Spare Parts List. EW-3500-C and D EW-4200-C and D Marine Diesel Generators

Transcription

1 ENTEC WEST, INC. Spare Parts List EW-3500-C and D EW-4200-C and D Marine Diesel Generators Every generator produced by Entec West, Inc. has been recorded in a master computer file by serial number. This file includes test data and other details. Any questions regarding your particular generator can be addressed more accurately, if you have the serial number available. The serial number is stamped into the crankcase. See the Crankcase parts page for the location. Table of Contents Crankcase... 2 Gear Cover... 3 & 4 Throttle Control... 5 Shut Off Solenoid Assembly C Series... 6 Fuel Control Valve D Series... 6 Crankshaft and Cylinder... 7 Cylinder Head... 8 & 9 Fuel System C Series Fuel System D Series Flywheel and Stub Shaft Generator C Series Generator D Series Water Pump Assembly Heat Exchanger and Exhaust Manifold Base and Mounts C Series Base and Mounts D Series Air Cleaner Starter and Hand Crank Water Pump Engine Control System Operation C Series Engine Control System Operation D Series SW 72nd Portland, Oregon (503)

2 Crankcase Serial Number Crankcase (includes Items 2, 3, and 4) Rear Cylinder Stud Front Cylinder Stud Stud, Main Bearing Plate Low Oil Pressure Switch, 12/18 PSI (C Series) (Normally Open) Low Oil Pressure Switch, 15 PSI (D Series) (Normally Open) Oil Cooler Gasket Oil Cooler, EW-4200-C (S/N 35166/01 and Later) Oil Cooler, EW-4200-C (S/N 35165/20 and Before) Socket Head Capscrew, M06 x 20 (Torque 7 ft.-lbs.) O-Ring, 99mm x 3.0mm Main Bearing Plate Internal Snap Ring, 80mm x 2.5mm Seal, 60mm x 80mm x 08mm, Type BA Nut, M08 (Torque 22 ft.-lbs.) Internal Tooth Lockwasher, M Oil Pump Oil Pump Gasket Split Spring Lockwasher, M Socket Head Capscrew, M06 x 20 (Torque 7 ft.-lbs.) Socket Head Capscrew, M06 x 30 (Torque 7 ft.-lbs) 2 Included in Complete Gasket Set SW 72nd Portland, Oregon (503) Entec West, Inc.

3 Gear Cover PARTS LIST Entec West, Inc SW 72nd Portland, Oregon (503)

4 Gear Cover ART Gear Cover Gear Cover Gasket Roll Pin, M10 x Split Spring Lockwasher, M Retainer Bolt, Injection Pump Follower (Torque 7 ft.-lbs.) Oil Fill Cap Gasket Oil Fill Cap Oil Dipstick, 124mm Stud, M08 x Oil Sump Screen Assembly Oil Drain Plug, 3/8-19 BSPP Copper Seal, M17 x 23 x Oil Sump Screen Assembly Gasket Copper Seal, M06 x 10 x Hex Head Bolt, M06 x 20 (Torque 7 ft.-lbs.) Socket Head Capscrew, M08 x 70 (Torque 22 ft.-lbs.) Extra Fuel Knob Fuel Limit Control Socket Head Capscrew, M08 x Injection Pump Shim, 0.2mm As Req Injection Pump Shim, 0.5mm As Req Injection Pump Shim, 0.4mm As Req Injection Pump Shim, 1.0mm As Req Injection Pump Gasket As Req Injection Pump Cam Follower Injection Pump Split Spring Lockwasher, M Nut, M08 (Torque 22 ft.-lbs.) Push Rod (Nearest to Cylinder is Intake) O-Ring, 32mm x 03mm Socket Head Capscrew, M05 x 30 (Torque 4 ft.-lbs.) Cam Follower, Compression Release Cam Follower Gasket Socket Head Capscrew, M08 x Ball Bearing, O-Ring, 32.7mm x 1.3mm External Snap Ring, 35mm x 01.5mm Camshaft Camshaft Gear Key, M06 x 04 x Stud, M06 x Fuel Pump Gasket Fuel Transfer Pump Curved Spring Washer, M Nut, M06 (Torque 7 ft.-lbs.) Water Pump Mounting Bracket Seal, 42mm x 55mm x 8mm, BA Viton Pump Bracket Gasket Brass Plug, 3/8-19, BSPP Copper Gasket, 17mm x 23mm Flat Head, Socket Screw, M06 x 16 (Torque 7 ft.-lbs.) Stud, M08 x 22, Special Drive Pulley 1 Included in Complete Gasket Set Included in Top End Gasket Set T-EW Units that have a groove in the camshaft should have this snap ring installed if it is not present SW 72nd Portland, Oregon (503) Entec West, Inc.

