Workshop Manual sB Electrical system Wiring diagrams 200) 31, 32, 41, 42, 43, 44, 300 seriesGroup 30 Electrical system Marine engines MD31A + TMD31B, D, L-A TAMD31B, D, S.O.L.A.S, L-A, M-A, P-A, S-A AD31B, D, L-A, P-A » KAD32P TMD41B, D, L-A TAMD41B, D, S.O.L.A.S, L-A, M-A, P-A, H-A, H-B D41B, D, L-A+ AD41B, D, L-A, P-A TAMD42AWJ, BWJ, WJ KAMD42A, B, P + KAD42A, B, P KAMD43P +» KAD43P KAMD44P-A, P-B, P-C + KAD44P-A, P-B, P-C KAMD300-A + KAD300-A Contents Safety information TAMD42AWY, BWJ, WJ 1.5-pole 31/41 1 5-pole 12 V. ;neral information 5 General informatio 31/41 1.5-pole 24 V. Special tools 6 44/300 Other special equipment 5 Wiring diagrams, instrument panel Design and function 7 Instrument panel, main station General 7 Instrument panel, tly bridge Generator 8 Instrument kit, main station Starter motor 8 Instrument kit, tly bridge Electrical connection box 9 Clutch contro! panel, waterjet Fuses and circuit breakers 10 Diode cable, 1.5-pole electrical sysiem Monitors 10 EDC control system Glow plugs 10 “Control pane's Sensors " Color-codes for EDC cables Solenoid valve 1 Electronic control Engine speed relay 12 Mechanical control Charging system 14 Wiring diagrams, Power trim General 14 sx, DP-S Technical data 14 290, SP, DP Faultinding 18 DPX yrams, engine 20 Corrosion protection system pole 20 “Active corrosion protection system KA(M)D42i43 1-pole 2 228SS EHSBSLS SBBB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 co:rect workshop literature is being used, Read the safety information and the Workshop Manual “General Information” and “Repair In- structions” carefully before starting work. Important 1 this book and on the engine you wil find the follow. ing special warning symbo's ZX 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 matfunction. ZA PORTANT! Used to draw your attention to somotiing that can cause damage, product rmaltunction or damage to property. NOTE!Used to draw your attention to important infor: ‘mation that wil faciitate work or operations. Below is a summary of the risks and safely precau- tions you should always observe or carry out when operating or servicing the engine AX immobitize the engine by turning off the power supply tothe engine at the main switch (switeh es) and lock it (them) in the OFF position before starting work. Set up a warning notice atthe en gine control point or heim. AX 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 uring. Approaching a running engine is dangerous. Loose clothing or long halr can fasten in rotating parts and cause serious personal injury. IF working in proximity to a running engine, care less movements or a dropped too! 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 noses 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. AN. Check thatthe warning o information decals on the product are avays leary visible. Replace locals that have booh damaged or painted ove AN ‘Never sta the engin without istaling he air cleaner (ACL). The rotating compressor in the Turbo ean cause serous persona ing. For eign objets entering tne intake ducts can also cause mechanical damage. AX ‘Newer use str spray o silo start the on- (ine. The slater ele may cause an expo- Sion inte inll manifold. Danger o personal iu. LX Avoid opening the coolant filing cap when the engine is hot. Steam or hot coolant can spray ‘out at the same time as the pressure which nas built up is lost. Open the filler cao slowly, and release the pressure in the cooling system if the filing cap or tap has to be opened, or ifa 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 AX Hotoil can cause burns. Avoid skin contact with hot oil, Ensure thatthe lubrication system is not under pressure