21509611 Volvo.Penta Roller kit

Illustration 1 g01023143
Typical circuit with EMCP IITest 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, and the harness and wiring are 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. Stop.Test 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 is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC. The ECM is receiving the correct voltage. Proceed to Test Step 6.
Not OK - The voltage is not 24 3 VDC. 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 the open circuit 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 open circuit voltage at the batteries is at least 24 1 VDC, and the batteries should pass the load test.Results:
OK - The open circuit voltage at the batteries is 24 1 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, "Electrical System". Stop.Test Step 4. Check the Voltage from the Generator Set Control.
Disconnect the engine harness connector J3/P3.
Remove wires P3-18 and P3-39 from the engine harness connector J3/P3.
Reconnect 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 is 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 P3-5 and P3-39 from 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 P3-5 and P3-39 at the 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 is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC.Repair: There is a problem in the generator set control or 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 generator set control and engine connector J3/P3. Stop.
Not OK - The voltage is not 24 3 VDC.Repair: Check the battery disconnect switch for proper operation. Ensure that the EMCPII breaker 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. Stop.Test Step 6. Check the Voltage at the Sensor Power Supplies.
Disconnect ECM connector J1/P1.
Remove the following wires from ECM connector P1. Install a wire jumper for each of the following wires that are removed.
P1-36 analog power 997-OR
P1-30 analog return 993-BR
P1-35 digital power A700-OR
P1-29 digital return 998-BR
Reconnect ECM connector J1/P1.
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.
Measure the voltage from digital sensor supply P1-35 to the digital sensor return P1-29.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Remove the wire jumpers. Replace all wires.Expected Result:The voltage is 5.0 0.2 VDC between P1-36 and P1-30. The voltage is 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.Repair: The problem may be intermittent. If the problem is intermittent, refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors". Stop.
Not OK - If the ECM is getting the correct voltage at the +Battery terminal, but the ECM does not supply the correct voltages to the sensors, replace the ECM.Repair: Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM". Stop.