boatowners mechanical and electrical manual third edition pdf

Boatowner’s Mechanical and Electrical Manual Third Edition www.TechnicalBooksPDF.com How to Maintain, Repair, and Improve Your Boat’s Essential Systems www.TechnicalBooksPDF.com www.TechnicalBooksPDF.com Third Edition Boatowner’s Mechanical and Electrical Manual Nigel Calder www.TechnicalBooksPDF.com Copyright © 1996, 2005 by Nigel Calder All rights reserved Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written permission of the publisher ISBN: 978-0-07-178406-1 MHID: 0-07-178406-3 The material in this eBook also appears in the print version of this title: ISBN: 978-0-07-143238-2, MHID: 0-07-143238-8 eBook conversion by codeMantra Version 2.0 All trademarks are trademarks of their respective owners Rather than put a trademark symbol after every occurrence of a trademarked name, we use names in an editorial fashion only, and to the benefit of the trademark owner, with no intention of infringement of the trademark Where such designations appear in this book, they have been printed with initial caps McGraw-Hill eBooks are available at special quantity discounts to use as premiums and sales promotions, or for use in corporate training programs To contact a representative please e-mail us at bulksales@mcgraw-hill.com NOTICE: Repairing, modifying, and maintaining your boat can expose you to potentially dangerous situations and substances Reference to brand names does not indicate endorsement of or guarantee the safety of using these products In using this book, the reader releases the author, publisher, and distributor from liability for any loss or injury, including death, allegedly caused, in whole or in part, by relying on information contained in this book www.TechnicalBooksPDF.com part, by relying on information contained in this book TERMS OF USE This is a copyrighted work and The McGraw-Hill Companies, Inc (“McGraw-Hill”) and its licensors reserve all rights in and to the work Use of this work is subject to these terms Except as permitted under the Copyright Act of 1976 and the right to store and retrieve one copy of the work, you may not decompile, disassemble, reverse engineer, reproduce, modify, create derivative works based upon, transmit, distribute, disseminate, sell, publish or sublicense the work or any part of it without McGraw-Hill’s prior consent You may use the work for your own noncommercial and personal use; any other use of the work is strictly prohibited Your right to use the work may be terminated if you fail to comply with these terms THE WORK IS PROVIDED “AS IS.” McGRAW-HILL AND ITS LICENSORS MAKE NO GUARANTEES OR WARRANTIES AS TO THE ACCURACY, ADEQUACY OR COMPLETENESS OF OR RESULTS TO BE OBTAINED FROM USING THE WORK, INCLUDING ANY INFORMATION THAT CAN BE ACCESSED THROUGH THE WORK VIA HYPERLINK OR OTHERWISE, AND EXPRESSLY DISCLAIM ANY WARRANTY, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE McGraw-Hill and its licensors do not warrant or guarantee that the functions contained in the work will meet your requirements or that its operation will be uninterrupted or error free Neither McGraw-Hill nor its licensors shall be liable to you or anyone else for any inaccuracy, error or omission, regardless of cause, in the work or for any damages resulting therefrom McGrawHill has no responsibility for the content of any information accessed through the work Under no circumstances shall McGraw-Hill and/or its licensors be liable for any indirect, incidental, special, punitive, consequential or similar damages that result from the use of or www.TechnicalBooksPDF.com consequential or similar damages that result from the use of or inability to use the work, even if any of them has been advised of the possibility of such damages This limitation of liability shall apply to any claim or cause whatsoever whether such claim or cause arises in contract, tort or otherwise www.TechnicalBooksPDF.com DEDICATION To Pippin and Paul: May