Workshop Manual e

Electrical system -<o-)

t---- -----<

2
Wiring diagrams

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 ......... ......... .......... ......... .......
General...............................................................
Generator............................................................
Starter motor . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . .
Electrical connection box ....... ........... .......... .......
Fuses and circuit breakers .................................
Monitors . . . .. . . . . .. . .. . . . . .. . .. . . . . .. . .. . . . . . .. . .. . . . . .. . .. . . . . .. . .. . .
Glow plugs..........................................................
Sensors ..............................................................
Solenoid valve .. . ........ ........ ......... ........ ........ ........
Engine speed relay .. ........ ....... ...... ........ ....... .......
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
2 TAMD42AWJ, BWJ, WJ 1.5-pole ....................... 24
31/41 1.5-pole 12 V ............................................. 26
31/41 1.5-pole 24 V ............................................. 28
6 441300 ................................................................. 30
6 Wiring diagrams, instrument panel .................... 34
7 Instrument panel, main station ........................... 34
7 Instrument panel, fly bridge ................................ 36
B Instrument kit, main station ................................ 3B
B Instrument kit, fly bridge ..................................... 40
9 Clutch control panel, water jet ............................ 42
10 Diode cable, 1.5-pole electrical system .............. 44
10 EDC control system ... .......... ......... ......... ......... ..... 46
10 Control panels..................................................... 46
11 Color-codes for EDC cables ............................... 58
11 Electronic control ................................................ 61
12 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
1
 Safety Precautions
Introduction
This Workshop Manual contains technical data, de-
scriptions and repair instructions for Volvo Penta
products or product versions contained in the con-
tents list. Ensure that the correct workshop literature
is being used.
Read the safety information and the Workshop
Manual "General Information" and "Repair In-
structions" carefully before starting work.
Important
In this book and on the engine you will find the follow-
ing special warning symbols.
& WARNING! If these instructions are not fol-
lowed there is a danger of personal injury, ex-
tensive damage to the product or serious me-
chanical 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 infor-
mation that will facilitate work or operations.
Below is a summary of the risks and safety precau-
tions 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 {switch-
es) and lock it {them) in the OFF position before
starting work. Set up a warning notice at the en-
gine control point or helm.
& Generally, all servicing should be carried out
with the engine switched off. Some work {carry-
ing out certain adjustments for example) re-
quires 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, care-
less 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 en-
gine is running or has been turned off immedi-
ately prior to starting work on it. Reinstall all
protective parts removed during service opera-
tions before starting the engine.
2
& 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. For-
eign objects entering the intake ducts can also
cause mechanical damage.
& Never use start spray or similar to start the en-
gine. The starter element may cause an explo-
sion in the inlet manifold. Danger of personal in-
jury.
& 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 en-
gine 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, en-
sure that exhaust gases and crankcase ventila-
tion 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!

A Avoid skin contact with oil. Long-term or repeat-
ed 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 oil-
soaked clothes and rags. Wash regularly, espe-
cially before meals. Use the correct barrier
cream to prevent dry skin and to make cleaning
your skin easier.
A 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 fol-
low safety instructions (using breathing appara-
tus, protective goggles and gloves for exam-
pie). 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 pres-
sure, it can penetrate body tissue and cause
serious Injury There is a danger of blood poison-
ing.
A All fuels and many chemicals are inflammable.
Ensure that a naked flame or sparks cannot lg-
nite fuel or chemicals. Combined with air in cer-
tain ratios, petrol, some solvents and hydrogen
from batteries are easily inflammable and explo-
sive. Smoking is prohibited! Ensure that ventila-
tion is good and that the necessary safety pre-
cautions have been taken before carrying out
welding or grinding work. Always have a fire ex-
tinguisher 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 de-
struction together with used lubricating oil, con-
taminated fuel, paint remnants, solvent, de-
greasing agents and waste from washing parts.
Safety Precautions
A 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 . lncor-
rect 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 equip-
ment. 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 im-
mediately with soap and plenty of water. If bat-
tery acid comes into contact with the eyes, im-
mediately 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 elec-
trical system.
& The clutch must be adjusted with the engine
shut off.
& Use the lifting eyes mounted on the engine/re-
verse 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 al-
taring its center of gravity, a special lifting de-
vice is required to achieve the correct balance
for safe handling.
Never carry out work on an engine suspended
on a hoist.
3
Safety Precautions

& Never remove heavy components alone, even
where secure lifting equipment such as secured
blocks are being used. Even where lifting equip-
ment 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 compo-
nents are not trapped and damaged when being
lifted.
When working on-board ensure that there is suf-
ficient 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 en-
gine must not be operated in environments with
adjacent explosive media.
& Fuel delivery pipes must not be bent or straight-
ened 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 Pen-
ta. 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.

4
 General information
About the workshop manual
This workshop manual contains wiring diagrams, de-
scriptions and repair instructions for the electrical
system used in the standard engines in the 31, 32,
41, 42, 43, 44 and 300 series.
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 per-
sonnel. 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 prod-
ucts. We therefore reserve the right to make chang-
es. 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 provid-
ed 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 Genu-
ine parts meet these requirements. Any type of dam-
age 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.
Certified engines
When doing service and repair on emission certified
engines, it is important to be aware of the following:
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 en-
gine.
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 in-
jectors 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 person-
nel.
The general advice in the instruction book about ope-
ration, care and maintenance applies.
.& IMPORTANT! Delayed or inferior care/mainte-
nance, and the use of non-original spares, mean
that AB Volvo Penta can no longer be re-
sponsible 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.
5
 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 998 8452 9510060

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 58 495 AMP 726 534 AMP 726 519

AMP 825 514 AMP 725 938 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.): 4.8 mm and 6.3 mm cable clamps: Male and
726 534-1 Terminal removal tool 1.6 mm pin width female spade terminals

726 519-1 Terminal removal tool 2.8 mm pin width 825514-1 Crimpingpliers

825514-1 Crimping pliers

6
 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 other-
wise differ in terms of equipment. The workshop man-
ual does not state what is standard equipment or op-
tions 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. Oil pressure sensor 6. Generator
2. Oil pressure sensor 7. Starter motor
3. Engine coolant temperature (ECT) switch 8. Solenoid valve (on injection pump)
4. Engine coolant temperature (ECT) sensor 9. Inductive engine speed (RPM) sensor (only 32, 42, 43)
5. Junction box

7
Design and function

Generator
The engines are equipped with 2 pole alternating cur-
rent 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 dif-
ferent 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, Alterna-
tor" chapter in the workshop manual.

Starter motor
All engines with the 12 V System have a geared start-
er 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, Alterna-
tor" chapter in the workshop manual.

8
 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 en-
gine 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. Automatic fuse (24V version has 2 x)
2. Resistor
3. Ground relay (only 1.5 pole version)
4. Starter relay

1 2 3 4

Junction box KAD32, KA(M)D42/43

1. Automatic fuse
2. Engine speed (RPM) relay
3. Resistor
4. Starter relay

1 2 3 4

Junction box KA(M)D44/300

1. Automatic fuse (2 x)
2. Main relay
3. Stop relay
4. Resistor
5. Ground relay
6. Starter relay

1 3 4 5 2 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 follow-
ing:
12 V (1-pole) or 12/24 V (2-pole) installed on thermo-
stat (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 tem-
perature 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 approxi-
mately 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.
Test Single instrument Flying bridge
temp. C 0 sensor 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.

Oil pressure sensor, (0-1 Obar)

Resistance tolerances, measuring with falling pres-
sure at 20"C
Single sensor Flying bridge
sensor
Obar 10 .Q. + 3 .Q.,-5 .Q. 5.Q.+1 .8 .Q.,-3 .Q.
2bar 52 .Q. 4 .Q. 25 .Q. 2.4 .Q.
4bar 88 .Q. 4 .Q.
6bar 124 .Q. 5 .Q. 61 .Q. 3 .Q.
8bar 78 .Q. 3 .Q.
Tightening torque: maximum 30 Nm

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

Type: Inductive sensor (cog counter). Internal resist-
ance 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), battery-

The engine speed (RPM) relay closes to ground via

S 1 and connects the supercharger. With an in-
crease 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 sec-
onds 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 +30
150 rpm.
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 4. Supercharger
2. Position sender 5. Automatic fuse
3. Engine speed (RPM) sensor 6. Diode

12
 Design and function

Fault-tracing
The supercharger is not engaged
Disconnect connector to the supercharger sole-
noid. 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 dam-
aged (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 con-
tact 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. 0
If the fuse blows despite the connector being
disconnected there is a short-circuit in the en-
gine speed relay.

