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Entec EW-4200D, Operating Instructions Manual

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Entec EW-4200D Operating Instructions Manual Download Page 8

16710 SW 72nd

•

Portland, Oregon 97224

•

(503) 624-7118

Entec West, Inc.

8

System Descriptions

EW-4200D

Off/Run/Start Switch
547-644H

Start Motor
547-3681

Start Relay
547-66-200

#87

+12 Volts
from Battery
#4 Gauge Min.

Green

Brown

Orange

Blue

Black

#86

#85

#30

Oil
547-50-03

Exhaust
547-50-03

Water
547-50-03

HourMeter
555-T4-1E45

Red

White

Fuel Control
Valve
257-04-82

Oil Press
237-40-07

Exhaust Temp
555-00-54

Water Temp
555-00-53

Panel Harness
547-06-13

Engine Harness
547-47-01

Extension Harness
547-06-12

White

L

L

L

ENGINE CONTROL SYSTEM (cont.)

Fuel Control Valve.

 The Fuel Control Valve (6/18) is mounted

on the Fuel Injection Pump. It is normally de-energized. In the
de-energized position, the high pressure output from the Injec-
tion Pump is bypassed into the fuel return line. The injector does
not receive fuel.

Off/Run/Start Switch.

+12 volts is taken from the
starter post, through the
wiring harness (red wire),
and applied to the terminals
of the Off/Run/Start switch
located on the control panel.

Run Position.

 When the

Off/Run/Start switch is
moved to the Run position,
+12 volts is applied back
through the harness (green
wire) to one side of the
water temperature switch.
This switch is normally
closed, so the +12 volts will
pass through the switch to
the exhaust temperature
switch, and also through the
harness (brown wire) to the
water lamp. The water lamp
will illuminate because the
engine coolant temperature
is below 185 degrees F.

Since the exhaust tempera-
ture switch is also closed,
the +12 volts goes to the oil
pressure switch, and also through the harness (orange wire) to
the exhaust lamp. The exhaust lamp will illuminate because the
exhaust temperature is also below 185 degrees F. The oil pres-
sure switch is normally open, so the +12 volts will stop at this
point with the two lamps illuminated.

Fuel Control Valve

Summary of Contents for EW-4200D

Page 1: ...e Engine for the First Time 10 11 Normal Engine Starting 12 Generating A C Power 13 Emergency Stop 13 Manual Hand Starting 14 Periodic Maintenance Changing the Oil 15 Air Cleaner 15 Valve Adjustment 16 Heat Exchanger 16 Raw Water Pump Maintenance 17 Theory of Operation How Compression Ignition Works 18 19 16710 SW 72nd Portland Oregon 97224 503 624 7118 ENTEC WEST INC Marine Diesel Generators Oper...

Page 2: ...w M06 x 30 Torque 7 ft lbs 2 Included in Complete Gasket Set 770 2618 Serial Number 2 12 How to Use this Manual EW 4200D We congratulate you on your purchase of the Model EW 4200D generator These operating instructions are based on the most recent state of development and every possibile effort has been taken to exclude errors and omissions All those involved in the installation and operation of t...

Page 3: ...Pump is pumping at a rate of approxi mately 3 17 gallons per hour The Fuel Injection Pump will only use 0 4 of a gallon per hour when the generator is producing 30 amps of electrical power The high volume of return flow provides a continuous cleaning action of the fuel through the vessel s filter This will help to keep the fuel in the tank clean Fuel Filter Fuel Pump Fuel Injection Pump WATER PUMP...

Page 4: ...nto the rear upper left corner of the Generator Housing 14 15 Heat Exchanger Outlet Generator Outlet Input Side Fresh Water Pump Bypass Tee After circulating through the Generator Housing it flows from the lower front right side of the Generator Housing through the Oil Cooler 2 8 in the base of the engine to the input side of the Fresh Water Pump front pump 15 9 The pump pushes the coolant across ...

Page 5: ...ptions EW 4200D Bypass Hose Reservoir Outlet Reservoir Fill Plug When the Thermostat opens the Cylinder and Cylinder Head flow goes through the thermostat and into the Reservoir where it joins the bypass flow From there the warm coolant returns to the Heat Exchanger hose 16 16 where the accumulated heat is transferred to the raw water The closed loop cooling system has been charged at the factory ...

Page 6: ...t exhaust gases to cool them It then flows with the exhaust gas into the typical wet marine exhaust system CAUTION Whenever the engine is cranked the Raw Water Pump continues to pump water through the raw water system With continued cranking it is possible to fill the Exhaust Percolating Muffler the Exhaust Hose the Exhaust Elbow and if the Exhaust Valve is open the engine combustion chamber with ...

