21698165 Volvo.Penta Gasket

Illustration 1 g01075681
Schematic for the ether injection system
Test Step 1. INSPECT ELECTRICAL CONNECTORS AND WIRING
Verify that there are no circuit breakers that have been tripped.
Turn the circuit breaker for the battery to the OFF position.
Turn the Engine Control Switch (ECS) to the OFF/RESET position.
Thoroughly inspect J1/P1,ECM connectors and J3/P3 Machine interface connector. Inspect all other connectors in the wiring harness. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Inspect the following components for damage, corrosion, and incorrect attachment:
Battery posts
Alternator
Breaker
Engine ground
Chassis groundExpected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring is free of corrosion, of abrasion, and of pinch points. All connections and grounds are tight and free of corrosion.Results:
OK - Proceed to Test Step 3.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 2. CHECK THE ETHER CANISTERS
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Remove the ether canister(s) from the ether solenoid(s). Determine if the canister contains any ether. Expected Result:The ether canisters must contain a sufficient amount of ether for the ether injection system in order to operate properly.Results:
OK - The canister contains a sufficient amount of ether. Proceed to Test Step 3.
Not OK - The ether canister is empty.Repair: Replace the ether canister. Verify that ether can be injected after replacing the empty canister.If the problem has not been eliminated proceed to Test Step 3.Test Step 3. CHECK THE STARTING AID SWITCH STATUS ON CAT ET
Remove the ether canister from the ether solenoid.
Connect the Caterpillar Electronic technician (ET) to the service tool connector.
Turn the ECS to the STOP position.
Press the starting aid switch to "MANUAL". Observe the "Starting Aid Switch Status" on Cat ET. Expected Result:When the starting aid switch is pressed, Cat ET displays the status of the starting aid switch as ON.When the starting aid switch is not pressed, Cat ET displays the status of the starting aid switch as OFF.Results:
OK - The starting aid switch is operating correctly. Proceed to Test Step 4.
Not OK - The ECM is not properly reading the signal from the starting aid switch. Proceed to Test Step 5.Test Step 4. CHECK THE RESISTANCE OF THE ETHER START VALVE
Disconnect J37/P37 (Ether solenoid connector).
Turn the ECS to the OFF/RESET position.
Measure the resistance between J37:1 and J37:2.
Reconnect J37/P37 (Ether solenoid connector). Expected Result:The resistance is less than 8 Ohms.Results:
OK - Proceed to Test Step 6.
Not OK - The relay is faulty.Repair: Replace the relay.Verify that the repair eliminates the problem.STOPTest Step 5. BYPASS THE ETHER STARTING AID SWITCH
Turn the ECS to the OFF/RESET position.
Remove wire F720-GN(Green) (Starting aid switch) and wire 998-BR(Brown) (Digital return) from the starting aid switch.
Turn the ECS to the STOP position. Observe the status of starting aid switch on Cat ET.
Turn the ECS to the OFF/RESET position and short wire F720-GN(Green) (Starting aid switch) to wire 998-BR(Brown) (Digital return).
Turn the ECS to the STOP position and observe the status of starting aid switch on Cat ET. Expected Result:When the wires are shorted, Cat ET displays the status of the starting aid switch as ON.When the wires are not shorted, Cat ET displays the status of the starting aid switch as OFF.Results:
OK - The starting aid switch is not operating correctly.Repair: Replace the starting aid switch.Verify that the repair eliminates the problem.STOP
Not OK - The starting aid switch is operating correctly. Proceed to Test Step 7.Test Step 6. CHECK THE SUPPLY VOLTAGE TO THE ETHER START VALVE
Illustration 2 g00743804
J1/P1 breakout
Note: The ether canister must be removed prior to activating this test.
Turn the ECS to the STOP position.
Access the diagnostic override screen on Cat ET and activate the ether system. Note: The diagnostic override will only activate the ether relay for three seconds.
Measure the supply voltage at J37:1 and J37:2. Expected Result:The supply voltage is 24.0 8.0 VDC.Results:
OK - Proceed to Test Step 8.
Not OK - The ECM is not reading the switch input properly.Repair: Verify your results. Replace the ECM. Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM.Verify that the repair eliminates the problem.STOPTest Step 7. CHECK FOR SHORTS IN THE HARNESS
Disconnect J1/P1 ECM connector. Remove wire F720-GN(Green) (Starting aid switch) and wire 998-BR(Brown) (Digital return) from the starting aid switch.
Measure the resistance between P1:25 (Starting aid switch) and P1:29 (Digital return).
Measure the resistance between P1:25 (Starting aid switch) and engine ground. Also measure the resistance between P1:25 (Starting aid switch) and all the other pins in the P1 (ECM connector). Expected Result:The resistance is greater than 20,000 Ohms for each measurement.Results:
Ok - Proceed to Test Step 9.
Not OK - There is a short in the harness between the starting aid switch and the ECM.Repair: Repair the wiring or replace the wiring. Verify that the repair has eliminated the problem.STOPTest Step 8. CHECK RESISTANCE AT THE ETHER RELAY COIL
Turn the ECS to the OFF/RESET position.
Disconnect the wires on terminal 85 and terminal 86 of the ether relay.
Measure the resistance between the ether relay terminals 85 and 86.
Reconnect the wires to the ether relay. Expected Result:The resistance is 360 100 VDC.Results:
OK - Proceed to Test Step 9.
Not OK - The ether relay is faulty.Repair: Replace the ether relay. Verify that the repair has eliminated the problem.STOPTest Step 9. CHECK RESISTANCE THROUGH THE HARNESS
Remove wire F720-GN(Green) (Starting aid switch) and wire 998-BR(Brown) (Digital return) from the starting aid switch.
Short wire F720-GN(Green) (Starting aid switch) to wire 998-BR(Brown) (Digital return).
Measure the resistance between P1:25 and P1:29. Expected Result:The resistance is less than 10 Ohms.Results:
OK - The resistance in the harness is within acceptable limits. Proceed to Test Step 11.
Not OK - There is an open circuit or excessive resistance in the harness.Repair