before commencing work ‘nit. Never start or operate the engine with the «il filler cap removed, otherwise oli could be ejected LX Stop the engine and close the sea cock before cartying out operations on the engine cooling system, AX oniystartte engine ina wellventlated are. operang he ongite lon enced space, ot- Sure that exhaust gases and crankcase vet fon emissions ae verllaie et che working ZX Aiways use protective goggles where there is @ danger of pieces of metal, sparks from grinding acid or other chemicals being tnrown into your eyes. Your eyes are very sensitive, injury can lead io loss of sight!Safety Precautions AX Ave skn contact wit ol Long orm or repeat edortact wih ol can remove ne naturales from your skin. Te result canbe iaton ry then, eozema and oer skin robems, Used als more dangerous to heath han new Oi. Use protective doves and avoid using ol Soaked clotes and rags. Wash regularly, ese Gilly befowe meals, Use the correct barier cream fo prevent dy skin and to make clearing your skin easier. AX Most chemicals usedin products (engine and transmission ols, glycol, perl and deseo) ane workshop chomlcals(soWents and pls) are hazardous to heath Read the insrucions ‘on the product packaging carefully! Always fol- iow safely instwtions (sing breathing appara- tus, protective goggles and loves for exam ble) Ensure that lhe personnel are nl trmetogly expoved fo hazardous nbelances toy breaning inom infor example). Ensue tat ventilation s good, Handle used and excess chemicals according to insuctions. AX Beextremely careful when tracing leaks in the {uel system and testing fuel injection nozzles. Use protective goggles! The jet ejected from a {ol injection nozzle is under very tigh pres sure, itcan penetrate body tissue and cause serious injury There is a danger of blood poison- ing AX Alltusts and many chemicals are inflammable. Ensure that a naked fame or sparks cannot ig tile fuel or chemicals. Combined wit arin cer tain ratios, petrol, some solvents and hydrogen {rom batteries are easly infiammable and explo sive. Smoking is prohibited! Ensure that ventia- tion is good and that the necessary safely pre- cautions have been taken before carrying out welding or grinding work. Aways have a ire ex- tinguisher to hand in the workplace. AX Store oil and fuel-soaked rags and fuel and oil fitters safely. In certain conditions oi-soaked rags can spontaneously ignite. Used fuel and oil fiters are environmentally dangerous waste and must be deposited at an approved ste for de- struction together with used lubricating ol, con- taminated fuel, paint remnants, solvent, de- greasing agents and waste from wasting parts. ZX Never allow a naked fame 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. Incor- 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. AX Never mix up the positive and negative battery terminals when instaling. Incorrect installation can result in serious damage to electrical equip- ment. Refer to wiring diagrams. AX Aways use protective goggles when charging and handling batteries. The battery electrolyte contains extremely corrosive sulturie acid, It this comes into contact wit the skin, wash im- mediately with soap and plenty of water. if bat- tery acid comes into contact with the eyes, im- mediately fush 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 eles- vical system. > The clutch mustibe adjusted with the engine shut of. AX Use te iting eyes mounted onthe engine: verse gear when tng the dve un ‘Aways check tat tng equipments in good ondton and has sufftent oad capacty to it the engine (engine weight including reverse gear and ary extra equipment installed). ‘Toensure sate handing and to avoid damaging