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Workshop Manual
Electrical system
Wiring diagrams

-<o-)

t----

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31, 32, 41, 42, 43,


44, 300 series

Group 30 Electrical system


Marine engines
MD31A TMD31 B, D, L-A
TAMD31 B, D, S.O.L.A.S, L-A, M-A, P-A, S-A
A0318, 0, L-A, P-A KA032P
TMD41 B, D, L-A
TAM041 B, 0, S.O.L.A.S, L-A, M-A, P-A, H-A, H-8
0418, 0, L-A A0418, 0, L-A, P-A
TAMD42AWJ, BWJ, WJ
KAM042A, 8, P KA042A, B, P
KAM043P KA043P
KAMD44P-A, P-B, P-C KAD44P-A, P-B, P-C
KAM 0300-A KA0300-A

Contents
Safety infonnation .. .......... .......... ......... ......... .......

General information ...... ......... .......... ......... ......... .. 5


Special tools .. .......... ......... .......... ......... ......... .......

Other special equipment .......... .......... ........ .........

Design and function ......... ......... .......... ......... .......

7
7

General...............................................................
Generator............................................................
Starter motor . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . .
Electrical connection box ....... ........... .......... .......
Fuses and circuit breakers .................................
Monitors . . . .. . . . . .. . .. . . . . .. . .. . . . . .. . .. . . . . . .. . .. . . . . .. . .. . . . . .. . .. . .
Glow plugs..........................................................
Sensors ..............................................................
Solenoid valve .. . ........ ........ ......... ........ ........ ........
Engine speed relay .. ........ ....... ...... ........ ....... .......

B
B
9
10
10
10
11
11
12

Charging system .................................................. 14


General ............................................................... 14
Technical data .. . ........ ........ ......... ........ ........ ........ 14
Faultfinding ... . ....... ........ ........ ........ ....... ........ ....... 15

Wiring diagrams, engine ..................................... 20


31/411-pole ........................................................ 20
KAD32, KA(M)D42/43 1-pole .............................. 22

TAMD42AWJ, BWJ, WJ 1.5-pole .......................


31/41 1.5-pole 12 V .............................................
31/41 1.5-pole 24 V .............................................
441300 .................................................................

24
26

28
30

Wiring diagrams, instrument panel .................... 34


Instrument panel, main station ........................... 34
Instrument panel, fly bridge ................................ 36
Instrument kit, main station ................................ 3B
Instrument kit, fly bridge ..................................... 40
Clutch control panel, water jet ............................ 42
Diode cable, 1.5-pole electrical system .............. 44

EDC control system ... .......... ......... ......... ......... ..... 46


Control panels..................................................... 46
Color-codes for EDC cables ............................... 58
Electronic control ................................................ 61
Mechanical control.............................................. 64

Wiring diagrams, Power trim .............................. 66


SX, DP-S ............................................................ 67
290, SP, DP ....................................................... 72
DPX .................................................................... 75

Corrosion protection system ....... .......... ......... .... 76


Active corrosion protection system .................... 76

Safety Precautions
Introduction
This Workshop Manual contains technical data, descriptions and repair instructions for Volvo Penta
products or product versions contained in the contents list. Ensure that the correct workshop literature
is being used.

&

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Read the safety information and the Workshop


Manual "General Information" and "Repair Instructions" carefully before starting work.

Important

&

In this book and on the engine you will find the following special warning symbols.

&
&

WARNING! If these instructions are not followed there is a danger of personal injury, extensive damage to the product or serious mechanical malfunction.

&

IMPORTANT! Used to draw your attention to


something that can cause damage, product
malfunction or damage to property.

NOTE! Used to draw your attention to important information that will facilitate work or operations.

&

Below is a summary of the risks and safety precautions you should always observe or carry out when
operating or servicing the engine.

&

&

Immobilize the engine by turning off the power


supply to the engine at the main switch {switches) and lock it {them) in the OFF position before
starting work. Set up a warning notice at the engine control point or helm.

&

&
Generally, all servicing should be carried out
with the engine switched off. Some work {carrying out certain adjustments for example) requires the engine to be running. Approaching a
running engine is dangerous. Loose clothing or
long hair can fasten in rotating parts and cause
serious personal injury.
If working in proximity to a running engine, careless movements or a dropped tool can result in
personal injury. Avoid burns. Take precautions
to avoid hot surfaces {exhausts, turbochargers,
charge air pipes and starter elements etc.) and
liquids in supply lines and hoses when the engine is running or has been turned off immediately prior to starting work on it. Reinstall all
protective parts removed during service operations before starting the engine.

&

Check that the warning or information decals on


the product are always clearly visible. Replace
decals that have been damaged or painted
over.
Never start the engine without installing the air
cleaner {ACL). The rotating compressor in the
Turbo can cause serious personal injury. Foreign objects entering the intake ducts can also
cause mechanical damage.
Never use start spray or similar to start the engine. The starter element may cause an explosion in the inlet manifold. Danger of personal injury.
Avoid opening the coolant filling cap when the
engine is hot. Steam or hot coolant can spray
out at the same time as the pressure which has
built up is lost. Open the filler cap slowly, and
release the pressure in the cooling system if the
filling cap or tap has to be opened, or if a plug or
coolant hose has to be removed when the engine is hot. Steam or hot coolant can stream out
in an unexpected direction.
Hot oil can cause burns. Avoid skin contact
with hot oil. Ensure that the lubrication system
is not under pressure before commencing work
on it. Never start or operate the engine with the
oil filler cap removed, otherwise oil could be
ejected.
Stop the engine and close the sea cock before
carrying out operations on the engine cooling
system.

Only start the engine in a well-ventilated area. If


operating the engine in an enclosed space, ensure that exhaust gases and crankcase ventilation emissions are ventilated out of the working
area.
Always use protective goggles where there is a
danger of pieces of metal, sparks from grinding,
acid or other chemicals being thrown into your
eyes. Your eyes are very sensitive, injury can
lead to loss of sight!

Safety Precautions

Avoid skin contact with oil. Long-term or repeated contact with oil can remove the natural oils
from your skin. The result can be irritation, dry
skin, eczema and other skin problems.
Used oil is more dangerous to health than new
oll. Use protective gloves and avoid using oilsoaked clothes and rags. Wash regularly, especially before meals. Use the correct barrier
cream to prevent dry skin and to make cleaning
your skin easier.

Most chemicals used in products (engine and


transmission oils, glycol, petrol and diesel oil)
and workshop chemicals (solvents and paints)
are hazardous to health Read the instructions
on the product packaging carefully! Always follow safety instructions (using breathing apparatus, protective goggles and gloves for exampie). Ensure that other personnel are not
unwittingly exposed to hazardous substances
(by breathing them in for example). Ensure that
ventilation is good. Handle used and excess
chemicals according to instructions.

&

Be extremely careful when tracing leaks in the


fuel system and testing fuel injection nozzles.
Use protective goggles! The jet ejected from a
fuel injection nozzle is under very high pressure, it can penetrate body tissue and cause
serious Injury There is a danger of blood poisoning.

All fuels and many chemicals are inflammable.


Ensure that a naked flame or sparks cannot lgnite fuel or chemicals. Combined with air in certain ratios, petrol, some solvents and hydrogen
from batteries are easily inflammable and explosive. Smoking is prohibited! Ensure that ventilation is good and that the necessary safety precautions have been taken before carrying out
welding or grinding work. Always have a fire extinguisher to hand in the workplace.

&

Store oil and fuel-soaked rags and fuel and all


filters safely. In certain conditions oil-soaked
rags can spontaneously ignite. Used fuel and oil
filters are environmentally dangerous waste and
must be deposited at an approved site for destruction together with used lubricating oil, contaminated fuel, paint remnants, solvent, degreasing agents and waste from washing parts.

Never allow a naked flame or electric sparks


near the batteries. Never smoke in proximity to
the batteries. The batteries give off hydrogen
gas during charging which when mixed with air
can form an explosive gas - oxyhydrogen. This
gas is easily ignited and highly volatile . lncorrect connection of the battery can cause a
spark which is sufficient to cause an explosion
with resulting damage. Do not disturb battery
connections when starting the engine (spark
risk) and do not lean over batteries.

&

Never mix up the positive and negative battery


terminals when installing. Incorrect installation
can result in serious damage to electrical equipment. Refer to wiring diagrams.

&

Always use protective goggles when charging

and handling batteries. The battery electrolyte


contains extremely corrosive sulfuric acid. If
this comes Into contact with the skin, wash immediately with soap and plenty of water. If battery acid comes into contact with the eyes, immediately flush with copious amounts of water
and obtain medical assistance.

&

Turn off the engine and turn off power at main


switch(es) before carrying out work on the electrical system.

&

The clutch must be adjusted with the engine


shut off.

&

Use the lifting eyes mounted on the engine/reverse gear when lifting the drive unit.
Always check that lifting equipment is in good
condition and has sufficient load capacity to lift
the engine (engine weight including reverse gear
and any extra equipment installed).
To ensure safe handling and to avoid damaging
engine components on top of the engine, use a
lifting beam to raise the engine. All chains and
cables should run parallel to each other and as
perpendicular as possible In relation to the top
of the engine.
If extra equipment is installed on the engine altaring its center of gravity, a special lifting device is required to achieve the correct balance
for safe handling.
Never carry out work on an engine suspended
on a hoist.

Safety Precautions

&

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Never remove heavy components alone, even


where secure lifting equipment such as secured
blocks are being used. Even where lifting equipment is being used it is best to carry out the
work with two people; one to operate the lifting
equipment and the other to ensure that components are not trapped and damaged when being
lifted.
When working on-board ensure that there is sufficient space to remove components without
danger of injury or damage.
Components in the electrical and fuel systems
on Volvo Penta products have been designed to
minimize the risks of explosion and fire. The engine must not be operated in environments with
adjacent explosive media.

&
&

&

Fuel delivery pipes must not be bent or straightened under any circumstances. Damaged pipes
must be replaced.
Remember the following when washing with a
high pressure washer: Never aim the water jet at
seals, rubber hoses or electrical components.
Never use a high pressure washer for engine
cleaning.
Always use fuels recommended by Volvo Penta. Refer to the Instruction Book. The use of
lower quality fuels can damage the engine. On
a diesel engine poor quality fuel can cause the
control rod to seize and the engine to overrev
with the resulting risk of damage to the engine
and personal injury. Poor fuel quality can also
lead to higher maintenance costs.

C 2001 AB VOLVO PENTA


We reserve the right to make modifications without prior notice.
Printed on environmentally compatible paper.

General information
About the workshop manual

Certified engines

This workshop manual contains wiring diagrams, descriptions and repair instructions for the electrical
system used in the standard engines in the 31, 32,
41, 42, 43, 44 and 300 series.