The supercharger disengages at the wrong

engine speed (RPM)
The disengagement engine speed is adjustable
with a 27 revolution potentiometer on the junc- Engine speed adjustment
tion box. Each revolution on the potentiometer
corresponds to 48 rpm, in total 1296 rpm plus or
minus at the potentiometer limit position.
If adjustment with the potentiometer does not
work the electronic module must be replaced.

The supercharger engages at the wrong en-

gine speed (RPM)
The cut-in speed is preprogrammed into the elec-
tronic box, except for "kickdown", when the posi-
tion 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 cur-
rent 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 dif-
ferent 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 bat-
tery 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 min-
utes 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 1

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.
Wash the battery with lukewarm water and dry. Re-
move the battery leads and clean the poles.
2
Connect+ terminal again.

& WARNING! Be especially careful that the supply

cables, clothing or similar do not come into con- 3
tact with the engine or generator pulleys or drive Switch off the ignition and any power consuming com-
belts when the engine is running. ponents connected to the starter battery.

4
Generator belt
Special tools: 1159 660

~~~~

~ 9~
"n

A mA COM '*
RPM

Check the belt tension and condition. Split, worn or

oily belts must be replaced. Adjust belt tension. Posi-
tion tool 1159 660 behind the multi- V pulley driving
edge. Adjust with belt tensioner (4).
Belt tension 20-25 kg.
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: Battery, load test

Check that there no short circuits or lead over Special tools: 951 0060
shorts occur at any terminal. Lead over shorts oc-
cur because of the dirty salt encrusted electrical
components. Clean and check all terminals.
1
Check that the battery retains at least 1.21 in acid
If the current loss is less than 0.1 A:
weight.
Check the batteries' charge condition

2
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)

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

cells is bubbling:
Check the charge condition using a hydrometer.
Measure the acid weight in all cells at +20 "C. Meas- Replace the battery and try again
urement must not occur directly after charging or fill- Voltage is 9.5 V (19 V) or higher:
ing with distilled water. The acid weight with a fully Battery OK; measure charge voltage according to
charged battery at +20"C should be 1.28. Charge the the next paragraph.
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 dif-
ference between the cells is 0.04 points or more
for example 1.28-1.24:
The cell is probably short circuited. Replace bat-
tery.
The acid weight is even between cells, the battery
is not fully charged:
The battery is sulphated. Light sulphating can of-
ten be broken down by charging for a further 10
hours. Replace the battery if it does not help.

16
 Charging system

Battery cable check 2

Special tools: 951 0060

1 f IY.00 1
,,,,,,,,,,,:,,,,:,,,',,,,,,,,,,,,,,,,,,.

~~~~

s;,, CJ ~ ~

B+

Connect the multimeter between the generator B+ and

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 ter-
minals.
The generator puts out approximately 14.0 V
(28.0V):
carry out test according to point 2.
The generator puts out more than 14.4 V (28.7 V}:
check the charging regulator, see Workshop man-
ual "Starter motor, Generator".
the generator B-. Run the engine at 2000 rpm. The
Generator output should be 14.0-14.4 V ( 28.0-
28. 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.

17
Charging system

Positive battery cable check Corrective action

3 & IMPORTANT! Switch off the ignition and discon-
nect the battery terminals before commencing
work on the charging circuit.

If the voltage drop in any of the tests according to

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.
points 3 or 4 is more than 0.2 V (0.5 V), the cable ter-
minals 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 ter-
minals.
Go through the terminals for the battery, main switch,
generator and starter motor.

Negative battery cable check

4

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 rem-
edied according to point 5.

18
19
 Engine

All models in the 31/41 series have a

1-pole electrical system

20
 Engine 31/41.1-pole Electrical system
4 3 1 16 5 13 6 7 15 14 10 11 2
14
11
1. Battery ...J ~ ~
2. Starter motor ~ ~ 11 9~ ~ Ci)
~ --.:
~ ~
'.J :::.
[(
3. Generator
4. Starter relay
11
5. Solenoid valve - Stop
6. Temperature sensor 8
7. Pressure sensor
8. Pressure switch NO 0.7 Bar
9. Temperature switch NO 97it
10. Circuit breaker, 8A(+) ~ ~
11. Splice section (cable terminal)
10
7
12. Main switch Cc
13. Connector, cannot be opened
14. CPC connector 16-pin
15. Resistor

NO =Normally open during operation

Cable cross sections not given =1.5 mm2

Abroken line indicates anon-Yo~o Penta cable

SB
85 5
Cable color
BL = Blue P = Pink
....
I

LBL = Light-blue R = Red "'J)'

BN = Brown SB= Black
RIY
LBN = Light-brown YO = Violet
GN = Green W= White p4,0
GR = Gray Y = Yellow
OR = Orange

R/0

B+ J1
I -"
I
vi I 2
"
!
tv
..J.
L_ --~
 Engine

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

1-pole

22
Engine 32/42/43. 1pole Electrical System 13 15 4

~ )..
~
1. Battery ~
1.5 Q: ~ ~ ~
2. Generator 14
3. Starter motor (i?
4. Starter relay
5. Control solenoid
6. Pressure switch NO 0.7 Bar 11
7. Pressure sensor
8. Temperature switch NO 97'C
9. Solenoid valve
12 ~
10. Temperature sensor
11. Engine speed (rpm) sensor
12. Circuit breaker, 8A
13. Connector
14. Engine speed relay
15. Position sender
15 SB

16. Main switch SB

17. CPC connector 16-pin
18. Resistor

NO =Normally open during operation 8

Cable cross sections not given =1.5 mm2

Abroken line indicates anon-Volvo Penta cable

R!Y 40
Cable color
BL = Blue P = Pink
LBL = Light-blue R = Red
BN = Brown SB = Black
LBN = Light-brown YO = Violet
GN = Green W= White
GR = Gray Y = Yellow
OR = Orange
 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 lo 15 4 8 ~1015211~17

1. Battery
2. Generator
3. Starter motor
4. Starter relay
5. Control solenoid*
6. Oil pressure sensor NO 0.7 Bar
7. Oil pressure gauge
8. Engine coolant temperature (ECT) switch NO 97'C
9. Solenoid valve - Stop
10. Engine coolant temperature sensor 12
11. Engine speed (rpm) sensor ...t
12. Circuit breaker, 8A(+)
13. Connector
- -15
14. Engine speed relay*
_._ SB / 18
15. Limit switch*
SB '/
16. Main switch
17. CPC connector 16-pin SB

18. Connector, cannot be opened n

19. Thermal trigger 8A(-)
20. Ground relay
21. Resistor
19 --J
*The components are not installed on the engine, although
the cables are in the wiring.

