Workshop Manual: Group 30 A

Workshop Manual A
Group 30 2(0)

D2-55, D2-75
Content
General Information
00-0 General ................................................................................................ 2
Specifications
03-3 Specifications, Electrical ................................................................... 3
Electrical System ........................................................................................ 3
Special tools
08-2 Special Service Tools ......................................................................... 4
General, Complete Vehicle Software

30-0 General ................................................................................................ 5
30-2 Fault Tracing ..................................................................................... 26
General ....................................................................................................... 26
Fault Codes ............................................................................................... 27
Cables and fuses

37-0 Wiring Diagrams ............................................................................... 52
Alphabetical index .................................................................................... 63
References to Service Bulletins .............................................................. 65
47704390 06-2013 © AB VOLVO PENTA 1

00-0 General
About this Workshop manual
General information Certified engines
This Service Manual contains technical data, descrip- When carrying out service and repair on emis-
tions and maintenance and repair instructions for sion-certified engines, it is important to be aware
standard model Volvo Penta products. A list of these of the following:
products may be found in the section Specifica-
tions. Certification means that an engine type has been
inspected and approved by the relevant authority.
The product designation and the serial number and The engine manufacturer guarantees that all engines
specification is indicated on the engine decal or type of the same type are manufactured to correspond to
plate. This information must be included in all corre- the certified engine.
spondence regarding the product. This places special demands on service and repair
work, namely:
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified person- • Maintenance and service intervals recom-
nel. It is assumed that any person using the Service mended by Volvo Penta must be complied with.
Manual has a fundamental knowledge of the product • Only spare parts approved by Volvo Penta may
and is able to carry out mechanical and electrical be used.
work to trade standard.
• Service on injection pumps, pump settings and
Volvo Penta continually develops its products; we injectors must always be carried out by an
therefore reserve the right to make changes. All infor- authorized Volvo Penta workshop.
mation in this manual is based on product data which
• The engine must not be converted or modified,
was available up to the date on which the manual was
except with accessories and service kits which
printed. New working methods and significant
Volvo Penta has approved for the engine.
changes introduced to the product after this date are
communicated in the form of Service bulletins. • No changes to the exhaust pipe and engine air
inlet duct installations may be made.
Spare Parts
• No warranty seals (where present on the prod-
Spare parts for the electrical and fuel systems are uct) may be broken by unauthorized persons.
subject to various national safety standards. Volvo
Penta Original Spare Parts meet these standards. No The general instructions in the Operator's Manual
damage of any kind caused by the use of spare parts concerning operation, service and maintenance
not approved by Volvo Penta will be compensated by apply.
any warranty undertaking.
IMPORTANT!
Neglected or poorly-performed care/service and the
use of spare parts not approved by Volvo Penta, will
mean that AB Volvo Penta no longer guarantees that
the engine conforms to the certified model.
Volvo Penta accepts no responsibility for damage or

costs arising as a result of failure to follow the above
mentioned standards.
2 47704390 06-2013 © AB VOLVO PENTA

03-3 Specifications, Electrical
03-3 Specifications, Electrical
Electrical System
Group 30: Electrical System
System voltage 12 V
Fuses 15 A
Battery capacity (starter battery) 88 Ah
Glowplugs
rated voltage 10.5 V
current 6.9 A
Alternator
Output voltage at +20°C (68°F)
With sensor 14.2 ±0.15 V
Without sensor 14.2 ±0.30 V
Max. current 115 A

Power, approx. 1,630 W
Suppression capacitor 2.2 μF
Starter motor
Power, approx. 2.0 kW
47704390 06-2013 © AB VOLVO PENTA 3

08-2 Special Service Tools
08-2 Special Service Tools

The following special tools are used when working on
the engine. The tools can be ordered from AB Volvo
Penta by specifying the number indicated.
p0005125
p0005128
9998699 Break-out box 88890016 Break-out cable 88890074 Multimeter
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30-0 General
30-0 General
Repair Instructions
General advice
The following advice must be followed to avoid dam-
age to the MDI unit and other electronics.
IMPORTANT!
The system must be disconnected from system volt-
age (by switching off the current at the main switch)
when the MDI connector is removed or reconnected.
Never switch off the current at the main switch when
the engine is running. Never disconnect a battery cable
when the engine is running.
Switch off the main switches or disconnect the battery
cables when fast-charging the batteries.
NOTICE! It is not necessary to switch off the main

switches during normal maintenance charging.
Only batteries may be used for starting. A jumpstart

unit is able to supply very high voltage and damage the
control unit and other electronics.
Take extreme care so that the harness terminals do
not come into contact with oil, water or dirt if a connec-
tor is removed from a sensor.
47704390 06-2013 © AB VOLVO PENTA 5

30-0 General
Fault tracing of cables and connectors
Tools:
88890074 Multimeter
Check all connectors visually Open circuit

Look for the following: Possible fault causes can be defective or chafed
cables or loose connectors.
• Look for oxidation which can impair contact in
Use the wiring diagram to check the cables that are
connectors.
relevant to the function. Begin with the most probable
• Check that terminals are undamaged, that they cable in the circuit.
are correctly inserted into their connectors, and
that the cable is correctly terminated in the ter- Look for the following:
minal. • Disconnect the relevant connector at both ends
• If possible, shake the cables and pull the con- of the harness.
nectors during measurement to discover • Use 88890074 Multimeter to measure the resist-
whether the cable harness is damaged. ance between the cable ends.
• Check that the cables are not damaged. Avoid Nominal value ~ 0 Ω.
clamping cables in tight bends close to the con- • If possible, shake the cables and pull on the
nector. connectors during test measurements to deter-
mine whether the harness is damaged.
Contact problems
Intermittent contact or occasional recurrent faults can • Check the next cable system in the wiring dia-
be difficult to trace and are often caused by oxidation, gram if no fault is found.
vibration or poorly connected cables.
Electrical Welding
Wear can also cause problems. For this reason, avoid
disconnecting a connector unless necessary. Remove the positive and negative cables from the
Other contact problems can be caused by damage to batteries. Then disconnect all connections to the alter-
pins, sleeves and connectors etc. nator, starter motor and the MDI.
Shake the cables and pull on the connector during test Connect the welder ground clamp to the component
measurements to find where the cable is damaged. to be welded, or as close as possible to the weld site.
The clamp must never be connected to the engine or
Contact resistance and oxidation in such a way that current can pass through a bearing.
The resistance in connectors, wiring and splitters
must be approx 0 Ω. However, there is always a cer- IMPORTANT!
tain resistance in connectors due to oxidation. When welding is finished the alternator cables must
However, if the resistance is too high problems will be reconnected before the battery cables are con-
occur. The amount of resistance that can be tolerated nected.
before a fault occurs varies depending on circuit load.
Starter motor
Starter motor fault tracing must be assigned to an
authorized marine electrical workshop with the nec-
essary test equipment.
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30-0 General
Fault finding glow plugs
Tools:
88890074 Multimeter
4 1 Remove both battery cables.
3 5
1 2 2 Remove the glow plug bus bar.
3 Measure the resistance between each glow plug
and the engine block with an ohmmeter. The
resistance must be 1.6 ± 0.16 Ω. If the meter
6 shows 0 the glow plug has a short circuit and must
8 be replaced with a new one.
7
P0008365
Replacing glow plugs
1 Glow element
1 Remove both battery cables.
2 Jacket
2 Wash clean around the glow plugs.
3 Seal
3 Remove the cable to the glow plug bus bar.
4 Sleeve
5 Nut 4 Remove the bus bar and unscrew the glow plug.
6 Magnesium oxide 5 Install the new glow plug. For tightening torque,
7 Insulation
refer to 03-2, Tightening torques.
8 Core 6 Reinstall the bus bar and connect the electrical

cable. Install the battery cables.
47704390 06-2013 © AB VOLVO PENTA 7

30-0 General
Charging system fault tracing

The engines are equipped with a rectified three-phase
delta-coupled 14V/60A (840W) alternator.
The alternator type designation can be found on a plate

on the rear of the alternator.
Checks and overhauling

Before disassembly of the alternator is begun, battery
circuit fault tracing must be performed in order to elim-
inate other possible faults. Testing should be per-
formed with the alternator “hot”. Run the engine at
2,000 rpm for about 3 minutes before measuring.
IMPORTANT!
The alternator, voltage regulator and battery circuit
connections must be connected and may not be dis-
connected with the engine running. Check carefully
that the measuring instrument is set to voltage meas-
urement (“V”) to avoid a short circuit between the alter-
nator connections.
WARNING!
Be extremely careful so that the measurement cables,
clothes or similar do not come into contact with the
drive beltor pulleys on the engine or alternator when
the engine is running.
Check the tension of the alternator belt and the belt

condition. Replace the belt if it is cracked, worn or oily.
Adjust belt tension as required. It should be possible
to depress the belt approx. 10 mm (0.4") between the
pulleys.
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30-0 General
Battery circuit fault tracing
Tools:
88890074 Multimeter
Note that other instruments may use different symbols

for the measurement function set.
1 Wash the battery with lukewarm water and wipe
clean. Remove the battery cables and clean the
terminals.
2 Connect the positive terminal (+) again.
3 Turn off the keyswitch or disconnect power to the
instrument panel and all other consumers con-
nected to the starting battery.
4 Set the multimeter for DC current measurement
(+20A). Connect the multimeter between the bat-
tery negative terminal (–) and the negative cable.
The current loss may not exceed 0.1 A with the
keyswitch or instrument panel disconnected.
If the current loss is greater than 0.1 A:
Check that no short circuits or leakage occurs at
any of the connection points. Leakage can occur
through dirty or salt-encrusted electrical compo-
nents.
Clean and check all connection points.
If the current loss is less than 0.1 A:
Check the charge status of the battery.
47704390 06-2013 © AB VOLVO PENTA 9