engine components ontop ofthe engine, use & iting bear oraise the engine. Allchains and cabs shoud run paral to each omer and as perpendcua’ as possbie in ean toe lop tthe engine. iexra equipments installed onthe engine a tering ts center of gravity, a special iting de- vices required to achive the correct balance tor sate handing Never eam oul workon an engine euspended ona hoistSafety Precautions AX Never remove heavy components alone, even where secure lifting equipment such as Secured blocks are being used. Even where liting equi- ‘ment is being used itis best to carry oul the ‘work with two people; one to operate the lting equipment and the other to ensure that compo: nents are not trapped and damaged when being lites. When working on-board ensure that there is sut- ficient space lo remove components without, danger of injury or damage. LX Components in the electrical and fuel systems. on Volvo Penta products have been designed to ‘minimize the risks of explosion and fre. The en- gine must not be operated in environments with agjacent explosive media, LX Fuel dotivery pipes must not be bent or straight- ened under any circumstances, Damaged pipes must be replaced, AX Remember the folowing when washing wih a high pressure washer: Never am the waar ott Seals rubber hoses o lotcal components, Never use a high pressure washer for engine dean, ZX Always use fuels recommended by Volvo Pen: ta. Refer to the Instruction Book. The use of ower quality fuels can damage the engine. On a diesel engine poor quality fuel can cause tne control rod to seize and the engine to overrev with the resulting risk of damage to tie engine ‘and personal injury. Poor fuel quality can also lead to higher maintenance costs. (© 200% AB VOLVO PENTA We coserve the right 10 make mocifieaions without por notice. Printed on eavionmentaly coma pazer.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 | [uel 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 elated mechanical and electrical work. Volvo Penta is continuously developing their prod- cts. We therefore reserve the right to make chang: es. All the information contained in this book is based 0n product data available atthe 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 tyoe 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, itis important to be aware ofthe following Certitication 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 ceriied en- gine. This makes special demands on service and repair work, as follows: + Maintenance and service itervalsrecommended 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 modifies, except for the accessories and service kits which Volvo Penta nas approved for the engine. + Noinstallation changes to the exhaust pipe and tengine air inlet ducts may be done. + Noseals may be broken by unauthorized person- nel ‘The general advice inthe instruction book about ope- ration, care and maintenance applies. AX montant! Delayed orinfrorcaremaini- ange, andthe use of non-oginal pare, mean that AB Volo Penta can no long’ bee. sporsble or quarartoaing tale engine complies wi the certified version. Damage, injury andlor costs which arise from this will not be compensated by Volvo Penta.Special tools In all cases where itis practical the tool number, except for the final digit, has been stamped on the tool, The final digit after the hyphen) 's a control number. 