465870 Volvo.Penta Gear, fuel inj. pump

Probable Causes
Active engine derate
Throttle Signal
Electrical connectors
Low Injection Actuation Pressure
Fuel supplyRecommended Actions
Active Engine Derate
If an active derate occurs, the warning lamp will flash. "Engine Derate" will appear on the status screen for the Caterpillar Electronic Technician (Cat ET). Verify that the set points for "Derate" that are in the Programmable Monitoring System have been programmed to the values that are correct. Throttle Signal from the Throttle Position Sensor
Verify that the "Top Engine Limit" and "High Idle" are programmed to the values that are correct. Monitor the parameters for the throttle on Cat ET. Use Table 1 to monitor the parameters.
Table 1
Throttle Parameters    "Desired Engine Speed"    "Throttle Position"    
"Low Idle"     Programmed to "low idle"     0%    
"High Idle"     Programmed to "high idle"     100%     The "Desired Engine Speed" and the "Throttle Position" should increase linearly. Both parameters should increase steadily to the Programmed "high idle". The Desired Engine Speed and the Throttle Position should decrease linearly. Both parameters should decrease steadily to the Programmed "low idle". Electrical Connectors
Use Cat ET to check for the following diagnostic code.
CID 168-FMI 02 System Voltage intermittent/erraticIf this diagnostic code is logged, refer to Troubleshooting, "Electrical Power Supply Circuit - Test".
Inspect the battery wires from the ECM back to the battery compartment. Refer to the Electrical System Schematic. Inspect the wires and the power relay. Check the power and ground connections to the ECM. Refer to Troubleshooting, "Electrical Power Supply Circuit - Test" for more information.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 recommendations of the engine manufacturer. Refer to Operation and Maintenance Manual for further details.
Crank the engine and monitor the Injection Actuation Pressure and the output of the Injection Actuation Pressure Control Valve. The High Pressure Oil system is operating properly if the pressure output is a minimum of 6 MPa (870 psi).
Connect Cat ET and check for the following diagnostic code.
CID 164-FMI 11 Injector Actuation Press Sensor mechanical failureIf this diagnostic code has been logged recently, refer to Troubleshooting, "Injector Actuation Pressure-Test".Fuel Supply
Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines. If problems are found with the fuel lines, repair the lines and/or replace the lines.
Check the fuel tank for foreign objects which may block the fuel supply.
Check for air in the low pressure fuel supply system if any of the following procedures have been performed:
Replacement of the fuel filters
Service on the low pressure fuel supply circuit
Replacement of unit injectorsNote: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Refer to Testing and Adjusting for more information.
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
Purge air from the low pressure fuel supply circuit. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.
Check fuel quality. In temperatures below 0 °C (32 °F), check for solidified fuel (wax). Refer to Special Instruction, SEBD0717, "Diesel Fuels And Your Engine".
Check the fuel pressure after the fuel filter while the engine is being cranked. Refer to Testing and Adjusting for the correct pressure values. If the fuel pressure is low, replace the fuel filters. If the fuel pressure is still low, check the following items: fuel transfer pump, fuel transfer pump coupling and fuel pressure regulating valve. Refer to Testing and Adjusting for more information.