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06 ELECTRICAL SYSTEM Table of Contents 06.00

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2. x 100 07 05 ill 1 A temperature gauge coolant D combined light preheating control amp B audible warning device warning light engine oil pressure warning light battery charge E warning light check engine light Operating condition During normal engine operation or indication in case of sensor defect while ignition is switched ON Event A Speed resp performance limitation during engine operation Indication status Fault Remarks 80 90 C oil pressure below min check oil level limit e OFF ON 07 05 11 2 OFF fault oil pressure check oil pressure sensor sensor or B18 and connection sensor connection FLASHING OFF 07 05 ill 3 Ix per sec NOTE Dee cap general D3 22 engine overload during reduce throttle position until light ON break in period goes OFF indication during first 2 I hours of operation Page ELECTRICAL SYSTEM 54 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES Indication status Fault 80 90 C high exhaust temperature off 80 C OFF OFF FLASHING 07 05 ill 4 2x per sec N an 43 engine coolant temperature to high 2x Ka an G defect engine coolant sensor 2x per sec sensor connection 07 05 ill 6 OFF 80 90 C instable idle speed no indication on tachometer OFF OFF OFF 07 05 ill
3. 80 21006 10 90 09 62 8 10 00008 EL SX 20 21006 10 01109 2 9 10 1109 ZL SX LOL 90 21006 L0 8LLO9 Z SX 10 21109 1 9 10 71909 geen 10 21109 DL SX SER 10 61916 62 5 10 71190 6 5 L0 8SSLE vo SX 10 61909 8 9 10 01809 Z SX LO SSSLE Z SX LO VSSLE co SX 10 91909 9 SX Ld LO OOLLE OZ SX 10 00191 6 4 0 000916 8 90 0001 6 2 5 0 61051 81 6 LO cLOOE Lex 50 0000 gt y lt 0 00019 f g gt S 0 02109 0 00006 00005 E0 0000 0 01809 09 193 Ta 0 12109 40 21006 MI 2 60 00008 60 0001 0 21909 40 00091 dur lt 1l ll lueW uutuos 0 00019 ULT EN 97 055002 06 72 10 00008 LOSS LEJ Gg o e 1051909 28 72 608 oo 0 2010 0005 98 7 20 000081 60 Z L00 50 2100 GO OOOLE 2 90 2100 EZX 1 21006 0 2 00606 223 01 21006 10 899 98 10 20 2106 48 223 01 000161 0001 4 0 20 2L00898 2M 10 02109 1 22 cox 0001 Li zL0080 1 929 0001 4 10 555 658 1 924 1 0001 10 5 Lv4128 L 92 90 0 2105198 1 924 o 6LX 107121091 61 Q 10 21
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5. 83 Sensor engine temperature B16 nn ee 83 Sensor engine speed B15 83 Sensor boost pressure Ierseng 83 Sensor rack position feedback 14 84 Sensor pressure EE 84 Potentiometer accelerator 13 84 Check sensors and switches 85 Check rack position feedback sensor B14 connector X14 85 Check throttle potentiometer B13 accelerator connector X13 87 Check boost pressure sensor 12 2 0 88 Check speed sensor B15 and or wiring 89 Check oil pressure sensor B18 and or wiring 90 Check oil pressure sensor VDO instrument option B19 91 Check coolant temperature sensor 16 92 Check audible Warner zes 93 falls 94 94 ELECTRICAL SYSTEM 2 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06 00 Wiring GENERAL For the STEYR Marine Engines wiring and plug connections have been defined according to standard DIN 72 552 In case of necessary repair of cable connection take special care that cable quality isolation crimping st
6. L0 000S1 81929 puodseJJoo Jo ACL 97 165 Page ELECTRICAL SYSTEM 63 y 2008 Z001019 0 6 Jul SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 29020 20 6626212 UJOO S40 OUJ J 9 S MW uonoeuuoo ou 0 X Ir uonoeuuoo ou 6 M H GL ME ZZ uondo N 7 103 sues Z 1 peg P og 8L I a u X Hes peg i I 0 0000S 1 1 EE E E A I r ea s ss s d Ir i L0 01809 Si i vL O Ir 1 N IF H 10 61909 el i W Ir i 91 0001 i GE ea bh VM i 1 1 10 1909 6 11 H 10 9009 i 1051916 A Li H 1 10 91909 Z 1 9 anr 1 1 20 0016 1 i e i si Ld i 80 21006 y I uols RH EH a 1
7. N N N Re 100 microbar absolute az ITTTTTT T 6543 2101 2 34 5 6 7 8 9 101112131415 16 17 18 19 20 2 PSI 10 05 ill 7 For engine models 164 174 246 256 266 Max pressure with 3 bar 3 5 absolut Supply voltage 5V 0 2V o gt Mr Connector position Si 5 5 B GND Signal 5 Q 5 O 10 05 ill 8 Absolut air pressure bar NOTE Before checking the boost pressure sensor check air filter sensor hose and connector Pressure test For a pressure test of the sensor disconnect the sensor hose and connect a pressure gauge with a short piece of hose to the sensor Carefully pressurize the sensor Read and record the values on the gauge input pressure and on the display output pressure for 5 spots between 0 and 1 5 bar Compare recorded input and output values with the chart lf values are not within tolerance limits replace the boost pressure sensor lf values are within tolerance limits the boost pressure sensor is functional and the turbocharger must be checked Page ELECTRICAL SYSTEM 88 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06 10 05 04 Check speed sensor B15 and or wiring 15012 06 60113 01 31000 03 10 05 1 9 On account of the sensor s integrated electronic system only the supply voltage and or the output signal and the continuity to control unit A5 can be
8. Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 49 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES Indication status Fault Remarks During start attempt ON Engine will not start Failure in governing circuit Failure in governing Positioning of rack circuit not possible OFF Trouble shooting of control solenoid rack control gear of unit injection ON rack position sensor 07 02 111 9 ELECTRICAL SYSTEM 50 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 51 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 07 03 Instrument panel for SOLAS only 101010101000 min x 100 07 03 ill 1 A tachometer with G push button START green service hour meter B temperature gauge coolant H blind plug installation option for C warning light battery charge oil pressure gauge or D combined light preheating control amp voltmeter 12V warning light engine oil pressure E warning light check engine light emergency cut off switch F push button ignition ON OFF red J audible warning device installed to rear side of panel NOTE Instrument gauges are automatically illuminated if ignition is turned ON NOTE In case an inversion occured the engine gets shut down automatically to re establish regular running and operat
9. in forward direction voltage drop from 0 4 to 0 6 volt backward direction reading is OL a by means of control lamp 01 04 ill 1 Diode and control lamp are connected in series in both forward and backward direction in an electric circuit Diodes permitting passage in both directions were mostly exposed to excessive voltages On the other hand diodes with an interruption in forward direction were mostly destroyed by excessive current or excessive heating ill 04 1 Lamp burning diode functional Lamp not burning diode interrupted ill 04 2 Lamp not burning diode functional Lamp burning diode had short circuit 01 04 ill 2 b by means of ohmmeter For diode testing only a simple battery powered ohmmeter may be used Measuring bridges are unsuitable as they indicate wrong values Under no circumstances hand generators may be used Their high voltage would destroy the diodes Aperfectdiode shows aresistance of only afew ohms 0 5 10 Ohm in forward direction but several kiloohms almost in backward direction Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 15 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 03 REPLACE STARTER MOTOR 1 Disconnect battery 2 Remove cover of E box Remove E box 3 Loosen terminal 30 ill 2 pos 1 on magnetic switch by means of SW13 4 Loosen start signal wiring terminal 50 ill 2 pos 2 by means of SW10 03 00 ill 1 5 Loosen two
10. 4 Turn screwdriver clockwise to increase the operating voltage and or anticlockwise to lower the operating voltage Adjust voltage range between 14 0 and 14 2 volt 28 0 to 28 4 volt for 24 volt plants ATTENTION Do not turn adjusting screw so far that it overtravels the stop to prevent damages to the governor 5 After adjustment remove screwdriver and voltmeter and lock the governor by means of removed plastic screw If voltage cannot be set to specified value replace governor and or alternator Check of slip pistons Disconnect battery and or main switch Unscrew governor Clean slip ring and wipers where appropriate replace wipers Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 7 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES For 6 cyl engines Technical data of alternator 14V 90 current version from eng 68224419 Musei EM ISKRA AAK5550 11 203 329 Minimum engine speed for voltage generation 550 1 min Controlled voltage 14 1 14 5 V mu 90A eon ME integratedl base governor Excitation winding 271 0 2770 01 03 ill 4 Error Detection Check battery Charging voltage too low All connections terminals Belt tension Acid concentration Output Filling level check refill if necessary Governor C
11. 54 BadSta M1 Pin50 K28 start assist relay no start signal from assist solenoid 55 NoPuls X15 B15 RPM sensor no speed signal during crank 56 Srpos Y14 B14 refer to setting rack pos rack calibration bad rack position outside tolerance field Page ELECTRICAL SYSTEM 40 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM REFER TO CODE ABBREV CIRCUIT INVOLVED DEVICE POSSIBLE CAUSE 57 Y14 B14 refer to setting rack pos zero position defect in governor solenoid wire circuit 20 main 99 FMSpwm X20 Y20 actuator solenoid relay K27 no frequency sent or govenor solenoid circuit connected 161 HiVTGc Y28 REA unit at turbo charger defect in circuit of actuator turbo charger short circuit 162 LoVTGc Y28 REA unit at turbo charger defect in circuit of actuator turbo charger missing connection 164 CELs L2 check engine lamp Current limit exceeded short circuit 165 CELo L2 check engine lamp missing connection or bulb blown 167 FPR s K24 fuel pump relay Current limit exceeded in relay circuit short circuit 168 FPR o K24 fuel pump relay no current detected in relay circuit disconnection 177 MR s K27 main relay no current detected in main relay circuit short circuit 178 o K27 main relay no current detected in main relay circuit disconnection 181 WarnLs L3 oil pressure lamp Current limit exceeded short
12. su s u 16 Moll NEE EE AGSUSS DH PM m ei HIM 97 0 dti ____ 10 91909 Ionuoo 10 01809 829 21927 ESCH n J Sue Gues woo 2 S MM 80 2100 2 6 aie 20 ZL00 SI e 2000081 10 0001 SSANLHOIT HLIM NOILVAONNI U19 X9 X09 3 AV 1 4 9 3NPHVM WVYDVIA SNPHIM SHOLOWAASLS 05 03 ill 8 Page ELECTRICAL SYSTEM 35 y 2008 2001019 0 6 Jul 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 06 Wiring ELECTRONICS GENERAL In case of necessary repair of a cable connection take special care that cable quality isolation crimping strand end soldering of cable sockets as well as protective varnish isolation and or connector locks meet the respective requirements Tools for crimp connections to be found in tool catalog P N Z001002 0 Level 4 06 06 01 Electronic Engine Management System The STEYR Marine engine is equipped with an Electronic Management System EMS that performs the following controls engine functions to ensure maximum efficiency self diagnostic to protect the engine from damage if operating parameter are exceeded stores diagnostic data of EMS server circuits for maintenance
13. un Ivan Je Is Ty E js iw L Ur la 0 0000S Tarare 10 91909 10701809 iie 2072100 1072100 20 0005 wir 10 00091 SSANLHOIT HLIM NOILVAONNI SAOLOWAASIS eee ee eee el tall d Live 4 TT T Es MAME ocea 98159 CAMEE za Ulp OZA J pu 300 zy Jopiv DE WE 55 HEJS Ssy 28 lt 1002 age Sd peg peg V OL Z4 V 0L 93 V 0L 93 VS 4 V 09 24 V 09 cd V 09 14 NVO sueg 095 G 2 1818 NDA lonuoo sues GL ub peg peg NOILdO 3104 2 H3QNIT1AO 9 7 05 03 ill 7 y 2008 2001019 0 6 Jul Page ELECTRICAL SYSTEM 34 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 81020 20 0 92621 2 D I Avel a 1 5 MMM 92 ang S3dAL 218 TV
