Volvo MD22 Wiring Diagrams.pdf

MD2010, MD2020, MD2030, MD2040MD22, TMD22, TAMD22

A

2(0)

Workshop ManualWiring diagram

1

Grupp 30 Electrical system

Contents

Wiring diagram

MD2010A/B/C/D, MD2020A/B/C/DMD2030A/B/C/D, MD2040A/B/C/D

MD22A, MD22L-B, MD22P-BTMD22A, TMD22-B, TMD22P-C

TAMD22P-B

Safety Information ......................................... 2

General Information ....................................... 5

Wiring diagram ............................................... 6Engine 2010 - 2040A ........................................ 6Engine 2010 - 2040B/C/D ................................ 8Engine MD22A - TAMD22P-B .........................10Instrument panel with ignition switch (option 1) . 12Instrument panel with ignition switch (option 2) 14Instrument panel with starter button ..................16

Instrument kit ....................................................18Diode cable ..................................................... 20SX Power Trim ................................................ 22Active anti-corrosion system ........................... 28................................................................................................................................................................................................................................................................................................................

2

Check that the warning or information decals onthe product are always clearly visible. Replacedecals that have been damaged or painted over.

Never start the engine without installing the aircleaner (ACL). The rotating compressor in the tur-bocharger can cause serious personal injury. Fo-reign objects entering the intake ducts can alsocause mechanical damage.

Never use start spray or similar to start the engi-ne. The starter element may cause an explosionin the inlet manifold. Danger of personal injury.

Avoid opening the coolant filler cap when the eng-ine is hot. Steam or hot coolant can spray out.Open the coolant filler cap carefully and slowly torelease pressure before removing the cap com-pletely. Take great care if a cock, plug or enginecoolant line must be removed from a hot engine.It is difficult to anticipate in which direction steamor hot coolant can spray out.

Hot oil can cause burns. Avoid skin contact withhot oil. Ensure that the lubrication system is notunder pressure before commencing work on it.Never start or operate the engine with the oil fillercap removed, otherwise oil could be ejected.

Stop the engine before carrying out operations onthe engine cooling system.

Start the engine only in a well-ventilated area. Ifoperating the engine in an enclosed space, ensu-re that exhaust gases are ventilated out of theworking area.

Always use protective goggles where there is adanger of pieces of metal, sparks from grinding,acid or other chemicals being thrown into youreyes. Your eyes are very sensitive, injury canlead to loss of sight!

Safety information

IntroductionThis Workshop Manual contains technical data, des-criptions and repair instructions for Volvo Penta pro-ducts or product versions contained in the contents list.Ensure that the correct workshop literature is beingused.

Read the safety information and the Workshop Ma-nual “General Information” and “Repair Instruc-tions” carefully before starting work.

ImportantIn this book and on the engine you will find the followingspecial warning symbols.

WARNING! If these instructions are not followedthere is a danger of personal injury, extensive da-mage to the product or serious mechanical mal-function.

IMPORTANT! Used to draw your attention to so-mething that can cause damage, product mal-function or damage to property.

NOTE! Used to draw your attention to important infor-mation that will facilitate work or operations.

Below is a summary of the risks and safety precautionsyou should always observe or carry out when operatingor servicing the engine.

Immobilize the engine by turning off the powersupply to the engine at the main switch (swit-ches) and lock it (them) in the OFF position befo-re starting work. Set up a warning notice at theengine control point or helm.

Generally, all servicing should be carried out withthe engine switched off. Some work (carrying outadjustments for example) requires that the engi-ne is running. Approaching a running engine isdangerous. Loose clothing or long hair can fastenin rotating parts and cause serious personal inju-ry. If working in proximity to a running engine, ca-reless movements or a dropped tool can result inpersonal injury. Avoid burns. Take precautions toavoid hot surfaces (exhausts, turbochargers,charge air pipes and starter elements etc.) andliquids in supply lines and hoses when the engi-ne is running or has been turned off immediatelyprior to starting work on it. Reinstall all protectiveparts removed during service operations beforestarting the engine.