When doing service and repair on emission certified


engines, it is important to be aware of the following:

However, electrical components in the EDC system


for engines in the 44 and 300 series are covered in a
separate workshop manual, see "EDC I fuel system".
This Workshop Manual has been developed primarily
for Volvo Penta service workshops and qualified personnel. Persons using this book are assumed to have
a grounding in marine drive systems and be able to
carry out related mechanical and electrical work.
Volvo Penta is continuously developing their products. We therefore reserve the right to make changes. All the information contained in this book is based
on product data available at the time of going to print.
Any essential changes or modifications introduced
into production or updated or revised service methods
introduced after the date of publication will be provided in the form of Service Bulletins.

Replacement parts
Replacement parts for electrical and fuel systems are
subject to statutory requirements (US Coast Guard
Safety Regulations for example). Volvo Penta Genuine parts meet these requirements. Any type of damage which results from the use of non-original Volvo
Penta replacement parts for the product will not be
covered under any warranty provided by Volvo Penta.

Certification means that an engine type has been


checked and approved by the relevant authority. The
engine manufacturer guarantees that all engines made
of the same type are equivalent to the certified engine.
This makes special demands on service and repair
work, as follows:

Maintenance and service intervals recommended


by Volvo Penta must be complied with.

Only Volvo Penta original spares may be used.

Service to injection pumps, pump settings and injectors must always be done by an authorized
Volvo Penta workshop.

The engine must not be converted or modified,


except for the accessories and service kits which
Volvo Penta has approved for the engine.

No installation changes to the exhaust pipe and


engine air inlet ducts may be done.

No seals may be broken by unauthorized personnel.

The general advice in the instruction book about operation, care and maintenance applies.

.&

IMPORTANT! Delayed or inferior care/maintenance, and the use of non-original spares, mean
that AB Volvo Penta can no longer be responsible for guaranteeing that the engine
complies with the certified version.
Damage, injury and/or costs which arise from
this will not be compensated by Volvo Penta.

Special tools
In all cases where it is practical the tool number, except for the final digit, has been stamped on the tool, The final
digit (after the hyphen) is a control number.

115 9660

9510060

998 8452

115 9660-8 Belt tensioner check tool

951 0060-8 Multimeter

998 8452-0 Digital probe tester

Other special equipment


The following tools are intended for use when working on the engines cable harness. The tools are not stocked by
Volvo Penta and can only be ordered via a local AMP dealer. If you have difficulty finding an AMP sales outlet,
contact Volvo Penta Quality Action Center for advice.

AMP 725 840

AMP 825 514

AMP 726 534

AMP 58 495

AMP 725 938

AMP 726 519

AMP 825 582

16 pin CPC connector, d=1.6 mm:

Pin and sleeve terminals 3.5 mm:

725 840-1

Terminal removal tool

725 938-0

Terminal removal tool

58 495-1

Crimping pliers

825 582-2

Crimping pliers

JPT connector (42-pin EDC, 2- and 3-pin Bosch etc.):


726 534-1

Terminal removal tool 1.6 mm pin width

4.8 mm and 6.3 mm cable clamps: Male and


female spade terminals

726 519-1

Terminal removal tool 2.8 mm pin width

825514-1

825514-1

Crimping pliers

Crimpingpliers

Design and Function


General
All of the engines have a 12-volt, 1-pole electrical
system as standard, with an alternator. The exception
is the KA(M)D44/300 which has a 1.5-pole system as
standard.
The TAMD31 M/41 H/41 M can have a 24V1.5-pole
electrical system as an option.

The electrical systems of engine versions can otherwise differ in terms of equipment. The workshop manual does not state what is standard equipment or options or accessories. It only describes the repair
methods.
The generator is ready to be equipped with a wall
mounted charge divider (twin diode) which divides the
charge current to two separate battery circuits.

Location of electrical components


1.
2.
3.
4.
5.

Oil pressure sensor


Oil pressure sensor
Engine coolant temperature (ECT) switch
Engine coolant temperature (ECT) sensor
Junction box

6.
7.
8.
9.

Generator
Starter motor
Solenoid valve (on injection pump)
Inductive engine speed (RPM) sensor (only 32, 42, 43)

Design and function

Generator
The engines are equipped with 2 pole alternating current Valeo generators. Engines with 12 V systems
have a 60 A generator, earlier versions have the same
type of generator but the 50 A version. The generators
are mechanically identical, electrically they have different winding resistances.
The engines with 24 V current have a 60 A generator,
mechanically identical to the 12 V version but with
larger dimensions.
The generator version is shown on a plate on the rear
end.
Renovation, please refer to the "Starter motor, Alternator" chapter in the workshop manual.

Starter motor
All engines with the 12 V System have a geared starter motor, Valeo D9R116. The starter motor is 2 pole
and has an output of 3 kW.
Engines with 24 V have Bosch JF starter motors. The
starter motor is 2 pole and has an output of 4 kW.
Renovation, please refer to the "Starter motor, Alternator" chapter in the workshop manual.

Design and function

Junction box
The junction box is located on the front left hand side
of the engine.
The components included differ depending on the engine type (see illustration) The relay location may be
different to that in the illustrations, always check the
cable colors at the terminals before commencing any
fault-tracing.

Junction box 31/41


1.
2.
3.
4.

Automatic fuse (24V version has 2 x)


Resistor
Ground relay (only 1.5 pole version)
Starter relay

Junction box KAD32, KA(M)D42/43


1.
2.
3.
4.

Automatic fuse
Engine speed (RPM) relay
Resistor
Starter relay

Junction box KA(M)D44/300


1.
2.
3.
4.
5.
6.

Automatic fuse (2 x)
Main relay
Stop relay
Resistor
Ground relay
Starter relay

6
9

Design and function

Fuses
The engines are equipped with an 8 A semi-automatic
fuse. The exception is KA(M)D44/300 and engines
with 24 V systems which has two.
The fuses are in the terminal box. The fuses are reset
with the button on the side of the box.

Switches
Coolant temperature switch
The engine coolant temperature (ECT) switches are
closed with rising temperature according to the following:
12 V (1-pole) or 12/24 V (2-pole) installed on thermostat (applies to older versions) closes at 95 3.
12 V (1-pole) or 12/24 V (2-pole) installed on exhaust

manifold closes at 97 3 .

Oil pressure sensor


The oil pressure switches are closed with falling temperature according to the following:
12/24 V (2-pin) closes at 69 kPa 14 kPa (0.7 bar
0.15 bar.

Tilt switch (S.O.L.A.S)


Detects tilt. When the angle is greater than 90 5
from horizontal the switch changes S 1b after approximately 0.5 seconds. After the switch a holding circuit
is activated until voltage 15+ at terminal 5 is broken.
S 1bis normally open when in operation.
S 1c is normally shut when in operation.
Supply voltage 10-30 V

Glow plugs (S.O.L.A.S)


2 pole, rated voltage 5.5 V 0.5 V, current 65.5 A,
output 650 35 W. The same glow plugs are used on
both the 12 V and 24 V systems.
The 12 V system normally has 2 glow plugs connected
in series, in certain driving conditions the engines are
modified to 4 glow plugs connected in series in groups
(2+2) and the groups are connected in parallel. The 24
V system has 4 glowplugs connected in series.

10

Design and function

Sensor
Engine coolant temperature (ECT) sensor
(1or2 pole)
Resistance tolerances, after 3 minutes temperature
equalization and with operating voltage.
Tightening torques maximum 20 Nm.
Single instrument
sensor

Flying bridge
sensor

604

134.0.Q.13.5.Q.

67.0 .Q. 6.5 .Q.

90 3

51.2 .Q. 4.3 .Q.

25.6 .Q. 2.1 .Q.

1003

38.5.Q. 3.0.Q.

19.3 .Q. 1 .5 .Q.

Test
temp. C 0

Oil pressure sensor, (0-1 Obar)


Resistance tolerances, measuring with falling pressure at 20"C
Single sensor
Obar

10 .Q. + 3 .Q.,-5 .Q.

2bar

52 .Q. 4 .Q.

4bar

88 .Q. 4 .Q.

6bar

124 .Q. 5 .Q.

8bar

Flying bridge
sensor
5.Q.+1 .8 .Q.,-3 .Q.
25 .Q. 2.4 .Q.

61 .Q. 3 .Q.
78 .Q. 3 .Q.

Tightening torque: maximum 30 Nm

Engine speed (RPM) sensor (KAD32, KA(M)D42/43)


Type: Inductive sensor (cog counter). Internal resistance 1050 .Q. 100 .Q..
Only for controlling the supercharger engine speed
(rpm) relay. The engine speed relay in the instrument
panel receives the input signal from the W output in
the generator.
Tightening torque: maximum 50 Nm

Solenoid valve (on injection pump)


Sliding electro-magnet activated when + is connected
on the terminal pins.
Tightening torque: 43 Nm.

11

Design and function

Engine speed (RPM) relay (KAD32,


KA(M)D42/43)
Function
Outputs:
S 1 (terminal 5), closes to ground and engages
the supercharger
G +(pin 4), +supply to position sender
Inputs:
G 1 (terminal 6), inductive engine speed (RPM)
sensor
G 2 (pin 3), +from position sender
15 + (terminal 7), ignition switch current
31 - (terminal 1), batteryThe engine speed (RPM) relay closes to ground via
S 1 and connects the supercharger. With an increase in engine speed S 1 closes at 1700 rpm and
breaks at 2400 rpm (KAMD) or 2600 rpm (KAD),
50 rpm.
With a reduction in engine speed 81 closes 4.5 seconds 2 seconds after the engine speed has gone
below the set value 1700-2400 rpm (KAMD) or
1700-2600 rpm (KAD) and disconnects at 1400 rpm
150 rpm.

+30

Between 600-3.100 rpm, S 1 closes if the "kick down"


position sender opens and breaks the + supply to G 2.

Supercharger control
1. Engine speed (rpm) relay
2. Position sender
3. Engine speed (RPM) sensor

4. Supercharger
5. Automatic fuse
6. Diode

w
R

12

Design and function

Fault-tracing
The supercharger is not engaged
Disconnect connector to the supercharger solenoid. Run the engine above 1700 rpm, check
that there is power supply at connector terminal
using a circuit tester.
If there is current the fault lies in the solenoid or
the cable to the connection.
The fault can also be due to the signal from the
engine speed (RPM) sensor not being retained.
Check sensor and wiring.
If the connector has no current the transient
protection in the magnetic clutch may be damaged (conducts through) which may cause
short-circuits. This in turn blows the fuse or
damages the engine speed (RPM) relay.

The supercharger engages/disengages within


the operating range (oscillates)
Oxide or loose connections within the engine
speed (RPM) sensor or the electronic module
connectors. Cable breakage. Check and clean.
The terminal pins should be smeared with contact grease.

The fuse blows when the compressor engages


Remove the supercharger connector and check
if the fuse still blows. If it did not there is a
short-circuit in the magnetic clutch.