5 Throttle Control Control Lever Spring Fuel Rack Control Lever Governor Adjusting Screw Lock Plate Locknut, M06 (Torque 7 ft.-lbs.) Throttle Shaft Retaining Clip Throttle Shaft O-Ring, 10mm x 02.2mm Throttle Arm Return Spring Control Plate Emergency Shut Off Arm Internal Tooth Lockwasher, M Nut, M08 (Torque 18 ft.-lbs.) Collar Bolt 1 NOTE: Generator engines operate at a fixed speed. The normal position of the control is a full counterclockwise position. The control should not be used to adjust engine rpm. Entec West, Inc SW 72nd Portland, Oregon (503)

6 Shut Off Solenoid Assembly C Series Generator C Series Generator Align Pin with Spring and lever when installing Shut Off Solenoid Assembly Socket Head Capscrew, M04 x 06, SS Curved Spring Washer, M04, Stainless Clevis Pin, M04 x Cotter Pin, M01 x Flat Washer, M04, Stainless Socket Head Capscrew, M04 x 30, SS Shut Off Arm Flat Washer,.390 x.625 x.063, SS Compression Spring, Stainless Shut Off Shaft O-Ring,.504 x.375 x Nylok Lock Nut, M04, Stainless Rack Pin Link Flat Washer, M04, Stainless Hardened Pin, 01.5 x 06, SS 4 Fuel Control Valve D Series Generator Copper Seal, 5.7mm x 7.9mm x 1.0mm Fuel Control Valve (Torque 12 ft.-lbs.) 1 A Fuel Control Valve Kit to replace the early style Shut Off Solenoid Assembly is available from Entec West. Call for further information SW 72nd Portland, Oregon (503) Entec West, Inc.

7 Crankshaft and Cylinder Crankshaft Assembly O-Ring, 32mm x 2.0mm Wear Ring for Seal Belleville Spring Washer (Large Diameters Touch) Flywheel Nut (Torque 190 ft.-lbs.) Crankshaft Gear Shell Bearing, Standard Shell Bearing,.25mm Undersize Shell bearing,.50mm Undersize Con Rod Bearing, Standard Con Rod Bearing,.25mm Under Con Rod Bearing,.50mm Under Key, 06mm x 04mm x 12mm Roller Bearing (Direct Replacement for Ball Bearing) Governor Assembly, 3600 rpm Governor Assembly, 3000 rpm Governor Spring Set, 3600 rpm Governor Spring Set, 3000 rpm Governor Pin, 04mm x 27.8mm Piston Assembly Piston Ring Set (Ring Gap.2mm to.8mm) Piston Pin Retainer Piston Pin Connecting Rod Assembly Connecting Rod Bolt Connecting Rod Nut (Torque 22 ft.-lbs.) Piston Pin Bushing Core Plug, 22mm Water Transfer Tube O-Ring, 10mm x 2.2mm Cylinder Assembly 1 Included in Complete Gasket Set Included in Top End Gasket Set T-EW Early cylinders had a removable water jacket. Contact the factory for assistance. Entec West, Inc SW 72nd Portland, Oregon (503)