1189660 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 aificuly finding an AMP sales out contact Volvo Penta Quality Action Center for advice, a AMP 726 519 ‘AMP 725 840 AMP 625 514 AMP 725 998 ‘AMP 225 582 16 pin CPC connector, d=1.6 mm: Pin and sleeve terminals 3.5 mm: 7288401 Terminal removaltool 725938-0 Terminal removel tool 58.495-1 Crimping pliers 8255822 Crimping pliers PT connector (42-pin EDC,2-and3-pin Boschetc): 4.8 mm and 6.3 mm cable clamps: Male and. female spade terminals 726534-1_ Terminal removal tool 1.6 mm pin width 825514-1 Crimping pliers 726519-1 Terminal removal ool 2.8 mm pin width 8255141 Crimping pliersDesign and Function General Allof the engines have a 12-volt, pole electrical system as slandard, with an alternator. The exception is the KA(M)D44/300 which has a 1.5-pole system as standard. The TAMD31M/41Hi41M can have a 24 V 1.5-pole electrical system as an option. ‘The electrical systems of engine versions can other- wise differ in terms of equipment. The workshop man- tual doos not state what is standard equipment or op- lions or accessories. Itonly 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. 42, 43, 44, 300 Location of electrical components 4. Ol pressure sensor 2. Oi pressure sensor 43. Engine coolant temperature (ECT) switch 4, Engine coolant temperature (ECT) sensor 5. Junction box 6 Generator 7. Starter motor £8, Solencid valve (on injection pump) 8. Inductive angine speed (RPM) sensor (only $2, 42, 43)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 2 60 A generator, mechanically identical to the 12 V version but wit larger dimensions. ‘The generator version is shown on a plate on the ear end, Renovation, please refer to the "Starter motor, Alterna- tor” chapter in the workshop manual Starter motor Allengines with the 12 V System have a geared start er motor, Valeo D9R1 16. The slarter motor is 2 pole and has an output of 3 kW. Engines with 24 V have Bosch JF starter motors. The starter motoris 2 pole and has an output of 4 kW. Renovation, please refer to he “Starter motor, Alterna- tor” chapter in the workshop manual.Design and function Junction box The junction box is located on the front left hand side ofthe engine. The components included differ depending on the en- gine type (see ilustraion) 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 4. Automatic fuse (24V version has 2 x) 2. Resistor 3. Ground relay (only 15 pole version) 4%. Starter relay Jlunation box KADS2, KA(M)D42143 1, Automatic fuse i 2. Engine speed (RPM) relay 3. Resistor 4%. Startor relay 1 2 3 4 Junction box KA(M)D44/300, ‘Automatic fuse (2 x) Main rolay Stop relay Resistor Ground relay Starter relayDesign and function Fuses ‘The engines are equipped with an8 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 resel with the button on the side ofthe box. ‘Switches Coolant temperature switch The engine coolant temperature (ECT) switches are closed with rising temperature according to the folow- ing} 12 (1-pole) or 12124 V (2-pole) installed on thermo- stat (applies to older versions) closes at 95°= 3°. 12 (1-pole) or 12:24 V (2-pole) installed on exhaust manifold closes al 97° 3°. ll pressure sensor The oil pressure switches are closed with falling tem- perature according to the following: 12124 V (2-pin) closes at 69 kPa = 14 kPa (0.7 bar= 0.15 bar. Tilt switeh (S.0.L.A.S) Detects tit. 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 untl voltage 15+ at terminal 5 is broken. 'S 1bis normally open when in operation. $ 1c is normally shut when in operation ‘Supply vottage 10-30 V Glow plugs (S.0.L.A.S) 2 pole, rated voltage 6.5 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 tne engines are modified to 4 glow plugs connected in series in grouos (22) and the groups are connected in paralel. The 24 \V system has 4 glowplugs connected in series. 10 WW & Sic stb Sia]Design and function Sensor Engine coolant temperature (ECT) sensor (10r2 pole) Resistance tolerances, aller 3 minutes temper equalization and with operating voltage. Tightening torques maximum 20 Nm. Test Single instrument Flying bridge temp.C° sensor sensor O°E 4? 