If the fuse blows despite the connector being


disconnected there is a short-circuit in the engine speed relay.

The supercharger disengages at the wrong


engine speed (RPM)
The disengagement engine speed is adjustable
with a 27 revolution potentiometer on the junction box. Each revolution on the potentiometer
corresponds to 48 rpm, in total 1296 rpm plus or
minus at the potentiometer limit position.

Engine speed adjustment

If adjustment with the potentiometer does not


work the electronic module must be replaced.

The supercharger engages at the wrong engine speed (RPM)


The cut-in speed is preprogrammed into the electronic box, except for "kickdown", when the position sender provides an impulse. Give full gas
"Forwards" on the throttle. Engine stationary!
Adjust the distance between the bracket (1) and
position sender (2) to 0.028"/0.7 mm.
Adjusting the position sender

13

Charging system
General
The engines are equipped with 2 pole alternating current Valeo generators. Engines with 12 V systems
have a 60 A generator, earlier versions have the same
type of generator but the 50 A version. The generators
are mechanically identical, electrically they have different winding resistances.
The engines with 24 V current have a 60 A generator,
mechanically identical to the 12 V version but with
larger dimensions.
The generator version is shown on a plate on the rear
end.

Technical Data
Generator
Type:
Rectified three phase alternating current
generators
Interference suppression condenser:
2.2 mF.
Voltage regulator type:
YV 77 (12V), ZV 37 (24V).
Output voltage:
14.2 V 0.15 Vat +20"C (12V)
28.5 V 0.15 Vat +20"C (24V),
temperature compensation -10 mV 2 mV/"C
Maximum current:
60 A alternatively 50 A (12 V), 60 A (24 V)

14

Charging system

Faultfinding

Current loss check

Before dismantling the generator fault-trace the battery circuit to eliminate other possible fault causes.
When testing with the generator it should be ''warm",
run the engine at approximately 2000 rpm for 3 minutes before measuring.

Specmltoo~:9510060

Fault tracing is carried out with 951 0060. Note that


other instruments may differ in the symbols displayed
for set functions.

&

&

WARNING! The generator, voltage regulator or


battery circuit terminals must be connected
when the engine is running. Do not disconnect
these terminals while the engine is running.
Carefully check that the measuring instrument is
set to voltage supply (V), so that there is no
short circuit between the generator terminals.
WARNING! Be especially careful that the supply
cables, clothing or similar do not come into contact with the engine or generator pulleys or drive
belts when the engine is running.

Generator belt

Wash the battery with lukewarm water and dry. Remove the battery leads and clean the poles.

2
Connect+ terminal again.

3
Switch off the ignition and any power consuming components connected to the starter battery.

Special tools: 1159 660

~~~~

~ 9~

"n

Check the belt tension and condition. Split, worn or


oily belts must be replaced. Adjust belt tension. Position tool 1159 660 behind the multi- V pulley driving
edge. Adjust with belt tensioner (4).
Belt tension 20-25 kg.

mA

COM

'*
RPM

Set the multimeter for measuring currents (mA) and


connect the multimeter between the battery negative
terminal and negative cable. The current loss must
not exceed 0.1 A with the ignition disconnected.

15

Charging system

If the current loss is greater than 0.1 A:


Check that there no short circuits or lead over
shorts occur at any terminal. Lead over shorts occur because of the dirty salt encrusted electrical
components. Clean and check all terminals.

If the current loss is less than 0.1 A:

Battery, load test


Special tools: 951 0060

1
Check that the battery retains at least 1.21 in acid
weight.

Check the batteries' charge condition

Charging condition check

Remove ignition coil - terminal

3
Connect a voltmeter between the battery poles

4
Turn the starter motor for approximately 10 seconds
and read off the start voltage which must not be less
than 9.5 V (19 V in a 24 V system).

5
See if any of the cells bubble when the starter motor
is turning (short circuit in the battery)

Check the charge condition using a hydrometer.


Measure the acid weight in all cells at +20 "C. Measurement must not occur directly after charging or filling with distilled water. The acid weight with a fully
charged battery at +20"C should be 1.28. Charge the
battery if the acid weight is lower than 1 .21 (half
charged). Charge with 5-6 A over approximately 10
hours.

&

WARNING! The battery generates hydrogen gas


and is highly flammable and explosive. Never
expose the battery to a naked flame or electric
sparks. Ventilate the battery compartment well,
especially after charging.

Check two hours after charging.


Acid weight is uneven between the cells. The difference between the cells is 0.04 points or more
for example 1.28-1.24:
The cell is probably short circuited. Replace battery.

The acid weight is even between cells, the battery


is not fully charged:
The battery is sulphated. Light sulphating can often be broken down by charging for a further 10
hours. Replace the battery if it does not help.

16

Voltage is lower than 9.5 V (19 V) or one of the


cells is bubbling:
Replace the battery and try again

Voltage is 9.5 V (19 V) or higher:


Battery OK; measure charge voltage according to
the next paragraph.

Charging system

Battery cable check

Special tools: 951 0060

IY.00 1

,,,,,,,,,,,:,,,,:,,,',,,,,,,,,,,,,,,,,,.

~~~~

s;,,

CJ

~ ~

B+

Connect the multimeter between the battery positive


and negative terminals. Run the engine at 2000 rpm.
Read off and note the voltage between the battery terminals.

The generator puts out approximately 14.0 V


(28.0V):
carry out test according to point 2.

Connect the multimeter between the generator B+ and


the generator B-. Run the engine at 2000 rpm. The
Generator output should be 14.0-14.4 V ( 28.028. 7 V). Permitted voltage drop - difference between
tests according to point 1 and point 2 should never be
more than 0.4 V (0. 7 V) in total.

Voltage drop less than 0.2 V (0.4 V):


Battery cables OK:

Voltage drop more than 0.3 V (0.6 V}:


Carry out test according to points 3 and 4.

The generator puts out more than 14.4 V (28.7 V}:


check the charging regulator, see Workshop manual "Starter motor, Generator".

17

Charging system

Positive battery cable check

Corrective action

&

IMPORTANT! Switch off the ignition and disconnect the battery terminals before commencing
work on the charging circuit.

Connect the multimeter between the generator B+ and


the battery positive terminal. Run the engine at 2000
rpm. The voltage drop must not be more than 0.2 V
(0.5 V). If the voltage drop is more than 0.2 V (0.5 V)
the cable terminals must remedied according to point 5.
Therefore carry out test according to point 4.

Negative battery cable check

8+

Connect the multimeter between the generator B- and


the battery negative terminal.
Run the engine at 2000 rpm. The voltage drop must
not be more than 0.2 V (0.5 V). If the voltage drop is
more than 0.2 V (0.5 V) the cable terminals must remedied according to point 5.

18

If the voltage drop in any of the tests according to


points 3 or 4 is more than 0.2 V (0.5 V), the cable terminals must be removed and oxides etc. cleaned off.
Spray with a moisture dispersing contact oil such as
Volvo Universal oil or equivalent and retighten the terminals.
Go through the terminals for the battery, main switch,
generator and starter motor.

19

Engine
All models in the 31/41 series have a

1-pole electrical system

20

Engine 31/41.1-pole Electrical system


14
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Battery
Starter motor
Generator
Starter relay
Solenoid valve - Stop
Temperature sensor
Pressure sensor
Pressure switch NO 0.7 Bar
Temperature switch NO 97it
Circuit breaker, 8A(+)
Splice section (cable terminal)
Main switch
Connector, cannot be opened
CPC connector 16-pin
Resistor

15 14 10 11 2

4 3 1 16 5 13 6 7
11

...J

9~

11

[(

~ Ci)

--.:

11

8
~

10

7
Cc

NO =Normally open during operation


Cable cross sections not given =1.5 mm2
Abroken line indicates anon-Yo~o Penta cable
SB

85

....

Cable color
BL = Blue
LBL = Light-blue
BN = Brown
LBN = Light-brown
GN = Green
GR = Gray
OR = Orange

P = Pink
R = Red
SB= Black
YO = Violet
W= White
Y = Yellow

"'J)'

RIY
p4,0

R/0
B+

J1
-"

vi

"

tv

..J.

L_

--~

~ ~

'.J

:::.

Engine
KAD32P, KA(M)D42A/B/P, KA(M)D43P

1-pole

22

Engine 32/42/43. 1pole Electrical System

15 4

13

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

Battery
Generator
Starter motor
Starter relay
Control solenoid
Pressure switch NO 0.7 Bar
Pressure sensor
Temperature switch NO 97'C
Solenoid valve
Temperature sensor
Engine speed (rpm) sensor
Circuit breaker, 8A
Connector
Engine speed relay
Position sender
Main switch
CPC connector 16-pin
Resistor

)..

Q:

1.5

~ ~

14
(i?

11

12

15

SB
SB

NO =Normally open during operation

Cable cross sections not given =1.5 mm2


Abroken line indicates anon-Volvo Penta cable
R!Y 40

Cable color
BL = Blue
LBL = Light-blue
BN = Brown
LBN = Light-brown
GN = Green
GR = Gray
OR = Orange

P = Pink
R = Red
SB = Black
YO = Violet
W= White
Y = Yellow

Engine
TAMD42AWJ, BWJ, WJ
1.5-pole*

1-pole during the start and stop phases, 2-pole at all other times .

24

Engine 42AWJ/BWJNIJ. 1.5-pole electrical system


1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Battery
Generator
Starter motor
Starter relay
Control solenoid*
Oil pressure sensor NO 0.7 Bar
Oil pressure gauge
Engine coolant temperature (ECT) switch NO 97'C
Solenoid valve - Stop
Engine coolant temperature sensor
Engine speed (rpm) sensor
Circuit breaker, 8A(+)
Connector
Engine speed relay*
Limit switch*
Main switch
CPC connector 16-pin
Connector, cannot be opened
Thermal trigger 8A(-)
Ground relay
Resistor

lo

8 ~1015211~17

15 4

12

...t
- -15

_._

SB

SB

'/

SB

n
19

--J

*The components are not installed on the engine, although


the cables are in the wiring.

NO =Normally open during operation

Cable cross sections not given =1.5 mm2

SB

RIY 40

30 87

Abroken line indicates anon-Yo~o Penta cable

Cable color
BL = Blue
LBL = Light-blue
BN = Brown
LBN = Light-brown
GN = Green
GR = Gray
OR = Orange

50

011

P = Pink
R = Red
SB = Black
YO = Violet
W= White
Y = Yellow

SB

31

30

v_____r HRr J . - -

......._.R

r----J

r-., ~

:M1
LJ
I

16

SB

=I
3

:
I

L---------------'

SB

16

18

Engine
All models in the 31/41 series have a
12 V, 1.5-pole electrical system*

1-pole during the start and stop phases, 2-pole at all other times.

