MadeinEngland

Quayworks–IsuzuMarineEngineControlPanelRefreshKits–ProductCodeQWRK1Thank-youforpurchasingyourrefreshkitfromQuayworks.Pleasecontactdirectshouldyouneedto:SmallCraftServicesLtd17StratfordRdAlcesterWarksB495AUinfo@quayworks.com-www.quayworks.comAboutYourQWRK1refreshkitiscustommadeforISUZUmarineenginessuppliedbyHMISUZUthroughoutthelate1990sandintothe2000s.Thekitconsistsoftwocomponentareas:FasciaStickerHighdurabilityself-adhesivevinyl,withUVresistanttoplayer.ThestickersaremadeinWorcestershire,England,toadesigndrawnbyQuayworks.ReplacementLensandSymbolsThelensandsymbolsareOEMpartssourcedinEuropeandimportedbyQuayworks.InstallationInstructionsNOTE:Therearetwoadditionalcablesthatbypassthemulti-plugwhereauxiliaryalternatorandrevcounterareinstalled.IMPORTANT:Beforecommencingreplacement,ensureyourboatisisolatedfromtheshoreACandinverters,generators,oranyotherpowersource.EnsuretheDCisolatorsareswitchedoff.

1. Unscrewthepanel,pullgentlyawayfromtheboat(youmighthavetorunascraperaroundtheedgestoreleasesealantorpaint).Pullthepanelgentlyawayfromtheboatuntilyouhaveaccesstothemulti-plugconnector.Disconnectthemulti-plugandthetwoadditionalcableconnectionsthatbypasstheconnectorasdescribedabove(iffitted).Youcanthenremovethepanelanditsloom.

2. Notedownthecoloursofthecablesandwhattheyconnectto.ForreferencetheOEMwiringguideisincludedattheendofthisdocument.Notethatitcan’tbeguaranteedthatyourexistingwiringmatchestheoriginaldesign.

3. Removethewiringfrompanel.Alltheconnectorsarepushconnectorsandcanbeeasilyreleased.

Takecarenottobreaktheresistorsonthealternatorchargelights(ifyoudoyourbatterieswillnotgetcharged).

4. Removethelamps,ignitionbarrel,stopbuttonanddials(wherefitted).Notewhichlampsgowhere.

5. Cleanthepanelfasciawithasolventcleaner–removeanynon-standardstickers.Smoothoffanydamagetoleaveacleansmoothsurface.

6. Takethefasciastickerandremovetheadhesivebacking.Linethestickerupwiththepaneland

apply.Whenyouaresureitiscorrectlylocated,applysmooth,evenpressuretoensureagoodbond.

7. Reinstallthewarninglampsandstopactuator,alongwiththeignitionbarrel.

8. Removethelensesfromthelamps.Theeasiestwayistouseafingernailandleverthemout;

alternativelyuseasmallflatscrewdriver.Removetheindicatorsymbols.Installthereplacementsymbolsandlenscovers–linethecorrespondingnotchesupandgentlypushthelensintoplace.NOTE:thestopbuttonlensreplacementisslightlyconcaveanddifferenttotheotherredlens.

9. Reinstalltherevcounteranddials(wherefitted).

10. Refitthewiringloom

11. Takethepanelandconnectthemulti-plugconnection.Ensuretheconnectionispushedtightlyon.

Someusersliketoaddacabletietotheplugtopreventanyaccidentaldisconnection–thisisoptional.Oncetheconnectionismade,ensuretherubberbootonispulledfirmlyovertheconnection.Iftherubberbootismissing,ordamaged,youshouldreplaceit.

12. Connectthex2cablesthatbypassthemulti-plug.

13. TurnontheengineormainDCbatteryisolator,andcarryoutthefollowingpreliminarychecks:

• Turntheignitionkeyto“1”• Thewarningalarmshouldnowsound• Theoillightandalternatorlight(s)shouldbeon.

Iftheaboveconditionsaremet,proceedtothenextstep.Iftheaboveconditionsarenotmet,checktheDCsupplyandthemulti-plugconnectionsandthebypassedconnectionsarecorrectlymade.

14. Ensureallterminalsandconnectorsareclearofthestructureofthevessel,toavoidshortcircuitsduringafulloperatingtest,asbelow:

A. Insertthekey,atposition“0”B. Turnthekeyclockwisetoposition“1”

Observethattheoilwarninglight,andthealternatorchargelight(s)comeon.Thewarningalarmwillsound.NOTEtheoverheatlightshouldnotilluminateatthistime.

C. Turnclockwiseandholdthekeyinthe‘HEATERPLUG’position,fortherequiredperiodof

timeforyourengine.Youmayhearaslightchangeinthetoneofthewarningalarm,andtheyellow‘HEATERPLUG’lightwillilluminate.