this book hasten the day when you take over the maintenance of the boat www.TechnicalBooksPDF.com Contents List of Troubleshooting Charts List of Tables Preface and Acknowledgments to the Third Edition Preface and Acknowledgments to the Second Edition Introduction CHAPTER 1 Establishing a Balanced Battery-Powered Electrical System Introduction Batteries Getting Down to Specifics Putting the Pieces Together Summary: A Balanced System CHAPTER 2 Electrical Systems for Energy-Intensive Boats Additional Energy Sources Dual-Voltage DC Systems Fuel Cells, Higher-Voltage DC Boats, and Electric Propulsion CHAPTER 3 Maintaining and Troubleshooting a BatteryPowered Electrical System Batteries www.TechnicalBooksPDF.com single-phase circuits, 145-51 single-sideband (SSB) radios: antennas, 338–39, 345–46, 756 installation, 353–54, 357 power consumption, 340 radio grounds, 351–53, 352 sintered bronze ground plates, 352 siphon breaks, 378–81, 542 slip rings, 86, 88, 100, 101 Smart Speed Control (Frigoboat), 481–82, 486 Smead, David, 245 smoke, 401–3 sniffers, 665 snubbers, 88-89 snubbing loads, 711–12 soap solutions for leak detection, 498 Society of Automotive Engineers (SAE), 164, 166, 533 soft-wall hoses, 533 solar panels, 18, 190, 236–37, 281–87 soldering, 170, 172, 173, 174, 530 solenoids, 315, 316, 318, 319, 322, 325 Solomon Technologies, 69 Southwest Windpower AirX, 268, 273, 274, 275, 276 spade rudders, 622, 623, 630, 631 spark (Piezo) igniters, 673, 675 spars, 732–48 aluminum, 737-43, 746 carbon fiber, 743-45, 746 installation, 730–31 maintenance, 746 wooden, 732–37, 746 specific gravity, 79–80 Spectra Clark Pump, 609, 610, 611, 612 spinnaker halyards, 743 spinnaker poles, 745–48, 746 split-charging diodes, 38–39, 92 split-phase motors, 307-8 spreader bars, 740, 741 spreader end caps, 762–63 spreader fittings/bends, 754 spreaders: aluminum, 737-43 carbon fiber, 744 installation, 730–31, 735 rot danger, 734 wooden, 732–37 spring scale, 439 spur-geared windlasses, 714–16 Spurs line cutter, 452 SSB radios See single-sideband (SSB) radios stainless steel: conductivity, 186 corrosion, 198, 199, 201–3, 204, 206, 208, 215, 218, 443, 456, 759 grades, 202–3, 522–23 stainless steel seacocks, 562 stainless steel tanks, 203, 522–24 stainless steel wire roap, 749 Sta-Lok terminals, 641, 751 standing rigging, 748–65 checklist, 757 corrosion, 759-60 fiber rigging, 754–55 fitting to a boat, 755–56 inspection, 756-60 interference from, 360 Kevlar rigging, 754 maintenance, 760 PBO rigging, 754 rod rigging, 748, 753–54, 762 standing rigging, 748–65 tuning a rig, 760-65 wire rope, 748–53, 756-57, 762, 763 starter motors, 4 cables, 164 circuits, 315–16 installation, 288–89 maintenance, 321-25 troubleshooting, 317–21, 318, 319, 320 types of, 316-17 voltage drop, 320 starting fluid, 385 static load test, 564–65, 568 static rig tensioning, 761–63 station wagon effect, 687, 688 stators, 85, 86, 100, 101, 102, 104, 305 stator windings, 292, 301 stays, 755, 756 steel, 199, 201, 202, 205, 206, 214 steel hulls, 215, 216, 217, 568-69 steel tanks, 524 steering and steering systems: autopilots, 648–49, 651 emergency steering, 646-47 installation, 620–21 maintenance and troubleshooting, 630–45 rudderstops, 645-46 stuffing boxes, 633, 634 twin installation, 628–30, 629 types of, 622–30 stemball fittings, 756, 762, 769 stem-type valves, 505-6, 511–14 stepped-square-wave output, 251 stern tubes, 422–23, 445, 449, 450 stoves, 154, 662–63, 677, 678–82 stranded wire rope, 757 stratification, 79 stray-current corrosion, 207-12, 218 stress corrosion cracking, 204, 205 struts, 449, 450, 451 stuffing boxes, 422–23, 424, 442–45, 449, 633, 634 sulfation, 9, 12, 19, 29, 84 sulfuric acid, 5–6 superheat adjustments, 507–9 surge capacitors, 229 surge-protection devices, 88–89 swaged terminals, 640-41, 750–51, 757, 758, 760 switches, ABYC standards, 602 switches, types of: air, 604 battery isolation/selector, 37-38, 42, 72–73, 186, 187, 338–39 bellows, 726 bilge