Page 7: ...eight for all season use System Descriptions EW 4200D ENGINE CONTROL SYSTEM The remote run stop control for the engine is accomplished through the use of a special high pressure valve When the valve is energized it closes and the injection pump is allowed to deliver high pressure fuel to the injector The engine is further controlled by three switches water temperature exhaust tem perature and oil ...

Page 8: ... Off Run Start Switch 12 volts is taken from the starter post through the wiring harness red wire and applied to the terminals of the Off Run Start switch located on the control panel Run Position When the Off Run Start switch is moved to the Run position 12 volts is applied back through the harness green wire to one side of the water temperature switch This switch is normally closed so the 12 vol...

Page 9: ...ery power is turned off the engine will stop System Descriptions EW 4200D ENGINE CONTROL SYSTEM cont Start Position Moving the Off Run Start switch to the Start position allows 12 volts to flow the same as in the Run posi tion In addition 12 volts flows through the harness white wire to the start relay located on the top of the generator by the start motor With 12 volts applied the relay energizes...

Page 10: ... Fuel Transfer Pump 3 50 on the upper right side of the engine Pump the Priming Lever for 20 to 30 strokes in order to supply vessel fuel to the engine Use the full move ment of the lever Only the last few degrees of motion will actually pump fuel Handcrank Priming Lever Small pin on the Compression Release Shaft Water Pump Drive Pulley 4 Locate the Compression Release Shaft 3 39 above the drive p...

Page 11: ...tic feature will not function when the small pin points anywhere between the 9 o clock and 12 o clock positions Use the second slot of the tab on the Handcrank to rotate the Compression Release Shaft to a position just past twelve o clock once again the Handcrank will stop against the valve cover This will program the Compression Release to index one step for each rotation of the camshaft The Comp...

Page 12: ...ough 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 is delivered to the injector pipe and thus to the Injector If the engine is operating normally it will start in 3 to 7 seconds 2 When it starts quickly release the Start Switch and set it to the Run position The control panel will s...

Page 13: ...inutes so it can cool down NOTE If the unit has been operating under heavy load and stopped without a cooling off period residual heat from the lower end of the engine can migrate upward and trip the Water Temperature Switch If this happens the alarm system will prevent re starting the engine until it has completely cooled down Operation EW 4200D EMERGENCY STOP If the engine cannot be stopped by t...

Page 14: ...g parts of the engine Each time the handcrank makes one revolution the compression release will automatically index one step On the seventh turn the Compression Release will reset itself to normal compression mode Do not slow down Your body energy added to the inertia will help you pull through the compression stroke and create ignition When this happens the engine will start All three lights on t...

Page 15: ...ontains a dry element filter Remove it and shake the accumulated dirt from it each time you change the oil The element should be replaced every 250 to 300 hours Air Cleaner Element Dipstick Oil Fill Cap Remove the oil Fill Cap and add one quart of approved oil Replace the oil Fill Cap and Dipstick Start the engine and let it run for one to two minutes Stop the engine and check the level on the oil...

Page 16: ...d through them Do not use a rod diameter greater than 11 64 The Heat Exchanger contains a sacrificial Zinc Insert in a plug 16 2 Examine it when checking the valve clearance and replace as necessary The Zinc is a readily available Type 1A Valve Cover Put the Handcrank into the Camshaft and rotate it counterclock wise until you feel hard resistance from compression Check the gap between the valve s...

Page 17: ...emoval If it is necessary to replace the Seals or Impeller 21 4 in the raw water pump follow these steps 1 Clamp the raw water Outlet Hose 16 13 with vise grip pliers This will prevent raw water from draining into the drip pan 2 Remove the four screws 21 14 from the End Cap using a 7mm socket and 1 4 drive ratchet A box or open end wrench can also be used but not as conveniently Pull the End Cap 2...

Page 18: ... in the piston cup so that it cannot escape into the cylinder walls etc the temperature of the compressed air will get very high Power Stroke At the top of the compression stroke the fuel is sprayed into the very hot compressed air and ignites As the fuel burns the hot combusted gases expand forcing the piston down The force applied to the top of the piston in the downward motion is converted into...

Page 19: ...ough to prevent the heat loss The same is true for hand cranking speed A timid hand cranker will never start the engine by hand Fuel Efficiency The injection pump is controlled by the engine governor 7 12 13 and throttle control 5 1 13 system that tells the injection pump how much fuel should be delivered to the injector This quantity is established every single time the engine reaches the end of ...

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