shutdown using the battery disconnects, instead of the key.
"Fuel Rail Pressure Relief Valve Test"
Result: The "Fuel Rail Pressure Relief Valve Test" was successful.
Proceed to Test Step 5
Result: The "Fuel Rail Pressure Relief Valve Test" was not successful.
Repair: Replace the PRV. Perform the "Fuel Rail Pressure Relief Valve Test" to verify that the fault has been eliminated.
Important: Always reset the "Fuel Rail Pressure Relief Valve Open Occurrences" count when a new PRV is installed. Use Cat ET to select "Service", then "Common Rail Pressure Relief Valve Replacement".
Proceed to Test Step 5.
5. Perform the "Fuel Rail Pressure Test" in Cat ET
"Fuel Rail Pressure Test"
Result: The "Fuel Rail Pressure Test" was successful.
Return the unit to service.
Result: The "Fuel Rail Pressure Test" was not successful.
Repair: Perform the "Injector Bypass Fuel Flow - Test". Refer to Testing and Adjusting, Injector Bypass Fuel Flow - Test.
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).