30-0 General
Check battery voltage
Tools:
88890074 Multimeter
General
If battery voltage falls below 12.4 V*, the starter motor
will not be able to crank the engine at normal speed.
A fully-charged battery has a voltage on an open circuit
of around 12.7 V (depending on ambient temperature).
When open circuit voltage falls to 12.5 V, the battery is
half charged.
NOTICE! * Measured at the batteries.
Voltage measurement, check

1 Check that battery voltage is at least 12.4 V when
the batteries are not under load by using
88890074 Multimeter to measure between the
battery terminals.
NOTICE! * Measured at the batteries.

2 Turn the main switch on.
P0008397
3 Check that the voltage between the terminals B+

and B– on the starter motor is the same as the
battery voltage.
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30-0 General
Charge status checks

Check the charge status with an acid hydrometer.
Measure the acid specific gravity in all cells at +25° C.
Measurement shall not be done immediately after
charging or filling with battery water.
The acid specific gravity of a fully charged battery at

+25°C (77°F) must be 1.28 g/cm3. Charge the battery
if acid density is lower than 1.24 g/cm3 (approx. 75 %
charged). Charge at 5-6A for 10 hours.
WARNING!
Explosion hazard. Batteries contain and give off an
explosive gas which is highly flammable and explosive.
A short circuit, open flame or spark could cause a vio-
lent explosion. Ventilate well.
Check 2 hours after charging

If the acid specific gravity of the cells is uneven, a cell
is probably short circuited. Replace the battery if the
difference between cells is 0.04 g/cm3 or more (i.e.
1.28 – 1.24 cm3).
If the acid specific gravity between cells is even, then

the battery is not fully charged.
Sulfated battery. Minor battery sulfating can be broken

down by an additional 10 hour charging.
Replace the battery if this does not help.
Load testing the battery

The battery acid specific gravity may not be less than
1.21 g/cm3.
1 Connect a voltmeter across the battery terminals.
2 Activate the stop function and run the starter
motor for about 10 seconds with the glow plugs
activated and read off the start voltage. It may not
be less than 9.5 V.
3 Check if any of the cells bubble when the starter
motor is operated (short-circuited cell).
4 If the voltage is less than 9.5 V or if any of the
cells bubble:
Change the battery and try again.
If the voltage is 9.5 V or higher:
The battery is fault free. Check the charging volt-
age (see next paragraph).
47704390 06-2013 © AB VOLVO PENTA 11

30-0 General
Checking the battery leads

Set the multimeter to voltage test and connect it across
the battery positive and negative terminals. Run the
engine at 2,000 rpm. Read off and note the voltage
across the battery terminals.
If the alternator delivers approx. 14.0 V carry out the

following test:
1 Connect the multimeter between the alternator
connections B+ and B-.
2 Run the engine at 2,000 rpm. The alternator must
deliver 14.0-14.4 V. The total voltage drop may
not exceed 0.4 V.
Voltage drop less than 0.2 V:

Battery leads fault free.
Voltage drop more than 0.3 V:

Perform a battery lead check.
The alternator supplies more than 14.4 V:

See sections “Alternator checks and fault tracing”, and
“Regulator checks”.
Positive (+) battery lead checks

connections B+ and the battery positive terminal.
2 Run the engine at 2,000 rpm. The voltage drop
may not exceed 0.2 V. If the voltage drop exceeds
this, the battery lead connections must be rem-
edied according to “Actions” below. Then perform
tests according to “Negative battery lead checks”.
Negative (-) battery lead checks

connections B- and battery negative terminal (–).
2 Run the engine at 2,000 rpm. The voltage drop
must not exceed 0.2 V. If the voltage drop
exceeds this, the battery lead connections must
be remedied according to “Actions”.
Actions
CAUTION!
Disconnect power and remove both battery cables
before working on the charging circuit.
If the voltage drop in any of the above tests exceeded

0.2 V , the battery lead connections must be removed
and cleaned from oxide etc. Then spray the connec-
tions with a water displacement contact oil and tighten
the connections once more.
Treat the connections at the battery, main switch,
starter motor, alternator, glow plug relay and glow
plugs.
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30-0 General
Check the charging system
Tools:
88890074 Multimeter
General alternator information Charging system fault tracing

Alternator voltage must be limited to prevent battery Battery (orange indication):
electrolyte from evaporating. Alternator output is con-
trolled (limited) by the voltage regulator in the alter- 1 Check that all battery connections are properly
nator. The maximum current that the alternator can installed.
deliver with a controlled output depends on alternator 2 Check the cables to the battery.
rpm. In order for the alternator to charge efficiently a
sensor line may be connected between the alternator 3 Check the battery electrolyte level.
and the battery plus terminal. A voltage drop in the 4 If possible, check the specific gravity in all cells.
cable between the alternator and the battery plus ter-
minal is compensated in this way. When the engine is No charge:
started a magnetization current is required to excite
1 Check the tension of the alternator drive belts.
the alternator.
NOTICE! It is power consumers (including the batter- 2 Check that the alternator and battery connectors
ies) that determine output current from the alternator. are correctly installed.
Measurements: 3 Check the condition of all charging system
cables.
1 Engine switched OFF.
4 Check that the alternator is receiving the correct
2 Use 88890074 Multimeter to perform a voltage
magnetization voltage.
test across the batteries. The nominal voltage
across a fully-charged battery is around 12.7 V 5 Regulator fault; check with another alternator.
(depending on ambient temperature).
Charge too low:
3 Start the engine. Run at 1,500 rpm.
1 Check the tension of the alternator drive belts.
4 Use 88890074 Multimeter to perform a voltage
test across the batteries. The nominal charge 2 Check that the alternator and battery connectors
voltage across the battery should be around are correctly installed.
13.8-14.6 V. 3 Check the condition of all charging system
cables.
4 Regulator fault; check with another alternator.
Over charge:
1 Possible regulator fault; check with another
alternator.
47704390 06-2013 © AB VOLVO PENTA 13

30-0 General
MDI gauge checks
Tools:
88890074 Multimeter
The gauges are of Easy-Link type and receive their

signals via a serial bus. The instrument cables com-
prise three wires: battery positive, battery negative and
a databus.
If a fault occurs in the instrument Easy Link bus, it can
PR
EHE
AT
be detected by the gauge needles stopping in the
same position on the instruments (they “freeze”). If
T
AR
ST
TT
none of the gauges function, check using

BA
88890074 Multimeter that there is +12 V between the

red (pin 1) and blue (pin 2) wires in the Easy link har-
ness.
P0008396
Since shared signals from various types of gauges

pass through the same cable, it is difficult to determine
whether information is lacking from the serial bus, or if
an individual gauge is faulty. If an instrument fault is
suspected, use the following procedure to determine
whether the gauges are faulty or not.
1 Start the engine and let it idle with the control lever
in the neutral position.
2 Disconnect the gauge that is suspected of being
faulty.
3 The fault disappears
- Check that there is no oxide or moisture in
the connectors to the gauge concerned.
- Change the disconnected gauge and check
if the fault is still absent when the new gauge
is connected.
The fault remains

Continue to disconnect gauges until gauge dis-
plays are correct. Then attempt to connect the
gauges again. Begin with the gauge that was dis-
connected first and continue to connect the
gauges that were disconnected until the indication
is no longer shown. Change the gauge connected
last.
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30-0 General
Alternator
Alternator checks and fault tracing

1 Remove the alternator electrical connections and
the alternator drive belt. Remove the alternator.
2 Undo the voltage regulator connection at the
alternator connection. B+. Unplug the blade con-
nectors at connections B+ and D+. Remove the
protective cover from the W connection.
3 Prise the plastic cover attachment lugs from side
to side off of the alternator. Undo the regulator's
connection cables to the diode bridge. Use flat
pliers or poke the cable shoes out with a screw-
driver. Do not pull on the cables!
P0007942
Changing alternator brushes

