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

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... 10 Fuel System D Series... 11 Flywheel and Stub Shaft... 12 Generator C Series... 13 Generator D Series... 14 Water Pump Assembly... 15 Heat Exchanger and Exhaust Manifold... 16 Base and Mounts C Series... 17 Base and Mounts D Series... 18 Air Cleaner... 19 Starter and Hand Crank... 20 Water Pump... 21 Engine Control System Operation C Series... 22 Engine Control System Operation D Series... 25 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118

Crankcase Serial Number 1 711-1187 Crankcase (includes Items 2, 3, and 4) 1 2 512-0884 Rear Cylinder Stud 2 3 512-0894 Front Cylinder Stud 2 4 512-0904 Stud, Main Bearing Plate 4 5 237-0032 Low Oil Pressure Switch, 12/18 PSI (C Series) (Normally Open) 1 237-40-07 Low Oil Pressure Switch, 15 PSI (D Series) (Normally Open) 1 7 770-1484 Oil Cooler Gasket 1 8 124-10-48 Oil Cooler, EW-4200-C (S/N 35166/01 and Later) 1 124-10-47 Oil Cooler, EW-4200-C (S/N 35165/20 and Before) 1 9 890-3106 Socket Head Capscrew, M06 x 20 (Torque 7 ft.-lbs.) 6 10 850-0214 O-Ring, 99mm x 3.0mm 1 11 727-0514 Main Bearing Plate 1 12 890-2023 Internal Snap Ring, 80mm x 2.5mm 1 13 890-5957 Seal, 60mm x 80mm x 08mm, Type BA 1 14 890-3805 Nut, M08 (Torque 22 ft.-lbs.) 4 15 890-6603 Internal Tooth Lockwasher, M08 4 16 724-0206 Oil Pump 1 17 770-1674 Oil Pump Gasket 1 18 890-7802 Split Spring Lockwasher, M06 3 19 890-3106 Socket Head Capscrew, M06 x 20 (Torque 7 ft.-lbs.) 1 20 890-3131 Socket Head Capscrew, M06 x 30 (Torque 7 ft.-lbs) 2 Included in Complete Gasket Set 770-2618 2 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

Gear Cover PARTS LIST Entec West, Inc. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 3

Gear Cover ART 1 718-07-94 Gear Cover 1 3 770-1454 Gear Cover Gasket 1 4 890-7202 Roll Pin, M10 x 16 2 8 890-1003 Split Spring Lockwasher, M06 1 9 512-0994 Retainer Bolt, Injection Pump Follower (Torque 7 ft.-lbs.) 1 10 850-0664 Oil Fill Cap Gasket 1 11 509-0184 Oil Fill Cap 1 12 762-1065 Oil Dipstick, 124mm 1 13 890-2814 Stud, M08 x 20 2 14 734-0328 Oil Sump Screen Assembly 1 15 890-3003 Oil Drain Plug, 3/8-19 BSPP 1 16 890-7425 Copper Seal, M17 x 23 x 01.5 1 17 770-1684 Oil Sump Screen Assembly Gasket 1 18 890-7404 Copper Seal, M06 x 10 x 01.5 2 19 890-3710 Hex Head Bolt, M06 x 20 (Torque 7 ft.-lbs.) 2 20 890-3129 Socket Head Capscrew, M08 x 70 (Torque 22 ft.-lbs.) 2 21 515-4014 Extra Fuel Knob 1 24 714-0118 Fuel Limit Control 1 25 890-3130 Socket Head Capscrew, M08 x 80 3 945-0094 Injection Pump Shim, 0.2mm As Req 26 945-0114 Injection Pump Shim, 0.5mm As Req 945-0184 Injection Pump Shim, 0.4mm As Req 945-0364 Injection Pump Shim, 1.0mm As Req 27 770-2014 Injection Pump Gasket As Req 28 536-2322 Injection Pump Cam Follower 1 29 536-0281 Injection Pump 1 30 890-1005 Split Spring Lockwasher, M08 2 31 890-3805 Nut, M08 (Torque 22 ft.-lbs.) 2 36 421-0514 Push Rod (Nearest to Cylinder is Intake) 2 37 850-0654 O-Ring, 32mm x 03mm 1 38 890-3104 Socket Head Capscrew, M05 x 30 (Torque 4 ft.-lbs.) 2 39 128-0108 Cam Follower, Compression Release 1 40 770-2034 Cam Follower Gasket 1 41 890-3135 Socket Head Capscrew, M08 x 90 1 42 890-2504 Ball Bearing, 6007 1 43 850-0884 O-Ring, 32.7mm x 1.3mm 1 44 890-1908 External Snap Ring, 35mm x 01.5mm 1 45 721-1155 Camshaft 1 46 452-0854 Camshaft Gear 1 47 890-6802 Key, M06 x 04 x 12 1 48 890-2805 Stud, M06 x 20 2 49 847-1234 Fuel Pump Gasket 1 50 175-0781 Fuel Transfer Pump 1 51 890-1103 Curved Spring Washer, M06 2 52 890-3803 Nut, M06 (Torque 7 ft.-lbs.) 2 53 118-08-00 Water Pump Mounting Bracket 1 54 890-59-99 Seal, 42mm x 55mm x 8mm, BA Viton 1 55 847-1214 Pump Bracket Gasket 1 56 890-29-01 Brass Plug, 3/8-19, BSPP 1 57 890-7425 Copper Gasket, 17mm x 23mm 1 58 890-8103 Flat Head, Socket Screw, M06 x 16 (Torque 7 ft.-lbs.) 4 59 890-43-13 Stud, M08 x 22, Special 2 60 501-19-00 Drive Pulley 1 Included in Complete Gasket Set 770-2618 Included in Top End Gasket Set 770-2618T-EW Units that have a groove in the camshaft should have this snap ring installed if it is not present. 4 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

