861154 Volvo.Penta Pulley

Illustration 1 g00782194
Typical schematic
Test Step 1. Check for Connector Damage.
Turn the keyswitch to the OFF position.
Turn the battery disconnect switch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and for pinch points. Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring should be free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and wiring are okay. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.STOPTest Step 2. Check the ECM Supply Voltage.
Turn the keyswitch to the ON position. The engine should be off.
Measure the voltage between P1-4 and P1-11 at ECM connector J1/P1. Expected Result:The voltage should be 24 3 VDC.Results:
OK - The voltage is 24 3 VDC. The voltage is correct. Proceed to Test Step 3.
Not OK - The voltage is not 24 3 VDC. The voltage is incorrect.Repair: Perform the diagnostic functional test Troubleshooting, "Electrical Power Supply".STOPTest Step 3. Check for Voltage at the Prelubrication Motor.
Turn the keyswitch to the OFF position.
Connect the Caterpillar Electronic Technician (ET).
Connect a voltmeter between the positive terminal of the prelubrication motor and the engine ground.
Turn the keyswitch to the ON position. The engine should be off.
Access the override for the prelubrication system.
Enable the override for the prelubrication system.
Monitor the voltage on the voltmeter. Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to Test Step 4.
Not OK - The voltage does not measure 24 3 VDC. Proceed to Test Step 5.Test Step 4. Check the Operation of the Prelubrication Motor.
Turn the keyswitch to the OFF position.
Connect one side of a suitable piece of 10 AWG wire to the + Battery terminal.
For one second, connect the other end of the wire to the positive terminal of the prelubrication motor. Expected Result:The prelubrication motor should start while the wire is connected to the positive terminal of the prelubrication motor.Results:
OK - The prelubrication motor starts. There is a problem in the wiring harness at the prelubrication motor.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOP
Not OK - The prelubrication motor did not start.Repair: The problem appears to be in the prelubrication motor. Install a new prelubrication motor.STOPTest Step 5. Check the Output Voltage from the Prelubrication Relay.
Connect a voltmeter between wire X337-WH(White) on terminal 87 of the prelubrication relay and the engine ground.
Turn the keyswitch to the ON position. The engine should be off.
Access the override for the prelubrication system.
Enable the override for the prelubrication system.
Monitor the voltage on the voltmeter.
Disable the override for the prelubrication system. Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to Test Step 6.
Not OK - The voltage does not measure 24 3 VDC. Proceed to Test Step 8.Test Step 6. Check the Voltage to the Coil of the Main Power Relay.
Connect a voltmeter between wire X337-WH(White) on the main power relay and the engine ground.
Turn the keyswitch to the ON position. The engine should be off.
Access the override for the prelubrication system.
Enable the override for the prelubrication system.
Monitor the voltage on the voltmeter.
Disable the override for the prelubrication system. Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to Test Step 7.
Not OK - The voltage does not measure 24 3 VDC. There is a problem in the wiring harness between the prelubrication relay and the main power relay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 7. Check Continuity from the Coil of the Main Power Relay to Ground.
Turn the keyswitch to the OFF position.
Disconnect wire 200-BK(Black) on the main power relay.
Measure the resistance between 200-BK(Black) on the main power relay and the engine ground.
Replace all wires. Expected Result:The resistance should measure less than 5 Ohms.Results:
OK - The resistance measures less than 5 Ohms.Repair: Verify that battery voltage is available to the normally open contacts of the main power relay. If voltage is not available to the normally open contacts of the main power relay, check the wiring between the battery and the main power relay. If necessary, repair the wiring. Recheck the system. If system voltage is available, replace the main power relay.STOP
Not OK - The resistance is greater than 5 Ohms.Repair: There is an open or an excessive resistance in the wire. Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 8. Check the Voltage to the Coil of the Prelubrication Relay.
Connect a voltmeter between wire X809-OR(Orange) on terminal 86 of the prelubrication relay and the engine ground.
Turn the keyswitch to the ON position. The engine should be off.
Access the override for the prelubrication system.
Enable the override for the prelubrication system.
Monitor the voltage that was measured on the voltmeter.
Disable the override for the prelubrication system. Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to Test Step 9.