26

Engine 31/41.12 VElectrical System 1.5-pole


1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Battery
Starter motor
Generator
Starter relay
Solenoid vawe - Stop
Temperature sensor
Pressure sensor
Pressure switch NO 0.7 Bar
Temperature switch NO 97it
Circuit breaker, 8A(+)
Circuit breaker, 8A(-)
Main switch
Connector, cannot be opened
CPC connector 16-pin
Ground relay
Glow plug relay*
Glow plugs*
Splice section
Inclination monitor (tilt sensor)**
Resistor

*These components are fitted on~ for S.O.L.A.S (Safety Of


LneAt Sea). They are available as an option for other system
designs.
** This component is fitted on~ for S.O.L.A.S (Safety Of Life
At Sea), however, the cabling contains the conductors for all
system designs.

NO =Normally open during operation

1 11 _.._..
5 11 1 6______
s 3
14..._4____

et~ll~~~ ~

18

----- - _,_,_._ -18


- 18
,-,- -

1i " 11

n 21

~~.,......

1~~~~

~RIBtl---+-t-!o-+-1---"'I
.,__,....
9

BN

ill
8
r--&
SB

~ ~I

~
~!
I

. .I
I
.

I'

:~
!'-0 - -

~ ~

Ct

SB

~(-87
~

-""i [\

SB

4 ei s1

1~

SB

--i

.
I

17

15
30 /J SB

RIW ----~-8""' ~

ss'---

HO

- 86

Cable cross sections not given =1.5 mm2

~1

ii
ii
..ii

19
- 311)
~fi{+)

Abroken line indicates aconductor that Volvo Penta


17
does not connect.
Adashed and dotted line indicates aconductor that I I,_.
, I
is fitted only to engines with preheating (glow plugs) I/

IRIBl

,,.

17
Cable color

tv
-..i

BL = Blue
LBL = Light-blue
BN = Brown
LBN = Light-brown
GN = Green
GR = Gray
OR = Orange

P = Pink
R = Red
SB = Black
VO = Violet
W= White
Y = Yellow

17
SB 11

58 f)
SB 11

~,Jllll,JlllllIJllll"lllll'Jlllll,Jlllll,..,Jllll,Jllll,Jlllll-'Jllll'""'Jlllll-'Jllll'JllllJJlllllIJllll,JlllllJlllll,JlllllJllllJ,..,Jllll,

Sta

Engine

All models in the 31/41 series have a

24 V, 1.5-pole* electrical system

1-pole during the start and stop phases, 2-pole at all other times .

28

14 I

Engine 31/41. 24 VElectrical System 1.5 pole


1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Battery
Starter motor
Generator
Starter relay
Solenoid valve - Stop
Temperature sensor
Pressure sensor
Pressure switch NO 0.7 Bar
Temperature switch NO 97it
Circuit breaker, 8A(+)
Circuit breaker, 8A(-)
Main switch
Connector, cannot be opened
CPC connector 16-pin
Ground relay
Glow plug relay*
Glow plugs*
Splice section
Inclination monitor (tilt sense~**
Resistor

*These components are fitted on~ for S.O.L.A.S (Safety Of


Life At Sea). They are available as an option for other system
designs.
**This component is fitted on~ for S.O.L.A.S (Safety Of LneAt
Sea), however, the cabling contains the conductors for all
system designs.

NO =Normally open during operation

BL = Blue
LBL = Light-blue
BN = Brown
LBN = Light-brown
GN = Green
GR = Gray
OR = Orange

P = Pink
R = Red
SB = Black
VO = Violet
W= White
Y = Yellow

1J

76 8

1S

u 10

11 2 J

,.- -1-+HI.....,--+---+-+-t-+--i
SB

ill
8

r--0--~i

13

~ ~

~--

~r-0
1Ct!

~---SB6
~

13\

ll4

-7\

.,

\~

~ .... SB-(,u--

~1110---==1---; - ~i----i
J

116

SB

.. 1

4c

15
S8
lO;SB
Rim .....____._ _~--11~1 871.
85 l\'!)..----i--jo-1

17

... 86

~~.~. ~ ~M r----=- -M:

17

17

Cable color

~ 5

18

Cable cross sections not given =1,5 mm2


Abroken line indicates aconductor that Volvo Penta
does not connect.
Adashed and dotted line indicates aconductor that
is fitted only to engines with preheating (glow plugs)

f. \5)
""' e

.Iii

1I

= ~I

11

3~
/1 21
_,R_~-- --------.! I
I
I
J

r-----

121 + I 1 112
17

L-0----J
SB 10

SB W
'
1-----1--11111111111111111

~ 1S 11

IR1at s~

')90'

fil!SB

JtJo
Sb

Engine

KA(M}D44P-A, P-8, P-C


KA(M} 0300-A

30

Engine KA(M)D44PA
1.
2.
3.
4.
5.
6.
7.
8.
9.
1O.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

Battery
Main switch
Starter motor
Generator
Battery connection to engine
Oil pressure sensor
Oil pressure gauge
Engine coolant temperature
(ECD sensor (instrument)
Starter motor relay*
Main relay*
Stop relay*
Ground relay*
Circuit breaker, BA*
Control Module
Charge air temperature sensor
Engine coolant temperature
(ECD sensor (EDC)
Position sender**
Fuel temperature sense~
Actuator**
Alpha control solenoid**
Stop solenoid**
Engine speed (rpm) sensor
Compressor
Connector
Resistor*
Data Link Connector DLC*
LED
Injection pump
Electronic gear
Manual reserve system

~ I 24

24

'j !.

>

r >
\
~

z]

~1)

24

25

f\~1=18,~
\S ---r---r--r--r-Hi~r-o-

,------i---~ ~1 \5 ~

26

j__

SBC._7i
{}

1,1.

402J'C

:tR:svo
----t

S8

07a

14
nn

22 37

1; i

6
SBJ.75

sa
1\5
32

~
D

ro

[ Cl

,7

**Located on the injection pump

3)

'
~

*Located in the tenninal box

'5 29

c c
\ \
r [ r ~
c0 w w
\

1 LB

1:

zrn D[

13

>

RU:

\
I

3,

,0

" "rc
" "

Cable color

I\;;:' I
l\J/

28

Bsm~
R'J.0

2\
I

Ii 1! :1 ,
29

I
I

I
I

L.1

1r--1

11

0 11 -[~]BAT-

r.J

30 ,----;:-:=: _______ J___,:


I

00=

3 J1~ r::~

El

NO =Normally open during operatic


Cable cross sections not given =0.5
Abroken line indicates anon-Vo~o I

P = Pink
R = Red
SB= Black
VO= Viole!
W= White
Y = Yellow

13

UJ

2~

I
I

I
I

t~::.:::::::=--J

I I

\ 2~~

rf],~~~,
I

,
0.78A.1'-J

I
aj!

40 42 1J 3'l 2i 3LLn

15

BL = Blue
LBL = Light-blue
BN = Brown
LBN = Light-brown
GN = Green
GR = Gray
OR = Orange

w
Motor KA(M)D44PB
I\)

-:::
2

1.
2a.
2b.
3.
4.
5.
6.
7.
8.

9L'O 18/M
9L'07B1

::: 9L'O NB1


Battery
Main switch
Main switch. Atwo-pole switch can be used
:;:
a'
Starter motor
~
Generator
Batter connection to engine
Oil pressure sensor
Oil pressure gauge
Engine coolant temperature
(ECT) sensor (instrument)
9. Starter motor relay*
-~
a
10. Main relay*
_,,.:
11. Stop relay*
~
12. Ground relay*
C\I
""'
"' 9'1NB I
13. Circuit breaker, BA*
~
14. Control Module
. NCIl!D
:2 NBIM
15. Charge air temperature sensor
16. Engine coolant temperature
rl
(ECT) sensor (EDC)
l!'...ill
""'C')
0
17. Position sende~
C')
,..
18. Fuel temperature sensor**
C') I
""'C\I.
19. Actuator**
/JO
9L'O!v7B
."' BS/IJ
20. Alpha control solenoid**
9'1 !!
.,"'
"' C')
C')
9L'ONBnB
~
21. Stop solenoid**
"'
_,
"'
"'"'
9LONDne ~
~ '-----+---~;;
22. Engine speed (rpm) sensor
___.._ __."
~
O'IBSIA
.,
"'a
1Bl!i
"'
23. Compressor
-;":
. O'IMIC/IJ
24. Connector
;;;
I'-~ "' 9L'019!A "'
9L 0 BS/!!D
25. Resistor*
C\I~
..~'--"__,___
26. Data Link Connector DLC*
<c ......______.._,,__,__,_____
9L 0 BSl!ID
'--"a ,--------1
27. Needle 1m sensor
,..""'
,..
~ I
C\I
28. Push button. Extra stop
9'1181!!
29. Standard fuse 7.5A
30. Standard fuse 55A
"' 9L'OBS/M
j.....:; O'I OA
31. LED
,___ _
......
32. Injection pump
01 !!!!ID
,,___ _,____ _ ___.__ ill
33. Electronic gear
9L'O 1B
NB
.,"'1--~-+------+~
::J"
9LOA
34. To power trim pump
"' 9L'OM/d
35. Manual reseive system
"' 9L'OM1VD
CD
,..
36. To push button panel, gas, gear
C')
,..
37. To instrument panel
"' 9L'OM
"'"'
" 9L'Od
:ll
"' fL'O ND
"' 9L ONB/ND
"'
Twinned
" 9L OBS/ND
"'
.,"'"' 9L'OBS
"' 9L'OCIOIND
"'a
"'
*Located in the terminal box
l!0/1B
"' 9L'ONND
"'
2
9L'OMIA
**Located on the injection pump

~~

(Q

______

M_-1-~

<1l

""'

Pl

NO =Normally open during operation


Cable cross sections not given =0.5 mm2
Abroken line indicates a
non-Volvo Penta cable

