818934 35 Mercury SCREW (M8X35)

Table 1
Diagnostic Codes
Code Description Conditions Notes
523541-3
(Does not apply to C3.8 Tier 4 Final / Stage IV) EGR Lift Sensor High None Voltage is 4.5 V or higher for 2.8 sec or more.
EGR stop
Warning Level 2
Engine Derates
523541-4
(Does not apply to C3.8 Tier 4 Final / Stage IV) EGR Lift Sensor Low None Voltage is .3 volts or less for 2.8 sec or more.
EGR stop.
Intake throttle is 100percent open.
Warning Level 2
Engine Derates
523578-2 No communication with EGR Battery voltage is normal.
Starter switch signal (P1/J1 Terminal 12) is not activated Interruption of CAN communication for 1.3 seconds or more.
EGR Stop
Intake Throttle 100 percent open
Warning Level 1
Engine Derates Note: A –3 code is detecting an open circuit or +B short circuit of sensor or wiring harness.Note: A –4 code is detecting a ground short circuit of the sensor or wiring harness.Note: The 523578-2 is also often caused by a harness problem.
Illustration 1 g03828605
Table 2
Troubleshooting Test Steps Values Results
1. Check the voltage at the EGR connector terminals 3 and 4.
A. The voltage should be between 10 and 16 V.
Voltage
Result: If OK, then continue to Test Step 2.
Result: If not OK, then fault is in the harness. Refer to Special Instruction, REHS7774 for the correct jumper harness, if the failure is at the connector.
2. Check the EGR connector for a short to ground or an open circuit at terminals 1 and 2.
Short or Open
Result: If OK, then replace the EGR.
Result: If not OK, then proceed to Test Step 3.
3. Check the connector at the ECM for a short or open circuit at P1/J1 Pins 16 and 36.
Short or Open
Result: If Not OK, then the fault may be in the connector to the engine ECM. Refer to Special Instruction, REHS7297 for available repair options.
Note: After repairing, run the engine until the coolant temp is above 65° C (150° F) to ensure that no diagnostic codes are created. Then perform an “EGR Valve Control Override” test in ET.NRS Valve Test
Table 3
Diagnostic Codes
Code Description Conditions Notes
523536-2 EGR Feedback Error Battery voltage is normal
During wrong duty feedback, activation will be attempted 30 times before error code. Warning Level 2
Engine Derate
523537-2 EGR DC Motor Temperature Error Battery Voltage Normal
Estimated temperature is 45° C (113° F) or above for one second or more. Warning Level 2
Engine Derate
523572-4 EGR Position Sensor Failure Battery voltage normal
No 523604-2 code present
EGR control line is normal
EGR position sensor error signal received from CAN for 2.8 seconds or more.
Engine Derated
EGR stop
523574-3 EGR Actuator Open Circuit Battery voltage is normal
No DTC of 523604 (CAN 1 Bus Off)
EGR Control line is normal EGR actuator open circuit error signal received via CAN for 2.8 seconds or more
EGR stop
Warning Level 2
Engine derates
523574-4 EGR Actuator Coil Short EGR actuator coil short error signal received via CAN for 2.8 seconds or more.
EGR stop.
Warning Level 2
Engine derates
523575-7 EGR Valve Stuck EGR actuator valve stuck error signal received via CAN for 2.8 seconds or more.
Engine derates.
EGR stop.
Warning Level 2
Engine derates
523576-2 EGR Motor Overheat EGR temperature error signal (125 C or more) received via CAN for 2.8 seconds or more.
EGR Stop
Warning Level 2
Engine derates
523577-2 EGR Motor Temperature Sensor Failure EGR temperature sensor error signal received via CAN for 2.8 seconds or more.
EGR Stop
Warning Level 2
Engine derates
523632-2 EGR "A" Control Circuit Range/ Performance IG switch signal (ECM: V13 V33, ACU: 18 terminal) is continuously activated more than 2 seconds
Starter switch signal (ECM: V1 terminal) is not activated except within 2 seconds after starter stopped
CAN communication is normal between DCU and engine ECM Inducement pattern: SCR-System Tampering NRS Valve - Test
Illustration 2 g06170543
(1) Terminal CAN1-H
(2) Terminal CAN1-L
(3) Terminal Ground
(4) Terminal Power (+12 V)
(a) Terminal Layout
(b) EGR Valve Assembly
(c) DCU Connector
(A) To Diagnosis Tool
Table 4
Troubleshooting Test Steps Value Results
1. Check for Codes
A. Establish communication between Cat® Electronic Technician (ET) and the ECM .
B. Turn the keyswitch to the ON position.
C. Confirm if code is active or logged.
Codes
Result: Diagnostic code is active.
Proceed to Test Step 2.
Result: If the code is logged, clear the code and operate the machine to confi