ELECTRICAL SYSTEM 4 D 72747 INSTRUMENTATION
Tle of Contents Pge Identifiction............................. 4D-1 Specil Informtion....................... 4D-1 Lighting Options....................... 4D-1 Commodore nd Interntionl Series.. 4D-1 QSI Series......................... 4D-2 Guges................................. 4D-2 Oil, Fuel nd Temperture.............. 4D-2 Testing............................ 4D-2 Bttery Guge........................ 4D-3 Testing............................ 4D-3 Cruiselog Meter....................... 4D-4 Testing............................ 4D-4 Vcuum Guge........................ 4D-4 Testing............................ 4D-4 Speedometer......................... 4D-4 Testing............................ 4D-4 Clirtion Chrt.................... 4D-4 Tchometer........................... 4D-4 Testing............................ 4D-4 Guge Replcement................... 4D-5 Senders................................. 4D-5 Oil Pressure.......................... 4D-5 Dul Sttion Sender Identifiction..... 4D-5 Testing............................ 4D-5 Pge Wter Temperture.................... 4D-6 Dul Sttion Sender identifiction..... 4D-6 Removl........................... 4D-6 Testing............................ 4D-6 Instlltion......................... 4D-7 Fuel Tnk Sender...................... 4D-7 Flnge Type........................ 4D-7 Cpsule Type....................... 4D-8 Switches................................ 4D-9 Ignition Key Switch.................... 4D-9 Testing............................ 4D-9 Lnyrd Stop Switches................ 4D-10 Testing........................... 4D-10 Strt/Stop Switch..................... 4D-11 Testing........................... 4D-11 Audio Wrning System................... 4D-11 Buzzer.............................. 4D-11 Testing........................... 4D-11 Oil Pressure Switch................... 4D-12 Testing........................... 4D-12 Wter Temperture Switch............. 4D-12 Removl.......................... 4D-12 Testing........................... 4D-13 Instlltion........................ 4D-15 NOTICE For informtion nd procedures on trouleshooting, refer to Section 1C. NOTICE For informtion nd procedures on Fuel Injection Engines, refer to Section 5C. 4D-0 - - INSTRUMENTATION
Identifiction NOTE: One of three distinct lines (Series) of Quicksilver guges my e instlled (if equipped with Quicksilver guges). Aside from different guge fce ppernces nd styling, the ck of the guges nd wiring connections re different s shown. Specil Informtion Lighting Options COMMODORE AND INTERNATIONAL SERIES These guges my e wired so tht the illumintion lighting is provided from the ignition switch or seprte instrumenttion lighting switch. By removing contct strip I from etween + terminl nd the screw s shown following, nd supplying seprte +12 V power supply to the screw connection, illumintion lights cn e operted independent of ignition switch. c 72746 Bck of Commodore nd Interntionl Series Guge - Typicl 72966 Ignition Switch Lighting Circuit - Positive (+) 12 Volt Power Supply From Ignition Switch - Contct Strip I c - Screw Connection c 72965 Bck of QSI Series Guge - Typicl 72967 Seprte Instrumenttion Lighting Circuit Wiring - Positive (+) 12 Volt Power Supply From Ignition Switch - Contct Strip I c - Screw Connection INSTRUMENTATION - 4D-1