NO =Normally open during operation

7
Cable cross sections not given =1.5 mm2 RIY 40 SB
30 87
Abroken line indicates anon-Yo~o Penta cable

50
Cable color 011
SB
5
BL = Blue P = Pink 30 31

LBL = Light-blue R = Red v_____r HRr J . - -

......._.R I
SB

SB
BN = Brown SB = Black r----J =I
~
LBN = Light-brown YO = Violet
! 3
GN = Green
GR = Gray
W= White
Y = Yellow
r-., ~ 16
1
16
OR = Orange
:M1
ILJ :
I
L---------------'
 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 14..._4____
1 11 _.._.. s 3
5 11 1 6______ 1i " 11
~~.,...... n 21

1.
2.
Battery
Starter motor 18
et~ll~~~ ~ 1~~~~
3. Generator ----- - - -
4. Starter relay
_,_,_._ -18
5.
6.
Solenoid vawe - Stop
Temperature sensor
- - BN ~RIBtl---+-t-!o-+-1---"'I
.,__,....
18
7. Pressure sensor ,-,- -
- - 9
8. Pressure switch NO 0.7 Bar ill
SB
9.
10.
Temperature switch NO 97it
Circuit breaker, 8A(+) - 8
11. Circuit breaker, 8A(-)
r--&
12.
13.
Main switch
Connector, cannot be opened ~ ~
14.
15.
CPC connector 16-pin
Ground relay ~ ~I ~! - Ct
16. Glow plug relay* I
SB

. .I
17. Glow plugs*
18.
19.
20.
Splice section
Inclination monitor (tilt sensor)**
Resistor
I
. I'
~ ~
-
~(-87
*These components are fitted on~ for S.O.L.A.S (Safety Of
LneAt Sea). They are available as an option for other system :~
!'-0 - -
-""i [\
4 ei s1
~

SB
n
5

1~
designs.
15
** This component is fitted on~ for S.O.L.A.S (Safety Of Life I
SB 30 /J SB
At Sea), however, the cabling contains the conductors for all --i
RIW ----~-8""' ~
1

system designs.
NO =Normally open during operation
. 17 HO ss'---
I - 86
~
~1
Cable cross sections not given =1.5 mm2
ii 19
Abroken line indicates aconductor that Volvo Penta
17
ii - 311)
~fi{+)
does not connect. ..ii IRIBl Sta
Adashed and dotted line indicates aconductor that I I,_.
, I
is fitted only to engines with preheating (glow plugs) I/
,,.
17
Cable color
BL = Blue P = Pink
LBL = Light-blue R = Red
BN = Brown SB = Black 17
LBN = Light-brown VO = Violet SB 11
GN = Green W= White
58 f)
tv GR = Gray Y = Yellow
-..i OR = Orange SB 11
~,Jllll,JlllllIJllll"lllll'Jlllll,Jlllll,..,Jllll,Jllll,Jlllll-'Jllll'""'Jlllll-'Jllll'JllllJJlllllIJllll,JlllllJlllll,JlllllJllllJ,..,Jllll,
 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
 Engine 31/41. 24 VElectrical System 1.5 pole 14 I 4 1 ~ 5 1J 76 8 J 1S u 10 11 2 J

1. Battery
2. Starter motor 18
3. Generator
4. Starter relay
5. Solenoid valve - Stop
6. Temperature sensor
7.
8.
Pressure sensor
Pressure switch NO 0.7 Bar
-.....,--+---+-+-t-+--i
,.- -1-+HI-
SB ill 9
9. Temperature switch NO 97it
10. Circuit breaker, 8A(+) 8
11.
12.
Circuit breaker, 8A(-)
Main switch r--0---
13. Connector, cannot be opened
14. CPC connector 16-pin
~i 13 ~ .... -
SB-(,u--
15. Ground relay -
16. Glow plug relay*
~---SB-
17.
18.
Glow plugs*
Splice section
- \~
13\ ~
6
-
~1110---==1---; - ~i----i
19. Inclination monitor (tilt sense~** ~ ~
20. Resistor J ll4
116
-
~--
*These components are fitted on~ for S.O.L.A.S (Safety Of -7\ SB 5
.. 1 n
Life At Sea). They are available as an option for other system
designs. ~r-0
., 4c
15
**This component is fitted on~ for S.O.L.A.S (Safety Of LneAt 1Ct!
S8 lO;SB
Sea), however, the cabling contains the conductors for all Rim .....____._ _~--11~1 871.
system designs.
85 l\'!)..----i--jo-1
NO =Normally open during operation 17 ... 86

Cable cross sections not given =1,5 mm2

Abroken line indicates aconductor that Volvo Penta

~~.~. ~ ~M r----=- -M: 9

f. \5)
""' e = ~I ~ 1S 11
17 .Iii 11
does not connect. 1I IR1at s~
Adashed and dotted line indicates aconductor that 3~ /1 21 ')90'
is fitted only to engines with preheating (glow plugs) _,R_~-- --------.! I I JtJo
I fil!SB Sb
Cable color
17 J
r----- i -
BL = Blue P = Pink
LBL = Light-blue R = Red 121 + I 1 112
BN = Brown
LBN = Light-brown
SB = Black
VO = Violet
17 L-0----J
SB 10
GN = Green W= White
GR = Gray Y = Yellow
~ OR = Orange ' SB W
1-----1--11111111111111111
 Engine

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

KA(M} 0300-A

30
Engine KA(M)D44PA
1. Battery
t ~ I 24 24 2 3 'j !. D I
2. Main switch
3. Starter motor z
r > ~ D
r
s
\ z] m
~
J \
4. Generator > ~ [ r ~1)

5. Battery connection to engine 24 25

6. Oil pressure sensor f\~1=18,~
\S ---r---r--r--r-Hi~r-o- 8
7. Oil pressure gauge
8. Engine coolant temperature
(ECD sensor (instrument)
26 ,------i---~ ~1 \5 ~ I

U
1,1.

,
j__ SBC._7i
{}

402J'C
9. Starter motor relay* :tR:svo
1O. Main relay* S8
07a
11. Stop relay* ----t

12. Ground relay*

13. Circuit breaker, BA*
14. Control Module 14
22 37 nn g 1; i
15. Charge air temperature sensor
6
16. Engine coolant temperature SBJ.75 ,
sa
(ECD sensor (EDC)
1\5 0.78A.1'-J
17. Position sender** 32 3) ) '5 29 r 1 LB 1: 40 42 1J 3'l 2i 3LLn
I
' aj!
18. Fuel temperature sense~
19. Actuator** s
20. Alpha control solenoid** ~
~
\
0
~
D
ro
~
\
c c
\ \
z
r [ r ~
l
[
\
zrn D[
J
J
13 13
,7 [ Cl c0 w w >
21. Stop solenoid**
22. Engine speed (rpm) sensor
23. Compressor
24. Connector
25. Resistor*
26. Data Link Connector DLC* RU:
27. LED \
28. Injection pump I
29. Electronic gear
30. Manual reserve system

*Located in the tenninal box

**Located on the injection pump UJ D

15 El 4 3 J1~ r::~
NO =Normally open during operatic 3, G Bsm~ 5
Cable cross sections not given =0.5 28 I\;;:' I 0 11 -[~]BAT-
Abroken line indicates anon-Vo~o I D
l\J/ I I I I
\
~
R'J.0 I I : :
0 I I
z ,0 I
I
I
I I I

" "rc
\ \
I
L.1 r.J
I I
I
I
I

" "
~ ]
30 ,----;:-:=: _______ J___,:
I I

Cable color I
I I
I

BL = Blue P = Pink I 2\ 2~ \ 2~~

LBL = Light-blue R = Red 00= 1r--1

Ii 1! :1 ,
I

rf],~~~,
I I I I

BN = Brown SB= Black

LBN = Light-brown VO= Viole! 29 11 I

t~::.:::::::=--J
GN = Green W= White
GR = Gray Y = Yellow
OR = Orange
w
I\) Motor KA(M)D44PB -:::
9L'O 18/M
2 9L'07B1
1. Battery ::: 9L'O NB1
2a.
2b.
Main switch
Main switch. Atwo-pole switch can be used
~~
:;:
3. Starter motor a'
~
4. Generator
5. Batter connection to engine
-
6. Oil pressure sensor
7. Oil pressure gauge
8. Engine coolant temperature
(ECT) sensor (instrument)
9. Starter motor relay*
10. Main relay* -~ a
_,,.:
11. Stop relay* ~
12. Ground relay*
""'
C\I
13. Circuit breaker, BA* "' 9'1NB I
~
14. Control Module . NCIl!D
15. Charge air temperature sensor :2 NBIM
16. Engine coolant temperature
rl
(ECT) sensor (EDC) l!'...ill ""'C')
17. Position sende~ 0
C')

18. Fuel temperature sensor** ,..

19. Actuator** C') I
(Q
""'C\I.
-
20. Alpha control solenoid** ."' BS/IJ
.,"'
/JO 9L'O!v7B

"' C')
21. Stop solenoid** ~ "' 9L'ONBnB
9'1 !!
- C')

22. Engine speed (rpm) sensor ______

_,
~ '-----+---~;; ___.._ __."
"' "'"'
~
.,
"'a
O'IBSIA
9LONDne ~

23. Compressor 1Bl!i

-;":
"'
. O'IMIC/IJ
24. Connector
25. Resistor*
26. Data Link Connector DLC*
I'-~ "' 9L'019!A "'