3

Avoid skin contact with oil. Long-term or repeatedcontact with oil can remove the natural oils fromyour skin. The result can be irritation, dry skin,eczema and other skin problems. Used oil ismore dangerous to health than new oil. Use pro-tective gloves and avoid using oil-soaked clothesand rags. Wash regularly, especially before me-als. Use the correct barrier cream to prevent dryskin and to make cleaning your skin easier.

Most chemicals used in products (engine andtransmission oils, glycol, petrol and diesel oil)and workshop chemicals (solvents and paints)are hazardous to health Read the instructions onthe product packaging carefully! Always followsafety instructions (using breathing apparatus,protective goggles and gloves for example). En-sure that other personnel are not unwittingly ex-posed to hazardous substances (by breathingthem in for example). Ensure that ventilation isgood. Handle used and excess chemicals accor-ding to instructions.

Be extremely careful when tracing leaks in thefuel system and testing fuel injection nozzles.Use protective goggles! The jet ejected from afuel injection nozzle is under very high pressure,it can penetrate body tissue and cause seriousinjury There is a danger of blood poisoning.

All fuels and many chemicals are inflammable.Ensure that a naked flame or sparks cannot igni-te fuel or chemicals. Combined with air in certainratios, petrol, some solvents and hydrogen frombatteries are easily inflammable and explosive.Smoking is prohibited! Ensure that ventilation isgood and that the necessary safety precautionshave been taken before carrying out welding orgrinding work. Always have a fire extinguisher tohand in the workplace.

Store oil and fuel-soaked rags and fuel and oil filt-ers safely. In certain conditions oil-soaked ragscan spontaneously ignite. Replaced fuel and oilfilters are environmentally harmful waste andshould be disposed of at proper disposal areastogether with engine and transmission oil, conta-minated fuel, old paint, degreasing agents, andcleaning residue.

Never allow a naked flame or electric sparks nearthe batteries. Never smoke in proximity to thebatteries. The batteries give off hydrogen gasduring charging which when mixed with air canform an explosive gas - oxyhydrogen. This gas iseasily ignited and highly volatile. Incorrect con-nection of the battery can cause a spark which issufficient to cause an explosion with resulting da-mage. Do not disturb battery connections whenstarting the engine (spark risk) and do not leanover batteries.

Never interfere with the terminals when the sys-tem is operative. A high energy pulse may be ge-nerated which will damage the electrical system.

Never mix up the positive and negative batteryterminals when installing. Incorrect installationcan result in serious damage to electrical equip-ment. Refer to wiring diagrams.

Always use protective goggles when chargingand handling batteries. The battery electrolytecontains extremely corrosive sulfuric acid. If thiscomes into contact with the skin, wash immedia-tely with soap and plenty of water. If battery acidcomes into contact with the eyes, immediatelyflush with copious amounts of water and obtainmedical assistance.

Turn off the engine and turn off power at mainswitch(es) before carrying out work on the electri-cal system.

Clutch adjustments must be carried out with theengine turned off.

Use the lifting eyes mounted on the engine whenlifting the drive unit. Always check that liftingequipment is in good condition and has sufficientload capacity to lift the engine (engine weight in-cluding any extra equipment installed).

To ensure safe handling and to avoid damagingengine components on top of the engine, use alifting beam to raise the engine. All chains andcables should run parallel to each other and asperpendicular as possible in relation to the top ofthe engine.

If extra equipment is installed on the engine alte-ring its center of gravity, a special lifting device isrequired to achieve the correct balance for safehandling.

Never carry out work on an engine suspended ona hoist.

Säkerhetsinformation

4

Never remove heavy components alone, evenwhere secure lifting equipment such as securedblocks are being used. Even where lifting equip-ment is being used it is best to carry out the workwith two people; one to operate the lifting equip-ment and the other to ensure that componentsare not trapped and damaged when being lifted.

The components in the electrical system and inthe fuel system on Volvo Penta products are de-signed and manufactured to minimize the risk offire and explosion. The engine must not be run inareas where there are explosive materials.

Always use fuels recommended by Volvo Penta.Refer to the Instruction Book. The use of lowerquality fuels can damage the engine. On a dieselengine poor quality fuel can cause the control rodto seize and the engine to overrev with the resul-ting risk of damage to the engine and personalinjury. Poor fuel quality can also lead to highermaintenance costs.