pump, 208–9, 603–7 electronic, 604–5 float, 208–9, 602–3, 605, 606 high-pressure, 601 level, 602–7 light-activated, 604–5 load-sensing, 605–6 low-pressure, 602 mercury float, 602–3 pneumatic, 604 pressure, 601–2 pump, 601–7, 602, 603, 604, 605 remotely operated, 192–94 ship-to- shore transfer, 151 swivel block, 695 synthetic oils, 367 T tachometers, 26, 34 Talurit fittings, 750 tank-level gauges, 413–14 tanks, 518-27 ABYC standards, 518, 520, 521, 525, 527 built-in, 518–20, 519 installation, 516–17 ISO standards, 518, 520, 521, 525 longer tank life, 527 materials, 519–24, 526 stainless steel, 203 types of, 516–17 UL standards, 524 U.S Coast Guard standards, 520 tapered-plug bronze seacocks, 562, 565–66 T-bolt clamps, 534 Teflon, 633 Teflon-impregnated grease, 444-45 temperature: batteries and, 75, 76, 78 battery charging and, 33, 34, 70 cable ampacity and, 161–63 temperature gauges, 411–13, 412 terminals and connectors, 168-75, 178–79, 181, 186 test lights, 124 thermocouples, 674, 675 Thermopure MSD, 560 thermostat, 401 thermostatic expansion valve (TXV), 493, 507-8, 509 thimbles, 640, 641, 749-50, 758 three-cable boat, 192–95 through-hull condensers, 484–85, 495 through-hulls, 560–69, 583 installation, 567-69 materials, 562–64, 563 testing, 564–65, 568 thrust bearings, 426, 435, 441, 442 tiller steering, 623, 646-47, 648, 651-52 tinned cables, 157, 158 titanium, 199, 205 toggles, 755 toilet pumps, 570–71, 577 toilets See marine toilets towed watermakers, 611 transformers, 238 transient voltage surge suppressors (TVSS), 228-29 transmission oil seals, 434–35 transmissions, 422–23 alignment, 438–41, 439, 440, 443, 449 control cables, 431–33 installation, 443–44, 448–49 maintenance, 428-29 operational principles, 424–28 troubleshooting, 429-35 types of, 424–28 transom-mounted rudders, 622–23 triacs, 238, 240 trickle charge, 239 trim tab wind vane self-steering, 655, 656 Trojan batteries, 5, 19 tube cutters, 528-29 turbochargers, 408-9 turnbuckles, 755, 757, 758-59 TV interference, 359 TVSS (transient voltage surge suppressors), 228-29 12/24-volt DC system, 57-65 The 12 Volt Doctor’s Alternator Book (Beyn), 99 24-volt equipment, 58 two-shaft transmissions, 425–26, 431–33, 435 U UL (Underwriters Laboratory) standards: cables, electrical, 158, 159, 166 carbon monoxide alarms, 689, 690 circuit breakers, 193–94 hoses, 533 tanks, 524 TVSS devices, 228 unattended boats, 584 unbonded boats, 219 Underwriters Laboratory (UL) See UL (Underwriters Laboratory) uninterrupted power supply (UPS), 60–61, 63, 64 U.S Coast Guard standards: cables, electrical, 159 fuel hoses, 536–37 fuel tanks, 214, 524 overcurrent protection, 188 radio grounds, 351 refrigerants, 462 tanks, 520 U.S National Electrical Code (NEC), 161 V VacuFlush toilets, 556, 557 vacuuming a unit, 514–15 vacuum insulation panels (VIP), 465–68, 466, 467, 471-72, 473, 474– 75 vacuum pump, 514 vacuum toilets, 555–56 valve regulated lead acid (VRLA) batteries See gelcell batteries vane pumps: applications, 577 chemical compatibility, 575, 576 maintenance and troubleshooting, 587, 590, 591 operational principles, 572–73 running dry, 574–75 variable-speed technology (VST), 303–5 variable-volume impeller pumps: applications, 577 chemical compatibility, 575, 576 head pressure, 574 maintenance and troubleshooting, 584–89 operational principles, 572–73 running dry, 574–75 Varifold propellers, 454 V-drives, 427, 443 vented loops, 516–17, 541, 542-43 venturi principle, 491 vertical lift, 577 vertical windlasses, 719 VHF radios See radios video displays, 360 vinegar, 546, 547 VIP (vacuum insulation panels), 465–68, 466, 467, 471-72, 473, 474– 75 voltage (volts), 85 clamping voltage, 228 dockside voltage, 145 measuring, 116, 117, 118, 119, 151, 310 water system analogy, 114–16 voltage drop: cables and, 164–68 diode-induced, 39 starter motors, 320 tables, 164, 165, 168 testing for, 91–93, 92 water system analogy, 114, 115–16 voltage regulator problems: no alternator output, 106–7 