C\I~
..~'--"__,___
- ;;;

x~
9L 0 BS/!!D

<c ......______.._,,__,__,_____
~~~
~
27. Needle 1m sensor -,..""'
9L 0 BSl!ID '--"a ,--------1
~ I
,..
28. Push button. Extra stop C\I
9'1181!!
29. Standard fuse 7.5A
30. Standard fuse 55A
31. LED
"' 9L'OBS/M j.....:; O'I OA
,___ _M_-1-~

......
32. Injection pump
33. Electronic gear ,,___ _,____ _ ___.__ ill
.,"'1--~-+------+-
9L'O 1B
~
<1l::J"
01 !!!!ID
NB
34. To power trim pump 9LOA

35. Manual reseive system "' 9L'OM/d

"' 9L'OM1VD
36. To push button panel, gas, gear CD
~

,..
37. To instrument panel
C')
- ,..
"' 9L'OM
" 9L'Od "'"'
"' fL'O ND :ll
"' 9L ONB/ND "'
" 9L OBS/ND Twinned "'
.,"'"' 9L'OBS
*Located in the terminal box
**Located on the injection pump
"' 9L'OCIOIND
"' 9L'ONND
~
-
""'
N
9L'OMIA
"'a
"'
2
Pl BS
x
l!0/1B

'C7
"'

NO =Normally open during operation BN = Brown SB = Black

Cable cross sections not given =0.5 mm2 LBN = Light-brown VO = Violet
GN = Green W= White
Abroken line indicates a
non-Volvo Penta cable GR = Gray Y = Yellow
OR = Orange
 Engines KA(M)D44P.C and KA(M)D300A 36
~---

241 I 2345678 2345 ' 8 124

1. Battery
2A Main switch
2B. Main switch for the
manual reserve system
3. Starter motor
4. Generator
5. -
6. Oil pressure sensor
7. Oil pressure gauge
8. Engine coolant temperature sensor
(instrument)
--~ ~~
I ITT
,......... ~ :
2- 1-l:lAR
9. Starter motor relay* ~ ~n 11 ,
;..\ sB
1 ffi
10. Main relay* ~11 ......... -1--41
81

12 6
11. Stop relay* II~ 3 2 8 35 3o 6 111131 22 37 II Ii 27219 2311 STOP IJ .___
~~
12. Ground relay* ~-m.11_,0-
~ GRCIJND

13. Circuit breakers, BA' EDC UNIT 14 ll,i SB urn1R1,1;

14. Control unit VO

5 ~ 2! I II 7 28 ll 4142 20 39 24 34 26
15. Boost temperature sensor ~
16. Engine coolant temperature sensor (ECC) ~ z [ Rl,i

.
m m
~ 0
17. Position sender** [ii ii m z
0
~

0
'0
m
'0
m 0 0 Bia
~ ~
~" m > m
w w m ~
18. Fuel temperature sensor** "m ii'
0
ii'
0
~
a: [
m
w
>=
w[
ii 0
----. 0 - - -
81
ii'
19. Actuator**
20. Solenoid valve, Alfa**
21. Stop solenoid**
22. Engine speed sensor t[Xl
23. Compressor

k~
R 11
24. Connector R1,1 \
25. Resistor* I
24
26. Diagnostic outlet* 24 24 t:P
27. Needle lift sensor** 11 2 3 6 5 I 11 2 I $._: 9
kl- START

~ ~ :~:~1~1:
ll:
28. Pushbutton, extra stop ~

R'I
29. Flat pin fuse, 7.5A I -GJ + ~11. Rll

30. Fuse, 55A

31. DC/DC converter 1s 1s 11 rn 19 20 21 22 23
32. Injector pump RPM

33. Connector (electronic gear)

34. To power trim pump
32 30 ~]
35. Manual reserve system
36. 2x8-pole con nectar (control panel)
37. 16-pole connector (instrument)
34
t!:!:!l 24
Cable color O():TVllltADIMSTEI 33
*Located in the tenminal box
**Located on the injection pump BL = Blue P = Pink
LBL = Light-blue R = Red
NO =Normally open during operation BN = Brown SB = Black
Cable cross sections not given =0.5 mm2 LBN = Light-brown VO = Violet
GN = Green W= White
w Abroken line indicates a
w non-Vo~o Penta cable GR = Gray Y = Yellow
OR = Orange
 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 Bl Bl.

7. Engine coolant temperature warning lamp SB

a Oil pressure warning lamp
9. Charge warning lamp ! 1,____ss_~I ! r
10. Warning lamp (not used)

~ ~
11. &Hitch, Instrumentation lamps
12. &Hitch - Alarm tesVacknowledge
13. Tachometer with built-in hours run meter
- V .---------m3
R!Bl . ~~
14. Ignition switch Ql ~
15. Alann ~uzzer) 2
16. Splice section R!Bl -
17. CPC connector 16-pin
18. Connector, turbo/reverse gear
19. Power supp~ 30 for tachometer (late production) 6 v
I
- r9(o\ ~
-I '..
Cable cross sections not given =1.0 mm2
-- 61
-+ -+
~h1 .RPH/h -~
_LJ S S
Cable color 1 a 9 10 I 11 M 13
BL = Blue P = Pink 14 0000 ~:'~
LBL = Light-blue R = Red
-r111- TE!f ml BAT G!OW ~ 12j
BN = Brown SB = Black JO @
0--

LBN = Light-brown VO = Violet ~~

c c
i ;' ~ ;~
' cc

~ ~ ~ ~ ~ ~~ -15

r
s n
GN = Green W= White 76Jil51~+_
l RIB!.
GR = Gray Y = Yellow W/lB
OR = Orange Bl/SB t5
SB

Spring loaded 16
R!Bl -Bl!Y 1,5
R15 19

Ill I1 1 2 46 16 15 14 5 7 12 13
Spring loaded
17 18
14
s15a15b 30 so 19

w
(11
 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. Instrument lighting
5. Connector for connecting extra warning display (accessory)
6. Alarm unit
7. Engine coolant temperature warning lamp
a Oil pressure warning lamp
9. Charge warning lamp
R15
10. Warning lamp (not used)
11. Switch, Instrumentation lamps
12. Switch - Alarm tesVacknowledge
13. Tachometer with built-in hours run meter
R!Bl
- 9l ~
14. Ignition switch 51 ~ 1
15. Alarm (buzze~ I 5
16. Splice section 6 v
/'\
IY-

17. CPC connector 16-pin

I
\ - 30 ~
18. Power supply 30 for tachometer (late production)
-
61
-I .. ..... +RPM/h _
tL-
Cable cross sections not given =1.0 mm2 -+ -+ 5- S
7 8 9 10 Llc 11 M 13
Abroken line indicates anon-Yo~o Penta cable
14
TEHP Oil BAT GlOW
12
Cable color
-- 30
15a
19J
()
,... ()
~
()

"
c<:>
~ +
1
10-
BL = Blue P = Pink
~ ~ ~ ~ "" ""
~~
s 19 ~~ ~ ~ ~ !);~
LBL = Light-blue R = Red i~L/ 76 J ' 1 52
+ - 15
BN = Brown
LBN = Light-brown
SB = Black
YO = Violet li1
I"'
~~
W!SB
~
GN = Green W= White
~ SB
GR = Gray Y = Yellow RIB/
OR = Orange 1 ~16
li1
li1 I.ii
.,..., li1 I.ii
.,..., li1 I"'
lt) I'' lt) I'' I.Ii lt) I"'

~
N I'' lt)
lt)

~~ Cti~ ~
N N
>.
~
I''
1lJ
~ ~ l:i~
I"'
~ ~ ~ ~
Spring loaded
Ct:
~ ~

I1 2 4 6 15 14 5 7 8 9 10 11 16 3 12 13

17
Ill
Spring loaded

14
s15a15b 30 50 19
 Instrument kit, main station

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

38
Instrumentation main control position
~to
1. lgnltbn switch lBll
\ 13 !Bil
2.
3.
Switch - Alarm tesVacknowledge
Switch, Instrumentation laJT4lS
SBW I I~
~
SB'O
lBIO

4. Alarm (buzzeq 16 - Q ~
".
5. Alarm unit with warning lamps for:
Temperature
Oillevel -
5
-I .
r
I
-
12
~
6
~w
12
.Jj,
v

7
sew aiO
12 S8W
-"
v

8
~a

u -"
12 5BtO
~

9
12 'JJW
rn , -.
v

10
Battery 61
-+
~~01
-t
Glow plugs
6. Engine coo~nt temperature (ECD gauge
00
.J r -
\ ~ 5 rl ~
~ G

7. Oil pressure gauge - engine m11 ll 1.ir m011 - - ~

~
a Voltmeter ~
~

"
~ ~
9. Boost pressure gauge .
~;
Q 0

i


.J
0

..
Q Q

.J ~
O! ~

10. Oil pressure gauge, reverse gear m~ ~

~ ~
~ ~
~ ~ n
11. Tachometer with built-in hours run meter 111 3 4 I 5 2