1340921350 67.092650 sorts 5120+ 430 2569+ 219 100°#3° 38504 300 19394 150 lll pressure sensor, (0-10 bar) Resistance tolerances, measuring with falling pres: sue at 2a Single sensor Fling bridge Py ronson 1) Obar 102+32-52 52+182-32 Vy abe = nea aEEAG tow sens4a - chy = tensa stag be - renzan Tightening torque: maximum 30 Nm Engine speed (RPM) sensor (KAD32, KA(M)D42/43) Type: Inductive sensor (cog counter). Internal resist- ance 1050 2+ 1009. Only for controling the supercharger engine speed (pm) 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 fon the terminal pin. Tightening torque: 43 Nm. 1"Design and function Engine speed (RPM) relay (KAD32, KA(M)D42/43) Function Outputs: + $1 (terminal), closes to ground and engages thesupercharger + G+ (pin 4), + supply to position sender Inputs: + G1 (Lerminal 6), inductive engine speed (RPM) sensor + G2 (pin), + from position sender + 15+ (terminal 7), ignition switeh current + 81-(lerminal 1) battery — The engine speed (RPM) relay closes to ground via $1 and connects the superciiarger. With an in crease in engine speed S 1 closes at 1700 rpm and ‘breaks at 2400 rpm (KAMD) or 2600 rpm (KAD), +250 1pm, With a reduction in engine speed S1 closes 4.5 sec: ‘onds + 2 seconds after the engine speed has gone below the set value 1700-2400 rpm (AMD) or 1700-2600 rpm (KAD) and disconnects at 1400 rpm +150 rpm. Between 600-3. 100 rpm, S 1 closes ifthe "kick down position sender opens and breaks the + supply to G2. ‘Supercharger control 1. Engine speed (pm) relay 4, Supercharger 2. Position sender 5. Automatic fuse 3. Engine speed (APM) sensor 6. Diode 12 @ bag EGE sranrerTaasDesign and function Faulttracing + The supercharger Is notengaged 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 (conduets through) which may cause short-circuits. This in turn blows the fuse or damages the engine speed (RPM) relay. + The supercharger engagesidisengages within the operating range (oscillates) Oxide or loase 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 tie supercharger connector and check ifthe fuse stil blows. If t did not there is a short-circuit in the magnetic clutch, Ifthe 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- 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 speeds preprogrammed into the elec- tronic box, except for "kickdown'”, when the pos! tion sender provides an impulse. Give full gas ‘Fonwards” on he throttle. Engine stationary! ‘Adjust the distance between the bracket (1) and Position sender (2) to 0.028'/0.7 mm. 2.03” ‘Agjusting the positon 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 nave dif- ferent winding resistances. ‘The engines with 24 V current have 2 60 A generator, mechanically identical to the 12 V version but with larger dimensions The generator version is shown on a plate on the ear 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: 14.2V £0.15 V at +20°C (12V) 28,5V+0,15 Vat +20°C (24V), temperature compensation — 10 mV =2 mV/°C Maximum current: 60 A alternatively 50 A (12 V), 60 (24.V) 14Charging system Faultfinding Before dismantling the generator faul-trace the bat tery circuit to eliminate other possible fault causes. When testing with the generator it should be ‘warm’, run the engine al approximately 2000 rpm for 3 min- before measuring AX WARNING! The generator, votage regultoror battery ccut terminals mistbe connected when the engine is unting. Do nt dsconnect these forinals wile the engine running Caretuly check na re measuring instumentis ‘set to vollage supply (V), so that there is no Shot cel between the generator eins ZX WARNING! 