Unscrew the voltage regulator. Unscrew the brush
holder. Check the length of the brushes. Change the
brushes if they are 5 mm (0.2") or shorter. The brush
and holder are replaced as a unit. Unsolder the con-
nection cables and solder on the new ones with acid-
free solder.
Rotor winding checks

Once the regulator and brushes have been removed,
it is possible to measure the resistance of the rotor
windings.
Set the meter to position Ω. Make sure the measuring

probe has good contact with between the slip rings.
Rotor resistance must be 3.0 - 5.0 Ω.
Also check for grounding faults by measuring between

the slip rings and ground.
Removing the diode bridge

In order to check the diode bridge and stator windings,
the diode bridge should be removed.
Unsolder the three stator windings. Do not use too

much heat as this can damage the diodes. Undo the
nuts (note how the nuts and washers are fitted).
Checking the diode bridge

Set the multimeter to position “Diode test”. Make cer-
tain that you have good probe contact for all measure-
ments.
47704390 06-2013 © AB VOLVO PENTA 15

30-0 General
Checking B+ diodes
1 Connect the multimeter positive probe to one of
the stator winding connections (1-2-3). Then con-
nect the instrument negative probe to the diode
plate B+ connection. Read off the instrument. A
normal value should be between 450 and 650
mV, which is the voltage drop across the diode.
Any other value indicates a faulty diode. 2. 3.
2 Check the other B+ diodes by moving the positive
probe to the other connections (1-2-3).
3 Then check the B+ diodes in the opposite direc-
tion by reversing the positive and negative
probes. Perform the same measurements as
above. In this measurement the instrument
should display a one “1” (furthest to the left). Any
other instrument value indicates a faulty diode.
Checking B- diodes
1 Connect the instrument positive probe to the
diode plate B- connection and the instrument
negative probe to one of the stator winding con-
nections (1-2-3).
2 Read off the instrument as previously. A normal
value should be between 450 and 650 mV. Any
other value indicates a faulty diode.
3 Then check the B- diodes in the opposite direction
by reversing the positive and negative probes.
Perform the same measurements as above. In
this measurement the instrument should display
a one “1” (furthest to the left). Any other instru-
ment value indicates a faulty diode. If any of the
diodes are faulty, the whole diode plate must be
replaced.
16 47704390 06-2013 © AB VOLVO PENTA

30-0 General
Checking D+ diodes
The three diode plate magnetization diodes are
checked in the same way as above.
1 Connect the instrument positive probe to each
stator winding connection (1-2-3) and the nega-
tive probe to D+. The voltage drop for each diode
should be between 450 and 650 mV.
2 Then check the B+ diodes in the opposite direc-
tion by reversing the positive and negative
probes. Perform the same measurements as
above. In these measurements the instrument
should display a one “1” (furthest to the left). Any
other instrument value indicates a faulty diode. If
any of the diodes are faulty, the whole diode plate
must be replaced.
Checking the stator windings

Once the diode bridge is removed, the stator windings
can be measured by setting the multimeter to “buzzer
mode”.
Measure the resistance of each winding.
NOTICE! First check the internal resistance of the

measurement wires. When measurement of the stator
windings is performed, the internal resistance of the
measurement wires (i.e. 0.10Ω) must be subtracted
from the value displayed.
Measure between all winding connections (three

measurements). The resistance must be 0.10 Ω.
Also measure the alternator casting by connecting the

instrument in the Ω position. Then measure between
each winding and the casting. In this measurement the
instrument should display a one “1” (which means
infinity).
If the instrument shows any other value, the stator

winding is faulty. If any of the stator windings are faulty,
the complete stator ring must be replaced.
47704390 06-2013 © AB VOLVO PENTA 17

30-0 General
Check the alternator brushes
Removal of alternator brushes

1 Pull back the black plastic cover.
P0008398
2 Use a screwdriver to loosen the plastic cover

above the brush holders.
P0008399
3 Unscrew the two Torx screws that retain the two

brush holders.
P0008405
18 47704390 06-2013 © AB VOLVO PENTA

30-0 General
4 Pull the brushes out.
04
P0008406 8
5 Measure the length of the brushes. If a brush is

so worn that the 5 mm (0.2") limit has been
exceeded the brush must be changed.
5mm
P0008407
Installation of alternator brushes

1 Make sure that the brushes are placed as illus-
trated when installing.
P0008408
47704390 06-2013 © AB VOLVO PENTA 19

30-0 General
Starter motor
General
The starter motor is a DC series motor. The starter
pinion is operated by a control solenoid and can be slid
axially along the rotor shaft.
The starter motor is fitted with a reduction gear, which

provides a higher torque.
Removal of start motor

1 Remove both battery cables.
2 Undo the electrical connections from the starter
motor.
3 Remove the starter motor retaining bolts and lift
away the starter motor.
Disassembling the starter motor

1 Clean the outside of the starter motor.
2 Remove the solenoid.
P0008368
3 Remove the protective cover from the rear bear-

ing casing. Remove the locking ring and where
fitted, the shim(s).
4 Remove the rear bearing casing.
5 Remove the brush plate. Remove the stator
housing from the gear housing.
P0008369
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30-0 General
6 Remove the lever arm that is fitted in the gear

housing and the rotor.
P0008370
7 Remove the starter gear that is fitted in the gear

housing.
First remove the retainer ring by striking the con-
tact ring with a suitable socket.
P0008371
47704390 06-2013 © AB VOLVO PENTA 21

30-0 General
Inspecting the starter motor

Fault tracing the starter motor should be assigned to
an authorized electrical workshop with the necessary
test equipment.
1 Test the rotor with regard to winding flashover
and open circuits with the test equipment
intended for this purpose.
2 Check that the brush contact surface on the com-
mutator is even and free from dirt and oil. If the
commutator is scratched or burned it may be pol-
ished using emery paper 500 or 600. Measure the
commutator with a dial indicator. Max permissible
runout is 0.05 mm (0.002").
3 Check that the insulation is at least 0.2 mm
(0.008") below the commutator surface. Remedy
as necessary.
4 Check the straightness of the rotor. Set the rotor
up between centers and measure the runout of
the rotor frame with a dial gauge. Max runout 0.08
mm (0.003"). The runout is half of the indicated
value.
5 Check the starter gear teeth. Replace damaged
gears. Also check the ring gear if the starter gear
P0008372 is damaged.
Field windings
Check with the test instrument that there is no open
circuit in the windings. Faulty field windings must be
changed.
Assembling the starter motor

Assembly is in reverse order to disassembly. Connect
+ and - from a 12 V battery to the terminals on the sol-
enoid and check that the starter gear is thrown forward
to the gear stop.
Installing the starter motor

1 Place the starter motor in position on the flywheel
housing and fasten it.
2 Connect the electrical wiring to the starter motor.
See wiring diagram for starter motor.
3 Connect the battery cables.
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30-0 General
Alternator
Voltage regulator with sensor system
The voltage regulator on the standard alternator (14V /
60A) is equipped with a sensor system.
The sensor system compares the charge voltage

1 between the alternator terminals, B+ and B-, with the
3 voltage across the battery positive and negative termi-
4 nals. The voltage regulator then compensates for any
voltage drop in the cables between the alternator and
2 the batteries, by increasing the charge voltage sup-
plied by the alternator as necessary.
When delivered from Volvo Penta, the sensor system

6
is not activated. However, connection was probably
made out during engine installation.
Connecting the sensor system

1 Disconnect the yellow sensor wire from the B+
alternator terminal.
+ 2 Splice the wire (yellow, 1.5 mm2) and run it to the

batteries. Connect the wire to the positive battery
- terminal (+).
5
8
Charge distributor
The standard engine alternator can be fitted with a
P0008362 7
charge distributor as extra equipment. Thus two inde-
pendent battery circuits can be charged at the same
1 Sensor wire (yellow, 1.5 mm2)
time. The charge distributor separates the two circuits
2 Charge distributor (extra equip.) from each other so that the engine starting battery is
3 Alternator kept fully charged even if the service batteries are
weak or almost totally discharged.
4 Fuse panel (extra equip.)
5 Starter motor
6 Main switch
7 Auxiliary batteries (extra equip.)
8 Start battery (engine)
47704390 06-2013 © AB VOLVO PENTA 23