8 Cylinder Head PARTS LIST SW 72nd Portland, Oregon (503) Entec West, Inc.

9 Cylinder Head ART Cylinder Head Assembly Crankcase Breather Valve Cylinder Head Gasket Intake Valve (Recess.004 to.008 ) Spacer Valve Guide Valve Guide Seal Intake Valve Spring Valve Spring Retainer Valve Keeper Exhaust Valve (Recess.004 to.008 ) Ring Valve Rotator Exhaust Valve Spring Push Rod Tube Retainer Stud, M05 x Flat Washer, M Nylok Lock Nut, M05 (Torque 4 ft.-lbs.) Rocker Arm Shaft Exhaust Rocker Arm Assembly Intake Rocker Arm Assembly Rocker Arm Adjusting Screw (Valve Clearance.007 Cold) Nut, M07 (Torque 11 ft.-lbs.) Fuel Injector Assembly (Opening Pressure 2900 PSI) Injector Gasket Injector Nozzle Injector Clamp Stud, M06 x Stud, M06 x Split Spring Lockwasher, M Nut, M06 (Torque 7 ft.-lbs.) Push Rod Tube O-Ring, 24mm x 03.5mm Core Plug, 22mm Core Plug, 18mm Rocker Cover Gasket Rocker Cover Nylon Gasket, M Lifting Eye Cylinder Head and Rocker Cover Nut (Torque Cylinder Head 22 ft.-lbs.) Core Plug, 18mm Water Temperature Switch, 185 F., Normally Open, C Series Water Temperature Switch, 185 F., Normally Closed, D Series Copper Seal, 14mm x 20mm x 01.5mm Socket Head Capscrew, M08 x 25 (Torque 18 ft.-lbs.) Split Spring Lockwasher, M Reservoir Plug, 1/2 NPT Expanding Plug, 7/8 (Early Units) Reservoir Gasket Thermostat, 167 F Reservoir Adapter 90, 3/8 NPT x 1/2 Barb, C Series Adapter 45, 3/8 NPT x 1/2 Barb, D Series Adapter Elbow, 3/8 NPT x 3/8 Barb Core Plug, 18mm Core Plug, 13mm Used on Early Units Adapter, 1/8 NPT x.170 Barb, D Series (Not Shown) 1 Included in Complete Gasket Set Included in Top End Gasket Set T-EW Entec West, Inc SW 72nd Portland, Oregon (503)

10 Fuel System C Series Generator Banjo to Hose Barb, 12mm x 1/ Copper Seal, 08mm x 12mm x 01.0mm Banjo Bolt, Male/Female Copper Seal, 12mm x 18mm x 01.5mm Copper Gasket, Special Banjo Bolt, M08 x Banjo Bolt, M08 x Banjo to Hose Barb, 8mm x 1/ Screw Clamp, 1/2, SS Fuel Filter Assembly High Pressure Injection Line Fuel Leak Off Line, C Series 1 Included in Complete Gasket Set Included in Top End Gasket Set T-EW SW 72nd Portland, Oregon (503) Entec West, Inc.

11 Fuel System D Series Generator Banjo to Hose Barb, 12mm x 1/ Copper Seal, 08mm x 12mm x 01.0mm Banjo Bolt, Male/Female Copper Seal, 12mm x 18mm x 01.5mm Copper Gasket, Special Banjo Bolt, M08 x Banjo Bolt, M08 x Banjo to Hose Barb, 8mm x 1/ Screw Clamp, 1/2, SS Fuel Filter Assembly High Pressure Injection Line Fuel Leak Off Line Assembly, D Series 1 Included in Complete Gasket Set Included in Top End Gasket Set T-EW Entec West, Inc SW 72nd Portland, Oregon (503)

12 Flywheel and Stub Shaft Flywheel Ring Gear Stub Shaft, C Series Stub Shaft, D Series Socket Head Capscrew, M08 x 35 (Torque 22 ft.-lbs.) Split Spring Lockwasher, M Stud, 5/16-24 Special (Torque 18 ft.-lbs.), C Series Hex Head Capscrew, M08 x 160 (Torque 22 ft.-lbs.), D Series SW 72nd Portland, Oregon (503) Entec West, Inc.

13 Generator C Series Bell Housing Stud, M10 x Lockwasher, M Nut, M10 (Torque 32 ft.-lbs.) KP-20 Voltage Regulator Capacitor Regulator Mounting Clamp, SS Screw, x 3/8,SS Crinkled Spring Washer, M05, SS Generator Stator Assembly, 60 Hz Generator Stator Assembly, 50 Hz Generator Rotor Assembly PT80 Rectifier, Rotating Field Ball Bearing, RS Generator Endbell Socket Head Capscrew, 5/16-18 x 6 (Torque 20 ft.-lbs.) 4 Entec West, Inc SW 72nd Portland, Oregon (503)

14 Generator D Series Stud, M10 x Lockwasher, M Nut, M10 (Torque 32 ft.-lbs.) KP-20 Voltage Regulator Capacitor Generator Rotor Assembly PT80 Rectifier, Rotating Field Ball Bearing, RS Bell Housing Generator Stator Assembly, 60 Hz Generator Stator Assembly, 50 Hz Generator Endbell Gasket, Endbell Lockwasher, M Socket Head Capscrew, M06 x 16 (Torque 7 ft.-lbs.) Socket Head Capscrew, M10 x 30 (Torque 32 ft.-lbs.) Lockwasher, M AC Outlet Box Cover, Outlet Box Sheet Metal Screw, x 3/ Button Head Screw, x 3/ Lockwasher, 3/ SW 72nd Portland, Oregon (503) Entec West, Inc.

