1990 200HP carb Alarm module bad?

[poseidon]

I have been getting a constant oil warning (beep..beep..beep!) alarm. It will only sound when the engine is running, not with key in on position. The motor gives the normal post of beeps saying everything is normal, then as soon as it starts it gives oil warning beeps while the motor is running. Top oil tank is always completely full.<br /><br />I have:<br />1) tested the float in the top oil tank and it checks out fine. Tried to purge any air from oil system and made sure oil pick up screen is clean in bottom tank.<br />2) measured the voltage from the motion sensor on oil pump and it checks out. (1-5 volt fluctuating on blue white and 12.8 on other wire)<br />3) Cranked the motor with plug wires pulled and oil pump, moved oil (not sure if volume was correct).<br />4) Oil is being used from main (bottom) tank, Gas has green tint going into carbs, and Engine has reassuring white cloud of smoke every time I start the motor.<br />5) I have checked the green and purple wire voltages they appear fine. Moved the green from #4 to # 6 position. (Noticed alarm still sounded with green wire disconnected).<br />6) I removed the tan wire from alarm module and beeping stops. I took temp sensors out of picture and it had no effect. One weird thing that happened was the TACH started working when I removed TAN wire from alarm module.<br /><br />I have learned the above from this group and it seems to plague allot of people. <br /><br />I’m ready to break down and spend $189 on a new alarm (MODULE ASY-LOWOILI’m currently running the boat with the TAN lead disconnected from the oil alarm module and would like to restore the system to normal but can not locate the source of the problem for sure. ). Is their any thing else I should try or repeat differently? Any feed back would be much appreciated.<br /><br />MERCURY (2.4L) <br />Serial Number: 0C157092 Model Number: 1200412GD <br /><br /><br />Thanks,

 

[wilde1j]

Re: 1990 200HP carb Alarm module bad?

If you don't have one, I would get an OEM shop manual. It gives specific tests for verify operation of the warning module.

 

[poseidon]

Re: 1990 200HP carb Alarm module bad?

Ok. Just ordered:<br />1 SERVICE MANUAL from Mercury part Express. Will wait the 2-4 weeks for delivery UGH!<br />thanks for the reply.

 

[KCLOST]

Re: 1990 200HP carb Alarm module bad?

You really should do a search on this topic... Especially check out this thread...<br /><br /> Oil Warning <br /><br />This could be a switchbox, stator or coil issue. Please read this thread, especially the end of it. <br /><br />Your sensor could be using comparing voltage off of the #2 or #4 coil. Both are from the outer switchbox... It's worth a check, in my opinion, to switch the switchboxes (inner with outer) and see if the condition continues or dissapears. If nothing changes it could be a switchbox, if the alarm goes away, it most likely is a stator problem.<br /><br />But you must test it this way..<br /><br />It's easy to test, only a few wires need to be removed/re-routed. You'll need to remove the bolts that hold on the outer switchbox to the block. After that, take a look at both boxes. One box, has a red and a blue wire connected at the top from the stator. The other box has a red/white and a blue/white wire at the top. Just switch those two leads from one switchbox to another. Fire up the engine and test...<br />Let us know.<br /><br />Good luck.

 

[poseidon]

Re: 1990 200HP carb Alarm module bad?

Fished tournament last night and now I have hardly any low end power to get out of the hole. Engine even died while giving it some gas. I revved the motor in neutral, a couple of time and then put into gear. Slowly got onto plane then ran normal 5600 RPM with engine responding normally. Every time I restarted the same situation occurred. Does this sound Stator related?<br />I have some work to do in order to straighten this out. I'll try changing the leads on the switchbox and report back.<br /><br />Thanks,

 

[KCLOST]

Re: 1990 200HP carb Alarm module bad?

Sounds like a low speed winding on the stator is your culprit... If I had to guess..

 

[poseidon]

Re: 1990 200HP carb Alarm module bad?

After reading the link you gave me above it must be that or the switch box in my mind. I will do an ohms test on the stator also when I swap switchbox wires. You mention a low speed stator, is their a single stator with separate functions, or physically two different units (say low and high)? I only see one listed Stator $337.77(OUCH!).<br /><br />Is their any place I can get stator tests or ohm values since my Merc. book is going to take 4 weeks?<br /><br />Thank You for helping me,<br />Bryon

 

[KCLOST]

Re: 1990 200HP carb Alarm module bad?

It's one stator with two sets of windings for voltage... Low and high speed...<br /><br />We can find you a better deal on that stator, but let's wait until we isolate the problem...<br /><br />Switching those leads will tell us a lot on what our problem is...<br /><br />I think these ohm readings are for your stator...<br />My seloc manual states...<br />Between blue and red stator wires = 4.5-6.2 x1000<br />Blue/White and Red/White = 5.4-6.2 x1000<br />Red to Ground = 125-175 x1<br />Red/White to Ground = 125-175 x1

 

[poseidon]

Re: 1990 200HP carb Alarm module bad?