30-0 General
Important information - electrical system
WARNING!
Always stop the engine and break the current using the
main switches before working on the electrical system.
Isolate shore current to the engine block heater, bat-
tery charger or accessories mounted on the engine.
Main switch
Never break the circuit between the alternator and the
battery while the engine is running. In other words, the
main switch(es) must never by switched off before the
engine has stopped. If the circuit is disconnected dur-
ing operations, the voltage regulator can be destroyed
and the alternator seriously damaged.
For the same reason, the charging circuits must never

be re-connected with the engine running. For simulta-
neous charging of two independent battery circuits, a
Volvo Penta charge distributor can be fitted to the
standard alternator (accessory).
Batteries
Never transpose the positive (+) and negative (-) bat-
tery terminals when installing batteries. Such a trans-
position can result in serious damage to electrical
equipment. Refer to the wiring diagram. The battery
terminals must be kept well cleaned and the cable
shoes must always be tightened and well greased to
avoid power loss.
Fast charging of the batteries must be avoided. If fast

charging must be resorted to, the battery cables must
always be disconnected first.
NOTICE! Follow applicable safety regulations when

charging batteries. During charging, unscrew the cell
plugs but leave them in the plug holes. Ventilate well,
especially if the batteries are charged in an enclosed
space. Always switch off the charging current before
the charging clips are removed.
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the battery or batteries.
WARNING!
The battery electrolyte contains extremely corrosive
sulfuric acid. Protect your skin and clothes when charg-
ing or handling batteries.
Always use protective goggles and gloves. If battery
electrolyte comes into contact with unprotected skin
whas off immediately using plenty of water and soap.
If battery acid comes in contact with the eyes, flush
immediately with plenty of water and obtain medical
assistance without delay.
24 47704390 06-2013 © AB VOLVO PENTA

30-0 General
Electrical wiring
Never make holes in cable insulation to perform meas-
urements with probes. In a corrosive atmosphere such
as that in a boat, it only takes 2 years for a small cable
with a pin hole to corrode apart.
If it is absolutely necessary to make a hole in the insu-

lation, the hole must be sealed with a suitable adhesive
after the test.
Connection of extra equipment

All extra equipment must be connected to a separate
connection box and correctly fused. Extra power take-
offs directly from the instrument panel should be
avoided. The total permitted extra take off is however
max 5 A (applies to all instrument panels together).
Galvanic corrosion
The S-drive is insulated electrically from the engine
and must never be used as a ground.
The S-drive is insulated (B) between the adapter plate

and the upper gear housing. An insulation bush (A)
must be installed on one of the lower bolts.
P0008363
IMPORTANT!
The S-drive must never be used as a ground or

be connected electrically to any other equipment,
such as radio, navigation equipment, rudder,
bathing ladder, etc.
Electrical Welding
Remove the positive and negative cables from the bat-
teries. Then disconnect all cables connected to the
alternator.
Always connect the welder ground clamp to the com-

ponent to be welded, and as close as possible to the
weld site. The clamp must never be connected to the
engine or in such a way that current can pass through
a bearing.
IMPORTANT!
After welding is finished connect the wires to the alter-
nator before reconnecting the battery cables.
47704390 06-2013 © AB VOLVO PENTA 25

30-2 Fault Tracing
30-2 Fault Tracing
General
Fault tracing refers only to engine models with MDI.
Function fault
Symptom Action
The alarm cannot be confirmed. Refer to the "Fault on keypad" section.
Charging problems. Refer to the "Battery warning" section, or to the "Check
charging system" section.
Coolant alarm. Refer to the “Warning, coolant temperature” section.
Engine does not start (due to electrical problems). Refer to the “Warning, start / preheat” section.
Warning, fuel level. Refer to the “Warning, fuel level” section.
Glowplug(s) not activated. Refer to the “Warning, start / preheat” section.
No dimmer function. Refer to the "Fault on keypad" section.
No indication of operating hours on the tachometer / Refer to the “Multilink fault” section.
display.
No indication of engine rpm on the tachometer / display. Refer to the “Multilink fault” section.
No data from the multisensor visible in the EVC display. Refer to the “Multilink fault” section.
Oil pressure alarm. Refer to the ”Oil pressure warning (engine)” section.
If the button does not energize the system. Refer to the "Fault on keypad" section.
The starter motor is not activated. Refer to the "Warning, start / preheat" section, or to the
"Check battery" section.
The stop solenoid is not activated. Refer to the "Stop solenoid" section, or to the "Fault on
keypad" section.
Alarm display
1 Lubrication oil pressure: When oil pressure falls

below a given value at a given engine speed, the
1 2
alarm lamp is lit.
2 Battery voltage: The alarm lamp is lit if the alter-
nator is not charging or if it overcharges.
3 Coolant temperature: When coolant temperature
! exceeds the alarm limit, the alarm lamp is lit.
4 Warning indication: The ”System fault” lamp is lit
4 if there is a short circuit, wiring break or AUX fault.
3
In the case of faults that require immediate action
by the helmsman, the alarm buzzer sounds contin-
uously.
5
5 Not used.
P0008409
26 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
Fault Codes
Oil pressure (engine) warning
Tachometer
The tachometer LCD screen will show a flashing oil
pressure icon and the alarm buzzer sounds.
Alarm display
P0007945
The oil pressure indication flashes in the alarm display
+ audible warning.
Circuit description
a The oil pressure in the engine is monitored by a pres-
sure switch. The output signal from the pressure switch
b can have two distinct positions, high/low, in the same
6 BL / W 1 way as a relay output. A pre-set limit value determines
SB 2
P when the switch switches from one distinct position to
1
the other one. The switch is closed when the oil pres-
sure is low and when the engine is off. Pin 6 in the
MDI engine interface connector at the MDI provides the
P0008410 switch with a voltage signal.
a Engine connector
b Oil pressure switch
Fault tracing
Fault condition
The oil pressure switch closes at a oil pressure lower
than 60 kPa (8.7 PSI).
The alarm is depended of the engine rpm.
<1000 rpm: oil pressure switch closed for more than

30 seconds.
>1000 rpm: oil pressure switch closed for more than

0.5 seconds.
Possible reason
• Oil level too low.
• Short circuit between oil pressure switch supply
cable and battery negative.
• Faulty oil pressure switch.
Suitable action
1 Check the oil level in the engine and the oil quality.
2 Check that the oil filter is not blocked. Change oil
filter and engine oil.
3 Check that no leakage occurs.
47704390 06-2013 © AB VOLVO PENTA 27

30-2 Fault Tracing
4 Check all wiring and connectors between the oil

pressure switch and the MDI.
5 Check the switch by checking the engine oil pres-
sure (see “Checking lubrication oil pressure” in the
mechanical workshop manual for the engine).
28 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
Measurements
Check MDI input for oil pressure switch
Tools:
88890074 Multimeter
9998699 Break-out box
88890016 Break-out cable
1 NOTICE! Cut the current with the main switch.
V 2 Connect 88890016 Break-out cable with
MDI 9998699 Break-out box between the MDI and the
engine connector.
3 Use 88890074 Multimeter for voltage measure-
ment.
4 Turn the main switch on and press the on button
on the button panel.
21
16
8
9998
9
69
1
0
9
2
2
11
2
2
3
9
1
2
2
3
3
4
0
6
1
3
2
5
3
3
1
1
7
4
4
3
2
3
6
2
3
8
5
2
0
7
3
3
9
4
2
5
8
1
4
0
4
6
5
3
2
5
4
1
4
5
7
3
4
2
4
5
8
4
4
9
5
5
5
6
P0008411
Measurement points Nominal value

16 (battery negative) - 21 U≈0V
(oil pressure switch sup- (switch closed)
ply)
5 Disconnect the oil pressure switch connector at

the oil pressure switch.

16 (battery negative) - 21 U ≈ 3,5 V
(oil pressure switch sup-
ply)
6 Reconnect the oil pressure switch connector at

the oil pressure switch.
7 Start the engine. Wait a minute before measuring.

16 (battery negative) - 21 U ≈ 3,5 V
(oil pressure switch sup- (switch open)
ply)
47704390 06-2013 © AB VOLVO PENTA 29

