40005838 Volvo.Penta Overhaul kit, reconditioning

Introduction
This Special Instruction provides information to troubleshoot 389-5860 Jacket Water Heater (120 V) and 475-3881 Heater As (240 V) on certain marine engines.Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.Safety Section
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.
When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.
Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.
Personal injury can result from improper handling of chemicals.Make sure you use all the necessary protective equipment required to do the job.Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.
Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.
Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.
Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.
Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.
Jacket Water Heater Part List
Table 1
Part List
Part Number Part Name
389-5860 Jacket Water Heater (120 V)
475-3881 Heater As ( 240 V) Heater Location
Illustration 1 g06489988
(A) Coolant return port into engine
(B) Coolant supply port from engine
(C) Coolant inlet port into pump
(D) Coolant return port from pump
(E) 120/240 V Power supplyNote: Check coolant hose connections and ensure coolant is filled and air is vented before applying power.
Mount the heater in proper orientation.
Mount the heater minimum 152 mm (6 inch) below the lowest point of the water jacket.
Ensure that the heater is mounted to vibration isolated surface.Plug Resistance
Table 2
Resistance Across Plugs
Part Number Resistance (In Ohms)
389-5860 13.3 to 15.5
475-3881 53.2 to 62.1