12. Instrument lighting
13. Connector, cannot be ~ned
~
14. Spite sectbn ~
15. CPC connector 16-pin
16. Connector for extra warning display Q
,:
(accessory) ~
~
.J

~~ ~
4
L....Jt_

13 - 1-;...

aJI
Cable color --
2 u
12
3
BL = Blue
LBL = Light-blue
P = Pink
R = Red
ll ..I.
..
"
v
~
~

Rl,5
11
BN = Brown SB = Black
LBN = Light-brown
GN = Green
YO = Violet
W= White
1
~
s 0
". ""
Q 0 ~
$ . S
,....

GR = Gray Y = Yellow
~ ~
' s
~
n ~~ ~
I
I 6 Ml. II ~ ~
OR = Orange ~ ~
~v
...... '-~ Mi 11
13 PJ9.ff Ria la
13
11/!l

P/1!5 14 Pl/~
~

VO!i ~

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

15 12J ' 5678 9

I
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. Push button, start -
2. Push button, stop
3. Switch, A~m tesVacknow~e
12
4. Switch, lnstrumentaoon ~ps 6
-
5.
6.
Alann ~uzzer)
Alarm unit with warning lamps for:
Temperature
-
61
-I ...
-+ - +
Oilevel
' Battery
Gbw plugs
7. Tachometer with built-in hours run meter
8. lnstru men! lghting rflfl II BA r fl&
9. Connector, r.annot be opened
10. ~lee section
11. CPC connector 16-pin
12. Connector for extra warning display (accessory) 5
+ - W/SB 10 I
I R/Bl 1,0

SB 10
NO =Normally ~n during operation
3

Cable color
_J_ Bl. 10
8
A

v
SB 10

BL = Blue P = Pink
LBL = Light-blue R = Red
BN = Brown SB = Black
LBN = Light-brown VO = Violet
GN = Green W= Whrre
GR = Gray Y = Yellow
OR = Orange
Ill !5

Gl/S8 t5
I
Rt5

- RIY 1~

11 If 2 3 4 s6 7 8 9 ,; 11 f2 1J u 1S 161
 Clutch control panel, Waterjet

TAMD42WJ I K22

r-----------------------------------------1
12
R/BL 1,5
11 +

VOLVO PENTA

12

8
3
L----, r-----1
4
R!BL 1,5
4 :.... I
R 1,5
3 3 R 15
3 3 +R 15 2 I
BUGN
2 2
y 1,5 y 1,5
2 2 BUGN15 I
BUBN w1,5 w15 BUBN 15
87a
SB 15 SB 15
R 15 I
4
BUBN
4 4 4
W1
...__ ____ _ I
L-----------------------------------------------

1. Relay, back flush Cable color

2. Relay, clutch in BL Blue p Pink
3. Cabling to gearbox
4. 4-pin cable terminal
LBL Light-blue PU Purple
5. Extension cables (3, 5, 7, 9 and 11 m) BN Brown R Red
6. Pushbutton, back flush LBN Light-brown SB Black
7. Pushbutton, clutch in GN Green VO Violet
8. Relay, clutch in GR Gray w White
9. Pushbutton, clutch out OR Orange y Yellow
10. Battery (-)
11. Battery (+)
12. Control panel

Cable areas not stated = 1.0 rnrn 2

A broken line indicates a non Volvo Penta cable.

42
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
2 3
- VD 1,5 VD 15 -2
-6
2 "''
VI
DR 1,5 1---
6
1--- ,__
BL/58 1,5
8 8

----1
R 1,5
,__
1
-3 R/BL 1,5 >--

-----
4
5
R/Y 1,5
BN 1,5 --
J
----4
5
-7 R/GN 1,5
7
-9 BL/Y 1,5 -9
-10 LBL 1,5 ----10
- 11
lBN 1,5 -
11
-12 GR 1,5 -12
-13 GR/SB 1,5 -1J
-14 W/Bl 1,5 -
14
-15 W/BN 1,5 -15
,....__ ,__
58 1,5
16 16
-

Cable color
BL Blue p Pink GN Green VO Violet
LBL Light-blue PU Purple GR Gray w White
BN Brown R Red OR Orange y Yellow
LBN Light-brown SB Black
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 1
I

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

I 3a~~ ~~sa
I
I :6.. "
I I "-
.r
3.(J 4
I
I
I
I ...______.,_____....,---+-~

I I
ar
I

6 ~z~ 4 5 I
I
1 'E 'E 'E 'E 'E 'E
I

I ...______.,_____....,---+-~
I E 0
E
0
E
0
E
0
E
0
E
0

I 5
~ ~ ~ ~ ~ ~

5 5 5 5 5 7,8
11 2 3 4 5 6 7 Bl
'E 'E 'E 'E 'E 'E _J
E E E E E E
~ ~ 0 0 0 ~
~ ~ ~

5 5 5 5 5 5 7,8
11 2 3 4 5 6 7 Bl
_J -
9/-1
(~r;-J I
-
I 13 1 21 2
1

R/BL R/BL
I I

~ ~
z z
l'l l'l

11 83456721 I7 1 6 4 3 2 5 I1 8345672 I 1~7~1_6~-4~-3~2~~~~~~-5~

7 8 7 8

Color code Position schedule (both wiring diagrams)

BL = Blue 1. Control panel
BN = Brown 2. Connector
GN = Green 3. Diagnostic button
OR = Orange 3a. LED (yellow):
P = Pink 4. Activation button
R = Red 4a. LED (red)
SB = Black 5. Neutral button
W = White Sa. LED (green)
Y = Yellow 6. LED for background illumination
7. 8-pin moisture-proof connection (male)
Cable areas= 0.75 mm 2 8. 8-pin moisture-proof connection (female)
9. Neutral position switch (only mechanically shifted reverse-
gears)
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
i..1a ,.1a

4a~ ._sa 3ai'> ,,,4a

3 41 3 4
L _____ _

9,10 1 ~ 4 5 9, 10 1 ~ 4 5

r--+-----'U r--+-----'U

I 715 4 3 2 5 110

Twin installation - twin lever control

'" 7a ""7a

'"' 3a,,. 4a"' ._Sa 3a ;... 4a"'

61'> 3
~

4 rs1( 3 4
--- --- -- -- ------ --~------------- -- --- - - - -
~
~

' - ~ ~~- ~i i~~

5:~~i~
" "
9,10 .L--r~------~L----~~J___j~-,'-------0,6~~,~-,~8
2
_J
3
5:5:i5:i5:i5:
9,10~,~_J:_,L_-_-~~2 ===J___j~_L_,~~,~~,~___,,I

1~/---1 11//--l
I ' I
: 3 1 2: 2 I 3 1 21 2
I I I I
I I I I

I 8a :: 8b :
I r9l II r=-, I
I .LLJ 11 l__!_\, I,
_ _~.c
3
Ii 1.1--1---.P21L r t ,
l3l ]-c _J : <::
H a ~ a ; r rio
!
~ ~
0

I 71 G 4 3 2 S 110 9 1
'
834 5 6721 I 71 G 4 3 2 S 110

Color code Position schedule {both wiring diagrams)

BL Blue 1. Control panel 7a. LED, 2 pcs {red) port and starboard.
BN Brown 2. Connector 8. Potentiometer, throttle opening I gear shift
GN Green 3. Diagnostic button 8a. Control adapter, throttle opening
OR Orange 3a. LED {yellow): 8b. Control adapter, gear shift
P Pink 4. Neutral button 9. 8-pin connection {male)
R Red 4a. LED {green) 10. 8-pin connection {female)
SB Black 5. Synchronization button 11. Neutral position switch {only mechanically shifted
W White Sa. LED {blue): reverse gears)
Y Yellow 6. LED for background illumination
7. Activation button
Cable areas= 0.75 mm 2

49
 Control panel Type II
Single installation
KA(M)D44P-A

1, 2 1, 2 1, 2 1, 2

@ VOLVO PENTA @ @ VOLVO PEN'I:A. @

1, 2

50
One helmsman's seat - single installation - One helmsman's seat - single installation -
single lever control twin lever control

NEUTRAL DIAGNOSIS NEUTRAL DIAGNOSIS 15 (IGNITION)

KEY SWITCH

r-;HROTTLE l !; HROTTLE
CONVERTER
-1 I GEAR SHIFT
CONVERTER

7 7
"'~ er:~ ~ "'
~ ~ ~
er:

"' "' "' ~

"
Q?
"' "' "' ~
"
Q?
GN/SB
GN/Y
""' "'" GN/SB
GN/Y
""' "'"
4 3 2 10 5 4 3 2 10

6 6

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

!; - HROTTLE
CONVERTER
l I GEAR SHIFT
CONVERTER

7 7
er:
"'
~
0 >-

"' ""' ""' ~ "

Q?
GN/SB
GNIY
GN/SB
GNIY "' "'"
4 3 2 10 4 3 2 10

6 6

VP Controls:
Late model
Color code Position schedule (all wiring diagrams)