30-2 Fault Tracing
Coolant temperature warning

Tachometer
The tachometer LCD screen will show a flashing cool-
ant temperature icon and the alarm buzzer sounds.
P0007947
Alarm display
The coolant temperature indication flashes in the alarm
display + audible warning.
Circuit description
a
The coolant temperature sensor consists of a thermis-
b tor. The property of a thermistor is that its resistance
LBN changes non-linearly with temperature in the medium
5 1 it measures. Pin 5 in the engine interface connector at
the MDI supplies the thermistor with a reference volt-
age of +5 Volt. The sensor is connected to battery
MDI negative via the engine. When the engine coolant is
P0008412 cold, the sensor resistance is high and the MDI senses
a voltage close to the reference level. When the cool-
a Engine connector ant heats up, the resistance in the thermistor falls and
b Coolant Temperature
the voltage drop across the thermistor changes.
30 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
Fault tracing
Fault condition
Coolant temperature exceeds +110 °C (+230 °F) for
more than 15 seconds.
Possible reason
• Low coolant level.
• Blocked sea water filter or sea water intake.
• Worn impeller in seawater pump.
• Kinked/leaking/blocked hose on the suction side
(sea water).
• Slipping or broken drive belt for circulation pump.
• Defective thermostat.
• Incorrect pressure cap on expansion tank.
• Fault in the coolant temperature sensor cable
between the MDI and the sensor.
• Faulty coolant temperature sensor.
• Blocked heat exchanger.
• Poor flow through the cooling system due to worn
coolant pump/seawater pump.
Suitable action
1 Check the coolant level.
2 Check that the system does not leak.
3 Check the drive belt tension for the coolant pump.
4 Check that the seawater intake is not blocked.
5 Check the impeller in the sea water pump.
6 Change the thermostat.
7 Check the pressure cap on the expansion tank. See
“Checking the pressure valve in the filler cap” in the
mechanical workshop manual for the engine.
8 Check the cables and the connectors between the
engine connector at the MDI and the coolant tem-
perature sensor.
9 Check the sensor.
10 Clean the heat exchanger. See “Clean the heat
exchanger” in the mechanical workshop manual for
the engine.
11 Change coolant pump / seawater pump.
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30-2 Fault Tracing
Measurements
Check MDI output for coolant temperature sensor
Tools:
88890074 Multimeter
V 2 Connect 88890016 Break-out cable with
MDI 9998699 Break-out box between MDI and the
engine connector.
ment.
4 Disconnect the coolant temperature sensor con-
nector at the coolant temperature sensor.
20
16
8
9998
9
699
1
0
2
2
11
2
2
3
9
1
2
2
3
3
4
0
6
1
3
2
5
3
3
1
1
7
4
4
3
2
3
6
2
3
8
5
2
0
7
3
3
9
4
2
5
8
1
4
0
4
6
5
3
2
5
4
1
4
5
7
3
4
2
4
5
8
4
4
9
5
5
5
6
P0008413

16 (battery negative) - 20 U≈5V
(coolant temperature)
6 Reconnect the coolant temperature sensor con-

nector at the coolant temperature sensor.

16 (battery negative) - 21 U ≈ 2–3 V at +20°C
(coolant temperature sen- (+68°F)
sor)
32 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
Checking the coolant temperature sensor
Tools:
88890074 Multimeter
2 Connect adapter cable 88890016 Break-out
MDI cable with 9998699 Break-out box and with the
engine connector. Do not connect the MDI.
3 Use 88890074 Multimeter for resistance meas-
urement.
NOTICE! All resistance values shall be seen as guide

line values.

20
16 - 20 R ≈ 1743 Ω at 0°C
16
16 - 20 R ≈ 1076 Ω at 10°C
16 - 20 R ≈ 677 Ω at 20°C
16 - 20 R ≈ 439 Ω at 30°C
16 - 20 R ≈ 291 Ω at 40°C
8
9998
9
699
1
0
2
2
11
16 - 20 R ≈ 197 Ω at 50°C
2
2
3
9
1
2
2
3
3
4
0
6
1
3
2
5
3
3
1
1
7
4
4
3
2
3
6
2
3
8
5
2
0
7
3
3
9
4
2
5
16 - 20 R ≈ 134 Ω at 60°C
3
8
1
4
0
4
6
5
3
2
5
4
1
4
5
7
3
4
2
4
5
8
4
4
9
5
5
16 - 20 R ≈ 97 Ω at 70°C
6
P0008414 16 - 20 R ≈ 70 Ω at 80°C
16 - 20 R ≈ 51 Ω at 90°C
16 - 20 R ≈ 38 Ω at 100°C
16 - 20 R ≈ 29 Ω at 110°C
16 - 20 R ≈ 22 Ω at 120°C
47704390 06-2013 © AB VOLVO PENTA 33

30-2 Fault Tracing
Multilink fault
Tachometer
No revolution speed is shown in the tachometer/
display. Engine hours might not be visible in the tach-
ometer / display.
P0007948
Alarm display
None.
Symptom
The button panel will function as normal.
a Circuit description
b The tachometer and the display recieves information
6 BL / W 1 from the MDI via the multilink bus. Connected to the
SB 2
P multilink is also, if they are used, the multisensor and
1
the NMEA interface . The multilink contains of two pairs
of CAN communiction wires and supply voltage. To be
MDI able to present engine revolution a flywheel sensor is
P0008421 used. The flywheel sensor is an inductive sensor. The
MDI uses the sensor signal to calculate the flywheel
a Engine connector speed which presents in the tachometer. The flywheel
b Flywheel sensor input in the MDI is at pin 2 and pin 3 in the engine
interface connector.
a A CAN L
B CAN L
b
Y / GR C CAN H
1 1 A
2 Y / GR 2 B
Y/W D Power supply negative
3 3 C
4 SB 4 D
Y/W E CAN H
5 5 E
6 R 6 F F Power supply positive
MDI
P0008422
a Engine connector
b Connector, multilink
34 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
Fault tracing
Fault condition 1
The tachometer shows engine hours but not engine
revolution due to that no flywheel speed signal is avail-
able.
Possible reason
• Fault in the flywheel sensor cable between the MDI
and the sensor.
• Incorrectly mounted sensor (incorrect distance to
flywheel, or loose sensor).
• Electrical interference on engine speed signal.
• Faulty flywheel sensor.
• Damaged flywheel.
Suitable action
1 Check the cables and the connectors between the
engine connector at the MDI and the flywheel sen-
sor.
2 Check that the flywheel sensor is correctly installed
and that no swarf has collected on the sensor.
3 Check the function of the flywheel sensor.
Fault condition 2
The tachometer and/or the display shows neither
engine hours nor engine revolution and easy link
instruments does not work. If fault in multilink CAN
communication the display shows “Connection lost”.
Possible reason
• Open circuit in multilink bus or multilink supply.
• Short circuit in multilink bus or multilink supply.
• Faulty tachometer/optional equipment such as dis-
play, NMEA interface, multi sensor.
Suitable action
1 Check multlink bus and connectors between the
multlink connector at the MDI and all connected
optional equipment such as display, NMEA inter-
face, multi sensor.
2 Try with another tachometer/optional equipment.
47704390 06-2013 © AB VOLVO PENTA 35

30-2 Fault Tracing
Measurements
Check speed sensor, flywheel
Tools:
88890074 Multimeter
Check 1
2 Connect 88890016 Break-out cable with
MDI 9998699 Break-out box between MDI and engine
connector. Do not connect the MDI.
3 Use 88890074 Multimeter for resistance meas-
urement.
18
17
8
9998
9
699
1
0
2
2
11
2
2
3
9
1
2
2
3
3
4
0
6
1
3
2
5
3
3
1
1
7
4
4
3
2
3
6
2
3
8
5
2
0
7
3
3
9
4
2
5
8
1
4
0
4
6
5
3
2
5
4
1
4
5
7
3
4
2
4
5
8
4
4
9
5
5
5
6
P0008423

17 - 18 R ≈ 0,9 kΩ
36 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
4 Remove the sensor from the flywheel casing.

V Check that the sensor has no external damage
MDI
and that no metal chips are stuck on the sensor.
5 Use 88890074 Multimeter for a AC voltage meas-
urement.
6 Move a metal object rapidly back and forwards
not more than 1 mm (0.039") in front of the sen-
sor. Check that the multimeter gives a reading.
7 Install the sensor.
18
17
8
9998
9
699
1
0
2
2
11
2
2
3
9
1
2
2
3
3
4
0
6
1
3
2
5
3
3
1
1
7
4
4
3
2
3
6
2
3
8
5
2
0
7
3
3
9
4
2
5
8
1
4
0
4
6
5
3
2
5
4
1
4
5
7
3
4
2
4
5
8
4
4
9
5
5
5
6
P0008424
47704390 06-2013 © AB VOLVO PENTA 37

30-2 Fault Tracing
Checking NMEA 2000 Gateway LED

There are two light emitting diodes on the interface.
One is lit when the NMEA bus has power supply. The
other has different lighting options.
Constant lit
The unit is powered up but receives no communication
from any side.
Flashes on-off repeatedly

The unit is receiving and transmitting valid NMEA and
MULTILINK data. Function is correct.
Flashes two strobes and than off repeatedly

Enheten tar emot MULTILINK-data men har ingen
NMEA-anslutning (tar inte emot NMEA velocity-data).
Flashes three strobes and than off repeatedly

