3801402 Volvo.Penta Servo unit

Illustration 1 g01023645
Typical circuit with EMCP II
Illustration 2 g01023927
Typical circuit with EMS 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 or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check the Engine Diagnostics on the Caterpillar Electronic Technician (ET).
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Connect Cat ET to the service tool connector J60/P60.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Determine if CID-FMI 545-05 Ether Start Relay open/short to +batt, 545-06 Ether Start Relay short to ground, 546-05 Ether Hold Relay open/short to ground or 546-06 Ether Hold Relay short to +batt is active or logged.Expected Result:No active codes or logged codes are present.Results:
OK - No active codes or logged codes are present. The ether injection system does not inject ether. Proceed to Test Step 3.
Active Code - Active diagnostics are displayed. Proceed to Test Step 4.
Logged Code - Logged Diagnostics are displayed. Check for an intermittent short or for an open in the wiring or in the connectorsRepair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 3. Check the Ether Canisters.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Remove the ether canister(s) from the ether solenoid(s). Determine if the canister(s) contains any ether.Expected Result:The ether canister(s) is not empty.Results:
OK - The ether canister(s) is not empty. Proceed to Test Step 4.
Not OK - The ether canister(s) is empty.Repair: Replace the empty ether canister with a full ether canister. Retry the system. Stop.Test Step 4. Check the Voltage from the Ether Start Relay.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Remove the ether canister(s) from the ether solenoid(s).
Connect Cat ET to the service tool connector J60/P60.
Connect a voltmeter between terminal 87 of the ether start relay and ground.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Select the "Diagnostic Tests" on Cat ET.
Select the "Override Parameters" screen on Cat ET.
Activate the ether override and observe the voltmeter while ether injection is activated.Note: Do not allow the ether to be activated for more than two minutes. Damage to the solenoid may occur.
Measure the voltage at the ether start relay with the voltmeter.
Deactivate the ether override.Expected Result:The voltage at the ether start relay is 24 3 VDC during the first two seconds of injection.Results:
OK - The voltage at the ether start relay is 24 3 VDC during the first two seconds of injection. Proceed to Test Step 5.
Not OK - 24 VDC - The voltage at the ether start relay is not 24 3 VDC during the first two seconds of injection. Proceed to Test Step 6.Test Step 5. Check the Voltage at the Ether Solenoids.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Disconnect the ether solenoid connector at the solenoid.
Connect a voltmeter to pin 1 and pin 2 of the ether solenoid connector.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Select the "Diagnostic Tests" on Cat ET.
Select the "Override Parameters" screen on Cat ET.
Activate the ether override and observe the voltmeter while ether injection is activated.Note: Do not allow the ether to be activated for more than two minutes. Damage to the solenoid may occur.
Measure the voltage at the ether solenoid connector with the voltmeter.
Deactivate the ether override.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Reconnect all connectors.Expected Result:The voltage at the ether solenoid is 24 3 VDC during the first two seconds of injection. The voltage then decreases to 3 1 VDC for the remainder of the injection duration.Results:
OK - The voltage