overcharged battery, 109 undercharged battery, 107–9, 108 voltage regulators, 28–35 adjustments, 106 battery chargers, 240–41 emergency voltage regulation, 109 features, 33–34 interference, 358–59 MPPT, 273, 284–85 multistep regulators, 31–35, 32, 33, 45 no alternator output, 98–99 operational principles, 104-5 overcharged battery, 94 series regulators, 40, 41, 45 settings, 30–31 solar panels, 284–85 testing, 96 types of, 105–6 undercharged battery, 93 wind generators, 270-74 wiring identification, 106 voltmeters, 123–27 Volvo inboard/outboard, 427 Volvo saildrive, 428 VST (variable-speed technology), 303–5 W warning lights and alarms, 411, 412 waste disposal systems, 516–17, 535-36, 541, 542, 544, 558–60, 559 water-cooled condensers, 484–85, 490–91, 496–97, 498, 505 water-driven generator, 18 water generators, 266, 267 water heaters, 155–56, 662–63 water hoses, 534, 537 water-lubricated lip seals, 447, 448 watermakers, 607–19 benefits of, 607 installation, 570–71, 614–15, 616, 617, 618 maintenance, 615-18 operational principles, 607-12 selecting, 612–14 troubleshooting, 618–19 Water Miser Safety Vent Caps, 6–7 water pumps, 484, 486 water tanks, 519, 523, 525, 526 watts-to-amps conversion, 17 wave-washer seals, 588, 589 WD–40, 385 wedges, 764 weld decay, 203, 522 welding cable, 158, 160 West, Gordon, 352–53 wet-cell batteries, 6–7, 12, 14–15 charging, 245 maintenance, 74-76 problems with, 83–84 reliability of, 257 temperature and, 75, 76 wheel clutch, 641, 642 wheel steering See steering and steering systems whisker poles, 745–48, 746 white gas appliances, 676, 685, 686-87 Whitlock Cobra rack-and-pinion systems, 636–37 wide-angle geometry, 637-38 winches, 692–93, 699–709 Barient winches, 705–6 coffee-grinder winches, 699 halyard winches, 699-701 multiple-speed winches, 701–2 operational principles, 700–702 powered winches, 708–9 self-tailing winches, 703–4, 708 servicing and overhaul, 702–8 wind generators, 266–81 choosing, 274–75 installation, 236–37, 271–73, 275-77 maintenance, 277–78 operational principles, 267-68 output, 18, 190, 274, 275 repairing, 279–81, 280 speed control, 269–70 troubleshooting, 278–79 types of, 268–75 voltage regulators, 270-74 windlasses, 709–28 batteries for, 41 chain difficulties, 709, 712–14, 713 corrosion, 710–11 electric windlasses, 710, 719–26, 720, 721, 723, 724, 725 hydraulic windlasses, 726-28 installation, 46–47, 288–89, 692–93, 710, 722-24, 725 maintenance, 714, 724–25 manual windlasses, 714–19 operation of, 724 overcurrent protection, 222–23 repairing, 717–19, 726, 728 snubbing loads, 711–12 troubleshooting, 725–26 Windseeker, 231 wind vane self-steering, 620–21, 648, 653–61, 654, 656, 657, 658, 659, 660 wire rope: breaking strength, 749 compression fittings, 751–53 construction, 748–49 eye terminals using thimbles, 749-50 inspection and maintenance, 756-57 spreader end caps, 762 stranded wire rope, 757 swaged terminals, 750–51 tensioning, 763 wooden hulls, 216, 217, 219, 562–63, 568 wooden spars and spreaders, 222, 732–37, 746 worm-drive steering, 623-24, 637-38 worm gears, 719, 721 X xenon lights, 326, 328–29 Y yawing, 660 Y-valves, 516–17, 541, 542 Z Z-Guard system, 608–9 zinc, 199, 201, 206 zinc anodes: corrosion protection, 135, 207-8, 214–17, 218, 375–76 propellers, 456 size, 216 transmissions, 428 unbonded boats, 219 zone of protection, 222–23 ...Boatowner’s Mechanical and Electrical Manual Third Edition www.TechnicalBooksPDF.com How to Maintain, Repair, and Improve Your Boat’s Essential Systems www.TechnicalBooksPDF.com www.TechnicalBooksPDF.com... www.TechnicalBooksPDF.com www.TechnicalBooksPDF.com Third Edition Boatowner’s Mechanical and Electrical Manual Nigel Calder www.TechnicalBooksPDF.com Copyright © 1996, 2005 by Nigel Calder All rights reserved... List of Tables Preface and Acknowledgments to the Third Edition Preface and Acknowledgments to the Second Edition Introduction CHAPTER 1 Establishing a Balanced Battery-Powered Electrical System Introduction