14. 07 01 ill 2 3 engine running after start SS OFF STEYRMOTORS 2 07 01 ill 3 lt do 17 Ca ai N 510 502 e Fame e 20 TT 602 D System check see light indication NOTE At low temperature condition cold weather the combined light for glow plug preheating amp warning light engine oil pressure will not extinguish after 0 7 sec glow plug preheating phase In this case start engine immediately after the light extinguishes Indication active error Normal condition NOTE Further information see Table Error indication on Instrument Panel Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 47 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 07 02 Chart Error indication on Instrument Panel 07 02 1 1 A temperature gauge coolant D combined light preheating control amp B audible warner warning light engine oil pressure warning light battery charge E warning light check engine Operating condition During normale engine operation or indication in case of sensor defect while ignition is switched ON Event A Speed resp performance limitation during engine operation Indication status Fault Remarks 80 90 C OFF oil pressure below min check oil level limit OFF fault oil pressure check oil pressure sensor sensor or B18 and conne
15. 09 09 09 09 L0 BILL 09 193 14 338A OND 10 10 9 n ool 09 09 HOLO3NNOO eg 9 LE pa BH eu 10 10 D 919 018 zio 607 ZLONdA SW 09 09 SL 139 999 LE 20 Li 854 Ha SL oe 1 van doi 10 90 907 000 09 0 10 000 799 91 LE Af 2607006097 M 20 0001 MM 20 00019 Se 7110 1109 10 90 09 BEN 10 1909 H 1071909 De 20 10019 10 0001 m Je Ze Je Ts n IAN ES 06 in J pu s do P SSW ues u B6 woll MII 0 0000S BA 20 00008 10 6191 10 91909 10 01809 80 01006 40 21006 2000061 00005 NOILVAONNI eee errr ls ya Ls D gt OZA 98158 WE ssy Yar lw m oeza 98158 Le ie 06128 98158 ve Liwa 1002 547 sues Hes Svig NODA 103009 SL ub peg ACL H3QNI
16. 28 048 199 2 21918 L T I 7 Ly 2 L E A 48 om L 6 10 103 103 780 duet eDneo 140 um 9 KR 99 N e Page ELECTRICAL SYSTEM 61 y 2008 Z001019 0 6 Jul ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 07 11 Description Wiring harness instrument panels 4 6 cyl marine engines current version fuse 10 A 23 pin plug switch switch switch switch lamp lamp lamp gauge gauge gauge warning horn lighting lighting lighting 1 pin plug 8 pin plug splice splice splice splice interm cable connection engine cable instrument cable ignition red start green emergency cut off orange key switch constant revolution optional charge control cel check engine lamp oil pressure preheating conrol engine coolant temperature oil pressure optional tachometer with running time meter engine coolant temperature gauge oil pressure gauge optional tachometer gauge connector illumination switch connector STEYR display battery battery ignition key switch constant revolution charge indicator Page ELECTRICAL SYSTEM 62 2001019 0 6 July 2008 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 29020 20 82 26212 09
17. K10 85 braun K10 86 wei SY 07 10 ill 1 2001019 0 6 July 2008 Page ELECTRICAL SYSTEM 59 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 6 Cyl Wiring harness instrument panel if alternator PRESTOLITE is used old version fuse 23 pin plug connection engine cable instrument cable switch ignition switch fix n speed selector switch optional relay charge control 90A PRESTOLITE L1 lamp charge control L2 lamp cel check engine lamp L3 lamp oil pressure pre heating control P1 gauge coolant P2 gauge oil pressure optional P3 gauge tachometer with running time meter P4 gauge trim optional H22 warning horn 58 1 plug to lighting switch instrument panel 59 2 pin plug charging control relay charging control wiring harness side 510 2 pin plug charging control relay charging control instrument side 1 51 4 pin plug ignition X2 L1 10 pin plug charge control lamp X3 L2 10 pin plug cel check engine lamp X4 L3 10 pin plug oil pressure warning lamp X5 E10 2 pin plug lighting coolant display X6 P1 3 pin plug coolant temperature gauge X7 E11 2 pin plug lighting oil pressure X8 P2 3 pin plug oil pressure gauge X9 S7 10 pin plug speed selector switch optional X11 P3 E12 8 pin plug speed instrument lighting speed instrument X12 E13 2 pin plug lighting trim optional X22 P4 3 pin plug trim optional Page ELECTRICAL SYSTEM 60 2001019 0 6 July 2008 IS ELECTRICAL S
18. battery size 92 AH length cable cross section AWG inm Q For6cyl engines only length inm In general take care that battery cable lengths are kept as short as possible Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 19 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 05 02 box base plate to eng no 482 17 000 05 02 ill 1 Page ELECTRICAL SYSTEM 20 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06 05 02 01 Components of box to eng no 482 17 000 E box control unit fuse 50 A main fuse fuse 50 A glow plugs fuse 50 A glow plugs fuse 5 permanent current module fuse 10 A switched current for module K27 fuse 10 fuel pump K24 plug 23 pole connection engine cable instrument cable relay fuel pump relay preheating realy preheating relay main circuit relay start assist relay plug 35 pole module 06 05 02 02 Connection start assist relay K28 05 02 ill 2 06 05 02 03 Connection relay socket for K24 K26 1 K26 2 and K27 05 02 ill 3 Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 21 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 05 02 04 Wiring harness to eng no 482 17 000 5 F1 F2 F3 F4 F5 F6 E box fuse 50A fuse 50A fuse 50A fuse 5A fuse 10A fuse 10A alternator battery 23 pole plug relay relay relay relay relay starter fuel pump glow pins 2
19. ill 1 pos 1 2 2 Remove belt 01 02 ill 1 3 Loosen screws ill 2 pos 1 2 remove alternator Assembly is done in reverse order For4cyl engines only 01 02 ill 2 Connections 1 3 1 B battery acc illustration 3 1 3 2 D charging control L1 ill 3 3 DF D field rotor winding 1 3 4 D on governor 4 engines only 01 02 ill 3 Governor ill 4 1 B acc illustration 4 1 4 2 ill 4 3 D 1 4 4 D 01 02 ill 4 Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 5 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 01 03 Technical data of alternator For 6 cyl engines only old version till eng no 68224418 Mod l PRESTOLITELEECE Neville 8RG2043 Minimum speed for voltage generation 580 1 min Controlled voltage range 2 nnn 13 9 14 2 V Tevez P 90A GOVENNOR MER EIE E LU integrated base governor Charge capacity approx 34 A a 25001 DEE maximum charge capacity gt san u kaku 2 2 UF 01 03 1 1 Charging circuit scheme rer battery 2 22 ground connection on engine 3 red 4 fuse 50A Diss starter engine 6 red 7 plug engine electrics instrument cable 8 fuse 10A 9 starter key lock 10 15000 xx 11 red 16 mm 12 generator 13 charging controll L1 14 61000 02 18 pole conn
20. of generator With engine running tester lamp extinguishes With engine running tester lamp glows With engine stopped install new governor and start engine again Tester lamp between B und D Tester lamp extinguishes Tester lamp still glows Test procedure Error and or Relief Generator control lamp L1 burned out and or disconnection in electric circuit of generator control lamp L1 between term 15 No 15000 xx and term D No 61000 02 on generator Short circuit of a positive diode Immediately disconnect starter battery from generator otherwise battery may be discharged on state gt replace generator Error wipers of governor worn out oxid film on slip rings disconnection of rotor winding gt replace governor and or generator Earth short circuit in lead betweeen generator control lamp and terminal D on generator Governor is defective gt replace governor Earth short circuit in the field of governor and connection DF see ill of generator earth short circuit in rotor winding gt replace generator Contact resistance in charging circuit or in conductor to generator control lamp L1 Governor or generator defective Disassembled governor defective Generator is defective gt replace was Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Check rectifier diode Measuring devices with diode test function will show the following results
21. optional sensor B19 gauge P2 single instruments double instruments requires special sensor sensor marking G 07 14 ill 3 one sensor for two displays Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 73 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 08 01 Potentiometer Accelerator B13 1 2 R1 R2 R3 Remove plug housing Unscrew hexagon nut of accelerator lever remove lever Loosen 2 hexagon screws Remove accelerator Throttle potentiometer B13 accelerator connector X13 In case of defective potentiometer accelerator B13 service codes 23 24 or 29 will flash NOTE First check cables and connections Resistance between terminals 3 and 1 approximately 1 2 kOhm resistance value switch to infinetely after moving throttle lever from idle position Switch contact should open within the first 10 of throttle lever pedal movement Resistance between terminals 5 and 4 1 2 Resistance between terminals 5 and 2 2 2 for normal position of potentiometer accelerator 1 4 kOhm at full speed max throttle position Wiring Circuit Potentiometer P N 2176860 0 08 01 ill 1 08 01 ill 2 HH S 08 01 ill 3 Page ELECTRICAL SYSTEM 74 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06 08 02 Voltage regulator 24V 12V equalizer Powersupply to equalizer
22. plug Steuermagnet Control solenoid Stecker Getriebeschalter Option Connector gear switch optional Inversionsschalter Nur bei SOLAS Inversion switch only for SOLAS Abschaltventil Nur bei SOLAS Blow by only for SOLAS Page ELECTRICAL SYSTEM 78 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM from engine number 48227000 CODE KURZNAME ABBREVIATION MAP CMD RACK RPM ECT EXT LPS fo Sen Q BESCHREIBUNG CODE DESCRIPTION Ladedrucksensor Boost pressure sensor Gaspedal Potentiometer accelerator Regelstangensensor Rack position sensor Motordrehzahlsensor Sensor engine speed K hlfl ssigkeittemperatursensor Sensor engine coolant temperature Abgastemperatursensor Sensor exhaust gas temperature ldrucksensor Lubricant pressure sensor KURZNAME ABBREVIATION J1 DIAG FMS BESCHREIBUNG DESCRIPTION Stecker lmanometer Option Connector oil pressure gauge optional Stecker Trimmanzeige Option Connector trim optional Haupt Verbindungsstecker Main connector Diagnose Stecker Diagnosis plug Steuermagnet Control solenoid Stecker Getriebeschalter Option Connector gear switch optional Inversionsschalter nur bei SOLAS Inversion switch only for SOLAS Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 79 ELECTRICAL SYSTEM
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24. SB 29 Q 0 Z 105 8 Z29 70 0000 Oe SEN aey 21006 9 2051921 7822 9024 0 70 21051 98 2 92M 20 00002 06 1 923 2010 9666 58 1 923 10 91041 28 1 923 0 0 21091 198 1 92 to eng no 482 17 000 harness iring Page ELECTRICAL SYSTEM 23 y 2008 2001019 0 6 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM LE 9 LIEZX 1890 OF 9 EZX a gt gt se 919 tL EL a 82 el pra aL az 62 4 WI 9 SL X vora 8 21024 P OSI z OHOVL 570 ER EECH SOdH zaad N3 LIN 139 143 193 JdHA QNO 01 8 Je Je Jee 8 OS IM MA T CZA 981 se 21967 oe ze y se
25. SS Av 19 uondo NDA 103909 NODA sues peg B sse peg 5 gt ee eee ee AR v L 8 L Z J lt gt EH 1 25 unss iq IO Met 6neo do 4 SS3SNLHIIT HLIM NOILVAONNI Wy SAOLOWAASI1LS 8X 1ojp uuoo UJOO SJ0 OUJ J 9 S M W 202 uonoeuuoo ou DL M IF uonoeuuoo ou og Kay 190 22 N 7 S TN L L 9I z L z 1 z L lt gt IA ACA lt Or La Lat RY QS 013 1 due due 193 Ionuoo uonu Bunubr1 1 Buyesya d 8 29 lt LE lt QL ST 20 00005 9 roo DL d W PL OIM reos EL HIH PIOUS 9L 000LE WI owes LL UH 1091909 Ob 10909 rosoe 8 HIH 1091909 4 9 W Z0 001 mc 9 3 W v QW amp OW 2000061 V Ir 10 0009