Säkerhetsinformation

5

• The engine must not be modified in any way apartfrom with accessories and service kits developed forit by Volvo Penta.

• No modifications to the exhaust pipes and air supplyducts may be undertaken as this may effect exhaustemissions.

• Seals may only be broken by authorized personnel.

IMPORTANT! Use only Volvo Penta GenuineParts. Use of non-original AB Volvo Penta spareparts will result in AB Volvo Penta being unableto assume liability for the engine meeting engi-ne certification requirements. No damage andcosts caused by the use of non-genuine replace-ment parts will be paid by Volvo Penta.

General information

About the workshop manualThis workshop manual contains technical data, descrip-tions and repair instructions for standard versions of theengine units.

This Workshop Manual has been developed primarilyfor Volvo Penta service workshops and qualified person-nel. Persons using this book are assumed to have agrounding in the repair and service of diesel enginesand be able to carry out related mechanical and electri-cal work.

Volvo Penta is continuously developing their products.We therefore reserve the right to make changes. All theinformation contained in this book is based on productdata available at the time of going to print. Any essenti-al changes or modifications introduced into productionor updated or revised service methods introduced afterthe date of publication will be provided in the form ofService Bulletins.

Replacement partsReplacement parts for electrical and fuel systems aresubject to statutory requirements (US Coast Guard Sa-fety Regulations for example). Volvo Penta Genuineparts meet these requirements. Any type of damagewhich results from the use of non-original Volvo Pentareplacement parts for the product will not be coveredunder any warranty provided by Volvo Penta.

Certificated enginesEngines certificated to meet national and regional envi-ronmental legislation carry with them an undertakingfrom the manufacturer that both new and existing engi-nes in use meet the environmental demands of the le-gislation. The product must be the same as the ex-ample approved for certification purposes. So that Vol-vo Penta, as a manufacturer, can guarantee that cur-rently operational engines meet environmentalregulations, the following service and replacement partrequirements must be observed:

• The Service Intervals and maintenance operationsrecommended by Volvo Penta must be observed.

• Only Volvo Penta genuine replacement parts, inten-ded for the certificated engine, may be used.

• The servicing of injector pumps, pump settings andinjectors must always be carried out be an authori-zed Volvo Penta workshop.

6

Engine

MD2010A–2040A

1,5-pole* electrical system

* 1 pole during the start and stop phases, 2 pole at all other times.

7

1. Battery2. Main switch3. Starter motor4. Ground relay5. Ground rail6. Glow plugs*7. Generator8. Starter relay9. Glow plug relay

10. Protective diode**11. Fuses (x4), maximum 15A (+)12. Fuses (x4), maximum 15A (–)13. Cable splice14. Engine oil pressure switch (normally open, closes below

0.3 ± 0.1 bar)15. Oil pressure sensor16. Coolant temperature switch (normally open, closes at

95° ± 3°C)17. Engine coolant temperature sensor18. Connector, 16-pin

* MD2010: x 2 Other engines: x 3** Non-standard on earlier models.

Cable colorBL = Blue P = PinkLBL = Light-blue PU = PurpleBN = Brown R = RedLBN = Light-brown SB = BlackGN = Green VO = VioletGR = Gray W = WhiteOR = Orange Y = Yellow

Cable cross sections in mm2 are indicated after the colourcodes in the wiring diagram.Cable cross sections not indicated = 1.5 mm².A dashed line indicates a non-Volvo Penta cable.