BL Blue 1. Indication lamp
BN Brown 2. 1-pin switch
GN Green 3. Position switch
OR Orange 4. Connector
P Pink 5. Potentiometer
R Red 6. 16-pin connection
SB Black Early model 7. 2-pin connection {diagnostic connector)
W White 8. Joint
Y Yellow

Cable areas= 0.75 mm 2

51
 Control panel Type II
Single installation
KA(M)D44P-B/C, KA(M)D300-A

1 2

@ VOLVO PENTA. @

52
Single installation - single lever control Single installation - twin lever control

NEUTRAL DIAGNOSIS ACTIVE STATION NEUTRAL DIAGNOSIS ACTIVE STATION

4 4

RIBL RIBL
R!BL R!BL
RIBL RIBL

RIBL
5 ii3
Sb
a:

~ ~
o:i n: o:i n:
0 0
~ ~ C'.J ~ ~ C'.J
C'.J
"'
C'.J C'.J <
~
C'.J
"'
C'.J C'.J <
~
"=o:i ~~ "=o:i ~~
:;::: < GN!SB C'.J :;::: < GN!SB C'.J
i:i:"'Ci'C'.J >:: ~ 0...
i:i:"'Ci'C'.J >:: ~ 0...
GN/Y GN/Y

3812 16 7 4 3 2 5 3812 16 7 4 3 2 5
7 8 7 8

Color code Position schedule (both wiring diagrams)

BL Blue 1. Press switch with indication lamp, "Neutral" (green)
BN Brown 2. Press switch with indication lamp, "Diagnostic" (yellow)
GN Green 3. Press switch with indication lamp, "Active station" (red)
OR Orange 4. Connector
P Pink S. Potentiometer, throttle opening I gear shift
R Red Sa. Potentiometer, throttle opening
SB Black Sb. Potentiometer, gear shift
W White 6. Neutral position switch
Y Yellow 7. 8-pin connection (male)
8. 8-pin connection (female)
Cable areas= 0.75 mm 2 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
1 X2
1 1 1 X1
1 X2 1

NEUTRAL,

7 RIBL SEE BELOW

8 8

GNIY GNIY
[[ al [[ z
al
Q c iii Q c '!'
"' z CfJ_
~mg?
z
(') Q_
"'al
Q_ U)
i!5
[[
z z z
(') (') (') "'
z
(') (')
z
(') Q_ Q_U) [[
z z z
(') (') (') "'
z
(')
z
(')

7 11 16 14 4 3 2 10 7 11 16 14 4 3 2 10 5

9 10

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

1 1 1 1 1 1
X1 X2 X1 X2 X1 X2

R/BL

8 "'"-7
GNIY
al [[ al [[ z
CfJ_ Q cz CfJ_ Q cz '!'
o_
~
o_
rn
(j)
~
[[
z z
(') (') (')
z
(') Q_
~
Q_
co
U)
~
[[
z z
(') (') (') "'z
(')
z
(')

7111614 432 10 7 11 16 14 4 3 2 10

9 10

VP Controls: Position schedule (both wiring diagrams)

Color code Late model NEUTRAL 1. Indication lamp
BL Blue 2. Switch
BN Brown 3. Connector
GN Green 4. Relay
OR Orange 5. Position switch
P Pink 5 6. Potentiometer
R Red 7. Connector, Port - Starboard cable kit
SB Black 8. 2-pin connection {diagnostic connector)
W White 9. 16-pin connection, Port engine
Y Yellow Early model 10. 16-pin connection, Starboard engine
2
Cable areas= 0.75 mm

55
 Control panel Type II
Twin installation
KA(M)D44P-B/C, KA(M)D300-A

2 3 6

1 4 5

56
 Twin installation - single lever control

~~
J-+-----+h
,J
7

R/EL

8
. -'!"
8 POLE PV-GONNECTOR (MALE)
e;
l:J
Cl

~
3
8 POLE PV-CONNEGTOR (FEMALE)
:>--

3
2
-~ ~! ', ;' ', :]ij,;c--,~,______-~_,_; ---~_,_,
8 POLE PV-CONNECTOR (MALE)
i-7-J

8 POLE PY-CONNECTOR (FEMALE)

Gc'-2

PORT ENGINE STARBOARD ENGINE

Twin installation - twin lever control

lA(iNOSS-Xtl ()W lA\iN()SS-Xt OW

2 3 4 6

f:il G c.~
--1-3 2
8 POLE PY-CONNECTOR (MALE) 8 POLE PV-CONNECTOR (FEMALE) 8 POLE PY-CONNECTOR (FEMALE)
PORT ENGINE STARBOARD ENGINE

VP Controls: Position schedule (both wiring diagrams)

Late model NEUTRAL 1. Press switch with indication lamp, "Neutral" - green
Color code 2. Press switch with indication lamp, "Diagnostic" - yellow
BL Blue 3. Press switch with indication lamp, "Active station" - red
BN Brown 4. Press switch with indication lamp, "Sync" - blue
GN Green 5. Press switch with indication lamp, "Neutral" - green
OR Orange 5 6. Press switch with indication lamp, "Diagnostic" - yellow
P Pink 7. Connector
R Red 8. Connector, Port - Starboard cable kit
SB Black 9. Relay
W White Early model 10. Potentiometer, throttle opening I gear shift
Y Yellow 1Oa. Potentiometer, throttle opening
1Ob. Potentiometer, gear shift
Cable areas= 0.75 mm 2 11. 8-pin connection (male) - Port engine
12. 8-pin connection (female) - Starboard engine
5 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. R 9. BUY
2. VO 10. LBL
3. BUR 11. LBN
4. R/Y 12. GR
5. BN 13. GR/SB
6. OR 14. BUW
7. R/GN 15. BN/W
8. BUSB 16. SB

Color code for connector, engine M

1. Y/W 9. SB/W
2. GN/Y 10. GN/W F
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

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 instal-

lation. In twin installations, all connectors
have the same Color code except the con-
nectors for the engine and the port and star-
board controls.

Color code
1. R 9. BUY
2. VO 10. LBL
3. BUR 11. LBN
4. R/Y 12. GR
5. BN 13. GR/SB
6. OR 14. BUW
7. R/GN 15. BN/W
8. BUSB 16. SB

MS unit

For MS unit,
port engine
Color code for connec- Color code for connec-
tor, controls for port tor, controls for star-
engine board engine
1. Y/W 9. SB/W 1. Y/W 9. SB/W
2. GN/Y 10. GN/W 2. GN/Y 10. GN/W
3. OR/GN11. P/W 3. OR/GN 11. P/W
4. GN/SB 12. y 4. GN/SB 12. SB
5. GN/R 13. BL 5. GN/R 13. BL M
6. GN 14. BUR 6. GN 14. BUR
7. p 15. 7. p 15. F
8. w 16. SB 8. w 16. SB
Color code
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
Y connector GN Green
GR Gray
OR Orange
Color code for connector, engine P Pink
1. Y/W 9. SB/W R Red
2. GN/Y 10. GN/W SB Black
3. GN/OR 11. P/W VO Violet
4. GN/SB 12. Y W White
5. GN/BN 13. BL Y = Yellow
6. GN 14. BUR
7. p 15. -
8. W 16. SB Engine

59
CJ) -----------,
0 0
0
0
iil
-I
::;
<D
<D
Gf\/~N

GN
e'.ji .___._
em N
Y1W

mJ/Y
=N
OFi
Q '" 0- H
OQ> o".l VO
sN
[)1
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e'" "'
R
VO
GNIBN
GN
IcJ" 0-1v,w
o'" o' GN(Y
GNrsN
mJ
I ti' 1v1w
fi' ~ GN/Y
BN
OR
Io'" o-IR
OOJ ON 1/0
BN

oRtf9vo
1 GN/81\

3N O 0
I
I
I CJ)
I "O
::E li
=~
P ."-..J. GWOR RJGN 0-....J OLAI R.IBL RiGN 1-~ "lniBL pIo: 0:1GN/OR P 1~ "IGN10~ R1GN I
0 : O:IRIBL R.IGN ~ ff rliEL p 0 '-.I d'" GWOR : m
::J !!!. W em e GN/SB BL/SB 0 m 0 " H/Y BL'SB ff' e R!Y W 0 0 GN;SB W ff' ff GN/SB BUSB Q Q FW Bli'SB n/Y 0
o:i
0
~ I (IJ
GN/SB I CT
9. g
:
~
::J CT
CT (D W/8
BLI o"' o- PIBL GR.'SB

Y/;L
ff' .-
ff' .,
BL/W

LBL
GR:ss

YIOL
1 a'" 0 -1 BL/w
LBL W/SB
BL e .-
e'" .,
R/BL

GNNI W/SB
9_ Qr..., O_._ A/BL

0 C) 0" ' GN,IW

GR/SB

Y/BL
t/
ti ~
BL.,l'N

LBL
~wm

90. li
""'" o
\'/BL o"'
crew:
o" LBL I
BL I e"' .-

~

tv
PJBL
I