26. Table Error Codes ATTENTION To exit from Error code indication Tool VR00135 1 must be removed connection between Pin 1 to 2 opened before ignition is turned ON again 06 06 04 Indication and Cancellation of memorized sensor and circuit faults Selection and clearing of stored error codes Procedure Ignition OFF Connect Tool VR00135 1 to Diagnostic Outlet Plug X 23 see 06 03 ill 1 Ignition ON Note The program changes automatically to indication of error codes If no error code is stored only repeating control code reading Cope 12 will be displayed Possible memorized codes are indicated as shown in the previous illustrated example blinking 3x Cope 12 i 3X ERROR copE 14 etc The sequence will be prolonged with additional codes if more then one ERROR 15 stored See Table Error copes for description To delete a determined ERROR cope from the Engine Management System concentrate for the 39 times flashing the desired ERROR cope While this ERROR cope is displayed the third time the button Tool VR00135 1 must be pushed and kept in this position contact open The indication on the Check Engine Light changes to a fast blinking of the lamp app 4 times per sec During this rapid flashing light the push button must be released close contact after app 2 sec to delete this ERROR CODE Note Any other ERROR copE have to be selected and cleared individually fo
27. and service Engine power is reduced if Operating Parameter High engine coolant temperature limit exceeded Defect engine coolant sensor or sensor connection Exhaust temperature limit exceeded Defect Exhaust temperature sensor or sensor connection Oil pressure below limit Defect Oil pressure sensor or sensor connection Insufficient boost pressure or defictive sensor Effect noticed Reduction of engine speed Reduction of engine speed Reduction of engine speed Reduction of engine speed Reduction of engine speed Reduction of engine speed Reduction of engine speed Panel Indication Horn ON 2x p sec Gauge reading gt 107 C Horn ON 2x p sec Gauge reading gt 120 C Horn and indication light CEL ON 2x sec Horn and indication light CEL ON 2x p sec Horn continuos and Oil indication light continuos switched ON Oilpressure indication light switched ON 1x sec Additional Tool Readings Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Power limitation Action or possible reason See table trouble shooting Cooling system Sensor or connector failure see service code table See table trouble shooting Raw water cooling system Sensor or connector failure see service code table See table
28. instruments 23 diag 23 diag alternator D shield 5 control unit 5 5 control unit A5 5 control unit A5 5 control unit A5 5 control unit A5 5 control unit A5 5 control unit A5 oil pressure gauge 5 control unit A5 K24 relay fuel pump 5 control unit A5 5 control unit A5 5 control unit A5 5 fixed rotation speed A5 5 control unit A5 J1 plug engine instruments 23 diag 5 control unit A5 5 control unit A5 5 control unit A5 J1 plug engine instruments S4 earth connection E box 12 11 33 9 30 10 27 optional 14 87 8 26 25 29 15 16 L was only built up for wiring harnesses up to engine No 48217020 no function J1 M on panel wiring harness free Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 27 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 05 03 E box base plate from eng no 482 18 000 682 18 000 SOLAS 05_2002 05 03 ill 1 Page ELECTRICAL SYSTEM 28 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06 05 03 01 Components of E box from eng no 482 18 000 682 18 000 SOLAS box control unit fuse 50 A main fuse fuse 50 A glow plugs fuse 50 A glow plugs fuse 5A permanent current module fuse 10A Switched current for module K27 fuse 10A fuel pump plug 23 pole connection engine cable instrument c
29. measured Make sure that with disconnected plug X15 and ignition ON an error code can be stored gt At completion of checking cancel the error code refer to 06 06 04 Use a standard voltmeter multimeter to measure the supply voltage and or the resistance Supply voltage Ubat 12V 2V ignition ON main relay K27 active measurement point GND on X15 3 against supply voltage on X15 1 Continuity from X15 2 to control unit X5 33 max resistance 2 ohms If supply voltage and transition from X15 2 to X5 33 are connect replace the speed sensor In case an error was detected during preceding measurements check wiring according to circuit diagram and wiring harness diagram Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 89 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 10 05 05 Check oil pressure sensor B18 and or wiring 31100 10 15100 07 60117 01 10 05 ill 10 On account of the sensor s integrated electronic system only the supply voltage and or the output signal can be measured Make sure that with disconnected plug X15 and ignition ON the error code 32 HiLPS is stored gt At completion of check the error code refer to 06 06 04 Use a standard voltmeter multimeter to mesure the supply voltage and or the resistance Supply voltage 5V 0 4V ignition ON main relay K27 active measuring point GND on X18 A against 5V on X18 B Continuity from X18 C to control unit X5 10 max resist
30. recomandet wire gauge size Starter must be connecting by customer use a wire min AWG 0 50 mm connect a red wire AWG 8 6 mm at battery A positiv terminal 12V connect a red wire AWG 6 10 mm at battery B positiv terminal 24V connect a black wire AWG 6 10 mm directly at battery A negativ terminal Battery equalizer GND 24V BLACK AWG 6 RED AWG 6 25A 20A OUT 12V 24V LOAD STARTER ALTERNATOR power supply glow 12V Protected Output RED AWG 8 08 02 111 1 Note Mainswitsches are mechanically interlinked 21 ARMATUREN PLUG 6 POLE gt USE ONLY 12 VOLT INSTRUMENTS 60810 gt check engine lampe 12V 2W pin2 60616 gt glow lamp 12V 2W pin3 60614 gt temperature instruments 12V pin4 60613 gt engine speed instruments 12V pin5 50000 gt starter terminal 50 detection of start pin6 15000 gt ignition connect it to the ignition switch of the vehicle protect with 5 Amp fuse Note The glow lamp has 2 functions gt at first it works as glow lamp after start it works as oil pressure lamp ALTERNATOR B must be connection by customer gt use a wire AWG 6 10 mm charging control gt must be connecting by customer 24V 3W K Connect it to alternator Diode generator terminal D ATTENTION ch Please observer and foll
31. se V 1969 28 se sg vox 05 02 ill 5 to eng no 482 17 000 ircuit diagram 2008 Z001019 0_6_Jul Page ELECTRICAL SYSTEM 24 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Line designations from to Wiring harness to eng 48 217 000 15000 01 J1 plug engine instruments 15000 02 J1 plug engine instruments 15000 03 5 control unit A5 15012 01 20 control solenoid Y20 15012 02 5 control unit A5 15012 03 K27 main circuit relay 15012 04 K26 1 relay preheating 15012 06 X15 speed sensor B15 15100 01 X5 control unit A5 15100 02 X13 pot accelerator B13 15100 05 X12 boost press sensor B12 15100 06 X14 pot rack position B14 15100 07 X18 oil pressure sensor B18 17415 01 F2 50A fuse glow plugs 17415 02 F3 50A fuse glow plugs 30000 03 K26 1 relay preheating 30000 04 K26 2 relay preheating 30000 05 1 50 main fuse 30012 01 X5 control unit A5 30012 02 K27 main circuit relay 30012 03 X23 diag 30012 04 K27 main circuit relay 30012 05 1 50 main fuse 30012 06 F1 50 main fuse 30012 07 F1 50 main fuse 30012 08 F1 50 main fuse 30012 09 F5 fuse control unit 2001019 0 6 July 2008 K24 relay fuel pump K24 relay fuel pump K24 relay fuel pump X5 control unit A5 K27 main circuit relay K26 1 relay preheating K26 2 relay preheat
32. series and provide a capacity of 115 Ah 24 V for the external supply of all electric components on the boat 12V supply of all electric and electronic components on the engine including instrument panel by center tapping Additional charge is guaranteed by charging equalization 9 For6cyl engines only Use a 12 V battery with a cold test circuit of 650 ampere at 18 C and a capacity of 115 Ah at 27 to guarantee the supply of the electric and electronic components Explanation Cold current test The cold current test is a specified load test of a battery The charge of battery with specified current e g 4504 After discharge for 30 sec the voltage should not drop bellow 39V Capacity With a current consumption of of specified capacity e g 92Ah the battery voltage must not fall below 10 V after 20 hours to guarantee the engine s starting ability Maintenance To guarantee long battery life the following tests should be carried out periodically 1 The level of battery acid must always be above plates and separators The acid level should reach the marking on the battery Acid may only be refilled by an expert when it was definitely stated that some of it has been spilled ATTENTION Battery fluid is an aggressive acid and must be handled with care In case of skin 9 contact rinse thoroughly with water and consult a doctor physician Page ELECTRICAL SYSTEM 94 2001019 0 6 July 2008 SERVICE MANUAL MARINE EN
33. trouble shooting Engine oil system Sensor or connector failure see service code table See table trouble shooting Air charge system Page ELECTRICAL SYSTEM 36 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Operating Parameter Engine speed sensor fault Engine speed remains at idle Governor position system Inverse position shut down SOLAS During break in phase Effect noticed Higher or unstable idle speed limited performance No increase of engine speed if throttle is moved to max Irregular engine speed or stalled engine Engine shut down beyond 70 deg angle Cel ON at high accelerator position more than 75 Panel Indication No RPM inication on tachometer After engine stop horn remains switched ON until ignition reset Indication light CEL is switched ON Additional Tool Readings Steyr Diag Service code Steyr Diag Service code Steyr Diag Service code Steyr Diag Break in phase Action or possible reason See table trouble shooting Speed sensor See table trouble shooting Accelerator potentiometer failure See table trouble shooting Governing system Reset through ignition OFF and then ON See information break in procedure Optical and audible warning signals as shown on the dash board are illustrated in chapter Operating Status and Error Report 06 06 02 Diagnostic system Th
34. 01 LYVLS juejoo3 Y90949 ejeipeuueju fAoueBieui3 euibu3 110 gt 93858 095 SSANLHOIT HLIM NOILVAONNI SNOLOWMABIS NOILdO 52106 142 9 7 TANWd MLSNI Weld ONIYIM y 2008 Z001019 0_6_Jul Page ELECTRICAL SYSTEM 66 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 67 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 07 13 ADJUST INSTRUMENTS 06 07 13 01 Tachometer with running time meter There are 2 possible settings Function PULSE Entry of pulse rate 12 18 per revolution inductive sender Function ADJUST Using a reference rpm meter manual rpm meter the rpm is compared and calibrated accordingly 07 13 ill 1 Selection of function Operating voltage off Press and hold down key on back of housing Operating voltage ignition on The display shows PULSE and ADJUST every 2 seconds in alternation To select shown function release the key for respective indication Function PULSE Taster Tausch ken Bainon peutsar Tega When the function PULSE is selected P12 18 07 13 ill 2 12 18 pulses per revolution appears for example onthe display after approx 3 seconds with a flashing last digit Immediately start entry ofknown pulse rate by repeated press
35. 1000781 d Ke lt 10 00181 g 8LX 000016 ZX gt OL OOLLEIV BLX L0 22109 L cX zX Too TX oO 10 o 102 2 A cof y S0 4 e 02x E 80 0 10 21109 a t LX D oco 60 00116 Yit LX i c T 7 1 96 AS N ZIX FUN 682 18 000 SOLAS Page ELECTRICAL SYSTEM 31 y 2008 2001019 0 6 Jul SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 8 1020 20 0 67262 sejoS SJ AU Ver 1901 0 9 EZX gt UJ09 SJO OUJ J 9 S MWMM OG Ave _ jeuondo ES EX TL O00LE e Ae Jepues 0 ESIEX 1062109 jeuondo 90 000 60 21006 Vos Jeof Hu E gt 10 80809 sz wu 6X ke Tn jer g 8 7 To 1 mae OW ErMagZ ON 1 ON 1902 ON L 199 ano SNOl1d30X3 SNIMOTIOS HUM S3dAL 3NION3 TV ez SM Da 7 9 10 00609 e 10 10609 JOSI 10 80809 SID d3HA L L L0 0 000 00 ebb 09 os SL 09 4 SSANLHOIT poo A3IS 5088 0 10 0 bo ea EI