8¢ especially careful thatthe supply cables, clothing or similar do not come into con- tact with the engine or generator pulleys or rive belts when the engine is cunning Generator belt ‘Special tools: 1159660 Check the bel tension and condition. Split, worn or cily belts must be replaced. Adjust bel tension. Post lion too! 1159 660 behind the mult V pulley driving edge. Adjust with belt tensioner (4) Belt tension 20-25 kg, Current loss check ‘Special tools: 951 0060 Fault tracing is carried out with 951 0060. Note that ‘other instruments may ciffer in the symbols displayed {or set functions. 1 ‘Wash the battery with lukewarm water and dry. Re- ‘move the baltery leads and clean the poles. 2 Connect + terminal again. 3 ‘Switch of the ignition and any power consuming com- ponents connected to the starter battery 4 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 0.1A with the ignition disconnected. 18Charging system Ifthe current loss is greater than 0.1 A: + Check that there no short circuits or lead over shorts occur a any terminal. Lead over shorts oc- ‘cur because of the diy salt encrusted electrical components. Clean and check all terminals. Ifthe current loss is less than 0.1 A: + Check the batteries’ charge condition Charging condition check ‘Check the charge condition using a hydrometer. Measure the acid weight in all cells at «20°C. Meas- ‘urement must not occur directly after charging or fil- ing with Gistiled water. The acid weight with a fully charged battery at +20°C should be 1.28. Charge the battery ifthe acid weight is lower than 1.21 (half charged). Charge with 5-6 A over approximately 10 hours. AX. wanwinc Te batory generates hycrogen ges Andis highly lammable andexplosWe, Never txp0s0 the batery to a naked fame or elecic Sparks, Vertate te battery compartment wel especialy ater charging Check two hours after charging. ‘Acid weight is uneven between the cells. The dit- ference between the cels is 0.04 points or more for example 1.28-1.24: + The celis probably short circuited. Replace bat tery. The acid weight is even between cells, the battery is not fully charged: + The batteryis sulphate. Light sulphating can of ten be broken down oy charging for a further 10 hours. Replace the battery if it does not help. 16 Battery, load test Special tools: 951 0060 (Check that the battery retains at least 1.21 in acid Weight 2 Remove ignition coil - terminal 3 Connect a vollmeter between the ballery poles 4 Turn the starter motor for approximately 10 seconds and read off the start voltage which must not be loss. than 9.5 V (19 Vina 24.V system). 5 ‘See if any ofthe cells bubble when the starter motor 's turning (shor cirouitin the battery) Voltage is lower than 9.5 V (19 V) or one of the cells is bubbling + Replace the battery and ty again Voltage is 9.5 V (19 V) or higher: + Battery OK; measure charge voltage according to thenextparagraph,Charging system Battery cable check Special tools: 951 0060 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 rminals. The generator puts out approximately 14.0 V 23.0}: + 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 Connect the multimeter between the generator B+ and the generator B-. Run the engine at 2000 ppm. 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): + Battery cables Ok: Voltage drop more than 0.3 V (0.6 V): + Garry out test according to points 3 and 4. 7Charging system Positive battery cable check Connect the multimeter between the generator B+ and the battery posite terminal, Run the engine at 2000 pm. The voltage drop must not be more than 0.2 V (0.5 V). Ifthe 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 Connect the muitimeter 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). Ifthe voltage drop is more than 0.2 V (0.5 V) the cable terminals must rem- cedied according to point 5. 