The unit is receiving NMEA data but has no MULTI-
LINK connection.
Manual fault tracing of bus cables
Tools:
88890074 Multimeter
NOTICE! Cut the current with the main switch.
It can be difficult to check whether there is a cable fault

in the bus cable when it is installed in the engine. For
this reason, always keep checked bus extension
cables in the fault-tracing equipment. Connect the
extension cable to one end of the boat’s bus cable and
run it back to the other end of the bus cable, to allow
each conductor to be checked individually. After this,
all the pins can be checked.
1 Use 88890074 Multimeter to check the bus
cables. The uninsulated parts of the conductors
in the bus cables should not be in contact. Dis-
connect the bus cable at both ends and measure
the resistance between all pins to check for short
circuit between conductors. The multimeter
should show infinite resistance between each pin.
If the resistance is less than infinite, there is a
fault.
2 Do a resistance check through each of the con-
ductors in the cable to detect if there is any open
circuit. Connect one probe to pin1 in one connec-
tor and connect the other probe to pin 1 in the
connector in the other end of the cable (this does
not apply to the Y-split which has a different pin
configuration). The resistance should be approx-
imately 0 ohm. Continue through all pins in the
connector.
38 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
Fuel level warning

Tachometer
The tachometer LCD screen will show a flashing warn-
ing icon + buzzer sound.
Alarm display
The fuel level indication flashes in the alarm display +
buzzer sound.
Circuit description
A fuel level sensor can be connected to the MDI , 3-
180 ohm. The MDI supplies the fuel level sensor with
a reference voltage of +5 V.
Fault tracing
Fault condition
The fuel level is 20% or less for more than 60 seconds.
Possible reason
• Fuel level is too low.
• Fault in the fuel level sensor wiring.
Suitable action
1 Check fuel level.
2 Check all wiring and connectors between the fuel
level sensor and the MDI.
47704390 06-2013 © AB VOLVO PENTA 39

30-2 Fault Tracing
Measurements
Checking the fuel level sensor
Tools:
88890074 Multimeter
2 Remove the connector from the fuel level sensor.
3 Use 88890074 Multimeter to measure the resist-
ance between the two terminal pins on the level
sensor.
B Nominal value
Empty tank (A) R ≈ 3 ±2 Ω
Full tank (B) R ≈ 180 ±15 Ω
4 Turn the main switch on.Turn the ignition on

5 Use 88890074 Multimeter to measure the voltage
between the two fuel level conductors from the
MDI. The fuel level sensor shall not be connected.
A Measurement points Nominal value

P0005110
MDI fuel level output U≈5V
40 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
Button panel fault

Tachometer
None.
Alarm display
None.
Symptom
No system response when a button is pushed.
Circuit description
The button panel contains of four buttons: stop button,
on/off button, acknowledge/dimmer button, start/ pre-
heat button. The buttons functions like switches and
closes to battery negative when activated. The power
switch must be closed before the system can be acti-
vated. The neutral switch must be closed before the
engine can be started.
a A Stop
b e B On/off
1 VO 1 A
R C Ack./dimmer
2 2 B
3 W 3 C D Battery negative
4 SB 4
Y D
5 5 E E Start/preheat
6 c
MDI
P0008425
d
a Connector, button panel

b Switch
c Neutral switch
d Buzzer
e Button panel
Fault tracing
Fault condition
The button panel does not function properly.
Possible reason
• The power switch is disconnected.
• The multilink connector and the button panel con-
nector at the MDI have been switched.
• Open circuit in the wiring between the button panel
and the MDI.
• Short circuit in the wiring between the button panel
and the MDI.
• Defective button panel.
47704390 06-2013 © AB VOLVO PENTA 41

30-2 Fault Tracing
Suitable action
1 Check that the power switch is connected.
2 Check all wiring and connectors between the button
panel and the MDI.
3 Check the button panel.
Measurements
Check button panel
Tools:
88890074 Multimeter
9998699 Break-out box towards the button panel.
3 Use 88890074 Multimeter to do a continuity
(diode) test.
MDI
13 - 10 OL* (button not pushed)
Battery negative - Stop
14 13 - 10 line (button pushed)
10 11
12 13 Battery negative - Stop
13 - 11 OL (button not pushed)
Battery negative - On/off
13 - 11 line (button pushed)
Battery negative - On/off
8
9998
9
699
1
0
2
2
11
2
2
3
9
Battery negative - Ack./

1
2
2
3
3
4
0
6
1
3
2
5
3
3
1
1
7
4
4
3
2
3
6
2
3
8
5
2
0
7
3
3
9
dimmer
4
2
5
8
1
4
0
4
6
5
3
2
5
4
1
4
5
7
3
4
2
4
5
8
4
4
9
5
5

5
6
P0008426 Battery negative - Ack./

dimmer
Battery negative - Start/
preheat
Battery negative - Start/
preheat
*OL = Open line
NOTICE! When testing a button be sure to also push

the other buttons to look for short circuits between but-
tons. There shall be no electrical connection between
buttons.
42 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
Stop solenoid fault

Tachometer
ing icon and the alarm buzzer sound.
P0007949
Alarm display
The warning indication flashes in the alarm display +
audible warning.
Symptom
The engine can not be shut down by pressing the stop
button.
a Circuit description
b The stop solenoid is an electromagnetic relay. When

4 VO 1 the stop button is pushed the stop solenoid is activated
1 SB 2 by the MDI output pin 4. The stop solenoid shuts off
the fuel supply at the injection pump.
MDI
P0008427
a Engine connector
b Stop solenoid
Fault tracing
Fault condition
The stop solenoid does not function properly.
Possible reason
• Open circuit in the wiring between the stop solenoid
and the MDI.
• Short circuit in the wiring between the stop solenoid
and the MDI.
• Faulty stop solenoid.
Suitable action
1 Check all wiring and connectors between the stop
solenoid and the MDI.
2 Check the stop solenoid.
47704390 06-2013 © AB VOLVO PENTA 43

30-2 Fault Tracing
Measurements
Check MDI output for stop solenoid
Tools:
88890074 Multimeter
V
MDI
9998699 Break-out box between MDI and the
engine connector.
ment.
19 Measurement points Nominal value

(stop button not pushed)
16 19 (solenoid positive) - 16 U ≈ 0 V
(battery negative) (solenoid not activated)
(stop button pushed)
19 (solenoid positive) - 16 U ≈ 0,9 x battery voltage
(battery negative) (solenoid activated)
8
9998
9
699
1
0
2
2
11
2
2
3
9
1
2
2
3
3
4
0
6
1
3
2
5
3
5 Disconnect the solenoid connector at the stop

3
1
1
7
4
4
3
2
3
6
2
3
8
5
2
0
7
3
3
9
4
2
5
8
1
4
0
4
6
5
3
2
solenoid.
5
4
1
4
5
7
3
4
2
4
5
8
4
4
9
5
5
5
6
P0008428 Measurement points Nominal value

(solenoid disconnected)
19 (solenoid positive) - 16
(battery negative) U ≈ Battery voltage
44 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
Check stop solenoid
Tools:
88890074 Multimeter
2 Disconnect the solenoid connector at the stop
solenoid.
LTS
VO

9998699 Break-out box to the stop solenoid.
4 Connect a power supply of +12 V, 6 A to the stop
solenoid. Connect the power supply positive to
the measurebox outlet 1 and connect the power
supply negative to the measurebox outlet 2. One
should notice a click in the solenoid when the sol-
2 enoid activates.
1
8
9998
9
699
1
0
2
2
11
2
2
3
9
1
2
2
3
3
4
0
6
1
3
2
5
3
3
1
1
7
4
4
3
2
3
6
2
3
8
5
2
0
7
3
3
9
4
2
5
8
1
4
0
4
6
5
3
2
5
4
1
4
5
7
3
4
2
4
5
8
4
4
9
5
5
5
6
P0008429
47704390 06-2013 © AB VOLVO PENTA 45

30-2 Fault Tracing
Start/preheat warning
Tachometer
ing icon and the alarm buzzer sound.
Alarm display
The warning indication flashes in the alarm display +
audible warning.
Symptom
The engine will not start/crank when pressing the start
button.
Circuit description
Inside the MDI there are two not replaceable relays.
One relay is used to activate the preheat function. The
other relay is used to activate the starter solenoid at
the starter motor.
The preheat function will be activated when the start/

preheat button is pushed if the coolant temperature is
below 50°C. The MDI preheat output will change its
potential from 0 volt to nearly battery voltage across
the glowing plugs when the preheat function is acti-
vated. When the start/preheat button is activated the
MDI start relay output will change its potential from 0
volt to battery voltage to activate the starter solenoid
at the starter motor.
46 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
Fault tracing
Preconditions
If preheating is activated the preheat symbol will be
visible in the tachometer and/or the display.
Fault condition 1
The engine does not crank when the start/preheat but-
ton is pushed.
Possible reason
• The neutral switch is not activated (switch open).
• The coolant temperature is below 50 °C (122 °F) and
therefore preheating is activated.
• Open circuit between the MDI start output and the
starter solenoid at the starter motor.
• Faulty starter solenoid at the starter motor.
• Faulty starter relay inside the MDI unit (not replace-
able).
Suitable action
1 Check that the neutral switch is activated (switch
closed).
2 Preheating is activated due to too cold coolant tem-
perature. Repress the start/preheat button within 10
seconds to activate the starter motor.
3 Check wiring and the connections between the MDI
start output and the starter solenoid at the starter
motor.
4 Check the starter solenoid at the starter motor.
5 Try with another MDI unit.
Fault condition 2
The preheat symbol is not visible in the tachometer
and/or the display.
Possible reason
• The coolant temperature is above 50 °C (122 °F)
and therefore preheating is not activated.
• Open circuit between the MDI preheating output and
the glowing plugs.
• Faulty preheat relay inside the MDI unit (not replace-
able).
Suitable action
1 Check the wiring and connections between the MDI
and the glowing plugs via the conductor rail.
2 Try with another MDI unit.
47704390 06-2013 © AB VOLVO PENTA 47

30-2 Fault Tracing
Measurements
Check MDI output for starter solenoid
Tools:
88890074 Multimeter
V 2 Loosen the rubber protection hood over the
starter output at the MDI to be able to do a meas-
urement.
ment.
on the button panel. The preheating could be acti-
vated due to too cold coolant temperature.
Repress the start/preheat button within 10 sec-
onds to activate the starter motor.