36. 110 01 X12 MAP B12 Page ELECTRICAL SYSTEM 26 F6 fuse fuel pump Z2 mass point Z2 mass point X15 speed sensor B15 Z2 link splice Z2 link splice X5 control unit A5 S2 link splice Z2 earth connection engine Z1 link splice Z1 link splice Z1 link splice Z1 link splice Z1 link splice Z1 link splice Z1 link splice Z1 link splice X5 control unit A5 X5 control unit A5 X5 control unit A5 K26 2 relay preheating X5 control unit A5 X5 control unit A5 X5 control unit A5 J1 plug engine instruments J1 plug engine instruments X5 control unit A5 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Line designations from to Wiring harness to eng 48 217 000 60111 01 60112 01 60113 01 60114 01 60116 01 60117 01 60118 01 60121 01 60122 01 60412 01 60613 01 60614 01 60616 01 60706 01 60808 01 60808 02 60808 03 60810 01 60900 01 60901 01 61000 02 network pot accelerator B13 14 RACK B14 15 speed sensor 15 X16 ECT B16 13 pot accelerator B13 18 oil pressure sensor 18 17 sensor exh gas temp B17 J1 plug engine instruments 2 gear switch S2 M2 fuel pump M4 posit J1 plug engine instruments N J1 plug engine instruments J1 plug engine instruments J1 plug engine instruments Z5 60808 Z5 60808 Z5 60808 J1 plug engine
37. 1AO 9 7 3SV8 3NIHVM SNIHIM 05 03 11 5 2008 2001019 0 6 ELECTRICAL SYSTEM 32 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 8 1020 20 0 9PE6LL2 ye W a 9 9g e lo UJO2 SJO OUJ J 9 S MMWM z ep ee eee EEN 8 81982 ON IS ShHOSZ OWN 1 agua 19397 ON 92 OW EECH 92 ano SNIMOTIOS S3dAL dvWizig 3NI9N3 5 10 10019 H i Selos AEN Conte uondo Sou LEX ees 19 29065 zz DM EZX I H 1941 06 M 9 EZX on el 1 1 NWO p 7X Z0 10609 97 T ul EL ve T H oe T z T Di T 6 0 02 62 T z NYO S EZX gt SM SO 180 SOdy _ 2039 103 Xnv ano 20 00609 1 1 Ki 10 10609 To 10 10 10 10 10 Dy 10 10 Wo 10 Lo ir 90 00 0 9n Di 00 000 i 4 TE PENVO 10 00609 pg 09 pu 09 09 09 09 09 09 09 09 D T n L0 0ZL09 12960 90800 LINN TO4LNOI IINOU4LI33 HOLOANNOO um um 10 10 lo 1o 10 10
38. 22 XS8 XS9 XS10 1 91 X2 L1 X3 L2 X4 L3 X5 E10 X6 P1 X7 E11 X8 P2 X9 S7 11 12 X12 E13 22 4 fuse 23 pin plug switch switch relay lamp lamp lamp gauge gauge gauge gauge warning horn 1 pin plug 2 pin plug 2 pin plug 4 pin plug 10 pin plug 10 pin plug 10 pin plug 2 pin plug 3 pin plug 2 pin plug 3 pin plug 10 pin plug 8 pin plug 2 pin plug 3 pin plug connection engine cable instrument cable ignition fix n speed selector switch optional charge control 90A PRESTOLITE charge control cel check engine lamp oil pressure pre heating control coolant oil pressure optional tachometer with running time meter trim optional to lighting switch instrument panel charging control relay charging control wiring harness side charging control relay charging control instrument side ignition charge control lamp cel check engine lamp oil pressure warning lamp lighting coolant display coolant temperature gauge lighting oil pressure oil pressure gauge speed selector switch optional speed instrument lighting speed instrument lighting trim optional trim optional Page ELECTRICAL SYSTEM 58 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 6 Cyl Wiring harness instrument panel if alternator PRESTOLITE is used old version 31000 61000 02 31000 61000 03 K10 30 braun K10 87a wei
39. 7 80 90 C Trouble in governing loop involved components control solenoid rack control gear of unit injector rack position sensor OFF 07 05 ill 8 2001019 0 6 July 2008 ELECTRICAL SYSTEM Remarks check raw water system strainer impeller pump after cooling down check engine coolant level after cooling down check engine coolant level sensor B16 and connection defect speed sensor B15 or sensor connection Failure in governing loop time limit exceed for rack positioning Restriction or high friction in control devices Stored failure code must be cleared memory Tools PC service program Page ELECTRICAL SYSTEM 55 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES Indication status Fault Remarks During start attempt On L Engine will not start Failure in governing circuit Failure governing Positioning of rack SS circuit not possible Trouble shooting of control solenoid rack control gear of unit injection rack position sensor ON OFF ON 07 05 ill 9 Page ELECTRICAL SYSTEM 56 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 57 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 07 10 6 Cyl Wiring harness instrument panel if alternator PRESTOLITE is used old version L1 12 L3 Pi P2 P3 P4 H
40. Cables and connections Governor Slip ring Internal components of alternator Alternator scheme 01 03 ill 8 gt O Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 13 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 01 04 Check alternator error detection for BOSCH alternator 4 engines Trouble features With engine stopped and ignition on generator control lamp L1 not shining or only slightly With both engine stopped and running generator lamp L1 constantly shines brightly With engine stopped generator control lamp L1 shines brightly with engine running only shines slightly Page ELECTRICAL SYSTEM 14 Tester lamp connected between B and on generator shining brightly Tester lamp connected between B and D on generator not shining but shining brightly when connected between D and ground Generator control lamp L1 does not shine in both cases Tester lamp connected between D and ground tester lamp and generator control lamp L1 glowing With engine stopped disassemble attached governor Generator control lamp L1 still shining brightly Generator control lamp L1 extinguishes Install governor again Connect ammeter between B and D on generator Exciting current is lower than specified 4 amp 0 4 Exciting current is higher than specified 4 amp 0 4 Connecttester lamp between B and D
41. ERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 90p81 290 0 0 Q 64 LZ UJOO SJO OUJ J O S MMM uonoeuuoo ou Oc x r 09 ee a ern uonoeuuoo OU sn 6L rer io ee tected E qM uondo Ionuoo ee OL QUA I gt noqa sues p EEN WR 1010075 EL 1 10 1 GDIBIJO ee peg i et Bb L MER enee peg i m I Fog E oai cuu M ME lt 9L Or ETT CT cmn 1 mom SL d W 4 i mss ek N L 1 pens _ 9100016 WII moore bh Vf i GE HE E T isse H gol cq 1 m ne ZZ os ee T i em NM mmi 9021008 Y ar r OI pic 1 20 2100 2 Ge een 5 f Sr 5 Se eg woe 8 12 ms im 1 1 1 11 1 64 50 00081 x bg A T E vol o Puodsa u09 Jo 13 9 z 13 13 28 228 98 58 en Lex 77 2 Lee ver 1 1 Ave zs LS due due Jojeoipu dwe yomg 440 NO onuoo susug 44
42. GINES ELECTRICAL SYSTEM 2 The battery should always be charged as full as possible Regularly check the state of charge with the battery acid tester We recommend to check the acid density and acid level periodically every two weeks Ifthe density is 0 04 kg dm below the value of full charge the battery is be removed and charged DENSITY WITH FULL CHARGE 1 260 kg dm at 27 C ATTENTION Never charge the battery on the boat The vapors resulting from charging could cause an explosion 12 01 ill 1 For a periodical check of the battery the following items are to be considered 1 Protect the boat against acid leakage 2 Clean battery 3 Check connections and cables 4 Clean battery contacts neg pos 5 Check holding device of battery 6 Check housing for damages acid leakage 7 Check acid density 8 Disassemble battery for test In case of less than 3 4 charge charge it by means of battery charger carry out charge test 9 Check acid level In case of a bad state of charge or excessive loss of water check charge circuit Clean battery contacts and terminals with a solution of soda and water This neutralizes the battery acid After cleaning with the solution rinse the surface with water by taking care thatthe solution does not penetrate into the battery ATTENTION When connecting the battery cables take special care of correct polarity Incorrect polarity destroys electronic compo
43. SERVICE MANUAL MARINE ENGINES 06 10 02 Component configuration 6 cyl engine CODE KURZNAME BESCHREIBUNG ABBREVIATION DESCRIPTION MAP Ladedrucksensor Boost pressure sensor PED Gaspedal Potentiometer accelerator RPOS Regelstangensensor Rack position sensor RPM Motordrehzahlsensor Sensor engine speed ECT K hlfl ssigkeitstemperatursensor Sensor engine coolant temperature EXT Abgastemperatursensor Sensor exhaust gas temperature 06000060969 LPS ldrucksensor Lubricant pressure sensor CODE 0000000909 KURZNAME ABBREVIATION J1 DIAG FMS to engine number 68226999 10 02 ill 1 BESCHREIBUNG DESCRIPTION Stecker lmanometer Option Connector oil pressure gauge optional Stecker Trimmanzeige Option Connector trim optional Verbindungsstecker Motor EMS Connector engine cable EMS Diagnose Stecker Diagnosis plug Steuermagnet Control solenoid Stecker Getriebeschalter Option Connector gear switch optional Inversionsschalter Nur bei SOLAS Inversion switch only for SOLAS Abschaltventil Nur bei SOLAS Blow by only for SOLAS Page ELECTRICAL SYSTEM 80 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM from engine number 68227000 CODE KURZNAME ABBREVIATION MAP CMD RACK RPM ECT EXT LPS BESCHREIBUNG CODE DESCRIPTION Ladedrucksensor Boost pressure sensor Gaspedal Potent
44. SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06 00 06 00 01 06 01 06 01 01 06 01 02 06 01 03 06 01 04 06 03 06 03 01 06 05 06 05 01 06 05 02 06 05 02 01 06 05 02 02 06 05 02 03 06 05 02 04 06 05 03 06 05 03 01 06 05 03 02 06 05 03 03 06 05 03 04 06 06 06 06 01 06 06 02 06 06 03 06 06 04 06 06 05 06 06 06 06 06 07 06 06 08 06 06 09 06 07 06 07 01 06 07 02 06 07 03 06 07 04 06 07 05 06 07 10 06 07 11 06 ELECTRICAL SYSTEM Table of Contents General u uuu cn an 3 Cable numbers and principal functions nn nn ne 3 Alternator uu uu nei 4 Adjust poly V belt tension 2 0000 4 R plac GEM Oh All ee 5 Technical data of alternator une 6 Check alternator error detection for BOSCH alternator 4 cyl engines 14 Replace starter MOTOT nn 16 Check starter re ee 17 Cables wiring harness general 19 Battery cable lengths and cross sections 19 E box base plate to eng no 482 17 000 20 Components of E DOX 21 Connection start assist relay 28 21 Connection relay socket for K24 K26 1 K26 2 and 27 21 Wiring harness
45. TEM 9 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES For 6 engines Technical data of alternator 28V 55A Option ISKRA AAK5170 11 201 894 Minimum engine speed for voltage generation 550 1 min Controlled voltage range u aaa 28 0 28 4 V rennen Cre scien A E integratedl base governor Excitation winding resistance 7 9 40 79 gt 5 Ire ez ya D DF 10 KIT 01 03 ill 6 Error Detection Check battery Charging voltage too low All connections terminals Belt tension Acid concentration Output Filling level check refill if necessary Governor Carry out load test Slip ring Excessive voltage Internal components of alternator Governor Loose connections NO charging voltage Battery Belt tension f Charging control lamp defective 24V 3W Output Cables and connections Governor Slip ring Internal components of alternator Page ELECTRICAL SYSTEM 10 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 11 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 4 engines only Technical data of alternator Model nn ae BOSCH No 6 033GB3 046 Minimum speed for voltag
46. YSTEM SL uondo 33944 1344 _ X1 3344 1344 MIL uo 3344 1343 NIW m mmm 3344 134 HEJS 5 Je JON uondO 2 1 6 01 0 7 HOLVOIGNI uondo lt S 2 5 EES EES HW LI peg Ve ere gb OIM 1 peg t 0000 Sk d W 1 4 hz LO LZLOg 10 1909 EL 3344 EE ehe pr 10 7 309 UL 0 90409 6 mu ww m k wm len ms zm mm mm EC DC DEU EE LO SL9LE 8 HIH 0 9 909 2 20 000 2 9 LO O00LE S ann 80 21006 y one baec 20 21008 00 00091 vi 10 00091 o puodsau109 payeays Jo 5 77 10 00091 6 Cyl Wiring harness instrument panel if alternator PRESTOLITE SERVICE MANUAL MARINE ENGINES used old version x x T T T 5 1 osnj ueuoeudsjue Bunjiejjeyue v Jap usques IN 4 k 9 1 Z 2 19 We eb Zi FL 2 L 12 2 2 k 06
47. _INI B30 timing position calibration bad position out of tolercance sensor IT Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 41 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 06 06 REPLACE FUSES Preparatory works Engine out of operation disconnect battery Replace automatic circuit breaker 1 Swing off E box base plate 2 Disconnect cable from automatic circuit breaker 3 Loosen 2 hexagon screws ill 1 pos 1 SW1 4 and take off thermal circuit breaker ill 1 pos 2 NOTE For assembly seal cable screw connections with rubber varnish 06 06 11 1 Replace fuses 1 Remove E box cover 2 Remove fuse protection cap Pull out fuses ill 1 pos 3 Replace defect fuse Page ELECTRICAL SYSTEM 42 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06 06 07 Connection J1 06 07 111 1 A B C D E F G H J K L M N O P Q R 5 T U V W x 15000 01 15000 02 30012 07 30012 08 31000 01 31000 02 60616 01 31615 01 60706 01 60614 01 61000 02 60613 01 60121 01 60810 01 50000 02 50000 03 60120 01 61001 02 60901 03 60900 03 ignition 15 ignition 15 terminal 30 terminal 30 ground connection ground connection lamp oil pressure L3 warning horn const speed switch temperature display alternator D blind plug tachometer speed oil pressure gauge optional check engine lamp ignition lock start ignition lock
