803542 Volvo.Penta Gear

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Certain 900 series K and M Compact Wheel Loaders engine may not start on the machines listed above. The problem is most prevalent at low operating hours and may present with a blown 10A fuse.Solution
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Table 1
Required Parts
Item Qty Part Number Part Name
1 1 385-5044 Starting Motor Assembly
2 1 115-1615 Relay As (12-VOLT) (START)
3 1 113-8490 Fuse (10-AMPERE)
4 1 265-8025 Relay As (12-VOLT) (MAIN) (B) Inspect the condition and connections of the parts listed in Table 1.If any defective components are found, replace with same part number.Rework procedure
Follow the Troubleshooting , UENR3422-18 , "C3.3B Engines for Caterpillar Built Machines" to determine the source of the problem.
Illustration 1 g06545144
Fuse block location
Illustration 2 g06545139
Fuse block
(3) 113-8490 Fuse (10-AMPERE)
Check the 113-8490 Fuse (10-AMPERE), make sure that the fuse has not blown, see Illustration 1. The 113-8490 Fuse (10-AMPERE) can be found in the bottom-left corner of the right hand (forward most) fuse block in the side console see Illustration 2.If the fuse has blown, carry out the remaining checks described in these instructions before replacing the fuse with the same part number.Note: A blown fuse, or a fuse that blows immediately after replacement is most likely cause of the machine not starting. A blown fuse may also be a symptom of another problem on the machine.
Take a photo of the 265-8025 Relay As (12-VOLT) (MAIN)(B). The Main Relay (B) can be found in the side console and is mounted on a horizontal block see Illustration 3.
Illustration 3 g06545156
Relay location
(4) 265-8025 Relay As (12-VOLT) (MAIN)(B)
Check that the Main Relay (B) is securely mounted into the relay block and not lose.If the relay is loose, disconnect the relay from the relay contact block. Check that the relay pins are not bent and check for abnormalities in the relay pins and contact block sockets. If no abnormalities are found, reinstall the relay so the connection is properly made.If any abnormalities are found, replace the required components.Test for a working relay. Turn the ignition key to the on position. The relay should energize, and power will be sent to the fuse panel.
Illustration 4 g06545167
Starter relay location
(2) 115-1615 Relay As (12-VOLT) (START)
Take a photo of 115-1615 Relay As (12-VOLT) (START) showing the general condition of the relay. See Illustration 4 for location.
Check that the connector in the base of the relay is secure and not loose.If the connector is loose, disconnect the harness from the relay. Check that the pins are not bent and check for abnormalities in the relay pins and sockets. If no abnormalities are found, firmly reconnect the harness to the relay so the proper connection is made.If any abnormalities are found, replace the required components.Test for a working relay. During engine startup, the relay should energize and 12V will be sent to the solenoid connection on the starter motor. The relay should de-energize and 12V should disappear once the starting cycle is complete.
Illustration 5 g06545180
Starter motor location
(1) 385-5044 Starting Motor Assembly
Take a photo of the 385-5044 Starting Motor Assembly showing the general condition of the starter motor. See Illustration 5.
Illustration 6 g06545684
Starter connections
(A) Starter wire
(B) Starter solenoid wire
Take a photo of the battery positive wire (A) and the starter solenoid wire connections (white wire) (B) on the starter motor. See Illustration 6.
Check that the spade terminal for the starter motor solenoid (white wire) (B) is not loose. There have been some reports from the field that this connection has become loose.If the connection is found to loose, push the spade terminal firmly onto the starter solenoid pin. If the connection still feels loose, replace the spade connector.
If the actions described in steps 2-9 have not remedied t