GN,W : "O
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~
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J
1
P/w BN1W 9J 9 11
LBN BN/W LBN ~LiW 1
.r,,::, P,."W BL/W Q.., 1 dJJ P/W 3NNI e' ~ LBN
........... ::J
CJ) - In
Bl\,M' 0 ...1 Ow LBN : .~ fl F.!W I g_
0
=I CT
::J
SBI Orn 0 y SB "' e GR SB GR SB e e
rn _..
Y SB Ow. 0-*'" v SB ,/ e GR
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-
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::J SB Qoo a :-:OR : SBle" . . y 5
<D <D
!l ..... m
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i 2:
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c: !1:1
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I 0-1 I"-1
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II II II II II II Ill
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OR I ff ~loo
Ill
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=~Q.~ a.~ 8::J I 5;: Z '
., "' o~ o"' .P 0'1 li
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........... ::J
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er ~
W W,1SB W .f-.
- ::J
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SB Io"' Ol~R SB ff GR ~
a
 Electronic controls
Single installation

Control panel
Type II
Control panel
Type I

..
..
I
I
I
I

..f

. - : ...
-~
I

. .... -
...
. _.._. ___ -
"'

. .. . ---.. ...
..'........ .. . ... ... ...... ... ..' . ..
.
;
'

/
The 16 pin engine
\/
The 2x8 pin engi-
connector is only
ne connector can
combined with a
be combined with
Type II control
a Type I or Type
panel
II control panel

61
 Electronic controls
Twin installation (control panel Type I)

Starboard

Port Color code

Y = Yellow
GN = Green
R = Red

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

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

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

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

I
The 16 pin engine
connector is only
v
The 2x8 pin engi-
combined with a ne connector can
Type II control be combined with
panel a Type I or Type
II control panel

64
 Mechanical twin lever control
Electric shifting

Control panel
Type I

'
'
. ..
'

.. . ..
'
'
'

The 16 pin engine The 2x8 pin engi-

connector is only ne connector can
combined with a be combined with
Type II control a Type I or Type
panel 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 @ -~--17

@ ~--""'".J.11.WJ..-
'--l--'"""-"""""-18
_ ____,

10a 10b

ll.IN1 18
RiPU 1 1
GNiW151

~--ao

I
I

2~
I
1- ~ 1 I

""'d
Cable color
1. Battery BL Blue P Pink
2. Main switch LBL Light-blue PU Purple
3. Starter BN Brown R Red
4. Circuit breaker SO A LBN Light-brown SB Black
Sa. Connector, 2-pole male GN Green VO Violet
Sb. Connector, 2-poe female GR Gray W White
6. Hydraulic pump
OR Orange Y Yellow
7. Connector with rubber cap, 3-pole
Ba. Fully cast connectors, 3-pole female
SB* Black ribbed SB** Black smooth
Bb. Fully cast connectors, 3-pole male
9a. Connector with rubber cap, 1-pole male Cable areas in (mm 2) are given after the cable color codes.
9b. Connector with rubber cap, 1-pole female Cable areas in brackets are AWG (American Wiring Gauge).
10a. Trim sender, digital
10b. Trim sender, analouge Conversion table:
11 . Connector, 7-pole
12. Extension cable, Y-connector
13. Control panel
mm 2 AWG
14. Triminstrument, analouge
0.5 20
1S. Instrument lightning 0.75 18
16. Connecting terminal, instrument lightning(+) to main panel 1.0 17
17. Connecting terminal, fuse box(-) to main panel 1.5 15-16
18. Connecting terminal, fuse box(+) to main panel 2.5 13
19. Circuit breaker 10 A 6 10
20. Circuit breaker 10 A* 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

18
@
15 @ 19
@ 20

12

r- -

'
,'
-

AC
-

9
- - - - - - - - - - -

SB151
- - - - - - - - - - - - - - - -.

'7 m
8!

AC B
B 9

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8
I BN.W1 1 I

....
8UW1 1
RiPU 1,51
GNIW15 1

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

r--------;,

2~
_r--jb
=
1 iI
0
- +

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

1. Battery andSX-R2
2. Main switch
3. Starter
Cable color
4. Circuit breaker SO A BL Blue P Pink
Sa. Connector, 2-pole male LBL Light-blue PU Purple
Sb. Connector, 2-poe female BN Brown R Red
6. Hydraulic pump LBN Light-brown SB Black
7. Not used GN Green VO Violet
8. Connector with rubber cap, 1-pole GR Gray W White
9. Connector with rubber cap, 3-pole OR Orange Y Yellow
10a. Fully cast connectors, 3-pole female
SB* Black ribbed SB** Black smooth
10b. Fully cast connectors, 3-pole male
11. Connector 1-pole, trim by-pass
12. Trim sender Cable areas in (mm 2) are given after the cable color codes.
13. Extension cable, Y-connector Cable areas in brackets are AWG (American Wiring Gauge).
14. Connector, 7-pole
1S. Control panel Conversion table:
16. Triminstrument, analouge
17. Instrument lightning mm 2 AWG
18. Connecting terminal, instrument lightning (+)to main panel
19. Connecting terminal, fuse box(-) to main panel
0.5 20
20. Connecting terminal, fuse box(+) to main panel 0.75 18
21. Circuit breaker 10 A 1.0 17
1.5 15-16
2.5 13
22. Circuit breaker 10 A* 6 10
10 7

A broken line indicates a non-Volvo Penta cable.

68
Power Trim SX, DP-S with trim limiter

19
@
@ ,,__~-- 20
16
@ '--+-""""""~- 21

13

DJ
m 9

5b 5a
r----------io
'
;
'
2~
,-----, 1 I
=a

Cable color
1. Battery BL Blue P Pink
2. Main switch LBL Light-blue PU Purple
3. Starter
BN Brown R Red
4. Circuit breaker SO A
Sa. Connector, 2-pole male LBN Light-brown SB Black
Sb. Connector, 2-pole female GN Green VO Violet
6. Hydraulic pump GR Gray W White
7. Not used OR Orange Y Yellow
Ba. Fully cast connectors, 3-pole female SB* Black ribbed SB** Black smooth
Bb. Fully cast connectors, 3-pole male
9. Connector with rubber cap, 3-pole Cable areas in (mm 2} are given after the cable color codes.
1O. Connector with rubber cap, 1-pole
Cable areas in brackets are AWG (American Wiring Gauge).
11. Trim limiter
12. Connector, 1-pole
13. Trim sender Conversion table:
14. Connector, 7-pole
1S. Extension cable, Y-connector mm 2 AWG
16. Control panel 0.5 20