48. able relay fuel pump relay preheating realy preheating relay main circuit relay start plug 2 pole inversion switch for SOLAS only inversion switch for SOLAS only plug 35 pole module 06 05 03 02 Connection relay K28 and K26 2 05 03 ill 2 06 05 03 03 Connection relay socket for K24 K26 1 and K27 05 03 ill 3 2001019 0 6 July 2008 Page ELECTRICAL SYSTEM 29 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 05 03 04 Wiring harness from eng no 482 18 000 682 18 000 SOLAS 5 Fi 2 F3 F4 F5 F6 F7 G1 G2 J1 K24 K26 1 K26 2 K27 K28 M1 M2 R10 X2 S2 X3 S3 X5 A5 X12 B12 X13 B13 X14 B14 X15 B15 X16 B 16 X17 B17 X18 B18 X19 B19 X20 Y20 X22 B22 x23 X26 Y26 Zi Z2 Z3 74 76 control unit fuse 50 A main fuse fuse 50 A glow plugs fuse 50 A glow plugs fuse 5A permanent current modul and K27 fuse 10 switched current module K27 fuse 10A fuel pump K24 fuse 10 A preheating control circuit alternator battery to be provided by customer plug 23 pole connection engine cable instrument cable relay fuel pump relay preheating control circuit relay preheating load circuit relay main circuit relay start starter fuel pump glow pins plug 2 pole gears switch plug 2 pole inversion switch only SOLAS plug 35 pole module plug 3 pole boost pressure sensor plug 5 pole potentiometer ac
49. agon screws SW10 remove boost pressure sensor ill 4 pos 2 NOTE For assembly take care of the 2 sealing cushions of plug housing 10 04 ill 4 Z001019 0_6 July 2008 Page ELECTRICAL SYSTEM 83 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES Boost pressure sensor B12 for engines 164 174 246 256 266 only 1 Remove cable strap lift shackle at plug and pull off plug 2 Loosen clamp SW6 and pull off hose 3 Loosen union nut SW17 by holding up at sensor SW32 Remove sensor Assembly is done in reverse order off disassembly NOTE Wetten the thread from the new sensor with LOCTITE 243 Thigthen union nut solid 06 10 04 05 Rack position feedback sensor B14 1 Remove retaining clip remove plug housing ill 6 pos 1 2 Disassemble control solenoid refer to 03 08 01 3 Loosen 2 cylinder screws with hexagon socket SW 3 remove sensor ill 6 pos 2 Assembly is done according to assembly of control solenoid refer to 03 08 06 10 04 06 Oil pressure sensor B18 1 Remove plug housing 2 Unscrew oil pressure sensor ill 7 pos 1 from mount ill 7 pos 2 ATTENTION Collect running out motor oil in a suitable vessel 06 10 04 07 Potentiometer Accelerator B13 1 Disassemble indexing plate ill 8 9 pos 1 2 Remove plug housing ill 8 9 pos 2 3 Unscrew hexagon nut of accelerator lever ill 8 9 3 remove lever 4 Loosen 2 hexagon screws Remove accelerator ill 8 9
50. ance 2 ohms Output signal depending on pressure see diagram Remove B18 and admit pressure when X18 is connected max 5 bars measuring point X18 C gt X18 B voltage via pressure 4 0 3 5 3 0 2 5 20 voltage voltage V 0 1 2 3 4 5 6 pressure bar 10 05 11 11 Page ELECTRICAL SYSTEM 90 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06 10 05 06 Check oil pressure sensor VDO instrument option B19 NOTE If oil pressure is questionable check oil level before starting the engine check minimum oil pressure Minimum oil pressure Idle 1 bar 1000 2 bar 2500 and above 4 bar Check minimum oil pressure Start engine and let engine run at idle speed 1000 and 2500 r p m Check tachometer and and oil pressure gauge Record oil pressure value for idle speed 1000 and 2500 r p m If values are not appropriate check the oil pressure gauge before checking the oil pressure sensor To check the oil pressure gauge disconnect cable from sensor turn on ignition key and shortly put the sensor cable to ground connection If gauge functions properly the pointer will shortly deflect to high values If there is no malfunction of the gauge replace the oil pressure sensor Check of oil pressure sensor 1 To check the oil pressure sensor disconnect the sensor cable and connect an ohmmeter to sensor terminal and sensor 2 Check resistance
51. arry out load test Slip ring Excessive voltage Internal components of alternator Governor Loose connections charging voltage Battery Belt tension f Charging control lamp defective 12V 2W Output Cables and connections Governor Slip ring Internal components of alternator Page ELECTRICAL SYSTEM 8 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM For 6 engines Technical data of alternator 28V 80A Option Model ER ISKRA AAN5161 11 203 220 Minimum engine speed for voltage generation 550 1 min Controlled voltage range 28 1 28 7V EE 80 eue integratedl base governor Excitation winding 7 9 40 79 Q 01 03 ill 5 Error Detection Check battery Charging voltage too low All connections terminals Belttension Acid concentration Output Filling level check refill if necessary Governor out load test Slip ring Excessive voltage Internal components of alternator Governor Loose connections No charging voltage Battery Belt tension f Charging control lamp defective 24V 3W Output Cables and connections Governor Slip ring Internal components of alternator Z001019 0_6_July 2008 Page ELECTRICAL SYS
52. at zero pressure resistance should be 240 Ohm 10 Ifresistance is out of tolerance limits replace the oil pressure sensor If resistance is within the tolerance range but function of oil pressure sensor is still questionable measure the resistance over the entire field es E e D dd EXE sd __ __ n an 100 170 140 172 180 200 220 240 RESISTANCE OHM 10 05 ill 12 Z001019 0 6 July 2008 Page ELECTRICAL SYSTEM 91 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES Check oil pressure sensor over entire pressure range 1 Disassemble sensor and connect it to a gauged pressure source 2 Connect ohmmeter and pressurize sensor Read andrecord pressure and resistance at different spots over the entire pressure range 3 Compare pressure and resistance values with chart If values are not within tolerance range at one spot replace sensor 06 10 05 07 Check coolant temperature sensor B16 To check the coolant temperature sensor make the following test with connected ohmmeter In case of failure replace the sender 1 Compare resistance value and ambient temperature to curve of diagram Range of tolerance is 10 kOhm 120 100 80 40 20 0 10 20 30 40 50 60 70 80 90 100 TEMP C 10 05 ill 13 Page ELECTRICAL SYSTEM 92 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 2 I
53. celerator plug 3 pole pot rack position plug 3 pole engine speed sensor plug 2 pole engine temperature sensor plug 2 pole exhaust gas temperature sensor plug 3 pole oil pressure sensor plug 1 pole oil pressure gauge optional plug 2 pole control solenoid without stop trim sensor optional plug 6 pole diagnosis plug 2 pole disconnection blow by only SOLAS splice spot earth connection sensor splice spot earth connection 31 on engine splice spot sensor supply 5V splice spot earth connection 31 on E box plate splice spot shield speed sensor line Cable numbers principal functions 15000 xx ignition positive 31100 xx not connect mass for sensors from ignition switch with battery negative 15012 xx 12 volt via main relay 601xx 01 Sensor signal to modulator unit and modulator unit A5 5 and or instruments 15100 xx 5 volt supply voltage for sensors 606xx 01 Exit from modulator unit 5 30000 xx battery positive not secured to display system tachometer 3001 2 xx battery positive secured temperature display 31000 xx battery negative GND Page ELECTRICAL SYSTEM 30 2001019 0 6 July 2008 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES v OLY 2 01 4 9 0 4 old S OLY vY9V VVV VVIN L OVM POL 0L 0 60v 2 SE GX L0 ELLO9 E SX LO cLOSL ZL SX 10 80809 26 5 10 10609 91 SX L0 ECLO9 LE SX 10 00609 S L SX L0 9LLO9 O SX 10 28109 vL SX 05 03 ill 4
54. circuit 182 WarnLo L3 oil pressure lamp no current in circuit of oil pressure lamp 186 BadPos Y20 governor solenoid Nominal actual value difference rack pos error rack jammed 187 HiFMSC X20 X20 governor solenoid defect in governor wire circuit resistance too high bulb blown or missing connection 188 LoFMSc X20 governor solenoid defect in governor wire circuit resistance too low 193 VTG Bad Y28 REA unit at turbo charger defect in output circuit short circuit or missing connection 194 GPR s K26 glow assist relay current limit exceeded in glow plug relay circuit short circuit 195 GPR o K26 glow assist relay no current detected in glow plug relay circuit disconnection 201 HiTEMP operation limit exceeded engine was operated with too high coolant temperature engine overheated 202 Lop operation limit exceeded engine was operated with too low lubricant pressure lubricant pressure too low 203 Manop operation limit exceeded engine operated with manual movement of rack position too high 251 ITSL_Bad B30 position sensor ITD signal level too low short circuit on injection timing sensor 252 ITV_LoCur Y29 proportional valve ITD defect in circuit of valve no current flow 253 ITV_HiCur Y29 proportional valve ITD defect in circuit of valve current value too high 254 SpvP_Bad B30 position sensor or ITD commanded timing position can not be achieved sensor or injection timing device defect eccenter shaft jammed 255 Spv
55. ct temporarily Pin Pos 1 with Pin Pos 2 of Diagnostic Plug X 23 before ignition is turned on at key switch Code indication and indication sequence 06 03 ill 1 After entering the error code indication modus the Engine Management System will display a blink code at the Check Engine Light on the dash panel The blinking sequence will always begin and end with control code indication 12 Each ERROR cope will be repeated 3 times to reassure your correct reading see below bar code illustration Example sequence check engine light ill 2 pos 1 Error code 14 06 03 ill 2 3 time 1 time 2 time 3 time 1 time CODE 12 CODE 14 CODE 14 CODE 14 CODE 12 0 3sec 4x0 3 sec 1 5 sec 3x 0 4 sec 3 0 sec 06 03 ill 3 Stroke Check Engine Light illuminated for 0 3 sec Light Off period within blink sequence 0 4 sec Dashed Line interruption within code indication 1 5 sec Solid Line interval interruption between error code 3 0 sec Page ELECTRICAL SYSTEM 38 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM If more then one error code is stored in the Engine Management System the indication sequence will be continued blinking additional stored error codes To delete amemorized error code see description Indication and Cancellation of memorized sensor and circuit faults For a description of the possible error codes refer to enclosed
56. ction sensor connection FLASHING 1x per sec OFF ON engine overload during reduce throttle position 2 ON break in period until light goes OFF indication during first 2 S hours of operation Page ELECTRICAL SYSTEM 48 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Indication statu 80 90 C ON al S 2x per sec high approx 105 C O00 5 4 G a O 1 FLASHING 2x per sec 07 02 ill 4 07 02 ill 5 07 02 ill 6 a Ka 07 02 ill 7 a gi o z 07 02 ill 8 Fault high exhaust temperature off 80 C engine coolant temperature to high defect engine coolant sensor or sensor connection instable idle speed no indication on tachometer Trouble in governing loop involved components control solenoid rack control gear of unit injector rack position sensor Remarks check raw water system strainer impeller pump after cooling down check engine coolant level after cooling down check engine coolant level sensor B16 and connection defect speed sensor B15 or sensor connection Failure in governing loop time limit exceed for rack positioning Restriction or high friction in control devices Stored failure code must be cleared memory Tool PC service program