Engine MD2010–2040A (1.5-pole electrical system)

8

Engine

MD2010–2040B/C/D

1-pole electrical system

9

1. Battery2. Main switch3. Starter motor4. Generator5. Glow plugs6. Starter relay7. Glow plug relay8. Fuses (x4), maximum 15 A9. Charging regulator resistance 33/9 W

10. Engine oil pressure switch (normally open, closes below0.3 ± 0.1 bar)

11. Oil pressure sensor12. Coolant temperature switch (normally open, closes at

100° ± 2°C)13. Engine coolant temperature sensor14. Connector, 16-pin



Engine MD2010–2040B/C/D (1-pole electrical system)

10

Engine

MD22A, MD22L-B, MD22P-BTMD22A, TMD22-B, TMD22P-C, TAMD22P-B

1,5-pole electrical system


11

1. Battery2. Main switch3. Starter motor4. Generator5. Ground relay6. Fuse 55 A7. Automatic fuse 8 A8. Starter relay9. Glow plug relay

10. Glow plugs (x4)11. Oil pressure switch - Engine, combined12. Oil pressure sensor - Engine, combined13. Solenoid valve14. Coolant temperature switch - Engine15. Coolant temperature sensor - Engine16. Automatic fuse 8 A17. Resistance18. Cable splice19. CPC connector, 16-pin



Engine MD22A – TAMD22P-B (1.5-pole electrical system)

12

Instrument panel with ignition switch (alt.1)

MD2010–2040A/B/C/DMD22A, MD22L-B, MD22P-B

TMD22A, TMD22-B, TMD22P-C, TAMD22P-B

13

Instrument panel with ignition switch MD2010 – 2040A/B/C/D and MD22A – TAMD22P-B

1. Instrument lighting2. —3. —4. —5. Connector for extra warning display (accessory)6. Alarm unit7. Engine coolant temperature warning lamp8. Oil pressure warning lamp9. Charge warning lamp

10. Warning lamp (not used)11. Instrument lighting switch12. Alarm test/acknowledgement switch13. Tachometer with built-in hours run meter14. Ignition switch15. Alarm (buzzer)16. Splice connector17. CPC connector, 16-pin18. Power supply 30 for the tachometer (only later models)



Spring loaded

Springloaded

14

Instrument panel with ignition switch (alt.2)



15

Instrument panel with ignition switch MD2010-2040A/B/C/D and MD22A – TAMD22P-B

1. Instrument lighting2. Voltmeter3. Oil pressure gauge4. Engine coolant temperature gauge5. Connector for extra warning display (accessory)6. Alarm unit7. Engine coolant temperature warning lamp8. Oil pressure warning lamp9. Charge warning lamp

10. Warning lamp (not used)11. Instrument lamp switch12. Alarm test/acknowledgement switch13. Tachometer with built-in hours run meter14. Ignition switch15. Alarm (buzzer)16. Splice connector17. CPC connector, 16-pin18. Connector (not used)19. Power supply 30 for the tachometer (only later models)


Cable cross sections in mm2 are indicated after the colour codes inthe wiring diagram.Cable cross sections not indicated = 1.5 mm².A dashed line indicates a non-Volvo Penta cable.

Spring loaded

Spring loaded

16

Instrument panel with starter button

MD2010–2040A/B/C/D

17

1. Tachometer with built-in hours run meter2. Instrument lighting3. Connector for extra warning display (accessory)4. Alarm unit5. Engine coolant temperature warning lamp6. Oil pressure warning lamp7. Charge warning lamp8. Glow plug warning lamp9. Voltage On/Off button

10. Start button11. Alarm (buzzer)12. Alarm/Glow plug rocker switch13. Neutral switch connector14. Semiconductor diode15. CPC connector, 16-pin16. Power supply 30 for the tachometer (only later models)



Instrument panel with starter button MD2010 – 2040A/B/C/D

18

Instrument kit



19

Instrument kit1. Ignition switch2. Alarm test/acknowledgement switch3. Instrument lighting switch4. Alarm (buzzer)5. Alarm unit with warning lamps for:

• Temperature• Oil level• Battery• Glow plugs

6. Engine coolant temperature gauge7. Engine oil pressure gauge8. Voltmeter9. Boost pressure gauge

10. Reverse gear oil pressure gauge11. Tachometer with built-in hours run

meter12. Instrument lighting13. Connector, cannot be opened

914. Splice connector15. CPC connector, 16-pin16. Connector for extra warning display

(accessory)

Cable colorBL = BlueLBL = Light-blueBN = BrownLBN = Light-brownGN = GreenGR = GrayOR = OrangeP = PinkPU = PurpleR = RedSB = BlackVO = VioletW = WhiteY = Yellow

20

Diode cable



1.5-pole* electrical system


21

Diode cable for 1.5-pole electrical systemThe diode cable is necessary for the engine to be stopped electronically, using the starter switch or the stop button. The diodecable also protects against short-circuits (cable burn out) if the battery positive terminal is unintentionally connected to theengine body.