QSI SERIES These guges re equipped with optionl illumintion lighting. Light ul socket cn e removed nd contcts cn e ligned to e used with ignition switch lighting circuit +12 V or seprte instrumenttion lighting circuit LT. IMPORTANT: Light socket must e removed from guge nd turned counterclockwise (fcing ck of guge) when djusting to desired setting. Turning socket while still instlled in guge could result in dmge to guge or socket. NOTE: For different lighting effects, colored sleeves re ville through the Quicksilver Accessories nd cn e ssemled to the ul. Guges Oil, Fuel nd Temperture IMPORTANT: If testing proves guge to e defective, it must e replced s there is no repir ville. 1. Turn ignition switch to OFF. 2. Remove wire from terminl S (SEND). Ignition Switch Lighting Circuit Position - Positive (+) 12 Volt Power Supply From Ignition Switch 72968 72965 Typicl - Terminl S (SEND) 3. Turn ignition switch to RUN. Guge eing tested must e t position A. 72969 Seprte Instrumenttion Lighting Circuit Position - Positive (+) 12 Volt Power Supply From Ignition - Positive (+) 12 Volt Power Supply From Seprte Instrumenttion Lighting Circuit Typicl Position A 72747 4. Turn ignition switch to OFF. 4D-2 - INSTRUMENTATION
5. Connect jumper wire from terminl G (GND) to terminl S (SEND). Bttery Guge 1. Remove cles from ttery nd fully chrge ttery. 2. Connect negtive ( ) jumper led from ttery to guge terminl G (GND). 3. Connect positive (+) jumper led from ttery to guge terminl I or +12 V. 72748 Typicl 6. Turn ignition switch to RUN. 7. Indictor needle of guge eing tested must red t position B. If not, replce guge. 72750 Typicl 4. Check guge reding; if not s shown replce guge. Position B 72749 Typicl 72751 Typicl INSTRUMENTATION - 4D-3
Cruiselog Meter 1. Connect jumper wire from negtive ( ) ttery terminl to negtive ( ) guge terminl. 2. Connect jumper wire from positive (+) ttery terminl to positive (+) guge terminl. Vcuum Guge 1. Disconnect vcuum hose from engine. Connect service vcuum guge to engine nd record engine vcuum redings t idle, 1000, 2000 nd 3000 RPM. Reconnect vcuum hose nd compre vcuum guge redings (t specified RPM) with service guge redings. Redings should e within 3 inches of vcuum of ech other. IMPORTANT: Mke sure tht vcuum hose etween guge nd engine is not leking nd tht ll connections re tight. Speedometer 72752 3. Oserve guge run indictor. If indictor is turning, guge is operle; if not, replce guge. IMPORTANT: When testing speedometer guge for ccurcy, the ir supply used for the test must e regulted to the specified ir pressure. Do not pply excessive ir pressure to speedometer guge. 1. Apply ir pressure directly to speedometer guge (specified in chrt) nd note guge reding. Light tpping of pressure guge is required during ccurcy check. 2. If guge redings re not within specifictions, guge is defective CALIBRATION CHART Air Pressure Guge PSI Speedometer Guge MPH (km/hr) 5.3 20±2 (32±1.6) 27.8 45±1 (72±1.6) 72753 Tchometer - Indictor 1. Connect service tchometer to engine nd compre redings. 2. Replce if not within specifictions. Tchometer Allownce 5000 RPM ± 150 RPM 4D-4 - INSTRUMENTATION
Guge Replcement 1. Disconnect ttery cles from ttery. 2. Remove wires from ck of guge. 3. Remove hoses (vcuum, speedometer guge). 4. Disconnect light socket. 5. Remove holding strp nd remove guge. 6. Position guge ssemly in pproprite mounting hole. 7. Instll holding strp nd nuts. Tighten nuts evenly nd securely. IMPORTANT: Do not distort cse or rcket y over-tightening. 8. Connect ground (BLACK) wire to ground terminl, if guge is not mounted in metl pnel. 9. Connect other wires to guge s shown in Section 4F. 10. Connect hoses (vcuum, speedometer guges). 11. Instll guge light socket. 12. Cot ll terminls with Quicksilver Liquid Neoprene. 13. Reconnect ttery cles to ttery. Senders Oil Pressure DUAL STATION SENDER IDENTIFICATION Sender will hve 353-AM stmped on hex of sender. IMPORTANT: Use following test procedure for checking ccurcy of oil pressure sender only. If oil pressure guge indictes zero oil pressure, refer to Section 1C - Trouleshooting. 1. Remove wire from sender terminl. 2. Connect ohmmeter etween sender terminl nd sender cse. Check ohms reding without engine running (zero pressure), then check reding with engine running. Compre oil pressure nd ohms redings s shown in following chrt: c d - Positive Led - Negtive Led c - Wire Removed d - Oil Pressure Sender 72754 Oil Pressure (PSI) Ohms Reding Single Dul 0 227-257 113.5-128.5 20 142-162.5 71-81.25 40 91.7-113.6 45.8-56.8 80 9-49 4.5-24.5 INSTRUMENTATION - 4D-5