57. e electronic engine management system controls the following parameters Oil pressure boost pressure coolant temperature hi riser bend temperature The electronic engine management system has an automatic self test program checking all data of electronic sensors As soon as a fault is found there is an optical or audible signal refer to chart Error Codes Occurred faults remain stored until cancellation Stored faults may be selected analyzed and cancelled by means of PC via diagnostic outlet A reference to one or several stored faults is the 5 second TESTING of the CHECK ENGINE LAMP and the WARNING HORN after ignition ON instead of usual 0 7 seconds refer to chart Operating Status On the CHECK ENGINE lamp E stored faults may be indicated by flashing codes With a special procedure 06 06 04 individual cancellation is possible Error codes are regarded both as flashing codes as will as display by diagnostic instrument There are three fault categories temporary faults non essential faults and essential faults Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 37 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 06 03 Reading Error Codes Entering and reading of stored faults via Check Engine Lamp and Diagnostic Outlet Plug X 23 Needed device Tool No VR00135 1 normally closed push button switch connected to Diagnostic Outlet Plug X23 In case this tool is not available Conne
58. e generation 550 1 min Controlled voltage range 13 9 14 7 V ceat e tor 90A elo i e integratedl base governor Charge capacity 750 d Dr e M ca 34 A at 3000 ED rM EN maximum charge capacity Gondensor capacity ana nete huuu cade ctr id 2 2 UF 12 GND Z ell 12 Ba 9 or DN S Le 01 03 ill 7 Charging circuit scheme eege battery 2 s Z2 ground connection on engine ias red 4 fuse 50 Bos starter engine porn plug engine electrics instrument cable 8 fuse 10A suus starter key lock 10 15000 qd red 16 mm 12 generator 13 5 charging control L1 14 61000 02 18 pole connecting cable Nr 11 15 blocking diode 1N4007 Page ELECTRICAL SYSTEM 12 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM For 4 engines only Error Detection Check battery All connections terminals Acid concentration Filling level check refill if necessary Carry out load test Excessive voltage Governor Loose connections Battery Charging voltage too low Belttension Output Governor Slip ring Internal components of alternator No charging voltage Belttension Charging control lamp defective 12V 2W Output
59. ecting cable No 11 15 relay K10 16 blocking diode 1 4007 Page ELECTRICAL SYSTEM 6 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 9 For 6 engines only old version eng 68224418 STATOR YEL STATOR YEL circuit diagr Pos output gt OUTPUT RED OUTPUT BLK 6 nee ce gt Governor GRN Red 57 SCH Field IGN KL15 gt STI ya pue GEM l STA T 01 03 ill 2 01 03 ill 3 Check of alternator and connections With engine stopped measure voltage on alternator output and output Measured voltage may be lower than the battery voltage by up to 1 volt only Where appropriate test wiring of cables and connections Check of control voltage and or alternator voltage NOTE For these works the battery s state of charge should be 95 at least Check tension of belt on alternator drive and make sure that cables are perfectly connected 1 Disconnect all electrical consuming devices and adjust engine to a speed of approx 1000 rpm 2 Connect voltmeter to alternator output B 3 Remove plastic screw on governor and apply screw driver with fine blade on adjusting screw ATTENTION The adjusting screw has a min max stop There is danger to damage the governor when turning by force the adjusting screw so far that it overtravels the specified control range
60. fthis check brings no information drain the coolant and remove the sensor Immerse sensor together with thermometer into a canister with coolant Connect a digital ohmmeter to the sensor and heat the fluid on a heater Monitor ohmmeter und thermometer The ohmmeter should show values corresponding to the values of the resistance curve with a tolerance range of 10 06 10 05 08 Check audible warner 0 7 sec with ignition ON gt function check and message no error stored 2001019 0 6 July 2008 Page ELECTRICAL SYSTEM 93 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 12 BATTERY 06 12 01 Battery Battery Acid Test The battery provides the starter engine with energy and supplies the required voltage for lighting and other electrical equipmentwhen the engine is notrunning During the starting procedure and when the generator does not generate any current the battery provides the electronic engine management system with voltage For4cyl engines only Use a 12 V battery with a cold test circuit of 450 ampere at 18 C and a capacity of 92 Ah at 27 C to guarantee the supply of the electric and electronic components for all operating conditions QQ For24V installation only Use two 12V batteries with a cold test circuit of 650 ampere each at 18 C and a capacity of 115 Ah at 27 C to guarantee the supply of the electric and electronic components for all operating conditions The batteries are connected in
61. g el Bugy 298 SS3NLH9I1 HLIM NOILVAONNI SHO LOWAASLS WOD SJ0 OUJ J 9 S MMM Y youms 8X II S 8 ou u D uonoeuuoo ou Bejuosuy auy DL M UP 22 NOILdO 52106 1 2 9 7 ULSNI A A z 9 2 L z d 1 ES 25 L due dwe dwe 4 193 103 u09 440100 1 18 Bunubr1 au dug lt L nir 0 00609 60 10609 ee AVERUNCO 8 lios CL HIH 10 lt 8L 8 r 9L 0 17 owe 9 d W 012109 lt VL OV wes cb NII d W Ir punoo 9L 0001 Fk MM oria Ob UM 10 90 09 H HW 9900 2 9 9 3 P 3 7 wax P Tame E 9 mo 9 1000091 VOL esnj 50 00061 81929 puodseuoo JO SINOJ09 ON Page ELECTRICAL SYSTEM 65 y 2008 Z001019 0 6 Jul S
62. hexagon screws ill 2 pos 3 SW13 of starter bracket 6 Loosen two screws SW8 ill 2 pos 4 remove starter 03 00 ill 2 NOTE Have starter motor repaired in an authorized STEYR workshop After assembly coat all electric supplies with rubber sealing Z909570 0 Page ELECTRICAL SYSTEM 16 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06 03 01 Check starter When switching on the starter battery discharged and or defective charge battery and or replace acutation of starterkey starter shaft not turning or only slowly starter terminals of starter battery are loose clean terminals andtighten treat with pinion not engaging and or oxidized bad ground pole grease provide ground connection connection earth short circuit of terminals of eliminate earth short circuit starter or carbon brushes carbon brushes not resting on depending on failure make work collector sticking in guide are carbon brushes clean or replace gt broken oily or worn out in case of very strong wear replace various parts and or starter starter key or starterrelay K28 and or replace starter key or relay actuating relay on starter defective voltage drop in lines too large lines checkstarter eventually replace damaged line connections loose clean links and tighten links oxidized starter keeps on running after starter starter does notinterrupt starterkey immediately t
63. i 9X 20521006 I 40 99UU0D FEES cr Z00009 k vi I 8 10 00091 H i E 1 1 1 ia N MJ T T BRR 1 R 1 T 43477 H f 10 0006 TT TT z 19 z i z oe 28 eze es ss 4 918 esn4 o puodsaJJo9 JO sJnojoo oN Im 52 5 Lal 55 gt 74 x V 7 CY 013 1 Ave L due due Jojeoipu due HS el 193 aumgieduel lqeO 1 uoniub BunuBr1 002 _ 72942 ejeipeuueju 710 Le PS amp lt SS3SNLHIIT HLIM NOILVAONNI SSIOLOWAMASLS NOILdO Av 9 7 13NVd LNINNALSNI y 2008 Z001019 0_6_Jul Page ELECTRICAL SYSTEM 64 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 29020 20 62 2 SL AN DE vemm i uondo Ionuoo i sues Shey WEIS neg pod dc ee ISLE A A A elen lt ee L 8 a ne
64. ing K26 2 relay preheating Z3 link splice 23 link splice Z3 link splice Z3 link splice Z3 link splice K26 1 relay preheating K26 2 relay preheating K28 starter relay K28 starter relay starter solenoid F4 fuse control unit F4 fuse control unit K27 main circuit relay F5 fuse control unit F5 fuse control unit F6 fuse fuel pump J1 plug engine instruments J1 plug engine instruments F4 fuse control unit Page ELECTRICAL SYSTEM 25 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES Line designations from to Wiring harness to eng 48 217 000 30055 01 K24 relay fuel pump 31000 01 J1 plug engine instruments 31000 02 J1 plug engine insruments 31000 03 24 earth connection in box 31000 04 fuel pump M2 M5 negat 31000 05 X23 diag 1 31000 06 S4 earth connection in box 31000 07 X2 gear switch S2 31000 08 S4 earth connection in box 31100 01 5 control unit A5 31100 02 X13 pot accelerator B13 31100 03 X13 pot accelerator B13 31100 07 16 ECT B16 31100 08 12 B12 31100 09 14 RACK B14 31100 10 X18 oil pressure sensor B18 31100 11 X17 sensor exh gas temp B1 7 31409 01 X20 control solenoid Y20 31554 01 K24 relay fuel pump 31555 01 K26 1 relay preheating 31555 02 K26 1 relay preheating 31558 01 K27 main circuit relay 31615 01 J1 plug engine instruments 50000 01 K28 starter relay 50000 02 K28 starter relay 50000 03 K28 starter relay 60
65. ing of key The flashing digit may be adjusted by activating the key possible pulse settings 0 50 to 399 99 After having adjusted the flashing digit wait for approx 3sec Then the next digit begins to flash At completion of pulse rate setting activate the key no more The display then changes over to counting of running time Thus the setting procedure is completed By repeated selection of function PULSE the selected pulse rate may be checked The pulse rate appears on the display and the individual digits begin to flash in sequence starting with the last digit 07 13 ill 3 Page ELECTRICAL SYSTEM 68 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Function ADJUSt When selecting the function ADJUST the rpm display may be adjusted between 30 and 100 of the measuring range Using a reference rpm meter manual rpm meter the rpm indicator is compared Fine adjustment requires two persons one to operate the instrument and the other one to operate the manual rpm meter on the axis of the engine s crankshaft Extreme caution is required Do not wear loose clothing When the function ADJUSt is selected UP or dn UP or DOWN appears in alternation on the display after approx 3 seconds If for example the key is pressed and held down when UP is displayed the pointer deflection changes upwards for dn analogously downwards If you release the key for 2 seconds and then pres
66. iometer accelerator Regelstangensensor Rack position sensor Motordrehzahlsensor Sensor engine speed K hlfl ssigkeittemperatursensor Sensor engine coolant temperature Abgastemperatursensor Sensor exhaust gas temperature ldrucksensor Lubricant pressure sensor 00000090 KURZNAME ABBREVIATION J1 DIAG FMS BESCHREIBUNG DESCRIPTION Stecker lmanometer Option Connector oil pressure gauge optional Stecker Trimmanzeige Option Connector trim optional Haupt Verbindungsstecker Main connector Diagnose Stecker Diagnosis plug Steuermagnet Control solenoid Stecker Getriebeschalter Option Connector gear switch optional Inversionsschalter nur bei SOLAS Inversion switch only for SOLAS Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 81 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 10 03 Calibration of rack position This procedure must be carried out if any of the following has been done Control solenoid has been disassembled or replaced refer to 03 08 01 Rack position sensor has been disassembled or replaced refer to 03 08 03 Engine control unit has been replaced Rack or linkage lever have been replaced or loosened 10 03 ill 1 10 03 ill 2 NOTE Ensure that the ignition is turned off 1 Remove threaded pin from position A ill 1 2 Manually move rack ill 1 B forward until borehole ill 1 C is over tapped hole ill 1 D and f