Outline diagram – Connection of diode kitA. Main panelB. Panel for alternative control positionC. Diode kitD. Y connectionE. Central electronic module (engine)


Diode kit (C)1. Diode2. 16 pin CPC, to instrument panel3. 16 pin CPC, to engine

Cable areas in mm2 are given after the color codes in thewiring diagram.

Power Trim

SX-drev

23

1. Battery2. Main switch3. Starter4. Circuit breaker 50 A

5a. Connector, 2-pole male5b. Connector, 2-poe female6. Hydraulic pump7. Connector with rubber cap, 3-pole

8a. Fully cast connectors, 3-pole female8b. Fully cast connectors, 3-pole male9a. Connector with rubber cap, 1-pole male9b. Connector with rubber cap, 1-pole female

10a. Trim sender, digital10b. Trim sender, analouge

11. Connector, 7-pole12. Extension cable, Y-connector13. Control panel14. Triminstrument, analouge15. Instrument lightning16. Connecting terminal, instrument lightning (+) to main panel17. Connecting terminal, fuse box (–) to main panel18. Connecting terminal, fuse box (+) to main panel19. Circuit breaker 10 A20. Circuit breaker 10 A*

Power Trim SX without trim limiter (early production)

* Only certain executions of SX-C1, SX-CLT1, SX-C1AC,SX-R1 and SX-R2


Cable areas in (mm2) are given after the cable color codes.Cable areas in brackets are AWG (American Wiring Gauge).

Conversion table:

mm 2 AWG0.5 200.75 181.0 171.5 15–16

mm 2 AWG2.5 136 1010 7

A broken line indicates a non-Volvo Penta cable.

24


5a. Connector, 2-pole male5b. Connector, 2-poe female6. Hydraulic pump7. Not used8. Connector, 1-pole9. Connector, 3-pole

10a. Fully cast connectors, 3-pole female10b. Fully cast connectors, 3-pole male

11. Connector 1-pole, trim by-pass12. Trim sender13. Extension cable, Y-connector14. Connector, 7-pole15. Control panel16. Triminstrument, analouge17. Instrument lightning18. Connecting terminal, instrument lightning (+) to main panel19. Connecting terminal, fuse box (–) to main panel20. Connecting terminal, fuse box (+) to main panel

Power Trim SX without trim limiterlate production



Conversion table:

mm 2 AWG0.5 200.75 181.0 171.5 15–16

mm 2 AWG2.5 136 1010 7


25

Power Trim SX, DP-S with trim limiter


5a. Connector, 2-pole male5b. Connector, 2-pole female6. Hydraulic pump7. Not used

8a. Fully cast connectors, 3-pole female8b. Fully cast connectors, 3-pole male9. Connector, 3-pole

10. Connector, 1-pole11. Trim limiter12. Connector, 1-pole13. Trim sender14. Connector, 7-pole15. Extension cable, Y-connector16. Control panel17. Trim instrument, analouge18. Instrument lightning19. Connecting terminal, instrument lightning (+) to main panel20. Connecting terminal, fuse box (–) to main panel21. Connecting terminal, fuse box (+) to main panel



Conversion table:

mm 2 AWG0.5 200.75 181.0 171.5 15–16

mm 2 AWG2.5 136 1010 7


26

1

2

34

5b 5a

6

7b 7a8

9

10

1113

14a

14b

15

12

16

1718

19

20

2122

23

24

Y 0,5 (20)

GN 0,5 (20)

BN 0,5 (20)

GR 0,5 (20)

W 0,5 (20)

SB 1,0 (17)

BN/BL 1,0 (17)

BL 1,0 (17)

SB 1,0 (17)

R/BL 1,0 (17)

GN

/W 0

,75

(18)

BL/

W 0

,75

(18)

R/P

U O

,75

(18)