Switched leads and reconnected alarm module. Same thing Beep..Beep..Beep. Took ohm reading and read:<br /><br />red to gnd 113.9 <br />blue red 3.95 K<br /><br />red/w to gnd 113.7 <br />red/w to blue/w 3.93K<br /><br />It looks like my readings are out of spec.

 

[KCLOST]

Re: 1990 200HP carb Alarm module bad?

Not necessariy!!!! A lot of variables will affect ohm readings... Since the beeping continued after the switching of the leads, I don't think it's you stator.....(by the way, I had stator ohm readings out of spec also, some very similar to yours, and it turned out to be a switchbox problem)... <br /><br />So to make sure, let's completely switch the boxes... You will have to remove all the leads and switch them from one box to another....All of them!!!! In this way you will change the voltage/sparks going to each bank from one box to another. If then, the beeping goes away, you will diffinitely know you have a bad switchbox that originally fed the 2,4,6 cylinders...

 

[KCLOST]

Re: 1990 200HP carb Alarm module bad?

By the way, the boxes have color indicators on the terminals... But make sure you keep track of where they should go. because one box has different color wires on it than the other (at certain terminals)... Good luck,,,<br /><br />This is free, doing it yourself, so don't get frustrated.. <br />I forgot to tell you, that I think you stator is not the culprit of your alarm problem..

 

[poseidon]

Re: 1990 200HP carb Alarm module bad?

More info:<br />pulled some plugs 3 & 4 and they looked good(not fouled). They were recently replaced. Checked spark on #4 it was their and jumping about 3/4 inch. Engine starts easy almost always on first crank.

 

[KCLOST]

Re: 1990 200HP carb Alarm module bad?

Did you check this after you switched the stator leads?

 

[KCLOST]

Re: 1990 200HP carb Alarm module bad?

Does anyone know why that tan wire would cause the tach to "start working" and stop the alarm?<br /><br />I assume poseidon, that your tach doesn't work?<br /><br />Maybe something is wired incorrectly... <br /><br />The alarm modual you are refering to, is that at the console or at the engine?

 

[poseidon]

Re: 1990 200HP carb Alarm module bad?

I'll take a digital picture before swapping it out. Will make change as you suggest and report back. <br />Thank you for your help!

 

[poseidon]

Re: 1990 200HP carb Alarm module bad?

Yes, I Did check this after I switched the stator leads. I did the check with the leads removed.<br /><br />TACH: Did not work since purchasing boat. Trouble shooting oil. Disconnected tan alarm wire and tightened up all lugs on outside switch box after moving green lead going to alarm from 4 to 6. Tach worked tonight with alarm (tan wire) reconnected. this leads me to beleive it was not related to alarm terminal connection.<br /><br />Alarm comes from console.

 

[poseidon]

Re: 1990 200HP carb Alarm module bad?

Completely switched the boxes and all the wires. Still Beep..Beep..Beep. I was hoping this would find the source. Switched alarm lead (Green) between both boxes, no change. Any more thing to try?

 

[KCLOST]

Re: 1990 200HP carb Alarm module bad?

Poseidon, I'm really trying to help, but I have to admit I'm stumped....<br /><br />If I were you, I'd go ahead and pull the oil pump, (it's easy to do), and check the gears on it... If there are a few broken teeth on either the block gear or the plastic gear on the pump, that's probably it...<br />My other thought is a possible shorted lead somewhere, but I bet you have already checked that thoroughly....<br />I've read on searched posts that you can check the metal gear in a certain way, but it's most likely the plastic gear on the pump.... If it looks good, at least you will be assured you are getting enough oil.<br /><br />I've heard also that the oil tank cap on the engine can be the culprit, as it can crack or something...<br /><br />Here is a link to schematics of the injection system...<br /><br /> Good Luck

 

[snarky]

Re: 1990 200HP carb Alarm module bad?

I just went through the exact same problem with my 1997 200hp offshore. After all the checking you went through, I just got a new warning module and literally just finished putting it on. The new warning module solved my problem. Engine back to running fine with no damn beep.<br /><br />I had the same symptoms including the beeping going away when I removed the tan/blue wire.<br /><br />I looked the part number up on Mercury's website (parts express) then actually ordered the part from : http://www.mercruiserparts.com/ Ordered on Sunday and received them today. Cost was $161.00<br /><br />Good luck

 

[poseidon]

Re: 1990 200HP carb Alarm module bad?

I pulled the Oil pump and inspected the gear. It is made of metal. Looked fine no signs of any gear damage or wear. Beep did not go away. <br /><br />My next step is to purchase an Alarm module as you have Snarky. I'm unaware of any test for it. Other than process of elimination. I'll update thread once I purchase one and install it.<br /><br />Thanks for all the help everyone,<br />Bryon