67. ion the push button Ignition F must be switched OFF and then ON again and engine must be restarted with push button START G Page ELECTRICAL SYSTEM 52 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06 07 04 Chart Operating Status for SOLAS only Instrument indication during normal operation 1 ignition ON until engine start 07 04 ill 1 System check see light indication NOTE At low temperature condition cold weather the combined light for glow plug preheating amp warning light engine oil pressure will not extinguish after 0 7 sec glow plug preheating light extinguishes phase In this case start engine immediately after the pus 9 9 e a e SX z z ES o o ON 0 7 sec 2 ignition ON until engine start 7 04 ill 2 Ge Indication active error ON HN 06 ON 5 sec 3 engine running after start 07 04 ill 3 Normal condition Ur gt o 4 2 10 50 me m 605 x Further information see Table Error indication on Instrument Panel Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 53 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 07 05 Error Indication Error indication on instrument panel for SOLAS only
68. ix with threaded pin The pin must be fastened hand tight and sit correctly in the rack see ill 2 above 3 Turn on ignition rack position will be automatically stored in the ECU A5 Storage process will take approx 20 sec 4 Turn off ignition 5 Loosen threaded pin and screw it into rear bulkhead wall ill 1 A NOTE If storage in ECU A5 was unsuccessful error code 56 will be detected Refer to Error Codes NOTE The rack position sensoris magnetism sensitive All external magnets must be kept away as the may disturb the sensor Page ELECTRICAL SYSTEM 82 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06 10 04 Replace Senders Sensors 06 10 04 01 Exhaust gas temperature sensor B17 1 Unlock plug ill 1 pos 1 and remove 2 Unscrew temperature sensor ill 1 pos 2 SW19 10 04 ill 1 06 10 04 02 Engine temperature sensor B16 1 Remove plug housing ill 2 pos 1 2 Unscrew engine temperature sensor 06 10 04 03 Speed sensor B15 1 Press catch spring and remove plug 2 Loosen hexagon screw SW10 pull out sensor ATTENTION For assembly use new 0 9 Grease O ring and put it on 06 10 04 04 Boost pressure sensor B12 for engines 94 114 144 126 166 236 only 1 Remove hose from exhaust manifold ATTENTION Do not remove hose from boost Pressure sensor 2 Press retaining clip against plug housing ill 4 pos 1 remove plug 3 Loosen two hex
69. llowing the above mentioned procedure to delete a determined ERROR CODE Note An ERROR CODE can only be deleted if no defect exists in this circuit In case of a present active failure the ERROR CODE keeps reappearing until the problem has been repaired and the circuit is properly working again Disconnect Tool VR00135 1 from Diagnostic Outlet Plug X 23 to exit from error code display Note Watch indication of the Check Engine Light and the Warning Horn after ignition contact If all ERROR CODES are deleted from the Engine Management System the indication resumes to 0 7 sec function test of Check Engine Light and the Warning Horn For more details see Chart Operating Conditions Instrument panel Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 39 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 06 05 Principle failure code list NOTE REFER TO CODE ABBREV CIRCUIT INVOLVED DEVICE Some codes may not apply due to different application POSSIBLE CAUSE 12 Control code this code is designated for beginning or end of loop 13 LoMap X12 B12 boost pressure sensor signal level too low short circuit or missing contact 14 HiMap X12 B12 boost pressure sensor signal level too high missing connection 17 LoEXH X17 B17 air charge temp sensor signal level too low short circuit or missing contact 18 HiEXH X17 B17 gt charge temp sens
70. nents Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 95
71. ngs etc Use only a cable stripper to strip the cables Adjust the cable stripper so that the individual strands are not damaged or cut off New connections should only be made using soft solder or with commercial crimp connectors Crimped connections should only be made using cable crimping pliers The safety instructions of the hand tool manufacturer must be observed Insulate exposed leads in such a way that short circuits cannot occur Caution Risk of short circuit through faulty junctions or damaged cables Short circuits in the electrical system can cause cable fires battery explosions and damage to other electronic systems For this reason all connections in the voltage supply system must be either soldered or fitted with weldable connectors and adequately insulated Pay particular attention to correct earth connections Incorrect connections can lead to short circuits The cables must only be connected in accordance with the electrical terminal connection diagram Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 71 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 07 14 02 Audible warner H22 control unit 07 14 ill 1 sensor sensor sensor exhaust gas engine coolant oil pressure temperature Page ELECTRICAL SYSTEM 72 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06 07 14 03 Circuit diagram voltmeter optional 07 14 ill 2 06 07 14 04 Circuit diagram oil pressure gauge
72. ning switch Solas inversion switch ISO 9141 diag cable engine speed sensor not busy approach line for control solenoid Page ELECTRICAL SYSTEM 44 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06 06 09 Fitting main connector 1 properly J1 Fitting Main Connector M1 01 ONN Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 45 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 07 INSTRUMENT PANEL 01910101009 min x 100 VDO e oS 5 mm Instrument panel standard amp e A tachometer G blind plug installation option for B engine temperature key switch constant revolution C warning light battery charge H blind plug installation option for D combined light preheating control amp oil pressure gauge or warning light engine oil pressure voltmeter 12V E warning light check engine audible warner F ignition key lock installed to rear side of paneel Page ELECTRICAL SYSTEM 46 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06 07 01 Chart Operating Status Instrument indication during normal operation 1 ignition ON until engine start light indication on 07 01 ill 1 2 ignition ON until engine start light indication on ON 0 7 sec Q
73. on Wiring harness instrument panels 4 6 cyl marine engines curent VEISION MEME Won HS 62 2001019 0 6 July 2008 Page ELECTRICAL SYSTEM 1 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 07 13 06 07 13 01 06 07 14 06 07 14 01 06 07 14 02 06 07 14 03 06 07 14 04 06 08 01 06 08 02 06 08 03 06 10 06 10 01 06 10 02 06 10 03 06 10 04 06 10 04 01 06 10 04 02 06 10 04 03 06 10 04 04 06 10 04 05 06 10 04 06 06 10 04 07 06 10 05 06 10 05 01 06 10 05 02 06 10 05 03 06 10 05 04 06 10 05 05 06 10 05 06 06 10 05 07 06 10 05 08 06 12 06 12 01 AULUSEINSIHUMENIS aussen ei 68 Tachometer with running time meter er ee 68 instruments nie 70 General notes on 70 Audible warner KE 72 Circuit diagram voltmeter Optional 73 Circuit diagram oil pressure gauge optional sensor B19 gauge P2 73 Potentiometer accelerator B13 74 Voltage regulator 24V 12V 75 in e To 76 Sender E inne 78 Component configuration 4 cyl engine 78 Component configuration 6 80 rack PO ict 82 Replace sender sensor ae 83 Sensor exhaust gas temperature 17
74. or signal level too high missing connection 21 LoECT X16 B16 water temp sensor signal level too low short circuit or missing contact 22 HiECT X16 B16 water temp sensor signal level too high missing connection 23 LoPed1 X13 B13 potentiometer accelerator signal level entry too low 24 HiPed1 X13 B13 potentiometer accelerator signal level entry too high 25 LoVPWR F5 K27 main relay low voltage supply to ECU F5 K27 26 HiVPWR F5 K27 main relay too high voltage on VPROT input 27 LoVREF 5 23 module connector too low voltage on sensor supply possible short circuit 28 HiVREF 5 71 module connector too high voltage on sensor supply 29 PedS X13 B13 accelerator potentiometer defect on pedal safety switch pin 1 2 31 LoLPS X18 B18 lubricant pressure sensor signal level too low short circuit or missing contact 32 HiLPS X18 B18 lubricant pressure sensor signal level too high missing connection 33 LoPed2 X13 B13 potentiometer accelerator signal level too low 34 HiPed2 X13 B13 potentiometer accelerator signal level too high missing connection 35 LoRPos X14 B14 rack position sensor signal level too low short circuit or missing contact 36 HiRPos X14 B14 rack position sensor signal level too high missing connection 37 LoLOP X18 B18 lubricant pressure sensor signal level too low short circuit 38 HiLOP X18 B18 lubricant pressure sensor signal level too high missing connection 53 N RFI X15 B15 RPM sensor radio interference sensor input
75. ow Original inclosed Connect itto ignition 24V 08 02 ill 2 manufactures recommentation Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 75 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 08 03 DC DC converter DC DC Converter IVO 8770 MASTERVOLT CIRCUIT DIAGRAM Page ELECTRICAL SYSTEM 76 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 77 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 10 CODE KURZNAME ABBREVIATION PED RPOS RPM ECT EXT LPS BESCHREIBUNG DESCRIPTION Ladedrucksensor Boost pressure sensor Gaspedal Potentiometer accelerator Regelstangensensor Rack position sensor Motordrehzahlsensor Sensor engine speed K hlfl ssigkeitstemperatursensor Sensor engine coolant temperature Abgastemperatursensor Sensor exhaust gas temperature ldrucksensor Lubricant pressure sensor 0000090 SENDER AND SENSOR OVERVIEW 06 10 01 Component configuration 4 cyl engine KURZNAME ABBREVIATION J1 DIAG FMS to engine number 48226999 10 01 ill 1 BESCHREIBUNG DESCRIPTION Stecker lmanometer Option Connector oil pressure gauge optional Stecker Trimmanzeige Option Connector trim optional Verbindungsstecker Motor EMS Connector engine cable EMS Diagnose Stecker Diagnosis
76. pole plug G1 G2 J1 K24 K26 1 K26 2 K27 K28 1 2 R10 X2 52 5 5 X12 B12 X13 B13 X14 B14 X15 B15 X16 B 16 X17 B17 X18 B18 X19 B19 0 2 35 pole plug 3 pole plug 5 pole plug 3 pole plug 3 pole plug 2 pole plug 2 pole plug 3 pole plug 1 pole plug 2 pole plug without stop 6 pole plug v2 B2 splice spot splice spot splice spot splice spot Cable numbers principal functions control unit main fuse glow plugs glow plugs permanent current modul and K27 switched current for module K27 fuel pump K24 to be provided by customer connection engine cable instrument cable fuel pump preheating load circuit preheating load circuit main circuit start gear switch module boost pressure sensor pot accelerator pot rack position engine speed sensor engine temperature sensor exhaust gas temperature sensor oil pressure sensor oil pressure gauge optional control solenoid trim sensor optional diagnosis earth connection sensor earth connection 31 on engine sensor supply 5V earth connection 31 on E box plate 15000 xx ignition positive 31100 xx Do not connect earth for sensors from ignition switch with battery negative 15012 xx 12 volt via main relay 601xx 01 Sensor signal to control unit and control unit A5 A5 and or instruments 15100 xx 5 volt supply voltage for sensors 606xx 01 Output from control unit A5 30000 xx batte
77. pos 4 10 04 ill 5 10 04 ill 6 10 04 ill 7 10 04 ill 8 Page ELECTRICAL SYSTEM 84 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 10 04 ill 9 06 10 05 Check Sensors and Switches 06 10 05 01A Check rack position feedback sensor B14 connector X14 In case of defective rack position feedback sensor B14 service codes 35 and 36 will flash NOTE First always check cables and connections 10 05 A ill 1 Final check Disassemble rack position feedback sensor from control solenoid 1 Check resistance between terminals A and C with a digital ohmmeter Resistance must be between 2 2 kOhm 10 96 10 05 A ill 2 2 Measure resistance between terminals with extended shaft Resistance must be 0 5 10 10 05 A ill 3 Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 85 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 3 Measure resistance between terminals BandC with inserted shaft Resistance must be 2 4 kOhm 10 When a failure was found during one of above checks replace rack position feedback sensor B14 10 05 A ill 4 06 10 05 01 B Check rack position feedback sensor B14 connector X14 In case of defective rack position feedback sensor B14 service codes 35 and 36 or 186 will flash NOTE First always check cables and connections 10 05 B ill 1 Final check Disassemble rack posi