Throttle Control 1 807-0114 Control Lever Spring 1 2 622-02-24 Fuel Rack Control Lever 1 3 513-0034 Governor Adjusting Screw 1 4 941-0274 Lock Plate 1 5 514-0992 Locknut, M06 (Torque 7 ft.-lbs.) 1 6 820-0114 Throttle Shaft Retaining Clip 1 7 403-0234 Throttle Shaft 1 8 850-0044 O-Ring, 10mm x 02.2mm 1 9 807-0354 Throttle Arm Return Spring 1 10 920-0094 Control Plate 1 11 905-1145 Emergency Shut Off Arm 1 12 890-6509 Internal Tooth Lockwasher, M08 1 13 890-3805 Nut, M08 (Torque 18 ft.-lbs.) 1 14 555-1442 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. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 5

Shut Off Solenoid Assembly C Series Generator C Series Generator Align Pin with Spring and lever when installing. 1 257-04-72 Shut Off Solenoid Assembly 1 2 890-31-99 Socket Head Capscrew, M04 x 06, SS 4 3 890-11-01 Curved Spring Washer, M04, Stainless 5 4 890-64-12 Clevis Pin, M04 x 12 2 5 890-07-15 Cotter Pin, M01 x 06 2 6 890-83-12 Flat Washer, M04, Stainless 1 7 890-31-79 Socket Head Capscrew, M04 x 30, SS 1 8 905-11-00 Shut Off Arm 2 9 890-83-13 Flat Washer,.390 x.625 x.063, SS 1 10 807-10-01 Compression Spring, Stainless 1 11 403-15-00 Shut Off Shaft 1 12 850-00-89 O-Ring,.504 x.375 x.070 1 13 890-47-01 Nylok Lock Nut, M04, Stainless 1 14 807-10-12 Rack Pin Link 1 15 890-83-12 Flat Washer, M04, Stainless 4 16 890-64-10 Hardened Pin, 01.5 x 06, SS 4 Fuel Control Valve D Series Generator 17 890-74-02 Copper Seal, 5.7mm x 7.9mm x 1.0mm 1 18 257-04-82 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. 6 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

