850327 Mercury SPRING

Recommended Actions
Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET) to the data link connector.
Check for active diagnostic codes. Repair any diagnostic codes that are present before continuing with this procedure. Electrical Connectors
Check the connectors for the Engine Control Module (ECM). Also check the vehicle harness connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Ensure that the following connectors have been installed correctly:
J1/P1 ECM connector
J2/P2 ECM connector
J300/P300 injector connector
J401/P401 primary engine speed/timing sensor connector
J402/P402 secondary engine speed/timing sensor connectorEngine Monitoring
Check the "Engine Monitoring Mode" parameter.
Verify that the "Engine Monitoring Mode" parameter is programmed to the desired option:
"Warning"
"Derate"
"Shutdown"Electronic System
Monitor the fuel position, the rated fuel limit and the FRC fuel limit. While the vehicle is operating under full load, the parameters should meet the following conditions:
The fuel position is equal to the rated fuel limit.
The fuel position is less than the FRC fuel limit.If the fuel position is equal to the rated fuel limit and the fuel position is less than the FRC fuel limit, the electronics are operating correctly. Proceed to "Fuel Supply".
If the fuel position is not equal to the rated fuel limit and/or the fuel position is not less than the FRC fuel limit, perform the following tests in order:
When the engine is off, place the keyswitch in the ON position. Check the boost pressure on the status screen. When the engine is off, the correct boost pressure is 0 kPa (0 psi).Accelerator Pedal Position Sensor
Monitor the status of the accelerator pedal position sensor. Operate the engine at high idle with the vehicle in neutral.If the engine cannot reach the top engine limit, check the duty cycle of the accelerator pedal position sensor in order to ensure that the duty cycle is within calibration (75 to 90 percent at high idle).If the accelerator pedal position is unstable, check the duty cycle of the accelerator pedal position sensor. Check the duty cycle of the accelerator pedal position sensor by slowly operating the accelerator pedal in order to verify that the accelerator pedal position sensor is within calibration. The accelerator pedal position sensor is within calibration when both of the following conditions are met:
10 to 22 percent at low idle
75 to 90 percent at high idleAlso, ensure that the duty cycle changes as the pedal position changes. If a problem with the accelerator pedal position sensor is suspected, refer to Troubleshooting, "Accelerator Pedal (Throttle) Position Sensor Circuit - Test".Vehicle Speed Signal
Monitor the vehicle speed signal. Ensure the accuracy of the vehicle speed signal by comparing the vehicle speed signal to the actual vehicle speed.If the vehicle speed is greater than the "VSL", the power is limited. If a problem is discovered, refer to Troubleshooting, "Vehicle Speed and Speedometer Circuit - Test".Power Train Data Link
Check the "Powertrain Data Link". Ensure that the power train data link is not limiting the power.
Monitor the "Powertrain Data Link" status screen while the vehicle is experiencing problems. If the "Powertrain Data Link" status screen indicates that the data link is limiting the power or the rpm, verify that this is not normal operation. If this is not normal operation, refer to the vehicle OEM for repairs.Fuel Supply
Monitor the exhaust for smoke while the engine is being cranked. If no smoke is present, there may be a problem with the fuel quality or there may be a problem with the fuel supply.
Check the fuel quality. Refer to Operation and Maintenance Manual, SEBU6385, "Caterpillar On-Highway Diesel Truck Engine Fluid Recommendations".
Check the fuel pressure. Refer to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test".
Ensure that the fuel system has been primed. Refer to Systems Operation/Testing and Adjusting, "Fuel System - Prime".
Check for fuel supply lines that are restricted.
Check the fuel filters.
If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
Check for air in the fuel system. Refer to Systems Operation/Testing and Adjusting, "Air in Fuel - Test". Torque Limit Switch
Check the setting for the customer parameter for the "Torque Limit". If the "Torque Limit" is programmed below 2712 N m (2000 lb ft), check the status screen for the torque limit switch. Ensure that the status screen indicates that the torque limit switch is off. If the status of the torque limit switch is on and a "Torque Limit" is programmed, the system is operating correctly. If the switch that is connected to this signal input is not switching on and switching off, refer to Troubleshooting, "PTO Switch Circuit - Test".Low Injection Actuation Pressure
Check the engine oil level. Engine oil is used to activate the high pressure hydraulic pump.
Ensure that the engine oil meets the Caterpillar recommendations. Refer to Operation and Maintenance Manual, SEBU6385, "Caterpillar On-Highway Diesel Truck Engine Fluid Recommendations".
Refer to Troubleshooting, "Injection Actuation Pressure -Test".