859111 Volvo.Penta Gasket

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Schematic for the engine shutdown switch (PM102)
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Schematic for the engine shutdown switch (AP755)Test Step 1. Inspect the Electrical Connectors and the Wiring
Remove the electrical power from the ECM.
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Left side engine view (typical example) (1) J1/P1 ECM connectors
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Left side model view (typical example) (2) Engine shutdown switch
Thoroughly inspect all of the connectors and thoroughly inspect all of the connections. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
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P1 ECM connector (P1-23) Engine shutdown switch (N/O) (P1-40) Engine shutdown switch (N/C)
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 allen head screw for each of the ECM connectors for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect" for the correct torque value.
Check the harness and the wiring for abrasion and for pinch points.Expected Result:All of the connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not OK.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Status of the Switch Inputs
Connect Cat ET to the service tool connector.
Toggle the engine shutdown switch to the RUN position.
Restore the electrical power to the ECM.
Check the status indicators on Cat ET with the power restored to the ECM.The status indicator for the user defined shutdown will not be active.
Toggle the engine shutdown switch to the STOP position.
Check the status indicators on Cat ET with the power restored to the ECM.Cat ET will display "Remote Shutdown" with the engine shutdown switch in the STOP position.
Return the engine shutdown switch in the RUN position. Remove the electrical power from the ECM.Expected Result:The status indicator for the "Remote Shutdown" is displayed on Cat ET per the above procedure.Results:
OK - The switch is operating normally.Repair: Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect" if the problem is intermittent.STOP
Not OK - The status of the switch is not displayed per the above specifications.Repair: Repeat this step for every shutdown switch in the circuit. Proceed to Test Step 3.Test Step 3. Test the Relay in the De-energized State
Disconnect the relay from the circuit.
Verify the operation of the relay in the de-energized state.
Measure continuity across the following terminals of the relay:
Terminal 1 to terminal 3
Terminal 5 to terminal 2
Terminal 1 to terminal 4Note: Refer to Illustration 1 or refer to Illustration 2 for the terminal locations for the relay.Expected Result:The following results were obtained:
Terminal 1 to terminal 3 indicated a short circuit.
Terminal 5 to terminal 2 indicated some measured resistance.
Terminal 1 to terminal 4 indicated an open circuit.Results:
OK - Each measurement was correct. Proceed to Test Step 4.
Not OK - A measurement was incorrect.Repair: Replace the relay and retest the circuit.STOPTest Step 4. Test the Relay in the Energized State
Verify the operation of the relay in the energized state.
Apply 24 VDC across the coil of the relay.
Measure continuity across the following terminals of the relay:
Terminal 1 to terminal 3
Terminal 1 to terminal 4Note: Refer to Illustration 1 or refer to Illustration 2 for the terminal locations for the relay.Expected Result:The following results were obtained:
Terminal 1 to terminal 3 indicated an open circuit.
Terminal 1 to terminal 4 indicated a short circuit.Results:
OK - Each measurement was correct. Proceed to Test Step 5.
Not OK - A measurement was incorrect.Repair: Replace the relay and retest the circuit.STOPTest Step 5. Short the Wires at the Switch
Remove the wires from the terminals on the engine shutdown switch.
Install a jumper wire between the wire for the engine shutdown switch (N/C) and the wire for chassis ground.
Restore the electrical power to the ECM.
Check the status indicators on Cat ET with the power restored to the ECM.The status indicator for the user defined shutdown will not be active.
Remove the electrical power from the ECM.
Remove the jumper wire.
Install a jumper wire between the wire for the engine shutdown switch (N/O) and the wire for chassis ground.
Restore the power to the ECM and monitor the status indicators on Cat ET.Cat ET will display the status indicator for "Remote Shutdown".
Remove the electrical power from the ECM.
Remove the jumper wire. Reconnect all wires to the original configuration.Expected Result:The correct status indicator for the engine shutdown switch is displayed on Cat ET.Results:
OK - The correct status indicator for the engine shutdown switch is displayed.Repair: The harness and the ECM are OK. There is a problem with the switch. Temporarily connect a new switch. Verify that the new switch solves the problem before you permanently install the new switch.STOP
Not OK - The correct status indicator for the engine shutdown switch was not