Crankshaft and Cylinder 1 715-0757 Crankshaft Assembly 1 3 850-0104 O-Ring, 32mm x 2.0mm 1 4 519-0344 Wear Ring for Seal 1 5 804-0064 Belleville Spring Washer (Large Diameters Touch) 2 6 514-0444 Flywheel Nut (Torque 190 ft.-lbs.) 1 7 452-0794 Crankshaft Gear 1 775-0324 Shell Bearing, Standard 1 8 775-0334 Shell Bearing,.25mm Undersize 1 775-0344 Shell bearing,.50mm Undersize 1 470-0084 Con Rod Bearing, Standard 1 9 470-0094 Con Rod Bearing,.25mm Under 1 470-0124 Con Rod Bearing,.50mm Under 1 10 890-6802 Key, 06mm x 04mm x 12mm 2 11 800-0252 Roller Bearing (Direct Replacement for Ball Bearing) 1 540-0301 Governor Assembly, 3600 rpm 1 12 540-0261 Governor Assembly, 3000 rpm 1 540-0302 Governor Spring Set, 3600 rpm 1 540-0262 Governor Spring Set, 3000 rpm 1 13 890-6106 Governor Pin, 04mm x 27.8mm 1 15 725-1018 Piston Assembly 1 16 535-0411 Piston Ring Set (Ring Gap.2mm to.8mm) 1 17 890-9101 Piston Pin Retainer 2 18 418-0144 Piston Pin 1 19 726-0335 Connecting Rod Assembly 1 20 510-0164 Connecting Rod Bolt 2 21 514-0374 Connecting Rod Nut (Torque 22 ft.-lbs.) 2 22 465-1554 Piston Pin Bushing 1 24 890-1705 Core Plug, 22mm 4 25 960-0544 Water Transfer Tube 2 26 850-0044 O-Ring, 10mm x 2.2mm 2 27 729-04-75 Cylinder Assembly 1 Included in Complete Gasket Set 770-2618 Included in Top End Gasket Set 770-2618T-EW Early cylinders had a removable water jacket. Contact the factory for assistance. Entec West, Inc. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 7

Cylinder Head PARTS LIST 8 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

Cylinder Head ART 1 731-1928 Cylinder Head Assembly 1 2 712-0325 Crankcase Breather Valve 1 3 771-0174 Cylinder Head Gasket 1 4 427-0304 Intake Valve (Recess.004 to.008 ) 1 5 927-0154 Spacer 2 6 426-0184 Valve Guide 2 7 861-0054 Valve Guide Seal 2 8 805-0444 Intake Valve Spring 1 9 531-0054 Valve Spring Retainer 2 10 527-0024 Valve Keeper 2 11 427-0164 Exhaust Valve (Recess.004 to.008 ) 1 12 521-2444 Ring 1 14 555-0012 Valve Rotator 1 15 805-0474 Exhaust Valve Spring 1 16 807-0414 Push Rod Tube Retainer 1 17 890-2801 Stud, M05 x 10 2 18 890-0801 Flat Washer, M05 2 19 890-4702 Nylok Lock Nut, M05 (Torque 4 ft.-lbs.) 2 20 415-0824 Rocker Arm Shaft 1 21 633-0355 Exhaust Rocker Arm Assembly 1 22 633-0345 Intake Rocker Arm Assembly 1 23 513-0174 Rocker Arm Adjusting Screw (Valve Clearance.007 Cold) 2 24 890-3804 Nut, M07 (Torque 11 ft.-lbs.) 2 25 537-0041 Fuel Injector Assembly (Opening Pressure 2900 PSI) 1 26 850-0704 Injector Gasket 1 27 537-2082 Injector Nozzle 1 30 928-0454 Injector Clamp 1 31 890-4366 Stud, M06 x 50 1 32 890-4365 Stud, M06 x 45 1 33 890-7802 Split Spring Lockwasher, M06 2 34 890-3803 Nut, M06 (Torque 7 ft.-lbs.) 2 35 921-0354 Push Rod Tube 1 36 850-0644 O-Ring, 24mm x 03.5mm 1 37 890-1705 Core Plug, 22mm 2 38 890-1704 Core Plug, 18mm 1 39 770-1424 Rocker Cover Gasket 1 40 651-0324 Rocker Cover 1 41 890-0815 Nylon Gasket, M08 2 42 924-0074 Lifting Eye 1 44 514-0374 Cylinder Head and Rocker Cover Nut (Torque Cylinder Head 22 ft.-lbs.) 6 45 890-1704 Core Plug, 18mm 1 47 555-0052 Water Temperature Switch, 185 F., Normally Open, C Series 1 555-00-53 Water Temperature Switch, 185 F., Normally Closed, D Series 1 48 890-7419 Copper Seal, 14mm x 20mm x 01.5mm 1 49 890-3111 Socket Head Capscrew, M08 x 25 (Torque 18 ft.-lbs.) 2 50 890-1005 Split Spring Lockwasher, M08 2 51 890-05-10 Reservoir Plug, 1/2 NPT 1 890-05-16 Expanding Plug, 7/8 (Early Units) 1 52 770-1084 Reservoir Gasket 1 53 555-0062 Thermostat, 167 F. 1 54 982-30-05 Reservoir 1 55 982-05-06 Adapter 90, 3/8 NPT x 1/2 Barb, C Series 1 982-05-07 Adapter 45, 3/8 NPT x 1/2 Barb, D Series 1 56 982-05-08 Adapter Elbow, 3/8 NPT x 3/8 Barb 1 57 890-1704 Core Plug, 18mm 1 918-0014 Core Plug, 13mm Used on Early Units 2 58 982-05-01 Adapter, 1/8 NPT x.170 Barb, D Series (Not Shown) 1 Included in Complete Gasket Set 770-2618 Included in Top End Gasket Set 770-2618T-EW Entec West, Inc. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 9