15 Water Pump Assembly Water Pump Assembly Key, Round End, M03 x 03 x Water Pump Pulley External Snap Ring, M12 x Pump Clamp Crinkled Spring Washer, M Nut, M08 (Torque 18 ft.-lbs.) Adapter 45, 3/8 NPT x 1/2 Barb Adapter, 3/8 NPT x 1/2 Barb Adapter, 45, 3/8 NPT x 1/2 Barb Screw Clamp, 7/8, SS Hose, Oil Cooler to Coolant Pump, C Series Hose, Oil Cooler to Coolant Pump, D Series Adapter Elbow, 3/8 NPT x 1/2 Barb Hose, Engine Pump to Bypass Screw, x 3/8, SS Crinkled Spring Washer, M05, SS Clamp Engine Coolant Bypass Stepless Hose Clamp, 11/16, SS Hose, Bypass to Reservoir Stepless Hose Clamp, 13/16, SS Water Pump Belt, 180-XL Entec West, Inc SW 72nd Portland, Oregon (503)

16 Heat Exchanger and Exhaust Manifold Heat Exchanger, C Series Heat Exchanger, D Series End Cover End Cover Gasket Cover Bolt Gasket Hex Head Bolt, 3/8-16 x 5/ Plug with Zinc Plug Only Zinc Replacement Heat Exchanger Clamp, Stainless Screw, x 3/8, Stainless Crinkled Spring Washer, M05, SS Exhaust Manifold, C Series Exhaust Manifold, D Series Exhaust Gasket Socket Head Capscrew, M08 x 80, SS Split Spring Lockwasher, M08, SS Adapter Elbow, 1/4 NPT x 1/2 Barb Stepless Hose Clamp, 13/16, SS Hose, Reservoir to Exhaust Manifold Hose, Sea Pump to Heat Exchanger Clamp Screw Clamp, 7/8, SS Hose, Reservoir to Heat Exchanger Hose, Heat Exchanger to Oil Cooler, C Series Hose, Heat Exchanger to Stator Housing, D Series Hose, Stator Housing to Oil Cooler, D Series Exhaust Temperature Switch, Normally Open, 140 F., C Series Exhaust Temperature Switch, Normally Closed, 185 F., D Series 1 Included in Top End Gasket Set T-EW SW 72nd Portland, Oregon (503) Entec West, Inc.

17 Base and Mounts C Series Generator Vibration Mount Engine Mounting Bracket Crinkled Spring Washer, M08, SS Nut, 5/16-18, SS (Torque 18 ft.-lbs.) Crinkled Spring Washer, M Socket Head Capscrew, M12 x 25 (Torque 34 ft.-lbs.) Base, EW-4200-C Jam Nut, 5/16-18, SS (Torque 18 ft.-lbs.) 1 Entec West, Inc SW 72nd Portland, Oregon (503)

18 Base and Mounts D Series Generator Vibration Mount Engine Bracket Hex Head Capscrew, M10 x Nylok Lock Nut, M10 (Torque 32 ft.-lbs.) Generator Bracket Socket Head Capscrew, M08 x 30 (Torque 22 ft.-lbs.) Lockwasher, M Socket Head Capscrew, M10 x 30, SS (Torque 32 ft.-lbs.) Hex Head Capscrew, M10 x 16, SS (Torque 32 ft.-lbs.) Lockwasher, M10, SS Base, EW-4200-D SW 72nd Portland, Oregon (503) Entec West, Inc.