R 0

,75

(18)

PU

/R O

,75

(18)

SB

1,5

(16

)

BN

/W 1

,5 (

16)

SB

*

SB

**

W

SB 1,5 (16)

BN/W 1,5 (16)

SB 6,0 (10)

SB 1,5 (16)

R/PU 6,0 (10)

SB 1,5 (16)

BL/W 6,0 (10)

GN/W 6,0 (10)

R/PU 6,0 (10)R/PU 6,0 (10)

GN/W

BL/W

BL 1,5 (16)

GN 1,5 (16)

R/PU 1,5 (16) R/PU 1,5 (16)

SB 6 (10)

R/PU 6 (10)

SB 6 (10) 22-SXSB 10 (7) 31-SX

R 6 (10) 22-SXR 10 (7) 31-SX

R 6 (10) 22-SXR 10 (7) 31-SX

SB 10 (7) 31-SXSB 6 (10) 22-SX

31-SX30

50

31

87a

8730

8685

87

87a

30

8685

A C

A C B

A C B

2 3 1 4 5 7 6

2 3 1 4 5 7 6

M

M

11

Power Trim SX without trim limiter


5a. Connector, 2-pole male5b. Connector, 2-pole female6. Fuse 10 A

7a. Connector, 2-pole male7b. Connector, 2-pole female8. Hydraulic pump9. Reley, down

10. Reley, up11. Connector with rubber cap, 3-pole12. Connector with rubber cap, 1-pole13. Not used

14a. Fully cast connectors, 3-pole female

14b. Fully cast connectors, 3-pole male15. Connector 1-pole16. Trim sender17. Connector, 7-pole18. Extension cable, Y-connector19. Control panel20. Triminstrument, analouge21. Instrument lightning22. Connecting terminal, instrument lightning (+) to main panel23. Connecting terminal, fuse box (–) to main panel24. Connecting terminal, fuse box (+) to main panel

Cable colorBL = Blue P = PinkLBL = Light-blue PU = PurpleBN = Brown R = RedLBN = Light-brown SB = BlackGN = Green VO = VioletGR = Gray W = WhiteOR = Orange Y = YellowSB* = Black ribbed SB** = Black smooth


Conversion table:

mm 2 AWG0.5 200.75 181.0 171.5 15–162.5 136 1010 7


27

Power Trim SX with trim limiter


5a. Connector, 2-pole male5b. Connector, 2-pole female6. Fuse 10 A

7a. Connector, 2-pole female7b. Connector, 2-pole male8. Hydraulic pump9. Reley, down

10. Reley, up11a. Fully cast connectors, 3-pole female11b. Fully cast connectors, 3-pole male

12. Connector with rubber cap, 3-pole13. Connector with rubber cap, 1-pole14. Not used15. Trim limiter16. Connector, 1-pole17. Trim sender18. Connector, 7-pole19. Extension cable, Y-connector20. Control panel21. Trim instrument, analouge22. Instrument lightning23. Connecting terminal, instrument lightning (+) to main panel24. Connecting terminal, fuse box (–) to main panel25. Connecting terminal, fuse box (+) to main panel

Cable colorBL = Blue P = PinkLBL = Light-blue PU = PurpleBN = Brown R = RedLBN = Light-brown SB = BlackGN = Green VO = VioletGR = Gray W = WhiteOR = Orange Y = YellowSB* = Black ribbed SB** = Black smooth

Cable areas in (mm2) are given after the cable color codes.Cable areas in brackets are AWG (American WiringGauge).

Conversion table:

mm 2 AWG0.5 200.75 181.0 171.5 15–162.5 136 1010 7


28


Active Corrosion Protection System 12 V

1. Battery2. Fuse 1 A3. Active anode4. Reference sensor5. Electronic unit6. LED light

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Refers to publication: .............................................................................................................................................

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Suggestion/reasons: ..............................................................................................................................................

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Date: ............................................................

Name: ..........................................................

AB Volvo PentaCustomer Support

Dept. 42200SE-405 08 Gothenburg

Sweden

7740536-3 English 05-2000

Documents

Volvo MD22 Wiring Diagrams.pdf