Fuel System C Series Generator 1 515-0224 Banjo to Hose Barb, 12mm x 1/4 1 2 890-7406 Copper Seal, 08mm x 12mm x 01.0mm 7 3 515-0164 Banjo Bolt, Male/Female 1 4 890-7416 Copper Seal, 12mm x 18mm x 01.5mm 2 5 850-0674 Copper Gasket, Special 1 6 890-7701 Banjo Bolt, M08 x 01 2 7 515-3572 Banjo Bolt, M08 x 01.25 2 8 515-0864 Banjo to Hose Barb, 8mm x 1/4 2 9 922-74-08 Screw Clamp, 1/2, SS 2 10 541-03-82 Fuel Filter Assembly 1 11 971-3215 High Pressure Injection Line 1 12 971-37-35 Fuel Leak Off Line, C Series 1 Included in Complete Gasket Set 770-2618 Included in Top End Gasket Set 770-2618T-EW 10 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

Fuel System D Series Generator 1 515-0224 Banjo to Hose Barb, 12mm x 1/4 1 2 890-7406 Copper Seal, 08mm x 12mm x 01.0mm 7 3 515-0164 Banjo Bolt, Male/Female 1 4 890-7416 Copper Seal, 12mm x 18mm x 01.5mm 2 5 850-0674 Copper Gasket, Special 1 6 890-7701 Banjo Bolt, M08 x 01 2 7 515-3572 Banjo Bolt, M08 x 01.25 2 8 515-0864 Banjo to Hose Barb, 8mm x 1/4 2 9 922-74-08 Screw Clamp, 1/2, SS 2 10 541-03-82 Fuel Filter Assembly 1 11 971-3215 High Pressure Injection Line 1 12 971-42-98 Fuel Leak Off Line Assembly, D Series 1 Included in Complete Gasket Set 770-2618 Included in Top End Gasket Set 770-2618T-EW Entec West, Inc. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 11

Flywheel and Stub Shaft 1 738-1744 Flywheel 1 2 453-0194 Ring Gear 1 3 407-00-01 Stub Shaft, C Series 1 407-00-02 Stub Shaft, D Series 1 4 890-3113 Socket Head Capscrew, M08 x 35 (Torque 22 ft.-lbs.) 4 5 890-1005 Split Spring Lockwasher, M08 4 6 890-99-01 Stud, 5/16-24 Special (Torque 18 ft.-lbs.), C Series 1 890-3661 Hex Head Capscrew, M08 x 160 (Torque 22 ft.-lbs.), D Series 1 12 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