BN = Brown
LBN = Light-brown
GN = Green
GR = Gray
OR = Orange

BS

SB = Black
VO = Violet
W= White
Y = Yellow

x
'C7

~~~
~

x~

36

Engines KA(M)D44P.C and KA(M)D300A


~---

1. Battery
2A Main switch
2B. Main switch for the
manual reserve system
3. Starter motor
4. Generator

5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.

241

Oil pressure sensor


Oil pressure gauge
Engine coolant temperature sensor
(instrument)
Starter motor relay*
Main relay*
Stop relay*
Ground relay*
Circuit breakers, BA'
Control unit
Boost temperature sensor
Engine coolant temperature sensor (ECC)
Position sender**
Fuel temperature sensor**
Actuator**
Solenoid valve, Alfa**
Stop solenoid**
Engine speed sensor
Compressor
Connector
Resistor*
Diagnostic outlet*
Needle lift sensor**
Pushbutton, extra stop
Flat pin fuse, 7.5A
Fuse, 55A
DC/DC converter
1s
Injector pump
Connector (electronic gear)
To power trim pump
Manual reserve system
2x8-pole con nectar (control panel)
16-pole connector (instrument)

' 8

,.........

NO =Normally open during operation


Cable cross sections not given =0.5 mm2

I ITT
;..\ sB

3 2 8 35 3o

6 111131

81

-1--41

IJ .___
~~

EDC UNIT
5

2! I II

~ ~

ll,i

ll 4142 20 39 24 34 26

7 28

~ z [
~ 0
[ii ii m

~"

>

w
ii'

"m

a: [

w
ii'

ii'

w[
ii 0

>=

t[Xl
11

R1,1

11 2 3 6

1s

11

t:P

19 20 21

----. 0 - - -

81

k~
9

$._:

5 I 11 2 I

rn

24

24

START

kl~

-GJ

22

R'I
Rll

~11.
23

RPM

30 ~]

32

t!:!:!l 24
Cable color
BL = Blue
LBL = Light-blue
BN = Brown
LBN = Light-brown
GN = Green
GR = Gray
OR = Orange

O():TVllltADIMSTEI

P = Pink
R = Red
SB = Black
VO = Violet
W= White
Y = Yellow

.
Bia

24

VO

Rl,i

'0

SB

'0

GRCIJND

14

33

34

~ ~n 11 ,

~11 .........

STOP

II Ii 27219 2311

22 37

~ ~ :~:~1~1:

**Located on the injection pump

124

--~ ~~

II~

*Located in the tenminal box

w Abroken line indicates a


w non-Vo~o Penta cable

2345

I 2345678

ll:

12

:
ffi

21-l:lAR

6
~-m.11_,0urn1R1,1;

Instrument panel, main station

All models in the 31/32/41/42/43/44/300 series

VOLVO PENTA

34

Instrument panel main control position


1. Instrument lighting
2. Voltmeter
3. Oil pressure gauge
4. Engine coolant temperature (ECD gauge
5. Connector for connecting extra warning display (accessory)
& Alarm unit
7. Engine coolant temperature warning lamp
a Oil pressure warning lamp
9. Charge warning lamp
10. Warning lamp (not used)
11. &Hitch, Instrumentation lamps
12. &Hitch - Alarm tesVacknowledge
13. Tachometer with built-in hours run meter
14. Ignition switch
15. Alann ~uzzer)
16. Splice section
17. CPC connector 16-pin
18. Connector, turbo/reverse gear
19. Power supp~ 30 for tachometer (late production)

Bl

Bl.

SB

R!Bl
.---------m3
.

- V

Ql

6
I

Cable color

-r111JO

-I '..
61

-+ -+

TE!f

ml

9 10 I 11
~:'~
BAT G!OW ~
12

'

Spring loaded

s15a15b 30 so 19

w
(11

13

Bl/SB t5

SB

-Bl!Y 1,5

R!Bl

16

15

14 5 7

17
14

S S
M

W/lB

R15

2 46

_LJ

0--

cc

16

I1 1

r9(o\ ~
~h1 .RPH/h -~

~ ~ ~ ~ ~ ~~
-15
76Jil51~+_
l RIB!.

r
Ill

i ;' ~ ;~

c c

~~

s n

Spring loaded

0000

14

R!Bl

--

P = Pink
R = Red
SB = Black
VO = Violet
W= White
Y = Yellow

~~

Cable cross sections not given =1.0 mm2

BL = Blue
LBL = Light-blue
BN = Brown
LBN = Light-brown
GN = Green
GR = Gray
OR = Orange

! 1,____ss_~I ! r

19

12 13

18

Instrument panel, fly bridge

All models in the 31/32/41/42/43/44/300 series

VOLVO PENT.A

36

Instrument panel, fly bridge


1.
5.
6.
7.

Instrument lighting
Connector for connecting extra warning display (accessory)
Alarm unit
Engine coolant temperature warning lamp
a Oil pressure warning lamp
9. Charge warning lamp
10. Warning lamp (not used)
11. Switch, Instrumentation lamps
12. Switch - Alarm tesVacknowledge
13. Tachometer with built-in hours run meter
14. Ignition switch
15. Alarm (buzze~
16. Splice section
17. CPC connector 16-pin
18. Power supply 30 for tachometer (late production)

R15

51

-I ..

14

--

Cable color

.....

-+ -+

+RPM/h _

tL-

5- S

P = Pink
R = Red
SB = Black
YO = Violet
W= White
Y = Yellow

BAT GlOW

Oil

TEHP

19J
()

,...

()
~

~ ~ ~

19

i~L/

15a

30

30

7 8 9 10 Llc 11

Abroken line indicates anon-Yo~o Penta cable

~~ ~

()

"

c<:>

"" ""
~~

12
10+

~ ~ !);~

76 J

'

1 52

li1

+ -

15

~~

W!SB

I"'

~
1

lt)
lt)
I"'

Spring loaded

Ct:

I1

li1

SB
RIB/

~16

I''

lt)

>.

~ ~ ~

2 4 6

I.ii
.,...,

~
15

li1

I''

I.Ii

I.ii
.,...,

~~ Cti~ ~
~
14 5 7 8 9 10 11

17
Ill

Spring loaded

14
s15a15b 30 50 19

/'\

61

1
IY-

9l
~

Cable cross sections not given =1.0 mm2

BL = Blue
LBL = Light-blue
BN = Brown
LBN = Light-brown
GN = Green
GR = Gray
OR = Orange

R!Bl

lt)
I''

16

li1

li1

I"'

1lJ

I"'

lt)
I''

~ ~ l:i~
3 12 13

13

Instrument kit, main station


All models in the 31/32/41/42/43/44/300 series

38

Instrumentation main control position


~to

1.
2.
3.
4.
5.

lgnltbn switch
Switch - Alarm tesVacknowledge
Switch, Instrumentation laJT4lS
Alarm (buzzeq
Alarm unit with warning lamps for:
Temperature
Oillevel
Battery
Glow plugs
6. Engine coo~nt temperature (ECD gauge
7. Oil pressure gauge - engine
a Voltmeter
9. Boost pressure gauge
10. Oil pressure gauge, reverse gear
11. Tachometer with built-in hours run meter
12. Instrument lighting
13. Connector, cannot be ~ned
14. Spite sectbn
15. CPC connector 16-pin
16. Connector for extra warning display
(accessory)

lBll

\ 13

SBW

I I~
~

16 -

-I .

61

-+

-t

~;
~

m~ ~

.J

12

~w

12
.Jj,

sew

aiO

12 S8W

~
5

rl

..

~ ~
~ ~

~a

-"
v

12 5BtO

12 'JJW

rn , -.

u -"

10

~
~

"

Q Q

.J

lBIO

".

1.ir m011 -

SB'O

Q ~

~~01
.J r -

00
m11 ll

!Bil

O!

4 I 5 2

111 3

,:

~
~

.J

~~

L....Jt_

aJI

Cable color
BL = Blue
LBL = Light-blue
BN = Brown
LBN = Light-brown
GN = Green
GR = Gray
OR = Orange

P = Pink
R = Red
SB = Black
YO = Violet
W= White
Y = Yellow

13

1-;...

--

ll

12
"

..I.
..

11

Rl,5

"

~
~
' s
~

I
I

...... '-~

13

. ""
n ~~

~ ~

Ml. II
Mi 11
PJ9.ff

~v

~ ~
Ria la

13

11/!l

14

P/1!5

. S
,....

Pl/~

VO!i

R!S

srn
Pl!il(l
W&t~
W/[il~

15

12J ' 5678 9

v nug ~ 6 ~ I

Instrument kit, fly bridge


All models in the 31 /32/41 /42/43/44/300 series

40

lnslrumentalion, fly-bridge
1.
2.
3.
4.

5.
6.

7.
8.
9.
10.
11.
12.

Push button, start


Push button, stop
Switch, A~m tesVacknow~e
Switch, lnstrumentaoon ~ps
Alann ~uzzer)
Alarm unit with warning lamps for:
Temperature
Oilevel
' Battery
Gbw plugs
Tachometer with built-in hours run meter
lnstru men! lghting
Connector, r.annot be opened
~lee section
CPC connector 16-pin
Connector for extra warning display (accessory)

12

-I ...

61

rflfl

-+ - +

II

BA

fl&

5
+ -

W/SB 10
R/Bl 1,0
SB 10

NO =Normally ~n during operation

_J_

Cable color
BL = Blue
LBL = Light-blue
BN = Brown
LBN = Light-brown
GN = Green
GR = Gray
OR = Orange

Bl.

10

P = Pink
R = Red
SB = Black
VO = Violet
W= Whrre
Y = Yellow
Ill !5
Gl/S8 t5
I

Rt5

RIY 1~

11 If

2 3 4

s6

7 8 9 ,; 11 f2 1J

u 1S

161

SB 10

Clutch control panel, Waterjet


TAMD42WJ I K22

r-----------------------------------------1
11

12

R/BL 1,5

VOLVO PENTA

12

L----,

r-----1

4
R!BL 1,5
BUGN
87a

3
2

BUBN

R 1,5

R 15

y 1,5

y 1,5

w1,5

w15

SB 15

SB 15

3
2

:....
+R 15
BUGN15
BUBN 15

R 15

...__

____ _ I

L----------------------------------------------Relay, back flush


Relay, clutch in
Cabling to gearbox
4-pin cable terminal
Extension cables (3, 5, 7, 9 and 11 m)
Pushbutton, back flush
Pushbutton, clutch in
Relay, clutch in
Pushbutton, clutch out
Battery (-)
Battery (+)
Control panel

Cable areas not stated = 1.0 rnrn 2


A broken line indicates a non Volvo Penta cable.

42

Cable color
BL
LBL
BN
LBN
GN
GR
OR

p
Blue
PU
Light-blue
Brown
R
Light-brown SB
VO
Green
Gray
y
Orange

W1

BUBN

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

I
I
I

Pink
Purple
Red
Black
Violet
White
Yellow

43

Diode cable

TAMD42AWJ, BWJ, WJ and all models in the 31 /41 series have a


12 V, 24 V, 1.5-pole* electrical system

"1 -pole during the start and stop phases, 2-pole at all other times .

44

Diode cable for 1.5-pole electrical system


The diode cable is necessary for the engine to be stopped
electronically, using the starter switch or the stop button.
The diode cable also protects against short-circuits (cable
burn out) if the battery positive terminal is unintentionally
connected to the engine body.