19 Air Cleaner Stud, Air Cleaner Air Cleaner Mounting Gasket Air Cleaner Mounting Base Socket, Low Head Capscrew, M08 x 20 (Torque 18 ft.-lbs.) Air Cleaner Cover Gasket Split Spring Lockwasher, M Nut, M08 (Torque 18 ft.-lbs.) Air Cleaner Element Air Cleaner Cover Flat Washer, M06, SS Nylok Type Wing Nut, M06 1 Included in Top End Gasket Set T-EW Entec West, Inc SW 72nd Portland, Oregon (503)

20 Starter and Hand Crank Starter Motor R Rebuilt Starter Motor Bushing Stud, M10 x 25, C Series Hex Head Capscrew, M10 x 45, D Series Split Spring Lockwasher, M Special 15mm Hex Nut, M10 (Torque 32 ft.-lbs.) C Series Nut, M10 (Torque 32 ft.-lbs.) D Series Hand Crank, (A = 105mm) C and D Series Hand Crank, (A = 173mm) all other Series 1 NOTE: The cost of the repair parts and labor to rebuild this starter are generally greater than the cost of a factory re-built starter SW 72nd Portland, Oregon (503) Entec West, Inc.

21 Water Pump Sea Water Pump Body Sea Water Pump Shaft Sea Water Pump Cam Impeller, B End Cap, Sea Water Pump Gasket, Sea Water Pump Wear Plate Guide Pin Bushing Seal, Sea Water Pump Copper Gasket Cam Screw, Special Pitch x 8.0mm Screw, Impeller Brass Screw, M04 x Internal Snap Ring, M28 x External Snap Ring Key, Round End, M03 x 03 x Pump Shaft, Engine Pump Ball Bearing, RS Seal, Engine Pump, 12 x 24 x Pump Body, Engine Pump Cam, Engine Pump Gasket, Engine Pump 1 Entec West, Inc SW 72nd Portland, Oregon (503)

22 Engine Control System Operation C Series The engine control system has been designed to not only start and stop the engine, but to also provide safety shut downs. The following conditions will be detected and cause the engine to stop: low engine oil pressure, high engine coolant temperature, or hot exhaust manifold temperature. The oil pressure switch is mounted on the left side of the engine, looking at the hand crank end (see Parts page 2, item 5). It is normally open and will close when the oil pressure falls to the range of 12 to 18 psi. The water temperature switch is located on the cylinder head (see Parts page 12, item 47). It is normally open and will close when the engine coolant temperature rises to 185 degrees F. The exhaust temperature switch is located on the upper surface of the exhaust elbow (see Parts page 22, item 18). It is normally open and will close when the surface temperature of the elbow rises to 140 degrees F. The control system has been designed to rest in a STATIC CONDITION OF READINESS, when it is not running. That is, it REQUIRES NO POWER to start and run the engine. A hand crank is provided as an alternative to electric start when the vessel s batteries are dead. Please refer to the Control System Schematic. Theory of Operation +12 Battery Cable: The +12 volt battery terminal is connected to the heavy terminal of the starter motor by battery type cable. -12 Battery Cable: The -12 volt battery terminal should be connected to the crankcase of the engine (this is control system ground) at any convenient point; preferably at one of the starter mounting bolts. Start/Stop Switch: +12 volts is taken from the starter post and applied to the rotating contact of the start/stop switch. Run Position: When the start/stop switch is rotated to the run position, +12 volts is applied to the hourmeter and the alarm light. Because the engine has not started yet, the oil pressure switch is still closed, and therefore ground is applied to the alarm light through diode D2, and the alarm light is turned on. This is normal. Starting the Engine: Rotating the start/stop switch to the start position feeds +12 volts through diode D3 to the alarm light, keeping it turned on, and to the start relay (located near the start motor) causing the start relay to energize. The internal heavy contacts of the start relay close and power is applied to the starter solenoid on the start motor. The start motor turns the engine over, and two things happen simultaneously. The engine starts, and the oil pump in the engine develops oil pressure, causing the oil pressure switch to open. When the oil pressure switch opens, the alarm light will go out. After the engine starts, place the rotary switch in the run position. CAUTION: If the alarm lamp does not go out within 7 seconds after the engine starts, it means there is an alarm condition and the ENGINE SHOULD BE STOPPED IMMEDIATELY. Begin troubleshooting procedures. CAUTION: Under normal conditions, the engine will start within 3 to 7 seconds after rotating the start/stop switch to the start position. If the engine does not start, DO NOT CONTINUE CRANKING. Begin troubleshooting procedures SW 72nd Portland, Oregon (503) Entec West, Inc.