Generator C Series 1 630-01-00 Bell Housing 1 2 890-2832 Stud, M10 x 25 4 3 890-1007 Lockwasher, M10 4 4 890-3807 Nut, M10 (Torque 32 ft.-lbs.) 4 5 547-KP-20 Voltage Regulator Capacitor 1 6 922-84-03 Regulator Mounting Clamp, SS 1 7 890-99-02 Screw, 10-32 x 3/8,SS 2 8 890-11-02 Crinkled Spring Washer, M05, SS 2 9 158-27-01 Generator Stator Assembly, 60 Hz 1 158-27-02 Generator Stator Assembly, 50 Hz 1 158-65-01 Generator Rotor Assembly 1 10 547-21-PT80 Rectifier, Rotating Field 2 890-25-05 Ball Bearing, 6203-2RS1 1 11 630-04-00 Generator Endbell 1 12 890-99-03 Socket Head Capscrew, 5/16-18 x 6 (Torque 20 ft.-lbs.) 4 Entec West, Inc. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 13

Generator D Series 2 890-2832 Stud, M10 x 25 4 3 890-1007 Lockwasher, M10 4 4 890-3807 Nut, M10 (Torque 32 ft.-lbs.) 4 5 547-KP-20 Voltage Regulator Capacitor 1 158-65-01 Generator Rotor Assembly 1 10 547-21-PT80 Rectifier, Rotating Field 2 890-25-05 Ball Bearing, 6203-2RS1 1 13 630-01-01 Bell Housing 1 14 158-27-88 Generator Stator Assembly, 60 Hz 1 158-27-90 Generator Stator Assembly, 50 Hz 1 15 158-27-89 Generator Endbell 1 16 770-38-01 Gasket, Endbell 1 17 890-7802 Lockwasher, M06 24 18 890-7006 Socket Head Capscrew, M06 x 16 (Torque 7 ft.-lbs.) 24 19 890-3119 Socket Head Capscrew, M10 x 30 (Torque 32 ft.-lbs.) 3 20 890-1007 Lockwasher, M10 3 21 999-09-03 AC Outlet Box 1 22 999-09-04 Cover, Outlet Box 1 23 890-79-01 Sheet Metal Screw, 10-32 x 3/8 2 24 890-30-01 Button Head Screw, 10-32 x 3/8 4 25 890-78-01 Lockwasher, 3/8 4 14 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

Water Pump Assembly 1 538-23-01 Water Pump Assembly 1 2 890-6843 Key, Round End, M03 x 03 x 12 1 3 501-20-00 Water Pump Pulley 1 4 890-1918 External Snap Ring, M12 x 1.0 1 5 538-2412 Pump Clamp 2 6 890-1106 Crinkled Spring Washer, M08 2 7 890-3805 Nut, M08 (Torque 18 ft.-lbs.) 2 8 982-05-07 Adapter 45, 3/8 NPT x 1/2 Barb 1 9 982-05-04 Adapter, 3/8 NPT x 1/2 Barb 1 982-04-07 Adapter, 45, 3/8 NPT x 1/2 Barb 1 10 922-74-07 Screw Clamp, 7/8, SS 2 11 860-32-01 Hose, Oil Cooler to Coolant Pump, C Series 1 860-32-20 Hose, Oil Cooler to Coolant Pump, D Series 1 12 982-05-06 Adapter Elbow, 3/8 NPT x 1/2 Barb 2 13 860-32-03 Hose, Engine Pump to Bypass 1 14 890-99-02 Screw, 10-32 x 3/8, SS 1 15 890-11-02 Crinkled Spring Washer, M05, SS 1 16 922-08-52 Clamp 1 17 982-05-09 Engine Coolant Bypass 1 18 922-17-00 Stepless Hose Clamp, 11/16, SS 2 19 860-32-11 Hose, Bypass to Reservoir 1 20 922-21-01 Stepless Hose Clamp, 13/16, SS 2 21 890-55-18 Water Pump Belt, 180-XL-037 1 Entec West, Inc. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 15