Outline diagram - Connection of diode kit
A. Main panel
B. Panel for alternative control position
C. Diode kit
D. Y connection
E. Central electronic module (engine)

1E
Diode kit (C)

1. Diode
2. 16 pin CPC, to instrument panel
3. 16 pin CPC, to engine
3

VD 1,5

-6

-2

VD 15

"''
VI

1---

DR 1,5

,__

1---

BL/58 1,5

----

-3

----4

R/BL 1,5

>--

R/Y 1,5

----4

--

BN 1,5

-7

R/GN 1,5

-9
-10

-9

BL/Y 1,5

11

-12
-13

LBL 1,5

----

lBN 1,5

11

GR/SB 1,5
W/Bl 1,5

-15

W/BN 1,5

,....__
16

10

-12
-1J
14
-15

GR 1,5

-14

p
Blue
Light-blue
PU
Brown
R
Light-brown SB

,__

R 1,5

Cable color
BL
LBL
BN
LBN

,__

58 1,5

16

Pink
Purple
Red
Black

GN
GR
OR

Green
Gray
Orange

VO

Violet
White
Yellow

Cable areas in mm 2 are given after the color codes in the


wiring diagram.

45

Control panel Type I


Single installation
KA(M)D44P-C, KA(M)D300-A

46

Single installation - single lever control

Single installation - twin lever control

,---------------,I

I
I
I
1 I I
I
I
6.. "
I I "I
I
I
'E
I E
I 5

,---------------,

I
I

~~sa

3a~~

.r

3.(J

I
I
I
I
I
I
I

...______.,_____....,---+-~

ar

6 ~z~

I
I

...______.,_____....,---+-~

'E

'E

'E

'E

'E

0
~

11

'E

'E

'E

7,8

Bl

_J

5
5

'E

11

'E

'E

7,8
6

Bl

_J

9/-1

(~r;-J I
I

R/BL

~
z

21

~
z

l'l

83456721

R/BL

11

13

l'l

I7

Color code
BL = Blue
BN = Brown
GN = Green
OR = Orange
= Pink
P
R = Red
SB = Black
W = White
Y
= Yellow
Cable areas= 0.75 mm 2

1 6

I1

8345672

1~7~1_6~-4~-3~2~~~~~~-5~

Position schedule (both wiring diagrams)


1. Control panel
2.
Connector
3.
Diagnostic button
3a. LED (yellow):
4. Activation button
4a. LED (red)
5.
Neutral button
Sa. LED (green)
6.
LED for background illumination
7. 8-pin moisture-proof connection (male)
8. 8-pin moisture-proof connection (female)
9.
Neutral position switch (only mechanically shifted reversegears)
10. Potentiometer, throttle opening I gear shift
1Oa. Control adapter, throttle opening
1Ob. Control adapter, gear shift

47

Control panel Type I


Twin installation
KA(M)D44P-C, KA(M)D300-A

48

Twin installation - single lever control

1---------------------------------------------------------------1i
:

i..1a

,.1a

._sa

4a~

41

,,,4a

3ai'>

L _____ _

9,10

9, 10

r--+-----'U

r--+-----'U

715

110

Twin installation - twin lever control

""7a

'" 7a

'"'

3a,,.

4a"'

61'>

rs1(

--- --- -- -~
~
-

'

------

3a ;...

._Sa

--~-------------

5:~~i~

" "

~~-

2
3
9,10 .L--r~------~L----~~J___j~-,'-------0,6~~,~-,~8

_J

4a"'
4

--

~i

--- - - - -

i~~

5:5:i5:i5:i5:

9,10~,~_J:_,L_-_-~~2 ===J___j~_L_,~~,~~,~___,,I

1~/---1

11//--l

: 3 1 2: 2

I
I

I
I

I
I

'
3

21

I
I

I 8a :: 8b :
I

Ii
H

r9l

I .LLJ

II r=-, I

11

l__!_\,
I,
3

_ _~.c

1.1--1---.P21L r t ,
l3l ]-c _J :
<::

rio
0

Color
BL
BN
GN
OR
P
R
SB
W
Y

code
Blue
Brown
Green
Orange
Pink
Red
Black
White
Yellow

Cable areas= 0.75 mm 2

71 G

110

'

834 5 6721

71 G

110

Position schedule {both wiring diagrams)


1. Control panel
7a. LED, 2 pcs {red) port and starboard.
2.
Connector
8.
Potentiometer, throttle opening I gear shift
3.
Diagnostic button
8a. Control adapter, throttle opening
3a. LED {yellow):
8b. Control adapter, gear shift
4.
Neutral button
9. 8-pin connection {male)
4a. LED {green)
10. 8-pin connection {female)
5.
Synchronization button
11. Neutral position switch {only mechanically shifted
Sa. LED {blue):
reverse gears)
6.
LED for background illumination
7.
Activation button

49

Control panel Type II


Single installation
KA(M)D44P-A

1, 2

1, 2

VOLVO PENTA

1, 2

1, 2

VOLVO PEN'I:A.

1, 2

50

One helmsman's seat - single installation single lever control


NEUTRAL

DIAGNOSIS

NEUTRAL

r-;HROTTLE

One helmsman's seat - single installation twin lever control

I GEAR
SHIFT
CONVERTER

HROTTLE
CONVERTER

er:

"'

""'

"
"'"

10

"' "' "'

GN/SB
GN/Y

-1

!;

"'~ er:~ ~

15 (IGNITION)
KEY SWITCH

DIAGNOSIS

~ ~ ~

GN/SB
GN/Y

10

Several helmsman's seats - single installation twin lever control

!; -

I GEAR
SHIFT
CONVERTER

HROTTLE
CONVERTER

"'

"'

GN/SB

er:

>-

""' ""'

GNIY

""'

Several helmsman's seats - single installation single lever control

Q?
"
"'"

"' "' "'

Q?

GN/SB
GNIY

10

"'

Q?
"
"'"

10

VP Controls:
Late model
Color
BL
BN
GN
OR
P
R
SB
W
Y

code
Blue
Brown
Green
Orange
Pink
Red
Black
White
Yellow

Early model

Position schedule (all wiring diagrams)


1. Indication lamp
2. 1-pin switch
3. Position switch
4. Connector
5. Potentiometer
6. 16-pin connection
7. 2-pin connection {diagnostic connector)
8. Joint

Cable areas= 0.75 mm 2

51

Control panel Type II


Single installation
KA(M)D44P-B/C, KA(M)D300-A

VOLVO PENTA.

52

Single installation - single lever control

NEUTRAL

DIAGNOSIS

Single installation - twin lever control

ACTIVE STATION

NEUTRAL

DIAGNOSIS

ACTIVE STATION

RIBL
R!BL
RIBL

RIBL
R!BL
RIBL

RIBL

ii3

Sb

a:

o:i

n:

C'.J

"'

"=o:i ~~
Ci'C'.J

:;::: <
>:: ~

i:i:"'

C'.J

C'.J

C'.J
GN!SB

0...

C'.J

16 7

3 2

code
Blue
Brown
Green
Orange
Pink
Red
Black
White
Yellow

Cable areas= 0.75 mm 2

"=o:i ~~
Ci'C'.J

i:i:"'

o:i

n:

C'.J

"'

<

GN/Y

3812

Color
BL
BN
GN
OR
P
R
SB
W
Y

3812

:;::: <
>:: ~

C'.J

C'.J

C'.J
GN!SB

0...

<

C'.J

GN/Y

16 7

3 2

Position schedule (both wiring diagrams)


1.
Press switch with indication lamp, "Neutral" (green)
2.
Press switch with indication lamp, "Diagnostic" (yellow)
3.
Press switch with indication lamp, "Active station" (red)
4.
Connector
S.
Potentiometer, throttle opening I gear shift
Sa. Potentiometer, throttle opening
Sb. Potentiometer, gear shift
6.
Neutral position switch
7.
8-pin connection (male)
8.
8-pin connection (female)
9.
Joint

53

Control panel Type II


Twin installation
KA(M)D44P-A

1, 2

1, 2

1, 2

1, 2

1, 2

1, 2

54

Several helmsman's seats- twin installation - single lever control

X1

X2

X1

1 X2

NEUTRAL,

RIBL

SEE BELOW

8
GNIY
al

(')

Q_

"'al
Q_

U)

"'

i!5

(')

[[

7 11 16 14

GNIY

[[

Q c
z z z
(')

(')

3 2

"'
z

(')

iii

~mg?
U)
[[

(')

(')

10

Q_

Q_

7 11 16 14

al
CfJ_

[[

(')

(')

Q c
z z z
4

"'
z

(')

(')

10

z
'!'
z
(')

10

Several helmsman's seats - twin installation - twin lever control


1
X1

1
X2

X1

X2

X1

1
X2

R/BL

"'"-7
GNIY

o_

o_

rn

(j)

[[

7111614

al
CfJ_

[[

(')

(')

z z

cz

(')

432

(')

10

Cable areas= 0.75 mm

NEUTRAL

5
Early model
2

co

U)

[[

[[

(')

(')

z z
4

cz

(')

"'z
(')

z
'!'
z
(')

10

10

VP Controls:
Late model

code
Blue
Brown
Green
Orange
Pink
Red
Black
White
Yellow

Q_

7 11 16 14

Color
BL
BN
GN
OR
P
R
SB
W
Y

Q_

al
CfJ_

Position schedule (both wiring diagrams)


1. Indication lamp
2. Switch
3. Connector
4. Relay
5. Position switch
6. Potentiometer
7. Connector, Port - Starboard cable kit
8. 2-pin connection {diagnostic connector)
9. 16-pin connection, Port engine
10. 16-pin connection, Starboard engine

55

Control panel Type II


Twin installation
KA(M)D44P-B/C, KA(M)D300-A

56

Twin installation - single lever control

~~

J-+-----+h
,J

R/EL

e;

Cl

:>--

l:J

3
3

8 POLE PV-GONNECTOR (MALE)

. -'!"

-~ ~! ', ;' ', :]ij,;c--,~,______-~_,_; ---~_,_,


i-7-J
Gc'-2

8 POLE PV-CONNECTOR (MALE)

8 POLE PV-CONNEGTOR (FEMALE)

8 POLE PY-CONNECTOR (FEMALE)

STARBOARD ENGINE

PORT ENGINE

Twin installation - twin lever control

lA(iNOSS-Xtl

()W

lA\iN()SS-Xt

OW

f:il

--1-3
8 POLE PV-CONNECTOR (FEMALE)

8 POLE PY-CONNECTOR (MALE)


PORT ENGINE

code
Blue
Brown
Green
Orange
Pink
Red
Black
White
Yellow

STARBOARD ENGINE

VP Controls:
Late model
Color
BL
BN
GN
OR
P
R
SB
W
Y

c.~

8 POLE PY-CONNECTOR (FEMALE)

NEUTRAL

5
Early model

Cable areas= 0.75 mm 2

Position schedule (both wiring diagrams)


1.
Press switch with indication lamp, "Neutral" - green
2.
Press switch with indication lamp, "Diagnostic" - yellow
3.
Press switch with indication lamp, "Active station" - red
4.
Press switch with indication lamp, "Sync" - blue
5.
Press switch with indication lamp, "Neutral" - green
6.
Press switch with indication lamp, "Diagnostic" - yellow
7.
Connector
8.
Connector, Port - Starboard cable kit
9.
Relay
10. Potentiometer, throttle opening I gear shift
1Oa. Potentiometer, throttle opening
1Ob. Potentiometer, gear shift
11. 8-pin connection (male) - Port engine
12. 8-pin connection (female) - Starboard engine
13. Neutral position switch (only mechanically shifted reverse