(start/crank button not acti-
vated)
BAT- MDI starter relay output -
battery negative U≈0V
PRE
BAT
T
H EAT
(start/crank button acti-
STA
RT
vated)
MDI starter relay output -
battery negative U ≈ Battery voltage
P0008430
48 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
Check MDI output for preheat function
Tools:
88890074 Multimeter
V 2 Loosen the rubber protection hood over the pre-

heat output at the MDI to be able to do a meas-
urement.
ment.
on the button panel. If the coolant temperature is
above 50 °C (122 °F) the prehating is not acti-
vated.

(start/preheat button not
activated)
MDI preheat output - bat-
BAT- tery negative U≈0V
(start/preheat button acti-
vated)
PRE
HEAT
BAT
T
STA
RT
MDI preheat output - bat-
tery negative U ≈ Battery voltage
5 Also do the above measurement at the glowing

plugs to verify that there is no open circuit to the
glowing plugs.
P0008431
47704390 06-2013 © AB VOLVO PENTA 49

30-2 Fault Tracing
Battery warning
Tachometer
The tachometer LCD screen will show a flashing bat-
tery icon and the alarm buzzer sound.
Alarm display
The battery indication flashes in the alarm display +
audible warning.
Fault tracing
Fault condition 1
The voltage input at the MDI is 15 V or higher for more
than 30 seconds.
Possible reason
Faulty alternator regulator.
Suitable action
1 Try another alternator.
Fault condition 2
The voltage input at the MDI is 13 V or less for more
than 10 seconds (engine running).
Possible reason
• Too slack alternator belt tension.
• Faulty assembled connectors.
• Poor condition of the cables in the charging system.
• Faulty excitation voltage/current to the alternator.
The alternator does not charge.
• Damaged or worn alternator brushes.
• Faulty alternator regulator.
Suitable action
1 Check the alternator belt tension.
2 Check that all connectors at the alternator and at
the battery are correctly assembled.
3 Check the conditions of all cables in the charging
system.
4 Check that the alternator recieves correct excitation
voltage/current.
5 Check the brushes length and condition.
6 Try another alternator.
50 47704390 06-2013 © AB VOLVO PENTA

30-2 Fault Tracing
Measurements
When the engine is started an excitation voltage/
current is needed to “wake up” the alternator.
Check altenator excitation voltage
Tools:
88890074 Multimeter
V 2 Disconnect the excitation cable on D+ on the
MDI alternator.
9998699 Break-out box between the MDI and the
engine connector.
ment.
5 Turn the main switch on.

16 - 22 U ≈ Battery voltage
16
22
8
9998
9
699
1
0
2
2
11
2
2
3
9
1
2
2
3
3
4
0
6
1
3
2
5
3
3
1
1
7
4
4
3
2
3
6
2
3
8
5
2
0
7
3
3
9
4
2
5
8
1
4
0
4
6
5
3
2
5
4
1
4
5
7
3
4
2
4
5
8
4
4
9
5
5
5
6
P0008432
47704390 06-2013 © AB VOLVO PENTA 51

37-0 Wiring Diagrams

Engine
D2-55 A/B/C/D, D2-75 A/B
4 16 1 6 7 12 13 11 15 10 14 5 3
GR/SB
W/BN
GN/R
W/BL
BL/R
LBN
LBL
R/Y
OR
GR
BN
SB
R
9
10 14
8
MAX 15A
(4x) NO 100 ± 2°C 13
33 / 9W
p
7
R 2,5
R 2,5
6
SB P
NO 0,3 ± 0,1 BAR
R/Y 2,5 12
30 87 SB
86 85 JOINT
86 85 R 2,5 87 30 R 2,5
11
BL/R
5 SB 10
50 B-
R10
M 30 B+
G D+/61
W
2 3
4 1
+ -
P0008376
52 47704390 06-2013 © AB VOLVO PENTA

1 Battery (orange indication) Cable colors

2 Starter motor BL = Blue OR = Orange
LBL = Light blue PU = Purple
3 Alternator BN = Brown R = Red
4 Main switch LBN = Light brown SB = Black
GN = Green W = White
5 Glowplugs GR = Gray Y = Yellow
6 Oil pressure monitor
Cable cross section in mm2 is indicated after the color
7 Oil pressure sensor
code in the wiring diagram.
8 Coolant temperature monitor Cable areas not specified = 1.0 mm2.
9 Coolant temperature sensor Cables shown with broken lines are not supplied by
Volvo Penta.
10 Fuses (4 pcs.), max. 15 A (+)
11 Start Relay
12 Glowplug relay
13 Magnetization resistance
14 Engine rpm sensor
47704390 06-2013 © AB VOLVO PENTA 53

Instrument Panel, alternative “A” *

* (without key switch)
D2-55 A/B/C/D, D2-75 A/B
20
x100
r/min
30
10 GLOW
40
0 ALARM TEST POWER
ON/OFF
SB 1,0
SB 1,0
START
R/BL 1,0
5 3 1
4 R/BL 1,0 SB 1,0
61
2
R/BL 1,0 RPM/h-
5 6 7 8 +
S- S+
TEMP OIL BAT GLOW

W/BN 1,0
W/SB 1,0
R/GN 1,0
W/BL 1,0
R/BL 1,0
BN 1,0
SB 1,0
7 6 3 4 1 5 2
R/BL 1,0
9 10 SB 1,0 13
W/SB 1,0
R/BL 1,0
1 3 4 6
14
11 2 5
R/Y 1,5
OR 1,5
12 R/BL 1,5
OR 1,5
GR/SB 1,5
W/BN 1,5
R/GN 1,5
W/BL 1,5
R/BL 1,5
R/Y 1,5
OR 1,5
GR 1,5
BN 1,5
SB 1,5
R 1,5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P0008157
15
54 47704390 06-2013 © AB VOLVO PENTA

1 Instrument lighting Cable colors

2 Tachometer with built-in operating hours coun- BL = Blue PU = Purple
ter (extra equip.). Or blanking plug BN = Brown R = Red
GN = Green SB = Black
3 Connector for connecting extra warning display GR = Gray W = White
(optional equipment) OR = Orange Y = Yellow
4 Electronic unit (alarm)
5 Warning lamp, coolant temperature
6 Warning lamp, oil pressure
7 Charge warning lamp
8 Indication lamp, glow plugs
9 Start button
10 Press switch. Instrument panel On/Off
11 Connector for connecting neutral position switch
(extra equip.)
12 Semiconductor diode
13 Alarm
14 Toggle switch. Glow – Alarm test / Acknowledge
15 16-pin connection
47704390 06-2013 © AB VOLVO PENTA 55

Instrument Panel, alternative “B” *

* (with key switch)
D2-55 A/B/C/D, D2-75 A/B
20
x100
r/min
30
10
40
0
ALARM TEST INSTR LIGHT
S
0
R/BL
R/BL
SB
5 3 1
4
SB
61
RPM/h-
+
S- S+
5 6 7 8 2
9
BL
11
TEMP OIL BAT GLOW
10
SB
15a
W/BN 1,0
W/SB 1,0
R/GN 1,0
W/BL 1,0
30 15b
R/BL 1,0
BN 1,0
SB 1,0
S
50
19 12
7 6 3 4 1 5 2
R/BL
R/Y 1,5
W/SB
SB
R/BL
13
GR/SB 1,5
W/BN 1,5
W/BL 1,5
R/GN 1,5
R/BL 1,5
R/Y 1,5
GR 1,5
VO 1,5
OR 1,5
BN 1,5
SB 1,5
R 1,5
1 2 4 6 15 14 5 7 8 9 10 11 16 3 12 13
P0008158 14
56 47704390 06-2013 © AB VOLVO PENTA

