825096T Mercury RELAY

Table 1
Diagnostic Trouble Codes
CDL Code Code Description
(code descriptions may vary) Comments
E539 (1) High Intake Manifold Air Temperature The code indicates that the temperature of the intake air into the engine has risen above a predetermined threshold.
Engine power may be derated.
E539 (2) High Intake Manifold Air Temperature The code indicates that the temperature of the intake air into the engine has risen above a predetermined threshold.
Engine power may be derated.
E539 (3) High Intake Manifold Air Temperature The code indicates that the temperature of the intake air into the engine has risen above a predetermined threshold.
Engine power may be derated.
Table 2
Troubleshooting Test Steps Values Results
1. Check for Diagnostic Trouble Codes
A. Establish communication between Caterpillar Electronic Technician (ET) and the Electronic Control Module (ECM) . Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Warranty Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
C. Determine if an associated code is active or logged. Table 2 lists associated diagnostic codes.
Codes
Result: An associated code is active.
Refer to Troubleshooting, "Diagnostic Trouble Codes" in order to troubleshoot the associated diagnostic code.
Result: An associated code is not active or logged.
Proceed to Test Step 2.
Result: A E539 diagnostic code is active.
Proceed to Test Step 2.
Result: A code is not active or logged.
Proceed to Test Step 2.
Illustration 1 g02023837
Inspection point
Table 3
Troubleshooting Test Steps Values Results
2. Check the Aftercooler for Leaks or Restrictions
A. Inspect the exterior surface of the ATAAC for excessive buildup of dirt or debris. Also verify that the fins of the ATAAC are not damaged.
Restrictions
Result: The ATAAC has an excessive buildup of dirt or debris.
Clean the ATAAC. Refer to the machine Test and Adjust manual. Verify that the problem has been resolved.
If the problem still exists, proceed to Test Step 3.
Result: The surface of the ATAAC is damaged.
Replace the ATAAC.
If the problem still exists, proceed to Test Step 3.
Result: The surface of the ATAAC is not damaged and the ATAAC does not have an excessive buildup of dirt or debris.
Proceed to Test Step 3.
3. Check the Operation of the Cooling Fan
A. Verify that the cooling fan that is being used to transfer heat from the ATAAC is working properly.
B. If the fan is belt driven, verify that the belt tension is adequate. Also, verify that the clutch is operating properly.
C. If the fan is hydraulically driven, verify that there is no leakage around the motor and that the pressure for the fan is adequate.
Cooling fan
Result: The fan drive system is not working properly.
Make the necessary adjustments to the clutch or the belt tension if the fan is mechanically driven . Refer to the machine Test and Adjust for the proper procedure. Repair leaks or make the necessary adjustments to the motor or the hydraulic pump if the fan is hydraulically driven . Refer to Testing and Adjusting for the proper procedure.
If the problem still exists, proceed to Test Step 4.
Result: The fan drive system is working properly.
Proceed to Test Step 4.
4. Check the Operation of the Intake Manifold Air Temperature Sensor
A. Remove the charge air cooler outlet temperature sensor. Allow the charge air cooler outlet temperature sensor to rest in ambient air for 2 minutes.
B. Connect to the engine ECM by using Cat ET.
C. Monitor the value of the charge air cooler outlet temperature sensor on Cat ET.
Sensor
Result: The value of the intake manifold air temperature sensor is within −9° C ( 15° F) of the ambient temperature.
Reinstall the sensor. Torque the sensor to the proper specifications. Return the unit to service.
Result: The value of the intake manifold air temperature sensor is not within −9° C ( 15° F) of the ambient temperature.
Replace the intake manifold air temperature sensor. Return the unit to service.
Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).