95394010 Mercury TUBING, (185 mm)

Operator Information
* What happened, and when?* Under what conditions? Was the engine rpm (speed) high or low?Was the engine under load?* Are there any customer or dealer installed systems that could cause this symptom?* What else occurred?* When did the symptoms begin (and what else happened at that time)?Logged Diagnostic Codes
* Do they correlate to probable causes?* Did they occur at the same time as the symptoms?* Are some codes Logged repeatedly?Other Symptoms
* Are they related to this symptom?* Do they have common probable causes?Finally, test each probable cause using the tests suggested by the procedure. Be sure to check connectors, especially on intermittent problems! Refer to Section 5: P-501: Inspecting Electrical Connectors for details.P-301: Engine Will Not Crank
Probable root causes:* Battery Cables/Batteries* Starting motor solenoid or circuit problem (in system wiring)* Starting motor/flywheel ring gear* Engine accessory* Hydraulic cylinder lock* Internal engine problem Perform the following tests in order:1. Check Master Disconnect Switch, battery posts and battery/starter cables for loose connections and corrosion. Remove and clean cables and connections if corroded. Load test batteries, refer to Special Instruction, SEHS9249 Use Of 4C4911 Battery Load Tester. If necessary, charge the batteries. Refer to Special Instruction, SEHS7633 Battery Test Procedure.2. Test starting motor solenoid operation. Check system wiring to starting motor solenoid. If equipped, inspect the Caterpillar Prelubrication System for proper operation.3. Test starting motor operation. Refer to Systems Operation, Testing & Adjusting Manual. Inspect starting motor pinion and ring gear for damage.4. Verify timing pin was not left in the flywheel housing after setting valve lash. Use the 9S9082 Engine Turning Tool and attempt to manually turn the engine. If unable to turn the engine, remove and inspect engine accessories that can lock up the engine (air compressor, oil pump, etc). Repair or replace as necessary. Refer to the engine System Operation Testing & Adjusting Manual.5. Remove injectors and check for fluid in the cylinders.6. Disassemble engine to inspect for internal components that may be seized, broken, bent, out of alignment, etc. Refer to the Disassembly & Assembly Manual.P-302: Engine Cranks But Will Not Start
Probable root causes:* Low Fuel or Oil Level* Starting aids/fuel gel (cold temperature operation)* Engine Shutdown Switch setting* An engine shutdown is Active* Machine/Engine wiring* Personality Module or ECM* Speed/Timing signal; injection timing, incorrect speed/timing wheel orientation assembly, Speed/Timing Sensor calibration error after replacement.* Electrical connections to the unit injector solenoids* Fuel supply: poor fuel quality or unit injector priming problem, low supply pressure, air in low pressure fuel supply circuit* Combustion problem Perform the following tests in order:1. Visually check fuel level (do not rely on fuel gauge only).2. If cold ambient conditions exist, check operation of starting aids. Replace ether canister if empty or low. Check cylinder block jacket water heater for malfunction and replace if required. Check for presence of congealed fuel (wax).3. Make sure the Engine Shutdown Switch is in the RUN position. Connect an Electronic Service Tool and verify Shutdown Switch position status. If Electronic Service Tool does not operate, Refer to P-307: Electronic Service Tool Will Not Communicate With ECM. If a shutdown occurs, the keyswitch must be turned to the OFF position for at least 15 seconds, then to the ON position before the engine will start.4. Use an Electronic Service Tool to verify a Shutdown is not Active. If a Shutdown is Active, determine the reason for the shutdown. After correcting the problem, turn the keyswitch to the OFF position for at least 15 seconds before trying to restart the engine. Aftermarket engine protection devices usually interrupt power to the ECM and prevent communications with the Electronic Service Tool. Check for correct installation and operation of aftermarket engine protection devices. Aftermarket devices may need to be bypassed to continue.5. Check for correct installation of the ECM connectors J1/P1 and J2/P2, Speed/Timing Sensor connector J20/P20, and Unit Injector Connector J4/P4. Refer to P-501: Inspecting Electrical Connectors. If the problem occurs only after the engine is warmed up, the circuit breakers may be exceeding the trip point because of overheating. Check the circuit breakers on the machine, reset if required.6. Verify there is not an Active 253-02 Diagnostic Code. If the diagnostic code is present, refer to Section 2: Programming Parameters.7. Observe the engine rpm on an Electronic Service Tool Status screen while cranking the engine. If the Electronic Service Tool displays 0 rpm while cranking the engine, there is a problem in the Speed/Timing Sensor circuit. Refer to P-514: Speed/Timing Sensor. If engine rpm is present (50 rpm or more while cranking) the Speed/Timing circuitry appears to be operating correctly. Verify that the timing reference gear is installed correctly and keyed to the camshaft by means of the locating dowel. If the gear was installed backwards or flipped over during assembly, the engine will not start. Check for proper orientation between crankshaft and camshaft drive gears, repair as required. Refer to procedure in Diassembly & Assemble Manual.8. Make sure the Unit Injector connectors are properly installed. Refer to P-515: Injector Solenoids and perform the Injector Solenoid Test as a quick check to confirm that the ECM can energize the unit injector solenoids.9. Monitor exhaust for smoke while cranking. If smoke is not present there may be a fuel supply problem. Check for air in the low pressure fuel supply system after replacing filters, working on the low pressure fuel supply circuit, or replacing unit injectors. Purge air from the low pressure fuel supply circuit with the hand priming pump and cranking the engine in 30 second cycles, pausing at least 2 minutes between cranking cycles to allow the starting motor to cool. Loosen low pressure fuel line fitting on inlet to pressure regulating valve and hand prime again if air in fuel continues. A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Check for restricted, collapsed, or pinched fuel lines and repair or replace as required. Refer to the Systems Operation, Testing & Adjusting Manual.Check fuel quality. In temperatures