Heat Exchanger and Exhaust Manifold 538-16-01 Heat Exchanger, C Series 1 538-16-03 Heat Exchanger, D Series 1 1 917-50-69 End Cover 2 770-03-32 End Cover Gasket 2 770-50-68 Cover Bolt Gasket 2 890-37-50 Hex Head Bolt, 3/8-16 x 5/8 2 890-29-90 Plug with Zinc 1 2 890-29-91 Plug Only 1 890-29-92 Zinc Replacement 1 3 922-13-00 Heat Exchanger Clamp, Stainless 2 4 890-99-02 Screw, 10-32 x 3/8, Stainless 6 5 890-11-02 Crinkled Spring Washer, M05, SS 6 6 617-02-75 Exhaust Manifold, C Series 1 617-02-85 Exhaust Manifold, D Series 1 7 770-1584 Exhaust Gasket 1 8 890-31-30 Socket Head Capscrew, M08 x 80, SS 2 9 890-78-03 Split Spring Lockwasher, M08, SS 2 10 982-05-05 Adapter Elbow, 1/4 NPT x 1/2 Barb 1 11 922-21-01 Stepless Hose Clamp, 13/16, SS 7 12 860-32-09 Hose, Reservoir to Exhaust Manifold 1 13 860-33-04 Hose, Sea Pump to Heat Exchanger 1 14 922-08-52 Clamp 2 15 922-74-07 Screw Clamp, 7/8, SS 1 16 860-32-07 Hose, Reservoir to Heat Exchanger 1 860-32-05 Hose, Heat Exchanger to Oil Cooler, C Series 1 17 860-32-18 Hose, Heat Exchanger to Stator Housing, D Series 1 860-32-15 Hose, Stator Housing to Oil Cooler, D Series 1 18 555-08-81 Exhaust Temperature Switch, Normally Open, 140 F., C Series 1 19 555-00-54 Exhaust Temperature Switch, Normally Closed, 185 F., D Series 1 Included in Top End Gasket Set 770-2618T-EW 16 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

Base and Mounts C Series Generator 1 534-05-05 Vibration Mount 3 2 614-06-01 Engine Mounting Bracket 2 3 890-11-06 Crinkled Spring Washer, M08, SS 3 4 890-99-25 Nut, 5/16-18, SS (Torque 18 ft.-lbs.) 2 5 890-1110 Crinkled Spring Washer, M12 4 6 890-3138 Socket Head Capscrew, M12 x 25 (Torque 34 ft.-lbs.) 4 7 614-03-00 Base, EW-4200-C 1 8 890-99-06 Jam Nut, 5/16-18, SS (Torque 18 ft.-lbs.) 1 Entec West, Inc. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 17

Base and Mounts D Series Generator 1 534-05-06 Vibration Mount 3 2 614-06-05 Engine Bracket 2 3 890-3641 Hex Head Capscrew, M10 x 65 4 4 890-4709 Nylok Lock Nut, M10 (Torque 32 ft.-lbs.) 4 5 924-00-12 Generator Bracket 1 6 890-3113 Socket Head Capscrew, M08 x 30 (Torque 22 ft.-lbs.) 2 7 890-1005 Lockwasher, M08 2 8 890-31-19 Socket Head Capscrew, M10 x 30, SS (Torque 32 ft.-lbs.) 3 9 890-37-37 Hex Head Capscrew, M10 x 16, SS (Torque 32 ft.-lbs.) 6 10 890-10-07 Lockwasher, M10, SS 9 11 614-03-00 Base, EW-4200-D 1 18 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

Air Cleaner 1 512-1634 Stud, Air Cleaner 1 2 770-1584 Air Cleaner Mounting Gasket 1 3 625-1964 Air Cleaner Mounting Base 1 4 890-7012 Socket, Low Head Capscrew, M08 x 20 (Torque 18 ft.-lbs.) 1 5 850-1804 Air Cleaner Cover Gasket 1 6 890-1005 Split Spring Lockwasher, M08 1 7 890-3805 Nut, M08 (Torque 18 ft.-lbs.) 1 9 541-0652 Air Cleaner Element 1 10 741-1615 Air Cleaner Cover 1 11 890-08-02 Flat Washer, M06, SS 1 12 514-0932 Nylok Type Wing Nut, M06 1 Included in Top End Gasket Set 770-2618T-EW Entec West, Inc. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 19