78. rand end soldering of cable sockets as well as protective varnish isolation and or connector locks meet the respective requirements Tools for crimp connections to be found in tool catalog P N Z001002 0 Level 4 06 00 01 Cable numbers principal functions 15000 xx 15012 xx 15100 xx 30000 xx 30012 xx 31000 xx ignition positive 31100 xx from ignition switch 12 volt via main relay 60 1xx 01 and control unit A5 5 volt supply voltage for sensors 606 01 battery positive not secured battery positive secured battery negative GND Do not connect earth for sensors with battery negative Sensor signal to control unit 5 and or instruments Output from control unit A5 to display system tachometer temperature display Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 3 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 01 ALTERNATOR 06 01 01 Adjust poly V belt tension 4 engines only Automatic initial tension of belt tension through spring loaded tightener ill 1 and ill 2 01 01 1 1 01 01 ill 2 For 6 cyl engines only As to tension of V belt for alternator refer to chapter 05 07 01 02 Page ELECTRICAL SYSTEM 4 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06 01 02 Replace alternator Preparatory work turn off engine disconnect battery 1 Disconnect two cables
79. ry positive not secured to display system tachometer 30012 xx battery positive secured temperature display 31000 xx battery negative GND Page ELECTRICAL SYSTEM 22 Z001019 0_6 July 2008 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 01 00015 2 22 0 02 09 22 10 2109 GLX 6X 120 0001 10 8109 50 0016 10 01109 90 0011 SIN 1494 WELX 10 6209 LLI 10 02 109 8 0 00008 LC 20 00008 10 01809 3 If FO LZLO9IO LT 10 21909 20 00019 10 V1909 9 LC L0 90209 10 41916 10 91909 20 00012 10 00016 80 ZL00 40 6100 20 00061 10 00091 HIT EI O H a r vir 10 21709 LO 60rLE 0 2106 2 02 02 90 00151 10 21 109 S vIX 60 00 20 00019 Ir 20 65 21 80 2100 20 21006 90 2100 90 21 002 WEIER 2
80. s it again the pointer deflection changes downwards Atthe beginning the pointer deflection changes very slowly which permits a very precise fine adjustment With a short release of the key the procedure is repeated With a longer pressing of the key the pointer deflection will change faster Release the key as soon as the fine adjustment corresponds to the reference rpm The display then changes to counting of running time Fine adjustment is completed Fine Adjustment During normal operation of the indicator a fine adjustment is possible by using the key The adjustment range is 20 96 of the actual reading Press the key with voltage supply on On the display appears 0 0 By pressing and holding the key the adjustment factor increases in steps of 0 596 If you release the key for 2 seconds and then press it again the adjustment factor decreases in steps of 0 5 Ifthe key is not pressed for more than 5 seconds the adjustment factor will be stored and the indicator switches back to the normal running time display 07 13 ill 5 Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 69 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 07 14 REPLACE INSTRUMENTS 06 07 14 01 General notes on safety A Safety instructions No smoking No open fire lights This product has been developed produced and tested in compliance with the basic safety requirements of EC directives and in accordance with the establi
81. shed state of the art Use our product for the intended purpose only The consequences of use of the product for other than the intended purpose may be personal injury and damage to property as well as environmental damage The unit is designed for use in sports boats Record data of other instruments with transient electronic memories Please note during installation The product should be installed by your boatyard or by a person specialised in the installation of such devices If you wish to carry out installation yourself wear suitable working clothing Do not wear loose fitting clothing This may be caught by moving parts If you have long hair wear a hair net When working on electric equipment do not wear any metallic or conductive jewellery such as chains bracelets rings etc Before beginning work disconnect the negative pole of the battery since otherwise there is a risk of a short ciruit Short circuits can cause cable fires battery explosions and damage to other electronic storage systems Please note that when the battery is disconnected all transient electronic memories lose the values entered and have to be reprogrammed With petrol engines allow the engine compartment fan to run before beginning work in the engine compartment At the installation site make sure there is sufficient space behind drilled holes or the installation aperture First drill small holes at the installation apertures and enlarge if necessary u
82. sing tapered drills compass saws fretsaws of files Deburr edges The safety instructions of the hand tool manufacturer must be observed If work has to be carried out without interruptions in voltage only insulated tools may be used The electrical outputs of the display unit and the connected cables must be protected from direct contact and damage To this end the cables used must have adequate insulation and or dielectric strenght and the contacts must be shockproof The electrical conductive parts of the connected consumers must also be protected from direct contact by suitable means The installation of bare metal cables and contacts is forbidden After installation please note Clamp the earthing cable firmly to the negative pole of the battery Enter program the values of the transient electronic memories again Test all functions Page ELECTRICAL SYSTEM 70 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM A Safety Instructions electrical connection To install the electric cables use existing cable ducts and looms but do not run the cables paralle to ignition cables or parallel to cables leading powerful consumers Secure the cables using cable binders or adhesive tape Do not run the cables over moving parts Ensure that the cables are not exposed to any tensile compressive or shear forces If the cables have to be run through drilled holes protect the cables using grommets or rubber bushi
83. start trim optional alternator B 24V DC ifused CAN high blind plug blind plug Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 43 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 06 08 Connection A5 and X5 30012 01 31000 06 15100 01 Vref free free 06 08 ill 1 Explication terminal 30 terminal 31 45V not busy not busy 60616 01 31555 01 60613 01 60114 01 60117 01 GPL GPR Tacho ECT LPS oil pressure lamp L3 preheating relay speed instrument engine coolant temperature sensor oil pressure sensor 60112 01 60111 01 50000 01 60122 01 60900 01 RPOS PED1 CRI CLS CANH pot rack position pedal 1 start signal identification gear switch canbus high 60901 01 15012 01 15012 02 15000 03 31100 01 CANL VPROT2 VPROT IGN Vref canbus low direct supply line to control solenoid protected 12V after K27 and protective wiring in governor ignition terminal 15 sensor ground connection free 31554 01 60810 01 31558 01 31615 01 free not busy fuel pump relay check engine lamp main relay K27 warning horn 60614 01 60118 01 60110 01 60706 01 60116 01 temperature display exhaust gas water temperature boost pressure sensor fixed speed pedal 2 60123 01 60808 01 60113 01 31409 01 war
84. tion feedback sensor from control solenoid 1 Supply terminals A minus and C plus with 5 0V DC 1 10 05 B ill 2 2 Sensor extended Measure between terminal A minus and B signal out Measured voltage must be 4 8V DC 5 10 05 B ill 3 Page ELECTRICAL SYSTEM 86 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 3 Sensor retracted Measure between terminal A minus andB signal out Measured votage must 0 12V DC 5 When a failure was found during one of above checks replace rack position feedback sensor B14 06 10 05 02 Check throttle potentiometer B13 accelerator connector X13 In case of defective potentiometer accelerator B13 service codes 23 24 or 29 will flash NOTE First check cables and connections Resistance between terminals 5 and 4 1 2 Resistance between terminals 5 and 2 2 2 kOhm for normal position of potentiometer accelerator 1 4 kOhm at full speed max impact Resistance between terminals 3 and 1 1 2 kOhm With approx 10 of max first route resistance value must increase infinetely high gt disconnection 10 05 B ill 4 10 05 ill 5 10 05 ill 6 2001019 0 6 July 2008 Page ELECTRICAL SYSTEM 87 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 10 05 03 Check boost pressure sensor B12 for engine models 94 114 144 126 166 236 24
85. to eng no 482 17 000 22 E box base plate from eng no 482 18 000 682 18 000 SOLAS 28 Components of E box een 29 Connection start assist relay K28 and 26 2 29 Connection relay socket for K24 K26 1 and 27 29 Wiring harness from eng no 482 18 000 682 18 000 SOLAS 30 Electronics general nenn 36 Electronic Engine Management System 36 SY E 37 Reading error 38 Idication amp cancellation of memorized sensor and circuit faults 39 Principle failure 40 Replace fuses nes ea ee 42 ep epe 43 Connection A Sand 6o TM 44 Fitting main connector J1 45 Instrument Panel una 46 Chart operating status normal 47 Chart error indication on instrument nenn 48 Instrument panel for SOLAS only nenne 52 Chart operating status normal operation for SOLAS only 53 Chart error indication on instrument panel for SOLAS only 54 6 Cyl Wiring harness instrument panel if alternator PRESTOLITE is Sed old Versi WEM 58 Descripti
86. urn off ignition key was released starter relay K28 actuating relay immediately disconnect battery on starter defective check key and or relay evenutally short circuit in wiring cable No replace check wiring 50000 xx connected to 12V in case of longer running time gt replace starter 2001019 0 6 July 2008 Page ELECTRICAL SYSTEM 17 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES THIS PAGE IS INTENTIONALLY BLANK Page ELECTRICAL SYSTEM 18 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06 05 CABLES WIRING HARNESS GENERAL Cable wiring In case of necessary repair of a cable connection take special care that cable quality isolation crimping strand end soldering of cable sockets as well as protective varnish isolation and or connector locks meet the respective requirements Tools for crimp connections to be found in tool catalog P N Z001002 0 KIT 3 06 05 01 Battery cable lengths and cross sections Determine the lenght of the positive cable from the positive pole of the battery to connection No 30 the starter Total lenght is the sum of cable length of positive cable and earth cable For example positive cable 3 0 m ground cable 2 0 m Total length 5 0 gt cable cross section 70 mm For ground connection determine corresponding cross sections as per chart For A engines only starter engine 2 kW 12 volt
87. zo 10 10 0 10 ot vio 989 9 9 018 20 60 999 Did 856 20 000 799 og om 09 09 si D e 3i n of 8l Ie 1 1nOM 94 Du Du 149 1309 Udo 1 un Ivan i Js 92 Je I 74 s v ya Ur ie lu i Je i 20 00609 T 20 00016 Se 1 T H 20 00019 YALYVLS m 9M T TI 10 90709 2 1 v vru l TT Tor 1 4 States Ge SERT Tess 10 71909 Ed i OZA Yom a mee eee d piousjos 20 10019 Boom wi 2 ES er aw 10 0001 key H Aejay peo Wed duind nd ues Bune u id Buneeyaig 10 02109 d nn 0 0000S oir Ss c0 10996 DIH L0 9 909 d VW 10 01809 80 21006 20 21008 HIH 20 0005 10 0009 SS3NLIHOSIT HLIM NOILVAONNI AALS Live 1002 1oJ q 547 84 VOL 43 V 0L 94 V 0L Sd VS bi V 09 24 V 09 d V 09 14 tg sues AG sues G uelis Svid 103009 sues GL yeg yeg NOILdO 2 9 Wei 05 03 ill 6 Page ELECTRICAL SYSTEM 33 y 2008 Z001019 0 6 Jul SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 8110 0 20 0 05 64 12

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