D. Afterallowingsuitabletimeon‘HEATERPLUG’,turnthekeyfurtherclockwisetoengagethe

startermotor.Assoonastheenginestarts,releasethekey,whichwillreturntoposition“1”automatically.

E. Ensureallwarninglightsareextinguishedandthattherevcounterisreading.

15. Applyabeadofnon-settingsealant(e.g.mastic)aroundtheedgeofthereplacementpanel,

ensuringthesealantisappliedaroundthepartsofthepanelthatwillbeflushagainsttheboat.

16. Pushthepanelupintoplaceandaddthefixingstoeachcorner.Donotover-tighten.Ensurethepanelissealedandremoveexcesssealant.

17. Conductafulloperatingtest.

GuidanceonWarningLightsandAlarmLIGHTLABEL,COLOUR FUNCTION ACTION‘TEMP’-Red

Warnsuserthatengineisclosetooverheatingduetoenginecoolanttemperaturebeingtoohigh.Thewarningalarmwillsound.

SWITCHOFFENGINEIMMEDIATELY.Establishthereasonsforoverheatingandrepairasnecessary.

‘OIL’-Red

Warnsuserthattheoilpressureislow.Thiscouldbeduetolowoillevelsoranoilleak.Thewarningalarmwillsound

SWITCHOFFENGINEIMMEDIATELY.Establishreasonsforlowoilpressureandrepair.

‘ALT1’-Red

Warnstheuserthatthereisnochargeoutputfromthelefthand(usuallystarterbattery)alternator.Thiscouldbeduetoabrokendrivebeltorcable.Thewarningalarmwillsound.Beawarethisbeltalsodrivesthecoolantpump.Ifthislightandtheoverheatlightbothcomeon,thelikelihoodisabrokenorloosebelt.

SWITCHOFFENGINEIMMEDIATELYEstablishthereasonsfornoalternatoroutputandrepair.

‘ALT2’-Red

Warnstheuserthatthereisnochargeoutputfromtherighthand(usuallyleisurebattery)alternator.Thiscouldbeduetoabrokendrivebeltorcable.ThewarningalarmwillNOTsound.

SWITCHOFFENGINEIMMEDIATELYEstablishthereasonsfornoalternatoroutputandrepair.

‘GLOW’–Amber

Informstheuserthatthekeypositionfortheengineglowplugshasbeensatisfactorilyengaged.

None

QUAYWORKSLTD–ISUZUPANELWIRING VER1.1

PURPOSE COLOUR CONNECTORREQUIRED NOTES

TEMPLAMP WHITE 4.8mmfemalespade

GREEN/YELLOW 4.8mmfemalespade

OILPRESSURELAMP WHITE 4.8mmfemalespade

BROWN/PURPLE 4.8mmfemalespade

CHARGELAMP1(ENGINESTARTERBATTERYALTERNATOR) WHITE 4.8mmfemalespade REQUIRESRESISTOR BROWN/YELLOW 4.8mmfemalespade

CHARGELAMP2(DOMESTICBATTERYALTERNATOR) WHITE 4.8mmfemalespade REQUIRESRESISTOR

BLACK/YELLOW 4.8mmfemalespade (BYPASSESMULTIPLUG)

IGNITIONBARRELTERMINAL17 RED/WHITE 9.5mmfemalespade

IGNITIONBARRELTERMINAL19 RED6.3mmfemalespade SHARESCONNECTOR

IGNITIONBARRELTERMINAL19 RED

IGNITIONBARRELTERMINAL15/54 WHITE6.3mmfemalespade SHARESCONNECTOR

IGNITIONBARRELTERMINAL15/54 WHITE

IGNITIONBARRELTERMINAL15/54 WHITE 6.3mmfemalespade

IGNITIONBARRELTERMINAL30 BROWN/YELLOW 9.5mmfemalespade

WARNINGBUZZER WHITE 6.3mmfemalespade

PURPLE 6.3mmfemalespade

STOPBUTTON WHITE Ferrule

WHITE/BLACK Ferrule

REVCOUNTER-NEGATIVE BLACK 4mmring

REVCOUNTER-IGNTIONFEEDPOSITIVE WHITE 4mmring

REVCOUNTER-WTERMINALFROMALTERNATOR BLACK/BLUE 4mmring (BYPASSESMULTIPLUG)

REVCOUNTER-BULBPOSITIVE WHITE 4mmring

REVCOUNTERSPAREPOSITIVE BLACK NONE

REVCOUNTERSPARENEGATIVE WHITE NONE

BLOCKINGDIODE-SUPPLY PURPLE

BLOCKINGDIODE-OUTPUT1 BROWN/YELLOW SHARESCONNECTOR

BROWN/YELLOW

BLOCKINGDIODEOUTPUT2 GREEN/YELLOW SHARESCONNECTOR

GREEN/YELLOW

BLOCKINGDIODEOUTPUT3 PURPLE/BROWN SHARESCONNECTOR

PURPLE/BROWN