18 Corrective action ZA IMPORTANT! Switch off the igition and discon- rect the battery terminals before commencing work on the charging circuit. vovo Ifthe voltage drop in any of the tests according to 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- mminals. Go through the terminals for the battery, main switch, ‘generator and starter motor.1920 Engine All models in the 31/41 series have a 4-pole electrical systemEng, tp etic stem Pras sth 007 Ba Terps sit NOS init tet 84 Spe sen ot on Ve Cameco, caro be opened (PC e690 5 Retr NO Nl pn de epan Cate ens ars tg =m? Aven ie dats ato Pera cate Cable color Vilet hie Yeon 43165867 15 14 1011 2]22 Engine KAD32P, KA(M)D42A/B/P, KA(M)D43P 1-poleEnyjne12428 ol Bebial sem Soenadrde Teper srs En seep) wes 2 Cini 84 Covet Eng sped Poi eke Nein CPO cent NO = Nara oe dig option Cate cs sein «1a? Akin indi robo Pea able Cable color BL = Bue P= Pik rte R= Red BN = Bown $B Bak UBN = Ligtbowm = Vat# GN = Gen W = ie i my OY OR = ame a 158 aegis qo] la, 4 j REBEL * iA 8 TT | i a al f Fil 4 l] ~ | | [8 4] y 7 4 IT {fs /\ a7\, {u fi od yb rife AA] #2Engine TAMD42AWJ, BWJ, Wd 1.5-pole* ‘plo dung the san and stop phases, 22ole a ll ctor snes. 24Engine 42AWWABVLIWN. 1 5:oe electrical system Batey Gear State mot State ey 8 Cor ait Opes se O07 Ba Olpesse gaze Enc ener Soenib ve -Sop En ote er Ensen) ses 2 init tea 84) Corea Eg spel? Live? Nest (20 cman tpt Come, crate ECT i OT "Thee clit nee att boca aninte ny NO Nor open ig epaton Cate ens eis rg =e Aven ie dca ato Pera cate Cable color = Be P= Pi ligsble A= Red BN = Brun SB = Bask BN = Ligon VO = Viet Green White Gay Y= Yehw Ouage ft a lis 4 a “4 "I g t 1 4 | aEngine All models in the 31/41 series have a 12 V, 1.5-pole electrical system* ‘pele during the start and sto phases, 2-00 at all ther mes. 26Eng, 2 Etiam 1p 4 Baty Sarr nar 1 3 S887] 4 t8sare : Gent State ay Seen ie -Sop Tengen srs Presse sr “np Citta, 844 Cinta 844 Nah th Carey, alt ees OFC cern 1h 5. Gnd ey Giang" Gh pis Sitesi ih es" Fs "Tse arr far SOLAS Sa Lid Pye saan noes ba in “Tiscnpet ite ry tr SOLAS yO | Seto fectirgericsteordostral jj sysen igs, t NO = Noy open ig epaton ij 4 Wd ii Aol ng rdetsacenductr tt Yoo Peta! | hes ot cone, ' Adasted ace ie ints contr | | Cae sss gien= 15 an? Cablecolor A = Ble P= Pik ligtue = Red Blk Bom iho VO Viet Geen W = Wie Gay Y= Yew OR = OeEngine All models in the 31/41 series have a 24 V, 1.5-pole* electrical system ‘pele during the start and sto phases, 2-20 atl ther Simos. 28Engine 314,24 Electrical System 1.5 pole wLi_teseret a saagg : i Terpesue es Pras ser swt \007 Ba Tepes sats NOTE ‘oat rea, BA oat rea, BA (| “2 Main swch Core, alt ed beer mri ses" Resor Sa oe ects eas a sys igs NO = Nol pe ig pron Cate sss retgien= 15 an? Abr ine aes a condor at Vo Pera dos ot ee Adasted ac dota ie ince aco tet ted oa anges wh pee on sas) Cable color BL = Be P= Pik lige R= Red AN = Bom B= Bak BN = Lih-rown VO Vil = Geen Wo White Gy = Yew OR = Oa30 Engine KA(M)D44P-A, P-B, P-C KA(M)D300-Aa 1, Sopsiid™ 2, Ene spe (pss B 4 Owretr & Resa" 5, De LekComent D.C 1.18 ‘tosoda tera aa ten NO Namaly open dn ope Callous ers ge = 05 Aken ne ea oo Calc BL We Ps Pink UBL = Utetue 8 = Rat BN = Boa SB Beck jorown VO= Vide Geen We While = Gy Y = Yew ne I @ GR R8 iy Uhr KAMP Batley 2a Nain witch A, Nal sar. A wpe switch canbe used, 4. Slater mar 4 Generaor Bate cornea wengre 6 Ol peowe sors 7 Ol es gue 4 Engee cod enor (21 seis Slater moor" ‘taney Sa “2 Gourd nda? 3 Ct beater, AY “A. Conta Mode 8 Chay