8192087 Volvo.Penta Gear, fuel inj. pump

Illustration 1 g00871125
Test Step 1. Inspect Electrical Connectors and Wiring
Illustration 2 g00830481
ECM connector P1 (wire side)
Thoroughly inspect the J1/P1 ECM connector, the battery connections, and the connections to the keyswitch. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the electrical power supply. Refer to Illustration 2.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasions and for pinch points from the battery to the ECM. Also, check the harness and wiring for abrasions and for pinch points from the keyswitch to the ECM.Expected Result:All connectors, pins, and sockets should be completely coupled and/or inserted. The harness and wiring should be free of corrosion, abrasion, and/or pinch points.Results:
OK - The wiring and the connectors are good. Proceed to Test Step 2.
Not OK - There is a problem with the connectors and wiring.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. Stop.Test Step 2. Check the Battery Voltage at the Batteries
Measure the no-load battery voltage and load test the batteries. Use the 4C-4911 Battery Load Tester. Refer to Special Instruction, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8 and 12 Volt Lead Acid Batteries" and Special Instruction, SEHS7633, "Battery Test Procedure".Expected Result:The battery voltage is OK and the batteries pass the load test.Results:
OK - The batteries are good. Proceed to Test Step 3.
Not OK - Recharge or replace the batteries.Repair: Recharge or replace the faulty batteries. Verify that the repair eliminates the problem. Stop.Test Step 3. Check the Unswitched Battery Voltage at the ECM
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ECM connector P1 (ECM side)
Ensure that the keyswitch is in the OFF/RESET position.
Disconnect the J1/P1 ECM connector.
Measure the voltage between all of the +Battery terminals and all of the -Battery terminals in the P1 ECM connector. Refer to Illustration 3.Expected Result:The measured voltage is a constant voltage that is within 1 VDC of battery voltage.Results:
OK - The ECM is receiving the correct unswitched battery voltage. Proceed to Test Step 4.
Not OK - The ECM is not receiving the correct unswitched battery voltage.Repair: If an intermittent condition is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".Isolate the circuit that is not providing the correct voltage. Repair the circuit. Verify that the repair eliminates the problem. Stop.Test Step 4. Check the Keyswitch Voltage at the ECM
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ECM connector P1 (ECM side)
Ensure that the J1/P1 ECM connector is disconnected.
Turn the keyswitch to the ON position.
Measure the voltage between P1:70 (Keyswitch (Run)) and P1:63 (-Battery).
Turn the keyswitch to the OFF/RESET position and reconnect the J1/P1 ECM connector.Expected Result:The measured voltage is a constant voltage that is within 1 VDC of battery voltage.Results:
OK - The ECM is receiving the correct voltage at this time. Proceed to Test Step 5.
Not OK - The ECM is not receiving the correct voltage.Repair: Repair the keyswitch circuit. Verify that the repair eliminates the problem. Stop.Test Step 5. Bypass the Machine Wiring
Batteries give off flammable fumes which can explode.To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery.
Do Not connect the bypass harness to the battery until the 20 Amp in-line fuse has been removed from the +Battery line. If the fuse is not removed before connection to the battery, a spark may result.
Illustration 5 g00781203
Bypass harnessNote: This bypass harness is only for test applications. This bypass harness may be left only temporarily on the machine. The bypass harness can be used in order to determine if the cause of the intermittent problem is interruptions in battery power to the ECM or the keyswitch circuit.
Turn the keyswitch to the OFF/RESET position.
Disconnect the J1/P1 ECM connector.
Connect a bypass harness to the J1/P1 ECM connector.
Remove the 20 Amp in-line fuse from the positive battery circuit of the bypass harness and connect the alligator clamps directly to the battery posts. Note: This bypass directly connects the circuit for the keyswitch to the ECM. The ECM will remain powered until the positive battery circuit is interrupted. Remove the 20 Amp fuse from the in-line fuse holder in order to power down the ECM. Do not connect the bypass to the battery posts without