Wter Temperture DUAL STATION SENDER IDENTIFICATION Sender will hve 362-BC stmped on hex. REMOVAL 1. Drin coolnt from closed cooling system into suitle continer s outlined in Section 6B. 2. Remove TAN wire from temperture sender. Typicl Wter Temperture Sender - TAN Wire - Wter Temperture Sender NOTE: Hoses re shown removed for clrity. 3. Remove temperture sender. 72611! WARNING The following test involves the use of intense het. Filure to follow pproprite procedures or wrnings cn cuse urns which cn result in severe personl injury. While performing the following test, oserve these generl precutions: Wer personl protective clothing such s ruer gloves, non-flmmle pron, nd eye protection - preferly full fce shield or sfety glsses. The pproprite het source should only e electric. Het source should e operted y qulified person. Be sure to follow ll instructions of the mnufcturer of the het source. The het source should e checked ech time it is used to e sure it is functioning properly. The thermometer used in the test should e high- temperture thermometer with mximum reding of t lest 300 F (150 C). Under no circumstnces should the opertor llow tempertures to exceed test specifictions. Perform test only in well ventilted re. Use suitle continer, such s metl, to hold the wter. Avoid use of glss continers unless the opertor first confirms for himself/ herself tht the glss continer is n pproprite high-temperture vessel. Becuse the components will rech high tempertures DO NOT hndle mterils or components until COMPLETELY cooled. 1. Connect n ohmmeter etween temperture sender terminl (+) nd hex (cse) for ground ( ) s shown. 72768 - Ohmmeter Leds - Wter Temperture Sender 4D-6 - INSTRUMENTATION
2. Follow these instructions:. With ohmmeter connected s outlined nd using suitle continer, thermometer nd het source, suspend sender with tip in wter.. Het wter nd oserve thermometer. c. As temperture rises ohmmeter redings must e within the rnges specified for ech temperture (see chrt elow). d. Turn het source off. Allow wter nd components to cool. NOTE: While wter cools you my recheck ohmmeter redings. INSTALLATION 1. Apply Loctite Pipe Selnt with Teflon to threds of temperture sender. 2. Instll sender in thermostt housing nd tighten securely. 3. Connect tn wire nd cot with liquid neoprene. e d 72611 Typicl Wter Temperture Sender - TAN Wire - Wter Temperture Sender c 72769 4. Refill closed cooling system with pproved coolnt s outlined in Section 6B. - Suitle Continer - Thermometer c - Het Source d - Wter Temperture e - Ohmmeter Leds Wter Temperture Ohms Reding 140 F (60 C) 121-147 194 F (90 C) 47-55 212 F (100 C) 36-41 3. Replce sender if ohmmeter redings re other thn s shown for ech temperture. Fuel Tnk Sender FLANGE TYPE Testing 1. Disconnect wire from terminl on sending unit nd ground wire from sending unit mounting screw. 2. Remove sending unit from fuel tnk. 3. Connect ohmmeter etween sending unit terminl nd sending unit housing. INSTRUMENTATION - 4D-7
