Volvo Penta Marine Engines - Wiring Diagrams [en]

Workshop Manual Wiring diagrams 61, 62, 63, 71, 72, 73, 74-series D 2(0)

Group 30 Electrical system Wiring diagrams Marine engines TAMD61A • TAMD62A TAMD63L-A • TAMD63P-A TAMD71A • TAMD71B TAMD72A • TAMD72P-A • TAMD72WJ-A TAMD73P-A • TAMD73WJ-A TAMD74A-A • TAMD74A-B TAMD74C-A • TAMD74L-A • TAMD74P-A TAMD74C-B • TAMD74L-B • TAMD74P-B Contents Safety information ............................................... 2 Introduction ......................................................... 2 Important ............................................................ 2 General information ............................................ 5 About the workshop manual ............................... 5 Spare parts ......................................................... 5 Certified engines ................................................. 5 Wiring diagrams, engine ..................................... 6 TAMD61A, TAMD71A (12V, 24V) ...................... 7 TAMD61A, TAMD62A, TAMD71A, TAMD71B, TAMD72A, TAMD72WJ–A (12V, 24V) ............... 8 TAMD63L-A, TAMD63P-A (12V, 24V) ............... 9 TAMD71B (12V, 24V) ........................................ 10 TAMD72WJ-A (12V, 24V) .................................. 11 TAMD72P-A (12V) ............................................. 12 TAMD72P-A (24V) ............................................. 13 TAMD73P-A (12V) ............................................. 14 TAMD73P-A (24V) ............................................. 15 TAMD73WJ-A, TAMD74A-A/A-B (12V, 24V) ..... 16 TAMD74C-A/L-A/P-A (12V) ............................... 17 TAMD74C-B/L-B/P-B (12V) ............................... 18 TAMD74C-A/L-A/P-A/C-B/L-B/P-B (24V) ........... 19 Block diagram – Instrument panels .................... 20 Wiring diagram – instrument panel, main control position ................................................... 22 Wiring diagrams – instrument panel for alternative control position (flying bridge) and auxiliary control panel ......................................... 24 Wiring diagram – instrument kit, main control position ............................................................... 26 Wiring diagram – instrument kit for alternative control position (flying bridge) ............................. 28 Wiring diagrams – control system (EDC) ............ 30 Wiring diagrams – general .................................. 37 Wiring diagram – EDC colour coding. ................. 38 Wiring diagrams – alternative control system for EDC controls ................................................. 40 Wiring diagram – water jet control panel ............. 44 Reversing bucket operation – water jet ............... 46 References to Service Bulletins ......................... 48

2 Safety information Introduction The workshop manual contains technical data, de- scriptions and repair instructions for products or product versions noted in the table of contents, supplied by Volvo Penta. Make sure you use the correct workshop literature. Read the available safety information, “General information” and “Repair instructions” in the workshop manual before you start to do any service work. Important The following special warning signs are found in the workshop manual and on the product. WARNING! Warns for the risk of personal injury, major damage to product or property, or se- rious malfunctions if the instruction is ignored. IMPORTANT! Is used to call attention to things which could cause damage or malfunctions to product or property. NOTE! Is used to call attention to important information, to facilitate work processes or operation. To give you a perspective on the risks which always need to be observed and precautions which always have to be taken, we have noted them below. Make it impossible to start the engine by cutting system current with the main switch(es) and lock it (them) in the off position before starting service work. Fix a warning sign by the helms- man’s seat. All service work should normally be done on a stationary engine. Some work, such as adjust- ments, need the engine to be running, however. Going close to a running engine is a safety risk. Remember that loose clothes, long hair etc. can catch on rotating components and cause severe injury. If work is done adjacent to a running engine, a careless movement or a dropped tool can lead to personal injury in the worst case. Be careful with hot surfaces (exhaust pipes, turbos, charge air pipes, starting heaters etc.) and hot fluids in pipes and hoses on an engine which is running or which has just stopped. Re-install all guards which have been removed during service work, before re-starting the engine. Make sure that the warning or information labels on the product are always clearly visible. Replace labels which have been damaged or painted over. Never start an engine without the air filter in place. The rotating compressor turbine in the turbocharger can cause severe injury. Foreign bodies in the inlet pipe can also cause severe mechanical damage. Never use start spray or similar products as a starting aid. Explosions could occur in the inlet manifold. Danger of personal injury. Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out at the same time as the pressure which has built up is lost. Open the filler cap slowly, and release the pressure in the cooling system if the filling cap or tap has to be opened, or if a plug or coolant hose has to be removed when the engine is hot. Steam or hot coolant can stream out in an unexpected direction. Hot oil can cause burns. Avoid skin contact with hot oil. Make sure that the oil system is de-pres- surised before doing any work on it. Never start or run the engine with the oil filler cap removed, because of the risk of oil spillage. Stop the engine and close the sea cocks before doing any work on the cooling system. Only start the engine in a well-ventilated area. When operated in a confined space, exhaust fumes and crankcase gases must be ventilated from the engine bay or workshop area. Always use goggles when doing any work where there is any risk of splinters, grinding sparks, acid splash or other chemicals. Your eyes are extremely sensitive, injury could cause blindness!

