Warning horn beeping

[phfrogy]

1994 Mercury 135hp V6 2L. Continuous beep beep beep from warning horn. A marine repair shop replaced the oil module and water pump. Okay for one trip to sea. Next trip I got the beeps intermittently, then constantly including immediately after starting engine. I disconnected wire from oil pump sensor and from oil reservoir cap but horn still beeping. Water temp is fine, Oil is being consumed, plenty of oil smoke which increases as rpms increase (which would seem to make sense and indicates pump is working - ?), and motor runs well, but the beeping continues. ????

 

[ClassyGlassy]

Re: Warning horn beeping

Check the wires that run acrossed the top of the powerhead from the VRO Control Box on the Port side and the Idle/Spark Advance Box bolted on top of the powerhead.

I just worked a '94 150 2L V6 that was doing the same thing. It had been run hot enough that the OEM wiring from those control boxes melted to the powerhead and began shorting and causing alarms. New thermostats, New wiring, rerouting of the wires off the powerhead, New impeller and it runs fine now!

Check those wires as Mercury put them right on the powerhead when installing them

 

[sschefer]

Re: Warning horn beeping

Check the wires that run acrossed the top of the powerhead from the VRO Control Box on the Port side and the Idle/Spark Advance Box bolted on top of the powerhead.

I just worked a '94 150 2L V6 that was doing the same thing. It had been run hot enough that the OEM wiring from those control boxes melted to the powerhead and began shorting and causing alarms. New thermostats, New wiring, rerouting of the wires off the powerhead, New impeller and it runs fine now!

Check those wires as Mercury put them right on the powerhead when installing them

That's definitely a possibility but would most likely cause the alarms the minute the key was turned on. This sounds more like a rotational sensor going off. Take it back to the shop and have them check that sensor and the oil pump. Just hedging a bet here but I would not run it until you find the problem.

 

[nosgsxr]

Re: Warning horn beeping

I am having almost the same problem. But mine is a 92 would this be the same. Is there any way u could post a pic of the parts u r talking about so i can look at mine and see. Thanks. I can unplug all wires except the one going to the power block on the starboard side and i still get the beeps.

 

[ClassyGlassy]

Re: Warning horn beeping

yes nos, I'll get some pics in a little while for you

 

[ClassyGlassy]

Re: Warning horn beeping

nos, if you disconnect the wires to the VRO control box you will get a constant alarm! This is the black box on the port side.......check the wires that go from that box to the top of the oil tank on the motor and check the wires going across the top of the powerhead.

The box mounted on top doesn't alarm anything........

 

[nosgsxr]

Re: Warning horn beeping

I have looked at what i thought was the vro but not sure. I replaced the oil control box but still have an alarm only after i turn the motot over. Beep beep beep beep. I can unhook just about all the wires going to the box and cant get rid of the beep. I replaced the oil control box because of some of the other post and some of the test. All wires from the oil tank,oil rotation sensor and wires that go to the coil or power are fine. I cant figure it out and its killing me

 

[nosgsxr]

Re: Warning horn beeping

Thanks i will be looking for the pics

 

[sschefer]

Re: Warning horn beeping

Thanks i will be looking for the pics

I'm probably going to sound like a broken record but you should really get a Merc Manual. They're on eBay right now on CD and they are cheap. With the manual you could follow the detailed troubleshooting guide in the manual to isolate your problem. Then when you had a question you could use terminology that is eaiser for us to understand and we can help you better.

Trust me, this is the best way to get rid of your frustrating problem.

 

[nosgsxr]

Re: Warning horn beeping

Yea i ordered one but still hasnt arrived yet and trying to use the boat But i know what u r saying

 

[sschefer]

Re: Warning horn beeping

Yea i ordered one but still hasnt arrived yet and trying to use the boat But i know what u r saying

Way to go.. If you don't want to wait there's a guy on eBay selling them in eBay motors in Merc Parts and Accessories. I can't post the link here but he'll send you what you need as an email attachment if you buy the CD. I got my CD in two day's.

 

[phfrogy]

Re: Warning horn beeping

Check the wires that run acrossed the top of the powerhead from the VRO Control Box on the Port side and the Idle/Spark Advance Box bolted on top of the powerhead.

I just worked a '94 150 2L V6 that was doing the same thing. It had been run hot enough that the OEM wiring from those control boxes melted to the powerhead and began shorting and causing alarms. New thermostats, New wiring, rerouting of the wires off the powerhead, New impeller and it runs fine now!

Check those wires as Mercury put them right on the powerhead when installing them

Thanks CG but wires in good shape, new impeller, new VRO control box, contacts all clean, etc.

 

[phfrogy]

Re: Warning horn beeping

That's definitely a possibility but would most likely cause the alarms the minute the key was turned on. This sounds more like a rotational sensor going off. Take it back to the shop and have them check that sensor and the oil pump. Just hedging a bet here but I would not run it until you find the problem.

I tend to think you may be right; symptoms point to rotational sensor. But, one more thing I just read about and have not tried yet - I will look at sensor (Float) in mounted oil reservoir. If no fix, will take to shop to check sensor on oil pump and oil pump flow. It is, however, consuming oil. Thanks guys. Will let you know the outcome.