gears)

57

Color codes, EDC cables


Single installation
KA(M)D44P-A
Pin numbers are marked on
the connector.

M = Male connection

F = Female connection

Color code for 16-pin connection, single installation.


In single installations, all connectors have the same color code
except the engine connector.

Color code

1.
2.

R
VO

9. BUY
10. LBL

3.
4.

BUR
R/Y
BN
OR
R/GN
BUSB

11.
12.
13.
14.
15.
16.

5.
6.
7.
8.

LBN
GR
GR/SB
BUW
BN/W
SB

Color code for connector, engine


1. Y/W
9. SB/W
2.
GN/Y
10. GN/W
3.
GN/OR
11. P/W
4.
GN/SB
12. y
5.
GN/BN
13. BL
6.
GN
14. BUR
7. p
15. 8. w
16. SB

M
F

Engine

58

Color codes, EDC cables


Twin installation
KA(M)D44P-A
Pin numbers are marked
on the connector.

M = Male connection

F = Female connection

Color code for 16-pin connection, twin installation. In twin installations, all connectors
have the same Color code except the connectors for the engine and the port and starboard controls.

Color code
1.
R
2.
VO
3.
BUR
4. R/Y
5. BN
6. OR
7. R/GN
8. BUSB

9.
10.
11.
12.
13.
14.
15.
16.

BUY
LBL
LBN
GR
GR/SB
BUW
BN/W
SB
MS unit

For MS unit,
port engine

Color code for connector, controls for port


engine
1.
Y/W
9. SB/W
2.
GN/Y 10. GN/W
3.
OR/GN11. P/W
4.
GN/SB 12. y
5.
GN/R 13. BL
6.
GN
14. BUR
p
7.
15.
8. w
16. SB

Color code for connector, controls for starboard engine


9. SB/W
1. Y/W
2.
GN/Y 10. GN/W
OR/GN 11. P/W
3.
GN/SB 12. SB
4.
5.
GN/R 13. BL
14. BUR
6.
GN
15.
7. p
16. SB
8. w

M
F
Color code
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
GN
Green
GR
Gray
OR
Orange
P
Pink
R
Red
SB
Black
VO
Violet
W
White
Y
= Yellow

Y connector

Color code for connector, engine


1. Y/W
9. SB/W
2.
GN/Y
10. GN/W
3.
GN/OR
11. P/W
4.
GN/SB
12. Y
5.
GN/BN
13. BL
6.
GN
14. BUR
7. p
15. 8.
W
16. SB

Engine

59

CJ)

0
iil

-I

::;

<D
<D

GN

::E li

=~

::J

!!!.

~
::J CT
0

Y1W

(D

W/8

o.. c:i"

Ill

::J

=I CT
<D <D

SBI Orn

OFi

'" 0- H

OQ>

o".l

GWOR

RJGN

GN/SB

BL/SB 0 m 0 "

Orn o"'IGN,.W
1

=N

mJ/Y

BLI o"' o- PIBL

<D 0
0

em

."-..J.
em e

9. g
CT

e'.ji .___._

Gf\/~N

P/w

sN

VO

BL'SB

H/Y

ff' .-

BL/W

Y/;L

ff' .,

LBL

YIOL
BN/W

BN1W

SB

9J

LBN

"'

GR

1-~

RiGN

GR.'SB

e'" "'

[)1

0-....J OLAI R.IBL

11

I"" -1

GR:ss

ff'

GNIBN
GN

VO

"lniBL

o'

o'"

GNrsN

GN(Y

R!Y

BL

e .-

LBL

W/SB

e'" .,

LBN

~LiW

GR

SB

.r,,::,

rn

_..

e e

I ti' 1v1w

mJ

fi'

1~

Io: 0:1GN/OR
W 0 0 GN;SB
p

1 a'" 0 -1 BL/w

SB

IcJ" 0-1v,w

9_

R/BL

~ GN/Y

Qr..., O_._ A/BL

GNNI

W/SB

0 C) 0" '

BL/W

Q.., 1

dJJ

P/W

Ow.

0-*'"

SB

Io'"

o-IR
OOJ ON 1/0

OR

"IGN10~
ff' ff GN/SB

P,."W
Y

BN

-----------,
BN

GR/SB
Y/BL

GN,IW

t/
ti ~

3NNI

e'

SB

,/

Bli'SB

BL.,l'N

~wm

90.
li
- <D

LBL

........... ::J
CJ) In

LBN

i:n

GR

<O (5"

::J
l\J
0
~::;Ill

Bl\,M'

SB

<D

d'"

BL I

e"' .~

.~ fl

SBle" . .

G)

GN
f.I

F.!W

g_

I o"'

0 -1v,w

Iom o"d.:i
0-.i

5
5

CJ)

IGN/Y

G\l/OR I~

' <D

Ill

!!
cs
:J

CT

BL I

ff'

<D

&

SB

ff

::J
In

g
~

PI

0:
Q Q

"

ff'

O Ci) Ci) r DJ r DJ O
JJJJz~z~r~
II

II

Ci) Ci)

II

II

II

II

c:

DJ

c: !1:1

II

c:
<D

::E

:E <
0
II

II

CJ)

DJ
II

JJ "1J
II

II

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GR/SB

o"' o-IBL;'N

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d.) VO

R.'CN
BL/SB

G~ISB

o"'ILBL

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BLNI
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LB\I

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c..._..,

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crew:

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GN/81\

n/Y

2:
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R.IGN

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BUSB Q Q FW

R1GN

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cs
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CD
fD

Electronic controls
Single installation

Control panel
Type II
Control panel
Type I

..
..
..
. - : ...
f

. .. . ---.. ...

-~

. .... -

. _.._. ___ "'

...

..'........ .. . ... ... ...... ... ..' . ..

;
'

/
The 16 pin engine
connector is only
combined with a
Type II control
panel

\/

The 2x8 pin engine connector can


be combined with
a Type I or Type
II control panel

61

Electronic controls
Twin installation (control panel Type I)

Starboard

Port

Color code
Y
= Yellow
GN = Green
= Red
R

62

Electronic controls
Twin installation (control panel Type II)

Starboard

Port

Color code
Y
= Yellow
GN = Green
R
= Red

63

Mechanical twin lever control


Mechanical shifting

.. .'
''

'

'

...
.....
. ...
.. .
.
........
..
...
..

'

'

.. ..
.. ----------------.
'

..................... ---------- ........

The 16 pin engine


connector is only
combined with a
Type II control
panel

64

The 2x8 pin engine connector can


be combined with
a Type I or Type
II control panel

Mechanical twin lever control


Electric shifting

Control panel
Type I

'

'

. ..

'

.. . ..
'

'

'

The 16 pin engine


connector is only
combined with a
Type II control
panel

The 2x8 pin engine connector can


be combined with
a Type I or Type
II control panel

65

Power trim
SX, DP-S,
290, 290-DP,
SP (all models), DP (all models),
DPX

66

Power Trim SX without trim limiter, early production

13

10a

-~--17

'--l--'"""-"""""-18
_ ____,

~--""'".J.11.WJ..-

10b

ll.IN1

18

RiPU 1 1
GNiW151

~--ao

I
I

2~
I

1- ~

""'d
Cable color
1.
2.
3.
4.
Sa.
Sb.
6.
7.
Ba.
Bb.
9a.
9b.
10a.
10b.
11 .
12.
13.
14.
1S.
16.
17.
18.
19.
20.

Battery
Main switch
Starter
Circuit breaker SO A
Connector, 2-pole male
Connector, 2-poe female
Hydraulic pump
Connector with rubber cap, 3-pole
Fully cast connectors, 3-pole female
Fully cast connectors, 3-pole male
Connector with rubber cap, 1-pole male
Connector with rubber cap, 1-pole female
Trim sender, digital
Trim sender, analouge
Connector, 7-pole
Extension cable, Y-connector
Control panel
Triminstrument, analouge
Instrument lightning
Connecting terminal, instrument lightning(+) to main panel
Connecting terminal, fuse box(-) to main panel
Connecting terminal, fuse box(+) to main panel
Circuit breaker 10 A
Circuit breaker 10 A*

BL
LBL
BN
LBN
GN
GR
OR
SB*

Blue
Light-blue
Brown
Light-brown
Green
Gray
Orange
Black ribbed

P
PU
R
SB
VO
W
Y
SB**

Pink
Purple
Red
Black
Violet
White
Yellow
Black smooth

Cable areas in (mm 2) are given after the cable color codes.
Cable areas in brackets are AWG (American Wiring Gauge).
Conversion table:

mm 2

AWG

0.5
0.75
1.0
1.5
2.5
6
10

20
18
17
15-16
13
10
7

A broken line indicates a non-Volvo Penta cable.


Only certain executions of SX-C1, SX-CLT1, SX-C1AC, SX-R1
andSX-R2

67

Power Trim SX without trim limiter, late production

15

18

19
20

12

r- -

'
,'

AC

8!

'7

AC B

SB151
BN.W1 1

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8
I

-.

8UW1

....

RiPU 1,51
GNIW15 1

SB6 (1~22.SX
SB1D 31..SX

r--------;,
2~

_r--jb
1 iI
=
-

1.
2.
3.
4.
Sa.
Sb.
6.
7.
8.
9.
10a.
10b.
11.
12.
13.
14.
1S.
16.
17.
18.
19.
20.
21.

Battery
Main switch
Starter
Circuit breaker SO A
Connector, 2-pole male
Connector, 2-poe female
Hydraulic pump
Not used
Connector with rubber cap, 1-pole
Connector with rubber cap, 3-pole
Fully cast connectors, 3-pole female
Fully cast connectors, 3-pole male
Connector 1-pole, trim by-pass
Trim sender
Extension cable, Y-connector
Connector, 7-pole
Control panel
Triminstrument, analouge
Instrument lightning
Connecting terminal, instrument lightning (+)to main panel
Connecting terminal, fuse box(-) to main panel
Connecting terminal, fuse box(+) to main panel
Circuit breaker 10 A

22. Circuit breaker 10 A*

Only certain executions of SX-C1, SX-CLT1, SX-C1AC, SX-R1


andSX-R2

Cable color
BL
LBL
BN
LBN
GN
GR
OR
SB*

Blue
Light-blue
Brown
Light-brown
Green
Gray
Orange
Black ribbed

P
PU
R
SB
VO
W
Y
SB**

Pink
Purple
Red
Black
Violet
White
Yellow
Black smooth

Cable areas in (mm 2) are given after the cable color codes.
Cable areas in brackets are AWG (American Wiring Gauge).
Conversion table:

mm 2

AWG

0.5
0.75
1.0
1.5
2.5
6
10

20
18
17
15-16
13
10
7

A broken line indicates a non-Volvo Penta cable.

68

Power Trim SX, DP-S with trim limiter

19

@
@
16

,,__~--

20

'--+-""""""~-

21

13

DJ

5b

r----------io

5a

'
'

2~
,-----, 1

=a
Cable color
1.
2.
3.
4.
Sa.
Sb.
6.
7.
Ba.
Bb.
9.
1O.
11.
12.
13.
14.
1S.
16.
17.
18.
19.
20.
21.
22.
23.