3 Safety information Avoid skin contact with oil! Long-term or repeat- ed skin contact with oil can make your skin dry out. The consequence is irritation, dry skin, ec- zema and other skin disorders. Used oil is more hazardous to health than new oil. Use protec- tive gloves and avoid oil-soaked clothes and rags. Wash regularly, especially before meals. Use special skin cream to avoid drying and facilitate skin cleaning. Most chemicals intended for the product (e.g. engine and transmission oils, glycol, petrol (gasoline) and diesel oil) or chemicals for workshop use (e.g. degreasers, paints and solvents) are hazardous. Read the instruction on the packages carefully! Always observe the safety advice (e.g. use of breathing protection, goggles, gloves etc.). Make sure that other personnel are not inadvertently exposed to hazardous substances, such as via the air they breathe. Ensure good ventilation. Handle used and sur- plus chemicals in the prescribed manner. Be very careful when searching for leaks in the fuel system and testing fuel injectors. Use goggles. The jet which comes from a fuel injector has very high pressure and considerable pene- tration ability. Fuel can force its way deep into body tissue and cause severe injury. Risk of blood poisoning (septicaemia). All fuels, and many chemicals, are flammable. Make sure that open flames or sparks can not set them alight. Petrol (gasoline), some thinners and hydrogen gas from batteries are extremely flammable and explosive when mixed with air in the correct ratio. Do not smoke! Provide good ventilation and take the necessary precautions before you start welding or grinding in the vicini- ty. Always have a fire extinguisher easily available near the workplace. Make sure that oil and fuel soaked rags, and used fuel and oil filters are stored in a safe place. Oil soaked rags can self-ignite in certain circumstances. Used fuel and oil filters are pol- luting waste and must be handed to an approved waste management facility for destruc- tion, together with used lubrication oil, contami- nated fuel, paint residue, solvents, degreasers and wash residue. Batteries must never be exposed to open flames or electric sparks. Do not smoke close to the batteries. The batteries generate hydrogen gas when charged, which forms an explosive gas when mixed with air. This gas is very flammable and highly explosive. A spark, which can be formed if the batteries are wrongly connected, is enough to make a battery explode and cause damage. Do not move the connection when you attempt to start the engine (risk of arcing), and do not stand and lean over one of the batteries. Never mix up the battery positive and negative poles when the batteries are installed. If the batteries are wrongly connected, this can cause severe damage to the electrical equipment. Please check the wiring diagram! Always use goggles when charging and handling batteries. Battery electrolyte contains highly corrosive sulphuric acid. If this comes into contact with your skin, wash at once with soap and a lot of water. If you get battery acid in your eyes, flush at once with a generous amount of water, and get medical assistance at once. Stop the engine and cut the system current with the main switch(es) before doing any work on the electrical system. The clutch must be adjusted with the engine shut off. The existing lugs on the engine/reverse gear should be used for lifting. Always check that the lifting devices are in good condition and that they have the correct capacity for the lift (the weight of the engine plus the reverse gear and extra equipment if installed). The engine should be lifted with a customised or adjustable lifting boom for safe handling and to avoid damaging components on top of the engine. All chains or cables should be parallel to each other and should be as square as pos- sible to the top of the engine. If other equipment connected to the engine has altered its centre of gravity, special lifting devices may be needed to obtain the correct balance and safe handling. Never do any work on an engine which just hangs from a lifting device. Never work alone when heavy components are to be dismantled, even when safe lifting devices such as lockable blocks & tackle are used. Even when lifting devices are used, two people are needed in most cases. One who operates the lifting device and other who makes sure that components move freely and are not damaged during lifting. When you work aboard a boat, always make sure that there is enough space for disassembly where you are working, with no risk for personal or material damage.

4 Safety information Components in the electrical and fuel systems on Volvo Penta products have been designed to minimise the risks of explosion and fire. The engine must not be operated in environments with adjacent explosive media. 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. Only use the fuels recommended by Volvo Pen- ta. Please refer to the instruction book. The use of fuel of inferior quality can damage the engine. In a diesel engine, poor fuel can cause the regulation rod to bind and the engine will over- rev, entailing a strong risk of personal injury and machinery damage. Poor fuel can also lead to higher maintenance costs. © 2000 AB VOLVO PENTA We reserve the right to make design changes and amendments without prior notice. Printed on environmentally compatible paper. WARNING! Fuel delivery pipes must not be bent or straightened under any circumstances. Damaged pipes must be replaced.