23 Alarm Light: In the run position, +12 volts is applied to the top of the alarm light. However, the light will not come on unless the oil pressure switch is closed, indicating an oil pressure problem; or one of the temperature switches is closed, indicating a problem with the cooling system. Stopping the Engine: Assuming the unit operates normally, and the oil pressure is high enough to keep the oil pressure switch open, the engine can then be stopped by rotating the start/stop switch to the stop position. A momentary contact is all that is required. Stop Position: In the stop position, the momentary +12 volts is applied to four places: the stop solenoid which energizes and pulls the injection pump fuel rack to the off position, the normally closed contacts HC1, the coil of relay RL1, and a contact of relay RL2. Relay R1 energizes, connecting +12 volts from the battery terminal on the start motor, through RL1 contacts to the bottom contact of HC1, and from there to the stop solenoid. At the same time +12 volts is connected through the contacts of HC1 to the coil of RL1, keeping RL1 (latched) energized. The closed contacts of RL1 also apply +12 volts to the heater element H1. After approximately 13 seconds, the heater element causes the contacts HC1 to open. When this happens, the +12 volts that came through the contacts of RL1, and the contacts of HC1 to the coil of RL1, keeping it energized, is disconnected, allowing R1 to de-energize. At the same time the contacts of HC1 open, the +12 volts is disconnected from the stop solenoid, returning it to the static condition. So far, relay RL2 is not involved in the process. It is part of the emergency stop system only. Safety Stops Start/Stop Switch: In the run position of the start/stop switch, +12 volts is applied to the alarm light. +12 volts also comes from the battery cable terminal on the starter and connects to a contact on RL1, a contact on RL2, and the coil of RL2. As long as there is no alarm condition, relay RL2 will not energize because the ground side of the coil is not connected to ground. Alarm Switches: If any of the three alarm switches has a momentary contact closure, ground will be applied to the bottom of coil RL2, through capacitor C1, and it will energize. When this happens, +12 volts will be applied through RL2 s contacts to the coil of RL1, and the stop sequence begins; the same as if a manual stop had been initiated by the start/stop switch. The capacitor C1 provides a momentary path for current to flow through RL2. Capacitor C1 will return to a static condition after 60 seconds, rearming the stop sequence for the next cycle of operation. If the engine has been properly maintained, and all of the external support systems, including sea water feed, fuel feed, battery power, etc., are functioning properly, Under normal conditions, the engine will start within 3 to 7 seconds after rotating the start/stop switch to the start position. If the engine does not start, DO NOT CONTINUE CRANKING. Begin troubleshooting procedures immediately. Call Entec West, Inc. for further assistance if required. Manually Stopping the Engine: If for any reason the control system will not energize the stop solenoid on the engine, the engine can be stopped manually. Apply pressure to the clevis at the end of the stop solenoid assembly and push the solenoid plunger into the solenoid body. Hold the plunger in the solenoid, for 10 to 12 seconds, or until the engine stops. Do not disconnect the solenoid from the control arm. CAUTION: Do not disconnect the Engine Control System from battery power when the engine is running. The Alarm System will not operate! Entec West, Inc SW 72nd Portland, Oregon (503)

24 Engine Control System Schematic C Series Panel Harness Start/Stop Switch US Extension Harness Engine Harness Off #1 #3 Run Stop #5 #6 Start D3 Hourmeter 555-T4-1E45 White #87 #86 #85 #30 Diode/Diode/Resistor Assy D3 D4 R R2 Start Relay Volts from Battery #4 Gauge Min. Red Start Motor Green Alarm Lamp Assy HC1 #87 #30 #30 #87 D4 Stop Solenoid D2 H1 #86 #85 RL1 #86 #85 RL2 Relay/ Timer Assy R1 C1 Capacitor Assy D Black Orange Oil Pressure Water Temp Exhaust Temp SW 72nd Portland, Oregon (503) Entec West, Inc.