a onpravesersor 8. Ene cml nowatve (2 sos} “7, Pasir sence fal epee ses” ‘6 da" 2 Abtacortd soit" 2, Spoke” 2, Engpe sped (pm) ss. 2, Ompesor A, Cornedor 5 Ress’ ‘BB Data Lik Cored DLC? 1, Nedeltsesr ‘2. Pst bat. Ete sep B, Sercerd hse 754 “SA, Stace ise S54 yD 2 bier pnp ‘8 Beene ger ‘A Tope tnpunp 8 Merl se gen 8 Tops ttn pn, gs, ar 3. Toishaner pr 37 ‘ozadintetenratu Lua en ang A NO = Nar open ig owen BN = Bown SB = Bask Cable cross sins nl glen = OS mn? LN = Ligttbown VO = Viet bok ine nds a l= Geen W = Whe ano Pre ce GR = Gy Y= elon OF = Oame 19 20 “Bi / 18Engrs KAMP Cand KAUDSIOA 5 Ie ee PR RA Rae 7 a 7. Of pressure gauge eb) 3 Eng ct epee srir 4 |insinamest) 4, Sato ry at Mina sf i ‘ Sap Tecciaaeeties TED ||| | 3 So CUNT 3 Choi veahes, €A* th u “4 Contd unt 8 ‘Boas enpertee sersar ew “6 Eng cael epee ser “7, Positon serder”* “fol orp sera” “9. Achaio** 2, Soenoidvave, Al" 2, Sop seni" D Enge speed sear 1B, Conger : 4, Corrector fe & Resiso’ Dagroste cute’ 1, Needle it sersar* 2%, Pusha, ext sng ‘Fase, 158 mr MO Fuse, S64 , DOOC convener $ 2. eat punp ‘8. arrose oi got ‘A. Taper sin pm 8 Manel msne gen $6. 2b poe cornecor foonto! panel) 4. ‘poe armed tune Sl SiG as B ‘osndntetratx “war engine NO = Nara open i opaten ake ssi gen = 05? L = Bue P= Pik UBL = lige A Red jo SB = Bask Ligon VO Vet W = Whe cg Abe inca &nlobo Peele34 Instrument panel, main station All models in the 31/32/41/42/43/44/300 seriesIse panel mainconel poston erty 2 iar 4 Olpesse gue 4 Erect ent 5 Oey coe & Mami 1. igre ok ncn arin inp 8 Ol pee wai np 4. aye wang kp 4. Wag a re Sa, rset gs Shr - Am ssh “Tadeo ee oz Spice ein CP cman tet Cate cs seinen «Ona? Cable color L = Bue P= Pik LBL = Ligue A = Red N = Bown $3 = Bak LEN Ligtiom YO = el GN = Gren W = ie GR = Gay Y= eb OR = Ome Spal A L/ 1 i, | rts ms us reall 1 836 Instrument panel, fly bridge All models in the 31/32/41/42/43/44/300 seriesstun pane ye beta ty 5. Came & aut 1. Ege co emt ain np 8 Oi pesse nancy ap a sig wary ey (a) a 4. Waring ap tse Soa, snips Suit - Mam estar oft Spice sion CFO crn th Poe ay 0 tora fa pod Cae ess sts retgien= 10 an? ‘Atvoken ine indcaes ron‘Viv Pera cable Cable color Be Ps Pik = gfttle R= Bron Lighronn VO Viet Geen W = hie Gy oY = Yew OR = Oame § 5 Ri Teo oe 6 4300) ison 11 1338 Instrument kit, main station All models in the 31/32/41/42/43/44/300 series‘Instrumentation main conrl poston gin th 2 Sih - Ram etal 4. Shi sme aps 4 Am fe} 8. am itt wags Tee + ile + Estey + hops 6: ng oto ECT gage 7. Ops gaan tne 8 Bl pss gage Oi ess gig ese gr “Teton hbase °2 tut ghey °X Omen, carl op “4 Sie secin “% OFC ovrae th “ Camece ea waig Spy (aes) Cable color as Ble (BL = ite BN = Bom LBW = igttomn YO kt N= Geen hie R=Gqy Y= Yew OR = Oaye {ili ereerse40 Instrument kit, fly bridge All models in the 31/32/41/42/43/44/300 seriesIstumeato y itge Pu stat Psa, Suet, Aa exit Sie, seri gs ‘shone wh bub ban ert itty Core carole ped Spice xin CPC cen tpt 2 Oar ir dpe sy NO = Nolen ig epton Cableclor Se Ps Pik ligtue R= Red Blak Viet ie = Yalow So |i 6 | Oat at bP a aT BW) e : ‘ Hug van wy a 3 I 5 ae Hitt ws in q is i ; as as ws de i TH | | | qylereseresoneense asClutch control panel, Waterjet TAMD42WJ / K22 io + i 0 - O _vorvorenrs, ! 9 | a To hy i 7 unt as 1s i * oar ! eR av i LL | ‘ Flay, osck fash 2. Roly cuchin sue Pine Spica tenbal Lightblua Pu Purple 5. Emension cables (3. 5, 7, 9 and 11m) BN = Brown R - Red 8. Pusrovton,sacc ish BN Lignt-brown $B Black 5 Pashbaton, chic oN Green VO Violet 8. Relay, clutch i» GR Gray w White 8. Pastbston rch out oR Orange Yellow 16, Baten ¢) 1, eaten () 42: Conta panel Cable areas not stated = 1.0 mm. [Abroken line indicates a non Volvo Penta cable, 4243