Starter and Hand Crank 1 547-3681 Starter Motor 1 547-3681R Rebuilt Starter Motor 1 2 547-0692 Bushing 1 3 890-2832 Stud, M10 x 25, C Series 2 890-3637 Hex Head Capscrew, M10 x 45, D Series 2 4 890-1007 Split Spring Lockwasher, M10 2 5 890-8501 Special 15mm Hex Nut, M10 (Torque 32 ft.-lbs.) C Series 2 890-3807 Nut, M10 (Torque 32 ft.-lbs.) D Series 2 6 110-2085 Hand Crank, (A = 105mm) C and D Series 1 7 110-1975 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. 20 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

Water Pump 1 538-01-350623 Sea Water Pump Body 1 2 538-01-45360 Sea Water Pump Shaft 1 3 538-01-42415 Sea Water Pump Cam 1 4 538-2192 Impeller, 09-808B 2 5 538-01-45359 End Cap, Sea Water Pump 1 6 538-2232 Gasket, Sea Water Pump 1 7 538-01-45087 Wear Plate 2 8 538-01-42400 Guide Pin 2 9 538-01-45110 Bushing 1 10 538-05-29502 Seal, Sea Water Pump 1 11 538-05-01120 Copper Gasket 2 12 513-0312 Cam Screw, Special Pitch x 8.0mm 2 13 538-05-04123 Screw, Impeller 2 14 538-05-04176 Brass Screw, M04 x 10 8 15 890-2008 Internal Snap Ring, M28 x 1.2 1 16 820-0342 External Snap Ring 1 17 890-6843 Key, Round End, M03 x 03 x 12 1 18 538-01-45669 Pump Shaft, Engine Pump 1 19 890-25-25 Ball Bearing, 6001-2RS1 2 20 890-5932 Seal, Engine Pump, 12 x 24 x 07 2 21 538-01-350963 Pump Body, Engine Pump 1 22 538-01-42910 Cam, Engine Pump 1 23 538-01-45400 Gasket, Engine Pump 1 Entec West, Inc. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 21

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. 22 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

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. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 23

Engine Control System Schematic C Series Panel Harness 547-43-00 Start/Stop Switch 547-10-US Extension Harness 547-06-11 Engine Harness 547-47-00 Off #1 #3 Run Stop #5 #6 Start D3 Hourmeter 555-T4-1E45 White #87 #86 #85 #30 Diode/Diode/Resistor Assy D3 D4 R2 547-45-00 R2 Start Relay 547-66-200 +12 Volts from Battery #4 Gauge Min. Red Start Motor 547-3681 Green Alarm Lamp Assy 547-40-00 HC1 #87 #30 #30 #87 D4 Stop Solenoid 257-04-72 D2 H1 #86 #85 RL1 #86 #85 RL2 Relay/ Timer Assy 547-44-00 R1 C1 Capacitor Assy 547-42-00 D1 547-41-00 Black Orange Oil Pressure 237-0032 Water Temp 555-0052 Exhaust Temp 555-08-81 24 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

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. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 25

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. 26 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 Entec West, Inc.

Engine Control System Schematic D Series Panel Harness 547-06-13 Off/Run/Start Switch 547-644H Extension Harness 547-06-12 #87 Engine Harness 547-47-01 #30 White #86 #85 Start Relay 547-66-200 +12 Volts from Battery #4 Gauge Min. Red Start Motor 547-3681 White Green Brown Orange Water Temp 555-00-53 Exhaust Temp 555-00-54 L Water 547-50-03 Blue Oil Press 237-40-07 L Exhaust 547-50-03 L Oil 547-50-03 HourMeter 555-T4-1E45 Black Fuel Control Valve 257-04-82 Entec West, Inc. 16710 SW 72nd Portland, Oregon 97224 (503) 624-7118 27