804127 1 Mercury THERMOSTAT COVER

Table 1
Diagnostic Trouble Codes
CDL Code CDL Code Description 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
Associated Diagnostic Trouble Codes
E1092 Probable Causes
Codes
Aftercooler leaks or restrictions
Cooling fan
Charge Air Cooler Outlet Temperature SensorRecommended Actions
Table 3
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Establish communication between Cat® Electronic Technician (ET) and the Electronic Control Module (ECM).
B. Download the "Warranty Report" from the engine ECM before 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.
Repair: Refer to Troubleshooting, "Diagnostic Trouble Codes" to troubleshoot the associated diagnostic code.
Result: An E539 diagnostic code is active.
Proceed to Test Step 2.
Result: A code is not active or logged.
Proceed to Test Step 2.
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.
Aftercooler
Result: The ATAAC is OK.
Proceed to Test Step 3.
Result: The ATAAC is NOT OK.
Repair: Clean the ATAAC. Refer to the machine Test and Adjust manual.
If the problem still exists, proceed to Test Step 3.
Result: The surface of the ATAAC is NOT OK.
Repair: Replace the ATAAC.
If the problem is not resolved, 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 OK.
Proceed to Test Step 4.
Result: The fan drive system is NOT OK.
Repair: 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 is not resolved, proceed to Test Step 4.
4. Check the Operation of the Charge Air Cooler Outlet 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.
The value should be within −9° C ( 15° F) of the ambient temperature.
Sensor
Result: The charge air cooler outlet temperature sensor is OK.
Repair: Reinstall the sensor. Torque the sensor to the proper specifications.
Result: The charge air cooler outlet temperature sensor is NOT OK.
Repair: Replace the charge air cooler outlet temperature sensor.
If the problem is not resolved, contact your Technical Communicator (TC). For further assistance, the TC can confer with the Dealer Solutions Network (DSN).