25 Engine Control System Operation D Series The remote run/stop control for the engine is accomplished through the use of a special high pressure valve. When the valve is energized with +12 volts from the control panel, it closes and the injection pump is allowed to deliver high pressure fuel to the injector. If the valve is de-energized (no +12 volt supply), the high pressure fuel is dumped into the return line and the injector will not receive fuel. The engine control system has been designed to not only start and stop the engine, but also to provide safety shut downs. Low oil pressure, high coolant temperature, and/or high exhaust elbow temperature will cause the engine to stop. There are three switches on the engine to monitor these functions. The oil pressure switch is mounted on the left side of the engine, looking at the hand crank end (see Parts page 2, item 5). It is normally open and is set to close when the oil pressure rises to 15 psi. If the pressure falls below 15 psi, it will re-open. The water temperature switch is located on the cylinder head (see Parts page 12, item 47). It is normally closed and will open when the engine coolant temperature rises to 185 degrees F. It will close again at approximately 160 degrees F. The exhaust temperature switch is located in the casting of the exhaust elbow (see Parts page 22, item 19). It is normally closed and will open when the internal temperature of the elbow rises to 185 degrees F. It will close again at approximately 160 degrees F. Please refer to the Control System Schematic. Theory of Operation +12 Battery Cable. The +12 volt battery should be connected to the large terminal on the starter motor slolenoid. -12 Battery Cable. The -12 volt battery cable terminal should be connected to the crankcase of the engine at any convenient point. Preferably at one of the starter mounting bolts, (this is control system ground). Start/Stop Switch. Plus 12 volts is taken from the starter post and thru the wiring harness, it is applied to two terminals of the start/stop switch, located on the remote control panel. Run Position. When the start/stop switch is moved to the run position, +12 volts is applied back through the harness to one side of the water temperature switch. The water temperature would normally be below 185 F., so the switch would be closed. The +12 volts will pass through the switch to one side of the exhaust temperature switch, and also to the water lamp on the control panel causing it to illuminate. Exhaust Temperature Switch. The exhaust temperature switch would normally be below 185 F., so it would also be closed. The voltage would pass through the switch and go to one side of the oil pressure switch. It would also go to the exhaust lamp, on the control panel causing it to illuminate. Oil Pressure Switch. The oil pressure switch is still open, because there is no oil pressure, and therefore the voltage will be blocked. The oil lamp will not light, the hour meter will not count, and the fuel control valve will not energize. Entec West, Inc SW 72nd Portland, Oregon (503)

26 Starting the Engine. Moving the start/stop switch to the start position feeds +12 volts to the start relay (located near the start motor) causing it to energize. The heavy internal contacts of the start relay close, and +12 volts is applied to the start solenoid on the start motor. The start motor cranks the engine, and two things happen simultaneously: the oil pump in the engine starts to pump oil into the galley; and oil flows to the bearings, lubricating them. The oil pressure rises from zero to operating pressure. When the pressure reaches 15 psi, the oil pressure switch closes and the +12 volts passes through the switch to the fuel control valve energizing it, and to the oil light causing it to illuminate. As soon as the fuel control valve is energized, high pressure fuel will be delivered to the injector pipe and thus to the injector. If the engine is operating normally, it will start within 3 to 7 seconds. The control panel will show a green board (all lights green), and the engine will be running. CAUTION: If the engine has been properly maintained, and all of the external support systems, including raw water feed, fuel feed, battery power, etc., are functioning properly, the engine will normally start within 3 to 7 seconds. If the engine does not start within this time period, try only one more cranking attempt. DO NOT CONTINUE CRANKING!!! Safety Stops Low Oil Pressure. If the oil pressure drops below the 15 psi level, the oil pressure switch will open, the OIL light will go out and the fuel control valve will de-energize causing the engine to stop. High Exhaust Temperature: If the sea water flow is not sufficient, the exhaust manifold will get hot and the exhaust switch will open. Both the EXHAUST light and the OIL light will go out, and the engine will stop. High Cylinder Head Temperature: If the cylinder head temperature rises to the 185 degree F. point, the water temperature switch will open. ALL of the lights will go out and the engine will stop. CAUTION: If battery power is turned off, the engine will stop! If for any reason, the control system will not stop engine, it can be stopped by rotating the external lever on the side of the engine, behind the water pumps, to the full clockwise position. After the engine stops, return the control to the full counterclockwise position SW 72nd Portland, Oregon (503) Entec West, Inc.

27 Engine Control System Schematic D Series Panel Harness Off/Run/Start Switch H Extension Harness #87 Engine Harness #30 White #86 #85 Start Relay Volts from Battery #4 Gauge Min. Red Start Motor White Green Brown Orange Water Temp Exhaust Temp L Water Blue Oil Press L Exhaust L Oil HourMeter 555-T4-1E45 Black Fuel Control Valve Entec West, Inc SW 72nd Portland, Oregon (503)