4. With flot rm in FULL position (rm horizontl), ohmmeter should red 30 ohms (+ 5 ohms). CAPSULE TYPE Testing 1. Disconnect wire from terminl on fuel tnk cpsule. 2. Remove two screws nd remove cpsule ssemly. 3. Plce mgnet under fuel cpsule. 4. Connect ohmmeter etween fuel cpsule terminl nd metl portion of cpsule housing. - Ohmmeter Leds - Verticl Flot Arm 72755 c 5. With flot rm in EMPTY position (rm verticl) meter should red 240 ohms (+ 5 ohms). Sender is defective if not within specifictions. - Ohmmeter Leds - Cpsule Assemly c - Mgnet 72757 5. Turn mgnet counterclockwise until fuel cpsule indictor reds EMPTY. Ohmmeter should red 240 ohms (+ 5 ohms). - Ohmmeter Leds - Verticl Flot Arm 72756 - Cpsule Reding Empty 72758 4D-8 - INSTRUMENTATION
6. Turn mgnet clockwise until fuel cpsule indictor reds FULL. Ohmmeter should red 30 ohms (+ 5 ohms). Fuel cpsule is defective if not within specifictions. - Cpsule Reding Full Switches 72759 3. With key switch in OFF position, there should e no continuity etween switch terminls. 4. With key switch in RUN position, continuity will exist etween switch terminls B to I. There should no continuity etween terminl S nd ny other terminls. 5. With key switch in START, continuity will exist etween terminls B to I nd B to S. 6. Terminls re to mke contct t ngles shown nd to sty in contct condition s switch is rotted towrd START. 7. If ignition key switch tests d, unsolder wire connections nd remove switch. Test switch gin, s in Steps 2-5, preceding. If switch tests good, wiring in hrness is d, There should e no continuity etween ny hrness wires with key switch removed. f e d c Ignition Key Switch! CAUTION Disconnect ttery cles from ttery efore testing ignition key switch with wires still connected to switch. 1. Disconnect ttery cles, if testing ignition key switch with wires connected to switch. 2. Before testing key switch, check ll fuses nd/or circuit rekers in electricl circuit which could prevent opertion of strter. Key View - Key - Off c - Continuity, B to I Terminls d - Run e - Continuity B to S Terminls f - Strt B S I Bck View 72760 INSTRUMENTATION - 4D-9
Lnyrd Stop Switches Remote Control Mounted Style Switch Electronic Fuel Injection (EFI) Engines - Switch Lnyrd - Leds (BLK/YEL) 1. Disconnect switch leds. 74061 2. Test switch s follows.. Connect n ohmmeter to leds.. There should e no continuity with switch lnyrd connected nd continuity with switch lnyrd disconnected. Remote Control Mounted Style Switch Crureted Engines - Switch Leds - Leds (PUR) 1. Disconnect switch leds. 74062 2. Test switch s follows.. Connect n ohmmeter to leds.. There should e continuity with switch lnyrd connected nd no continuity with switch lnyrd disconnected. 72762 Toggle Style Switch - Switch Cp - Switch 4D-10 - INSTRUMENTATION
IMPORTANT: The BLK/YEL led is not used. It should e well insulted nd tped to hrness. 1. Disconnect switch leds. 2. Connect n ohmmeter to switch leds. 3. Switch should hve continuity with toggle in the RUN position nd no continuity with toggle in the OFF position. Strt/Stop Switch! WARNING Disconnect ttery leds t ttery efore testing. 1. Disconnect ttery leds. 2. Check for continuity etween the terminls on the strt switch with continuity meter. 6. If continuity exists when in the OPEN (not depressed) stte, replce pnel utton. Audio Wrning System NOTICE For repir procedures on Fuel Injection Engines, refer to Section 5C. Buzzer! WARNING The following test involves the use of electricity. Filure to follow pproprite procedures cn cuse urns or shock which cn result in severe personl injury or deth. 1. Turn key to RUN position (engine off). 2. Wit 7 to 14 seconds for horn to sound. 3. If horn does not sound:. Connect jumper wires s shown.. If horn does not sound, replce it. 4. If horn worked in Step 3:. Connect jumper wires s shown.. Repet Step 2. 72763 3. No continuity should exist. 4. Depress switch utton nd continuity should exist. 5. Check stop switch in the sme mnner. INSTRUMENTATION - 4D-11