 

[j_martin]

Re: Warning horn beeping

There are 3 inputs to the alert module. The switch in the oil cap must be open. If it's closed, and either of the other inputs starts, the alarm goes off.

The second input is the coil drive from one cylinder, usually #2. It is a pulse train when the engine is running.

The third input is a pulse train from a proximity (rotational) sensor at the pump. if the two pulse trains are either both missing, or both there, the alarm does not sound. If either is missing, the alarm sounds.

Another possibility is if the power supply to the module goes down too far during cranking, and it starts right away, it could set the alarm off. To see what I mean, turn the key on, hear the test beeps, then turn the key off and quickly back on. The alarm will sound.

hope it helps
John

 

[phfrogy]

Re: Warning horn beeping

Thanks j.
I checked your suggested tests. All seem to be okay.
Finally located a small manual and performed troubleshooting tests. Everything checks except oil flow. At 1500 rpm with oil pump link arm attached, I only get about 2 1/2 cc's in 3 minutes rather than 6.8 cc. Without link arm, getting 7 1/2 rather than 17 (assuming conversion of 1 cc = 1 ml). Soooo, does this mean the pump drive system not working properly (if at all) or is a gear in the pump itself wearing out? I can see teeth of the drive gear in the driven shaft hole and when I re-insert driven shaft I have to rotate it to mesh in those teeth, so hopefully those internal parts are ok. I sure hope it is not the drive gear on the crankshaft!
If it is the pump itself, I fail to see how that can trigger the alarm; the sensor appears to simply detect rotation of the drive gear.
I don't like the way this is leaning! Thoughts?

 

[j_martin]

Re: Warning horn beeping

Thanks j.
I checked your suggested tests. All seem to be okay.
Finally located a small manual and performed troubleshooting tests. Everything checks except oil flow. At 1500 rpm with oil pump link arm attached, I only get about 2 1/2 cc's in 3 minutes rather than 6.8 cc. Without link arm, getting 7 1/2 rather than 17 (assuming conversion of 1 cc = 1 ml). Soooo, does this mean the pump drive system not working properly (if at all) or is a gear in the pump itself wearing out? I can see teeth of the drive gear in the driven shaft hole and when I re-insert driven shaft I have to rotate it to mesh in those teeth, so hopefully those internal parts are ok. I sure hope it is not the drive gear on the crankshaft!
If it is the pump itself, I fail to see how that can trigger the alarm; the sensor appears to simply detect rotation of the drive gear.
I don't like the way this is leaning! Thoughts?

It could be that several teeth are missing on the drive gear, and it skips and runs slow. You can look down the hole and slowly turn the flywheel to examine it. 1 revolution and you've seen it all.

If that's good, you likely have something else going on, like a collapsed innertube in the oil line to the reservoir, or a worn out pump. At any rate, if it's turning steady, the new oil alert module is bad if you get the right readings on everything else.

hope it helps
John

 

[phfrogy]

Re: Warning horn beeping

It could be that several teeth are missing on the drive gear, and it skips and runs slow. You can look down the hole and slowly turn the flywheel to examine it. 1 revolution and you've seen it all.

If that's good, you likely have something else going on, like a collapsed innertube in the oil line to the reservoir, or a worn out pump. At any rate, if it's turning steady, the new oil alert module is bad if you get the right readings on everything else.

hope it helps
John

Okay, I'll examine drive gear more closely. If that turns out okay, I'll go for a new pump since it is currently pumping at half rate and the alert module is fairly new.

Thanks for your time John,
Bill

 

[j_martin]

Re: Warning horn beeping

Okay, I'll examine drive gear more closely. If that turns out okay, I'll go for a new pump since it is currently pumping at half rate and the alert module is fairly new.

Thanks for your time John,
Bill

That might be it, or it might be a bad $2.00 hose.

hope it helps
John

 

[sschefer]

Re: Warning horn beeping

That might be it, or it might be a bad $2.00 hose.

hope it helps
John

Or check valve.

 

[phfrogy]

Re: Warning horn beeping

Or check valve.

John/sschefer,
Oil line and 3 gallon oil tank one year old and in good shape. Oil reservoir on motor full with enough pressure to flow out if cap loosened. Drive gear on crankshaft good. No apparent wear or malformation of worm gear & small verticle gear in pump but ran the volume check again (using pump outlet tube disconnected above the check valve) and still get only about 1/2 the volume listed in manual for 3 minutes with and without link arm.
Double checked electrics - could not get reading from wire to #2 coil at coil or at junction box. However I did get 12 v on white from vro to oil sensor and 5 v on oil sensor blue/white to vro as manual specifies. Even if there is a missing pulse train, that is a problem with alarm & it doesn't negate the fact that the pump is at very reduced volume. Can the rotational sensor detect resistance and/or pressure differences in a worn pump???? I will probably take to shop this week as they have testers that I don't have but wanted to do some investigation and homework first - shop has reputation; if you get my drift.
Anxious to get after those salmon in a couple weeks.
Thanks,
Bill