Battery
Main switch
Starter
Circuit breaker SO A
Connector, 2-pole male
Connector, 2-pole female
Hydraulic pump
Not used
Fully cast connectors, 3-pole female
Fully cast connectors, 3-pole male
Connector with rubber cap, 3-pole
Connector with rubber cap, 1-pole
Trim limiter
Connector, 1-pole
Trim sender
Connector, 7-pole
Extension cable, Y-connector
Control panel
Trim instrument, analouge
Instrument lightning
Connecting terminal, instrument lightning (+)to main panel
Connecting terminal, fuse box (-) to main panel
Connecting terminal, fuse box(+) to main panel
Circuit breaker 10 A
Circuit breaker 10 A*

BL
LBL
BN
LBN
GN
GR
OR
SB*

Blue
Light-blue
Brown
Light-brown
Green
Gray
Orange
Black ribbed

P
PU
R
SB
VO
W
Y
SB**

Pink
Purple
Red
Black
Violet
White
Yellow
Black smooth

Cable areas in (mm 2} are given after the cable color codes.
Cable areas in brackets are AWG (American Wiring Gauge).
Conversion table:

mm 2

AWG

0.5
0.75
1.0
1.5
2.5
6
10

20
18
17
15-16
13
10
7

A broken line indicates a non-Volvo Penta cable.


Only certain executions of SX-C1, SX-CLT1, SX-C1AC, SX-R1
andSX-R2

69

Power Trim SX without trim limiter


22

23
19

24

16

13
11

11
SB 1,5 16
BN/W15 16

12
BL 1,5 16

Sb Sa
8

7b 7a

o~
1.
2.
3.
4.
Sa.
Sb.
6.
7a.
7b.
8.
9.
10.
11 .
12.
13.
14a.
14b.
1S.
16.
17.
18.
19.
20.
21.
22.
23.
24.

70

Battery
Main switch
Starter
Circuit breaker SO A
Connector, 2-pole male
Connector, 2-pole female
Fuse 10 A
Connector, 2-pole male
Connector, 2-pole female
Hydraulic pump
Reley, down
Reley, up
Connector with rubber cap, 3-pole
Connector with rubber cap, 1-pole
Not used
Fully cast connectors, 3-pole female
Fully cast connectors, 3-pole male
Connector 1-pole
Trim sender
Connector, 7-pole
Extension cable, Y-connector
Control panel
Triminstrument, analouge
Instrument lightning
Connecting terminal, instrument lightning (+)to main panel
Connecting terminal, fuse box (-) to main panel
Connecting terminal, fuse box(+) to main panel

Cable color
BL
LBL
BN
LBN
GN
GR
OR
SB*

Blue
Light-blue
Brown
Light-brown
Green
Gray
Orange
Black ribbed

P
PU
R
SB
VO
W
Y
SB**

Pink
Purple
Red
Black
Violet
White
Yellow
Black smooth

Cable areas in (mm 2) are given after the cable color codes.
Cable areas in brackets are AWG (American Wiring Gauge).
Conversion table:

mm 2

AWG

0.5
0.75
1.0
1.5
2.5
6
10

20
18
17
15-16
13
10
7

A broken line indicates a non-Volvo Penta cable.

Power Trim SX with trim limiter

@>
20

-~-- 24
25

.........,....._~~~-

17

oe=-a
8

1.
2.
3.
4.
Sa.
Sb.
6.
7a.
7b.
8.
9.
10.
11 a.
11 b.
12.
13.
14.
1S.
16.
17.
18.
19.
20.
21.
22.
23.
24.
2S.

7b 7a

Battery
Main switch
Starter
Circuit breaker SO A
Connector, 2-pole male
Connector, 2-pole female
Fuse 10 A
Connector, 2-pole female
Connector, 2-pole male
Hydraulic pump
Reley, down
Reley, up
Fully cast connectors, 3-pole female
Fully cast connectors, 3-pole male
Connector with rubber cap, 3-pole
Connector with rubber cap, 1-pole
Not used
Trim limiter
Connector, 1-pole
Trim sender
Connector, 7-pole
Extension cable, Y-connector
Control panel
Trim instrument, analouge
Instrument lightning
Connecting terminal, instrument lightning (+)to main panel
Connecting terminal, fuse box (-) to main panel
Connecting terminal, fuse box(+) to main panel

Cable color
BL
LBL
BN
LBN
GN
GR
OR
SB*

Blue
Light-blue
Brown
Light-brown
Green
Gray
Orange
Black ribbed

P
PU
R
SB
VO
W
Y
SB**

Pink
Purple
Red
Black
Violet
White
Yellow
Black smooth

Cable areas in (mm 2) are given after the cable color codes.
Cable areas in brackets are AWG (American Wiring Gauge).
Conversion table:

mm 2
0.5
0.75
1.0
1.5
2.5
6
10

AWG
20
18
17
15-16
13
10
7

A broken line indicates a non-Volvo Penta cable.

71

Power trim 290, 290A, 290-DP and 290A-DP (version 1)

9
11-

11,
~I'
1m1 ~
1-1 I
z1".n I

"J-iI

C>t
I

I 10 I
I

I
I

I ..JI
___ _.ml
r-+--+--+-1--.
I
__ J

I
I

I
____ _JI

1 =Up
2 =Positive {+)
3 =Down
4 = Override button

.J

'

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

72

Oil pump
Fuse, 55 A
Trim sender
Trim indicator
Switch
Switching relay, "beach" position
Connector, instrument panel
Instrument lighting
Throttle-mounted switch {accessory)
Fuse, 5 A
Control relay, down
Control relay, up
Hydraulic hose, low pressure
Hydraulic hose, high pressure

'

--,

'T

Cable colors
BL
LBL
BN
LBN
GN

GR
OR

Blue
Light blue
Brown
Light brown
Green
Gray
Orange

PU
R
SB

VO

Cable cross sections not given = 1.5 mm2

Pink
Purple

Red
Black
Violet
White
Yellow

Power trim 290, 290A, 290-DP, 290A-DP, SP, DP (version 2)

-"'
1 =Up
2 =Positive (+)
3 =Down
4 = Override button

at

+1-

, '

..,.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Oil pump
Fuse
Trim sender
Trim indicator
Switch
Switching relay, "beach" position
Connector, instrument panel
Instrument lighting
Throttle-mounted** switch (accessory)
Motor type relay (the arrow refers to the trim function,
up/down.)

Cable colors
BL
LBL
BN
LBN
GN

GR
OR

Blue
Light blue
Brown
Light brown
Green
Gray
Orange

PU
R
SB

VO

Pink
Purple

Red
Black
Violet
White
Yellow

Cable cross sections not given = 1.5 mm2

73

Power trim SP, DP (version 3)

11
r---------------

10

!@@@

I
I
I
I
I
I
I
I

t_

;..&.,~...;....o.,,;:o......-.--,

16

---'

-.
13

18

u ____j__ _ __JSB!!J1l.l!O'---------t--l-.kt===t:=======t===========+==:::::'....-l--~L!L~ 8 - - - - - - - - - - - - - - L--------i.----l--1-....IIL..........ll..j 5

- - - - - - - - - - - - - - ...

L-~~.j.._~~..J&l.!L~~~..j......+1_7+-----4~17:....._~~~~~~+-~+-..lloL.Loil.......j~::~~~.~~--:_~4:
17

G 15
BL 1 5

'----

G 15

16

S86

3
1
I I

.,!..
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

74

------

'

[6""""61+

l..L...J
Battery
Starter
Fuse 55 A
Hydraulic pump
Trim sender
Reley, up
Reley, down
Reley, by-pass
Reley, lift stop
Trim instrument
Control panel
1-pole two-way switch, up and down
1-pole switch, by-pass standard
1-pole switch, by-pass with hold function
Lamp
Connecting terminal, can not be opened
Connecting terminal, can not be opened
Connector, to main panel

cable color
BL
LBL
BN
LBN
GN
GR
OR

p
Blue
Light-blue
PU
Brown
R
Light-brown SB
Green
VO
w
Gray
y
Orange

Pink
Purple
Red
Black
Violet
White
Yellow

Cable areas in (mm2) are given after the cable color codes.
A broken line indicates a non-Volvo Penta cable.

IJ

o er r
9
r-----------------,
@ @ @)
10

5
BUR 1 0

10
GN 15

8
5

BL1 5

CD

IC

6
R

SBB

3
N/W
I

1
r------,
I
I
I

....L

I
I
I
I
I

GN/W33
Bl.JW3 3

1. Battery
2. Starter
3. Fuse 55 A
4. Hydraulic pump
5. Connector
6. Connecting point, cannot be opened
7. Reley, down
8. Reley, up
9. Control panel
10. Connector, to main panel

C8blecolor
BL
LBL
BN
LBN
GN
GR
OR

Blue
Light-blue
Brown
Light-brown
Green
Gray
Orange

PU
R
SB
VO

Pink
Purple
Red
Black
Violet
White
Yellow

Cable areas in (mm2 ) are given after the cable color codes.
A broken line indicates a non-Volvo Penta cable.

75

Active Corrosion Protection System


12

I }

I>

IJ

er:
BN

--

2[ ~

OR

er:

CQ

1.
2.
3.
4.
5.
6.

Battery
Fuse 1 A
Active anode
Reference sensor
Electronic unit
LED light

Cable color
BL
LBL
BN
LBN
GN
GR
OR

76

Blue
Light-blue
Brown
Light-brown
Green
Gray
Orange

P
PU
R
SB
VO
W
Y

ro

Pink
Purple

Red
Black
Violet
White
Yellow

References to Service Bulletins


Group

No.

Date

Regarding

77

Notes

78

Notes

79

80

Report form
Do you have any complaints or other comments about this manual? Please make a
copy of this page, write your comments down and post it to us. The address is at
the bottom of the page. We would prefer you to write in English or Swedish.

From: ............................................................................

Refers to publication: .............................................................................................................................................


Publication no.: ..................................................................... Issued: ....................................................................

Suggestion/reasons: ..............................................................................................................................................

Date: ........................................................... .
Name: ......................................................... .

AB Volvo Penta
Customer Support
Dept.42200
SE-405 OB Gothenburg
Sweden

8N
6