5 General information About the workshop manual This workshop contains the wiring diagrams for the standard versions of engines TAMD61A, TAMD62A, TAMD63L-A, TAMD63P-A, TAMD71A, TAMD71B, TAMD72A, TAMD72P-A, TAMD72WJ-A, TAMD73P-A, TAMD73WJ-A, TAMD74A-A, TAMD74A-B, TAMD74C-A, TAMD74L-A, TAMD74P-A, TAMD74C-B, TAMD74L-B, TAMD74P-B. The engine designation and number are noted on the number plate. The engine designation and number must always be given in all correspondence about an engine. The workshop manual has been primarily prepared for Volvo Penta service workshops and their qualified personnel. This assumes that people who use the Manual have basic knowledge of marine drive systems and can do the tasks of a mechanical or electrical nature associated with the trade. Volvo Penta constantly improves its products, so we reserve the right to make modifications without prior notification. All information in this manual is based on product data which was available up to the date on which the manual was printed. Any material changes introduced into the product or service methods after this date are notified by means of Service Bulletins. Spare parts Spare parts for electrical and fuel systems are subject to various national safety requirements. Volvo Penta Original Spares comply with these requirements. No damage whatever, occasioned by use of non-original Volvo Penta spares for the product, will be compensated by the warranty offered by Volvo Penta. Certified engines When service or repairs are done to an emission certified engine, which is used in an area where exhaust emissions are regulated by law, 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 engine. This put special demands on service and repair work, as follows: Maintenance and service intervals recommended by Volvo Penta must be complied with. Only Volvo Penta original spares may be used. Service to injection pumps, pump settings and injectors must always be done by an authorised 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. Installation changes to the exhaust pipe and engine air inlet ducts must not be done. No seals may be broken by unauthorised personnel. The general advice in the instruction book about operation, care and maintenance applies. IMPORTANT! Delayed or inferior care/maintenance, and the use of non-original spares, mean that AB Volvo Penta can no longer be re- sponsible for guaranteeing that the engine com- plies with the certified version. Damage, injury and/or costs which arise from this will not be compensated by Volvo Penta.

6 Wiring diagrams – engines

Wiring diagrams 7 1. Batteries (12V, 24V) 2. Main switch 3. Starting heater 4. High power relay 5. Starter motor 6. Alternator 7. Stop solenoid 8. Circuit breaker, 8A (+) 9. Circuit breaker, 8A (–) 10. Engine speed sensor 11. Oil pressure sensor, reverse gear 12. Oil pressure monitor, engine 13. Oil pressure sensor, engine 14. Pressure sensor, charge pressure 15. Coolant temperature monitor 16. Coolant temperature sensor 17. Starter relay 18. Fuse 8A (24V), and 16A (12V) 19. Timer relay 20. Stop relay 21. Earthing point 22. Connector, instrument panel 23. Earth cable Cable colour BL = Blue P = Pink LBL = Light blue PU = Purple BN = Brown R = Red LBN = Light brown SB = Black GN = Green VO = Violet GR = Grey W = White OR = Orange Y = Yellow Cable areas (mm²) are specified after the colour code in wiring diagrams. Unspecified areas = 1.0 mm². A broken line indicates a non Volvo Penta cable. Engines: TAMD61A*, TAMD71A* (12V, 24V) * Up to engine No. 1101021541/xxxx.

Wiring diagrams 8 1. Batteries (12V, 24V) 2. Main switch 3. Starting heater 4. High power relay 5. Starter motor 6. Alternator 7. Stop solenoid 8. Circuit breaker, 8A (+) 9. Circuit breaker, 8A (–) 10. Engine speed sensor 11. Oil pressure sensor, reverse gear 12. Oil pressure monitor, engine 13. Oil pressure sensor, engine 14. Pressure sensor, charge pressure 15. Coolant temperature monitor 16. Coolant temperature sensor 17. Starter relay 18. Fuse 8A (24V), and 16A (12V) 19. Timer relay 20. Stop relay 21. Earthing point 22. Connector, instrument panel 23. Earth cable 24. Fuse (150A) Engines: TAMD61A*, TAMD62A, TAMD71A*, TAMD71B**, TAMD72A, TAMD72WJ-A** (12V, 24V) * As from. engine No. 1101021542/xxxx. ** Up to engine No. 207181083/xxxx. Cable colour BL = Blue P = Pink LBL = Light blue PU = Purple BN = Brown R = Red LBN = Light brown SB = Black GN = Green VO = Violet GR = Grey W = White OR = Orange Y = Yellow Cable areas (mm²) are specified after the colour code in wiring diagrams. Unspecified areas = 1.0 mm². A broken line indicates a non Volvo Penta cable.

Volvo Penta Marine Engines - Wiring Diagrams [en]

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