3819998 Volvo.Penta Solenoid

Troubleshooting Index
1. Engine will not crank2. Engine cranks, but will not start3. Engine starts, but stalls immediately4. Erratic or unstable engine speed (rpm)5. Engine misfires or runs rough6. No or poor response to throttle7. Low power/Engine speed (rpm) restricted8. Intermittent engine shutdowns or power reduction9. Low engine oil pressure10. Excessive lubrication oil consumption11. High exhaust temperature12. Abnormal engine coolant temperature13. Excessive fuel consumption14. Alternator fails to charge/charging rate high, low or unsteadyIf you have a problem that does not appear in this index, refer to the Service Manual for your engine and/or contact your Caterpillar dealer.1. Engine will not crank
Batteries: Make sure battery cables are corrosion free and securely attached. Check battery output and charge or replace. Starting Circuit Wiring: Check wiring to starting motor solenoid. Starting Solenoid: Inspect starting motor cables for corrosion, damage or loose connections. Starting Motor: Test solenoid and starting motor operation.2. Engine cranks, but will not start
Fuel Supply: Check for empty fuel tank, plugged fuel tank connections, obstructed or kinked fuel suction lines, plugged fuel filter, air in fuel system or kinked, leaking or broken fuel lines. Fuel Transfer Pump: At cranking speed, the fuel transfer pump should supply fuel to the engine at 3 psi (20 kPa). If fuel pressure is less than 3 psi, replace the fuel filters. Check for air in the fuel system, sticking, binding or defective fuel bypass valve. Check lip-type seal on transfer pump drive shaft. When the engine is fully loaded the transfer pump should supply fuel at 20 to 30 psi (138 to 208 kPa). Engine Timing: See your authorized dealer. Shutoff Solenoid: Actuate the control that operates the shutoff solenoid and listen for a "clicking" sound. Power Supply to ECM: Check electrical connectors, wiring and voltage from battery to ECM. Power to ECM should measure 22 to 27 volts. Shutoff Solenoid: Check electrical connectors and wiring. Mechanically override the shutoff solenoid by attaching a lever to the fuel pump. Push lever backward to override the solenoid or forward to shut off fuel supply. Overspeed Protection: Check to ensure control is properly set. Engine Speed Signal: (Magnetic Pickup) Check electrical connectors and wiring. Speed sensor failure will initiate automatic electronic default. Replace or adjust. Rack Controls: Check electrical connectors and wiring from ECM to rack position sensor and to rack BTM. Measure the signal output to the ECM. Also check for binding of servo or rack.3. Engine starts, but stalls immediately
Fuel Supply: Check for empty fuel tank, plugged fuel tank connections, obstructed or kinked fuel suction lines, plugged fuel filter, air in fuel system or kinked, leaking or broken fuel lines. Fuel Injection Nozzle/Pump: If the engine is misfiring or engine speed (rpm) is restricted, run the engine at the speed where the problem is most pronounced. Momentarily loosen the fuel line nut on the injection pump to "cut out" that cylinder. Check each cylinder in this manner. If one is found where loosening makes no difference in irregular operation, the pump and nozzle for that cylinder should be inspected for damage, wear and proper operation. Inspect components for leaks and replace as needed. Shutoff Solenoid: Actuate the control that operates the shutoff solenoid and listen for a "clicking" sound. Idle Speed: See your authorized dealer. Auxiliary Attachments: Inspect, align, tighten and check for excessive parasitic loading. Shutoff Solenoid: Check electrical connectors and wiring. Mechanically override the shutoff solenoid by attaching a lever to the fuel pump. Push lever backward to override the solenoid or forward to shutoff fuel supply. Power Supply to ECM: Check electrical connectors, wiring and voltage from battery to ECM. Power to ECM should measure 22 to 27 volts. Rack Controls: Check electrical connectors and wiring from ECM to rack position sensor and to rack BTM. Measure the signal output to the ECM. Also check for binding of servo or rack. Engine Speed Signals: (Magnetic Pickup) Check electrical connectors and wiring. Speed sensor failure will initiate automatic electronic default. Replace or adjust.4. Erratic or unstable engine speed (rpm)
Fuel Supply: Check for empty fuel tank, plugged fuel tank connections, obstructed or kinked fuel suction lines, plugged fuel filter, air in fuel system or kinked, leaking or broken fuel lines. Rack Controls: Check electrical connectors and wiring from ECM to rack position sensor and to rack BTM. Measure the signal output to the ECM. Also check for binding of servo or rack. Throttle Position Signal: Check electrical connectors and wiring. Supply voltage to sensor should be between 22 and 27 V DC. Engine Speed Signal: (Magnetic Pickup) Check electrical connectors and wiring. Speed sensor failure will initiate automatic electronic default. Replace or adjust. ECM or Personality Module: Check electrical connectors and wiring. Remove Personality Module cover and inspect O-ring seal, module and socket for physical damage or corrosion.5. Engine misfires or runs rough
Fuel Injection Nozzle/Pump: If the engine is misfiring or engine speed (rpm) is restricted, run the engine at the speed where the problem is most pronounced. Momentarily loosen the fuel line nut on the injection pump to "cut out" that cylinder. Check each cylinder in this manner. If one is found where loosening makes no difference in irregular operation, the pump and nozzle for that cylinder should be inspected for damage, wear and proper operation. Inspect components for leaks and replace as needed. Valve Lash: Adjust valves to specified clearances. Fuel Injection Timing: See your authorized dealer. Inlet & Exhaust System: Check for plugged air filter, aftercooler restrictions, aftercooler leaks, high inlet air temperature. Inspect all gaskets and piping for leaks. Check Exhaust System for any restrictions. Fuel Supply: Check for empty fuel tank, plugged fuel tank connections, obstructed or kinked fuel suction lines, plugged fuel filter, air in fuel system or kinked, leaking or broken fuel lines. Rack Controls: Check electrical connectors and wiring from ECM to rack position sensor and to rack BTM. Measure the signal output to the ECM. Also check for binding of servo or rack.6. No or poor response to throttle
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