65800 Mercury PACKING, CARRIER

Recommended Actions
Table 1
Troubleshooting Test Steps Values Results
1. Check to See if the Engine is Derated
A. The engine may be derated due to dirty air filters or other factors. Use the Caterpillar Electronic Technician (ET) in order to check for engine derates.
Engine Derate
Result: The engine is not derated.
Proceed to Test Step 2.
Result: The engine is derated.
Repair: Repair or replace any worn or damaged components that are causing the engine to derate.
2. Check the Cold Mode Operation
A. Monitor the status screen on Cat ET in order to verify that the engine has exited cold mode. Observe the reading for coolant temperature on the Cat ET. Refer to Troubleshooting, "System Overview" for additional information.
Cold Mode
Result: The engine is not in cold mode.
Proceed to Test Step 3.
Result: The engine is in cold mode.
Repair: Take the engine out of cold mode.
3. Check that the Correct Flash File Is Installed
Flash File
Result: The correct flash file is installed.
Proceed to Test Step 4.
Result: The correct flash file is not installed.
Repair: Install the correct flash file.
4. Check the Throttle Position Sensor
A. Monitor "Throttle Status" on Cat ET.
B. Verify that the throttle position is stable and that the engine is able to reach high idle rpm.
Throttle Position Sensor
Result: The throttle position sensor is stable.
Proceed to Test Step 5.
Result: The throttle position sensor is not stable.
Repair: Refer to Troubleshooting, "Throttle Position Sensor Circuit - Test" for the proper troubleshooting procedure.
5. Check the Electrical Connectors
A. Check for correct installation of the J1/P1 and J2/P2 connectors for the Electronic Control Module (ECM). Check for correct installation of the JH300/P300 unit injector connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Electrical Connectors
Result: The electrical connectors are OK.
Proceed to Test Step 6.
Result: The electrical connectors are NOT OK.
Repair: Repair or replace any worn or damaged components.
6. Check the Unit Injectors
A. Use Cat ET to determine if there are any active diagnostic codes for the unit injectors.
B. Perform the injector solenoid test on Cat ET in order to determine if all of the injector solenoids are being energized by the ECM. Refer to Troubleshooting, "Injector Solenoid Circuit - Test" for the proper procedure.
C. Perform the cylinder cutout test on Cat ET in order to identify any injectors that might be misfiring. Refer to Troubleshooting, "Injector Solenoid Circuit - Test" for the proper procedure.
Unit Injectors
Result: The unit injectors are OK.
Proceed to Test Step 7.
Result: The unit injectors are NOT OK.
Repair: Replace the unit injectors.
7. Check the Fuel Position, Rated Fuel Limit, and FRC Fuel Position
A. Monitor the status of "Fuel Position" and "Rated Fuel Limit" while the engine is operating under full load. If "Fuel Position" equals "Rated Fuel Limit" and "Fuel Position" is less than "FRC Fuel Limit", the electronics are operating correctly.
B. Verify that there are no active diagnostic codes for the boost pressure sensor.
C. Monitor the "Boost Pressure" and "Atmospheric Pressure" for normal operation. When the engine is not running, "Boost Pressure" should be 0 kPa (0 psi).
Fuel Position, Rated Fuel Limit, and FRC Fuel Position
Result: Fuel position, rated fuel limit, and FRC fuel position are OK.
Proceed to Test Step 8.
Result: Fuel position, rated fuel limit, and FRC fuel position are NOT OK.
Repair: Repair or replace any worn or damaged components.
8. Check the Air Inlet and Exhaust System
A. Check for an air filter restriction indicator. Clean plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance Manual.
B. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System".
Air Inlet and Exhaust System
Result: The air inlet and exhaust system is OK.
Proceed to Test Step 9.
Result: The air inlet and exhaust system is NOT OK.
Repair: Repair or replace any worn or damaged components relating to the air inlet and exhaust system.
9. Check the Fuel Supply
A. Check the fuel lines for the following problems: restrictions, collapsed lines, and pinched lines. If problems are found with the fuel lines, repair the lines and/or replace the lines.
B. Check the fuel tank for foreign objects which may block the fuel supply.
C. Prime the fuel system if any of the following procedures have been performed:
• Replacement of the fuel filters
• Service on the low-pressure fuel supply circuit
• Replacement of unit injectors
D. Check the fuel pressure after the fuel filter while the engine is being cranked. Refer to Testing and Adjusting for the correct pressure values. If the fuel pressure is low, replace the fuel filters. If the fuel pressure is still low, check the following items: fuel transfer pump, fuel transfer pump coupling, and fuel pressure regulating valve. Refer to Systems Operation/Testing and Adjusting for more information.
Fuel Supply
Result: The fuel supply is OK.
Return the unit to service.
Result: The fuel supply is NOT OK.
Repair: Repair or replace any worn or damaged components relating to the fuel supply.