c. If horn sounds, prolem is in tn/lue wire ck to engine or switches on engine. c e f Oil Pressure Switch 1. Remove wire from sender terminl. 2. Connect continuity meter etween sender terminl nd sender hex. (Sender shown removed for clrity.) + g d 72612 Buzzer For 1994 Model And Older Crureted Engines - Jumper Wire To 12 Volt (+) Step 3 - Jumper Wire To Negtive ( ) Step 3 c - Jumper Wire To 12 Volt (+) Step 4 d - Jumper Wire To Negtive ( ) Step 4 e - PURPLE Wire f - RED Wire g - TAN/BLUE Wire 72764 3. With engine not running, meter should indicte full continuity. 4. Strt engine. With engine running nd engine oil pressure ove 6 PSI (41 kp), meter should indicte NO continuity. Wter Temperture Switch REMOVAL 1. Drin coolnt from closed cooling system into suitle continer s outlined in Section 6B. 2. Remove tn/lue wire from temperture switch. 74046 Buzzer For EFI nd 1995 Model And Newer Crureted Engines (No Timer Circuit) - TAN/BLUE Wire - Wter Temperture Switch 72613 4D-12 - INSTRUMENTATION
NOTE: Coolnt hoses shown removed for clrity. 3. Remove switch. 1. Connect n ohmmeter etween wter temperture switch terminl (+) nd hex (cse) for ground ( ) s shown. - Ohmmeter Leds - Wter Temperture Switch 2. Switch should red no continuity. 72765! WARNING The following test involves the use of intense het. Filure to follow pproprite procedures or wrnings cn cuse urns which cn result in severe personl injury. While performing the following test, oserve these generl precutions: Wer personl protective clothing such s ruer gloves, non-flmmle pron, nd eye protection - preferly full fce shield or sfety glsses. The pproprite het source should only e electric. Het source should e operted y qulified person. Be sure to follow ll instructions of the mnufcturer of the het source. The het source should e checked ech time it is used to e sure it is functioning properly. The thermometer used in the test should e high- temperture thermometer with mximum reding of t lest 300 F (150 C). Under no circumstnces should the opertor llow tempertures to exceed test specifictions. Perform test only in well ventilted re. Use suitle continer, such s metl, to hold the snd. Avoid use of glss continers unless the opertor first confirms for himself/ herself tht the glss continer is n pproprite high-temperture vessel. Becuse the components will rech high tempertures DO NOT hndle mterils or components until COMPLETELY cooled. INSTRUMENTATION - 4D-13
! WARNING Use only clen, dry snd such s used for generl sndlsting purposes. Use of snd contining contminnts could result in hzrds such s fire, short circuiting, hot-spots, or other hzrds. 3. Follow these instructions:. With n ohmmeter connected s outlined nd using suitle continer, thermometer nd het source, suspend sender with tip in snd.. Het snd nd oserve temperture on thermometer. c. As temperture rises, switch will close nd ohmmeter will indicte continuity. Refer to chrt elow for specifictions. 48952 Switch Opens 150-170 F (60-77 C) Closes 190-200 F (88-93 C) 87-86080 Switch Opens 175-195 F (60-77 C) Closes 215-225 F (88-93 C) e d c 72767 - Suitle Continer - Thermometer c - Het Source d - Wter Temperture Switch e - Ohmmeter Leds 72766 Switch Identifiction - 48952 Switch With Red Mylr Sleeve - 87-86080 Switch With Blck Mylr Sleeve 4. Turn het source off. Allow snd to cool. Note thermometer reding to ensure switch opens up t specified temperture. 5. Replce switch if switch fils to either open or close within the specified tempertures. 4D-14 - INSTRUMENTATION
INSTALLATION 1. Apply Loctite Pipe Selnt with Teflon to threds of wter temperture switch. 2. Instll switch in thermostt housing nd tighten securely. 3. Connect tn/lue wire nd cot connection with liquid neoprene. 72613 - TAN / BLUE Wire - Wter Temperture Switch 4. Refill closed cooling system with pproved coolnt s outlined in Section 6B. INSTRUMENTATION - 4D-15