17. Trim instrument, analouge 0.75 18
18. Instrument lightning 1.0 17
19. Connecting terminal, instrument lightning (+)to main panel
1.5 15-16
20. Connecting terminal, fuse box (-) to main panel
21. Connecting terminal, fuse box(+) to main panel 2.5 13
22. Circuit breaker 10 A 6 10
23. Circuit breaker 10 A* 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~
Cable color
1. Battery
2. Main switch
BL Blue P Pink
3. Starter LBL Light-blue PU Purple
4. Circuit breaker SO A BN Brown R Red
Sa. Connector, 2-pole male LBN Light-brown SB Black
Sb. Connector, 2-pole female GN Green VO Violet
6. Fuse 10 A GR Gray W White
7a. Connector, 2-pole male OR Orange Y Yellow
7b. Connector, 2-pole female
SB* Black ribbed SB** Black smooth
8. Hydraulic pump
9. Reley, down
10. Reley, up Cable areas in (mm 2) are given after the cable color codes.
11 . Connector with rubber cap, 3-pole Cable areas in brackets are AWG (American Wiring Gauge).
12. Connector with rubber cap, 1-pole
13. Not used Conversion table:
14a. Fully cast connectors, 3-pole female
14b. Fully cast connectors, 3-pole male mm 2 AWG
1S. Connector 1-pole
0.5 20
16. Trim sender
17. Connector, 7-pole
0.75 18
18. Extension cable, Y-connector 1.0 17
19. Control panel 1.5 15-16
20. Triminstrument, analouge 2.5 13
21. Instrument lightning 6 10
22. Connecting terminal, instrument lightning (+)to main panel 10 7
23. Connecting terminal, fuse box (-) to main panel
24. Connecting terminal, fuse box(+) to main panel
A broken line indicates a non-Volvo Penta cable.

70
Power Trim SX with trim limiter

@>
@ -~-- 24
20
25
.........,....._~~~-
@

17

oe=-a8 7b 7a

1. Battery Cable color

2. Main switch BL Blue P Pink
3. Starter
LBL Light-blue PU Purple
4. Circuit breaker SO A
Sa. Connector, 2-pole male BN Brown R Red
Sb. Connector, 2-pole female LBN Light-brown SB Black
6. Fuse 10 A GN Green VO Violet
7a. Connector, 2-pole female GR Gray W White
7b. Connector, 2-pole male OR Orange Y Yellow
8. Hydraulic pump SB* Black ribbed SB** Black smooth
9. Reley, down
10. Reley, up
Cable areas in (mm 2) are given after the cable color codes.
11 a. Fully cast connectors, 3-pole female
11 b. Fully cast connectors, 3-pole male Cable areas in brackets are AWG (American Wiring Gauge).
12. Connector with rubber cap, 3-pole
13. Connector with rubber cap, 1-pole Conversion table:
14. Not used
1S. Trim limiter mm 2 AWG
16. Connector, 1-pole 0.5 20
17. Trim sender 0.75 18
18. Connector, 7-pole
1.0 17
19. Extension cable, Y-connector
20. Control panel 1.5 15-16
21. Trim instrument, analouge 2.5 13
22. Instrument lightning 6 10
23. Connecting terminal, instrument lightning (+)to main panel 10 7
24. Connecting terminal, fuse box (-) to main panel
2S. Connecting terminal, fuse box(+) to main panel A broken line indicates a non-Volvo Penta cable.

71
Power trim 290, 290A, 290-DP and 290A-DP (version 1)

11-

11,
~I'
1m1 ~
1-1 I
z1".n I
C>t
I
"J-i-
I
I 10 I
I I I
I I I
I ..JI
__ J
___ _.ml
r-+--+--+-1--. I
I
I
I
____ _JI

m 1 =Up
2 =Positive {+)
3 =Down
4 = Override button
.J
m
8 +
--,
' '
'T
7

1. Oil pump
2. Fuse, 55 A Cable colors
3. Trim sender BL Blue p Pink
4. Trim indicator LBL Light blue PU Purple
5. Switch
6. Switching relay, "beach" position
BN Brown R Red
7. Connector, instrument panel LBN Light brown SB Black
8. Instrument lighting GN Green VO Violet
9. Throttle-mounted switch {accessory) GR Gray w White
10. Fuse, 5 A OR Orange y Yellow
11. Control relay, down
12. Control relay, up Cable cross sections not given = 1.5 mm2
13. Hydraulic hose, low pressure
14. Hydraulic hose, high pressure

72
Power trim 290, 290A, 290-DP, 290A-DP, SP, DP (version 2)

~
2

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

at 8
+1-

, ' ..,.

1. Oil pump Cable colors

2. Fuse p
BL Blue Pink
3. Trim sender
4. Trim indicator LBL Light blue PU Purple
5. Switch BN Brown R Red
6. Switching relay, "beach" position LBN Light brown SB Black
7. Connector, instrument panel GN Green VO Violet
8. Instrument lighting GR Gray w White
9. Throttle-mounted** switch (accessory) OR Orange y Yellow
10. Motor type relay (the arrow refers to the trim function,
up/down.)
Cable cross sections not given = 1.5 mm2

73
Power trim SP, DP (version 3)

11
10 r---------------
8 9
!@@@
I
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 - - - - - - - - - - - - - - ...
IJ
I

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

G 15 G 15
BL 1 5
6 7

16

S86
3
1
I - - - ~ ------
'
I [6""""61+
.,!.. l..L...J

1. Battery cable color

2. Starter BL Blue p Pink
3. Fuse 55 A LBL Light-blue PU Purple
4. Hydraulic pump
BN Brown R Red
5. Trim sender
6. Reley, up
LBN Light-brown SB Black
7. Reley, down GN Green VO Violet
8. Reley, by-pass GR Gray w White
9. Reley, lift stop OR Orange y Yellow
10. Trim instrument
11. Control panel Cable areas in (mm2) are given after the cable color codes.
12. 1-pole two-way switch, up and down A broken line indicates a non-Volvo Penta cable.
13. 1-pole switch, by-pass standard
14. 1-pole switch, by-pass with hold function
15. Lamp
16. Connecting terminal, can not be opened
17. Connecting terminal, can not be opened
18. Connector, to main panel

74
o er r

9
r-----------------,
@ @ @)
10

5
BUR 1 0

10
GN 15

8 7
5

BL1 5

CD
IC

6
R

SBB

3 5
N/W GN/W33
I
I Bl.JW3 3
I
1 I - -
I
r------, I
I
I
I
....L
D
1. Battery C8blecolor
2. Starter BL Blue p Pink
3. Fuse 55 A LBL Light-blue PU Purple
4. Hydraulic pump
5. Connector
BN Brown R Red
6. Connecting point, cannot be opened LBN Light-brown SB Black
7. Reley, down GN Green VO Violet
8. Reley, up GR Gray w White
9. Control panel OR Orange y Yellow
10. Connector, to main panel
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 v

+ - A R L
5 I } I> J IJ

er:

BN --
3

2[ ~ OR ro
-
4
er: CQ

1
+ -

1. Battery
2. Fuse 1 A
3. Active anode
4. Reference sensor
5. Electronic unit
6. LED light

Cable color
BL Blue P Pink
LBL Light-blue PU Purple
BN Brown R Red
LBN Light-brown SB Black
GN Green VO Violet
GR Gray W White
OR Orange Y Yellow

76
 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