3886264 Volvo.Penta Expansion tank kit

Illustration 1 g00835551
Test Step 1. Check for Connector Damage.
Turn the ECS to the OFF/RESET 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 6.0 N m (55 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 Voltage to the ECM.
Remove ECM connector J1/P1.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Measure the voltage between P1-6 and P1-5.
Measure the voltage between P1-4 and P1-11.
Measure the voltage between P1-23 and P1-11.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Reconnect ECM connector J1/P1.Expected Result:The voltage should be 24 3 VDC from the voltage at the battery terminals.Results:
OK - The voltage is 24 3 VDC from the voltage at the battery terminals. The ECM is receiving the correct voltage. Proceed to test step 6.
Not OK - The voltage is not 24 3 VDC from the voltage at the battery terminals. The voltage is incorrect. The battery or the alternator may be causing the problem. Proceed to test step 3.
Not OK - ECM Keyswitch - The voltage is not 24 3 VDC. Proceed to test step 4.Test Step 3. Check the Battery Voltage.
Measure no-load voltage at the battery terminals. Refer to Testing and Adjusting, "Test Tools for the Electrical System" for the proper procedures to check the batteries.
Load test the batteries. Use the 4C-4911 Battery Load Tester. Refer to the Operating Manual, SEHS9249. Refer to Special Instruction, SEHS7633.Expected Result:The no-load voltage at the batteries should be at least 24 0.5 VDC, and the batteries should pass the load test.Results:
OK - The no-load voltage at the batteries is 24 0.5 VDC, and the batteries pass the load test.Repair: There is a problem in the harness. Repair the connectors and/or wiring or replace the connectors and/or wiring between the battery and the ECM.STOP
Not OK - The battery voltage is incorrect and/or the battery fails the load test.Repair: The batteries or the alternator are causing the problem. Recharge the batteries or replace the batteries. Verify that the original condition is resolved. Refer to Testing and Adjusting, "Charging System".STOPTest Step 4. Check the Voltage from the Generator Set Control.
Disconnect the generator and the engine harness connector J3/P3.
Remove wires P3-18 and P3-39 from the generator and engine harness connector J3/P3.
Reconnect the generator and the engine harness connector J3/P3.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Measure the voltage between P3-18 and P3-39 at the generator and engine harness connector J3/P3.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Replace all wires.Expected Result:The voltage should be 24 3 VDC.Results:
OK - The voltage is 24 3 VDC.Repair: The wire from the ECM to the connector J3/P3 and/or the connectors are damaged. Repair the connectors and/or wiring or replace the connectors and/or wiring.STOP
Not OK - The voltage is not 24 3 VDC. Proceed to test step 5.Test Step 5. Check the Voltage to the Generator Set Control.
Remove wires J3-5 and J3-39 from the generator and engine harness connector J3/P3.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Measure the voltage between J3-5 and J3-39 at the generator and engine harness connector J3/P3.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Replace all wires.Expected Result:The voltage should be 24 3 VDC.Results:
OK - The voltage is 24 3 VDC.Repair: There is a problem in the generator set control or in the harness wiring between the engine and the generator. Check the generator set control for diagnostic codes. Check the ECS for proper operation. Repair the connectors and/or wiring between the GSC+ and the harness connector for the generator and engine J3/P3.STOP
Not OK - The voltage is not 24 3 VDC.Repair: Check the battery disconnect switch for proper operation. Ensure that the EMCPB is not tripped. Repair the connectors and/or wiring or replace the connectors and/or wiring between the battery and the engine connector J3/P3.STOPTest Step 6. Check the Voltage of the Sensor Power Supplies at the ECM Connector.
Remove wires P1-36, P1-30, P1-35, and P1-29 from ECM connector P1. Install wire jumpers into the following sockets: P1-36, P1-30, P1-35 and P1-29.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Measure the voltage from the analog sensor supply P1-36 to the analog sensor return P1-30 at the wire jumpers.
Measure the voltage from digital sensor supply P1-35 to the digital sensor return P1-29 at the wire jumpers.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Remove the wire jumpers and replace ECM connector J1/P1.Expected Result:The analog voltage supply should be 5.0 0.2 VDC between P1-36 and P1-30. The digital voltage supply should be 8.0 0.4 VDC between P1-35 and P1-29.Results:
OK - The sensor power supplies are functioning properly. The ECM is powered up. The problem is not in the electrical system. There may be a mechanical problem.Repair: Check the system for any diagnostic codes.STOP
Not OK -