1 Instrument lighting A
2 Tachometer with built-in operating hours coun- I
ter (extra equip.). Or blanking plug II
3 Connector for connecting extra warning display
(optional equipment)
0 III
4 Electronic unit (alarm) A
5 Warning lamp, coolant temperature
6 Warning lamp, oil pressure S
7 Charge warning lamp
8 Indication lamp, glow plugs S 15a15b 30 50 19
P0008159
9 Switch, instrument lighting
10 Switch - Alarm test / Acknowledgment A Spring return
11 Key switch
Cable colors
12 Alarm BL = Blue R = Red
13 Connector for connecting neutral position switch BN = Brown SB = Black
(extra equip.) GN = Green VO = Violet
GR = Gray W = White
14 16-pin connection OR = Orange Y = Yellow

Cable areas not specified = 1.0 mm2.
47704390 06-2013 © AB VOLVO PENTA 57

Instrument Panel, alternative “C”

D2-55 A/B/C/D, D2-75 A/B
F200 60 Psi90 Volt

150 30 120
100 250 0 150
80 100 2 4 6 8 10
12
10
40 120 0 10 8 16
- +
20 30
X100
r/min
R/100
10
40 40
120 ALARM TEST INSTR.LITHT
BL BL
SB
SB
1 1 1
SB
SB
SB
R/BL
+V - + Pa - +ºC -
3 G G
4
R/BL
BL
2
R/BL
SB
SB
5
5 1
R/BL
6 BL
SB
RPM/h
61 -+ -+ + -
S - S+
7 8 9 10 11 13
14
TEMP OIL BAT GLOW
12
SB
15a
30 15b
W/BN 1,0
W/BL 1,0
R/GN 1,0
W/SB 1,0
R/BL 1,0
BN 1,0
SB 1,0
S 19
50 10
7 6 3 4 1 5 2
+ - 15
R/Y 1,5
R/BL
W/SB BL/SB 1,5
SB
BL/Y 1,5
16 R/BL
W/BN 1,5
W/BL 1,5
R/GN 1,5
R/BL 1,5
GR/SB 1,5
LBN 1,5
LBL 1,5
R/Y 1,5
OR 1,5
GR 1,5
VO 1,5
BN 1,5
SB 1,5
R 1,5
3 1 2 4 6 16 15 14 5 7 10 12 13 11 8 9 2 1
17 18
P0008377
58 47704390 06-2013 © AB VOLVO PENTA

1 Instrument lighting A
2 Voltmeter I
3 Oil pressure gauge II
4 Coolant temperature gauge

0 III
5 Connector for connecting extra warning display
A
(optional equipment)
6 Electronic unit (alarm)
7 Warning lamp, coolant temperature S
8 Warning lamp, oil pressure

S 15a15b 30 50 19
9 Charge warning lamp P0008159
10 Indication lamp, glow plugs

A Spring return
11 Switch, instrument lighting
12 Switch - Alarm test / Acknowledgment Cable colors
13 Tachometer with built-in operating hours coun- BL = Blue OR = Orange
ter (extra equip.) LBL = Light blue R = Red
Or blanking plug BN = Brown SB = Black
LBN = Light brown VO = Violet
14 Key switch GN = Green W = White
15 Alarm GR = Gray Y = Yellow
16 Connector for connecting neutral position switch

(extra equip.) Cable cross section in mm2 is indicated after the color
17 16-pin connection Cable areas not specified = 1.0 mm2.
18 2-pole connector (for possible additional panel)
47704390 06-2013 © AB VOLVO PENTA 59

MDI
D2-55 E/F, D2-75 C/F
CONN. A
MDI
CONN. C
111213 3 1 4 1 4 6 3 2 5 7 8
8
10 GN 1,5
LBN 1,5
1
1
GN/SB 1,5
2
GR 1,5
6
11 R/BL 1,5 GR/SB 1,5
1
2
1
SB 1,5
2
9
W/BL 1,5
1
P SB 1,5
W/BL 1,5
1 P
5 OR 6
7
VO 1,5 SB 1,5
SB 1,5 SB 1,5
SB TBD
R/Y 1,5
50 4 B-
R 10 30 31 B+ W
M G
S
3 R 16
61+
Y 1,5
BN 1,5
2 1
P0008434
60 47704390 06-2013 © AB VOLVO PENTA

1 Battery (orange indication) Cable colors

2 Main switch BL = Blue R = Red
BN = Brown SB = Black
3 Starter motor GN = Green VO = Violet
4 Alternator GR = Gray W = White
OR = Orange Y = Yellow
5 Glowplugs
6 Flywheel sensor Cable cross section in mm2 is indicated after the color
7 Stop solenoid valve
8 Coolant temperature sensor
9 Oil pressure monitor
10 Fuel level sensor
11 Input for accessory monitor
Keypad Multilink Engine harness

1 Stop 1 CAN L 1 Battery negative
2 On, off 2 CAN L 2 Flywheel sensor +
3 Ackn. / dimmer 3 CAN H 3 Flywheel sensor –
4 Battery negative 4 Multilink negative supply 4 Stop solenoid valve
5 Start / preheat 5 CAN H 5 Coolant temperature sensor
6 Buzzer 6 Multilink voltage supply 6 Oil pressure monitor
7 Magnetization
8 Not used
47704390 06-2013 © AB VOLVO PENTA 61

Alphabetical index
A
About this Workshop manual..................................... 2
B
Battery warning........................................................ 50
Button panel fault..................................................... 41
C
Coolant temperature warning................................... 30
E
Electrical System........................................................ 3
F
Fault Codes.............................................................. 27
Fault Tracing............................................................ 26
Fuel level warning.................................................... 39
Function fault............................................................ 26
G
General............................................................. 2, 5, 26
Group 30: Electrical System....................................... 3
M
Multilink fault............................................................. 34
O
Oil pressure (engine) warning.................................. 27
R
Repair Instructions..................................................... 5
S
Special Service Tools................................................. 4
Specifications, Electrical............................................. 3
Start/preheat warning............................................... 46
Stop solenoid fault.................................................... 43
W
Wiring Diagrams....................................................... 52
47704390 06-2013 © AB VOLVO PENTA 63

References to Service Bulletins
Group No. Date Refers to
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65
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From:...............................................................................
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Concerns publication:...............................................................................................................................................
Publication No.:............................................................Date of issue:......................................................................
Proposal/Motivation:.................................................................................................................................................
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Date:..............................................................
Name:............................................................
AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Gothenburg
Sweden
47704390 English 06-2013

Workshop Manual: Group 30 A

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Workshop Manual A

General, Complete Vehicle Software

Cables and fuses

47704390 06-2013 © AB VOLVO PENTA 1

Volvo Penta accepts no responsibility for damage or

2 47704390 06-2013 © AB VOLVO PENTA

03-3 Specifications, Electrical

Max. current 115 A

47704390 06-2013 © AB VOLVO PENTA 3

08-2 Special Service Tools

9998699 Break-out box 88890016 Break-out cable 88890074 Multimeter

4 47704390 06-2013 © AB VOLVO PENTA

NOTICE! It is not necessary to switch off the main

Only batteries may be used for starting. A jumpstart

47704390 06-2013 © AB VOLVO PENTA 5

Fault tracing of cables and connectors

Check all connectors visually Open circuit

6 47704390 06-2013 © AB VOLVO PENTA

Fault finding glow plugs

8 Core 6 Reinstall the bus bar and connect the electrical

47704390 06-2013 © AB VOLVO PENTA 7

Charging system fault tracing

The alternator type designation can be found on a plate

Checks and overhauling

Check the tension of the alternator belt and the belt

8 47704390 06-2013 © AB VOLVO PENTA

Battery circuit fault tracing

Note that other instruments may use different symbols

47704390 06-2013 © AB VOLVO PENTA 9

Check battery voltage

NOTICE! * Measured at the batteries.

Voltage measurement, check

NOTICE! * Measured at the batteries.

3 Check that the voltage between the terminals B+

10 47704390 06-2013 © AB VOLVO PENTA

Charge status checks

The acid specific gravity of a fully charged battery at

Check 2 hours after charging

If the acid specific gravity between cells is even, then

Sulfated battery. Minor battery sulfating can be broken

Load testing the battery

47704390 06-2013 © AB VOLVO PENTA 11

Checking the battery leads

If the alternator delivers approx. 14.0 V carry out the

Voltage drop less than 0.2 V:

Voltage drop more than 0.3 V:

The alternator supplies more than 14.4 V:

Positive (+) battery lead checks

Negative (-) battery lead checks

If the voltage drop in any of the above tests exceeded

12 47704390 06-2013 © AB VOLVO PENTA

Check the charging system

General alternator information Charging system fault tracing

47704390 06-2013 © AB VOLVO PENTA 13

MDI gauge checks

The gauges are of Easy-Link type and receive their

none of the gauges function, check using

88890074 Multimeter that there is +12 V between the

Since shared signals from various types of gauges