Information injection-pump assembly
BOSCH
9 460 611 906
9460611906
ZEXEL
104700-2002
1047002002

Rating:
Components :
0. | INJECTION-PUMP ASSEMBLY | 104700-2002 |
1. | _ | |
2. | FUEL INJECTION PUMP | 104600-2002 |
3. | NUMBER PLATE | 148633-1100 |
4. | _ | |
5. | CAPSULE | |
6. | ADJUSTING DEVICE | 105141-8033 |
7. | NOZZLE AND HOLDER ASSY | 105141-2971 |
8. | Nozzle and Holder | 16600-1C310 |
9. | Open Pre:MPa(Kqf/cm2) | 12.7{130} |
10. | NOZZLE-HOLDER | 105071-1361 |
11. | NOZZLE | 105000-2210 |
Scheme ###:
1/6. | [1] | 146601-0900 | PACKING RING |
6. | [1] | 146100-0020 | SUPPLY PUMP |
9. | [1] | 148103-0400 | COVER |
10. | [2] | 139104-0000 | FLAT-HEAD SCREW |
12. | [1] | 148200-0620 | DRIVE SHAFT |
12/3. | [1] | 146201-0000 | WOODRUFF KEY |
17. | [1] | 146204-0000 | PLAIN WASHER |
20. | [1] | 148210-0120 | ROLLER SET |
24. | [1] | 146303-0000 | BEARING PIN |
25. | [1] | 146304-0000 | BEARING PIN |
26. | [1] | 146305-0000 | CLAMPING BAND |
27. | [1] | 146205-0000 | SLOTTED WASHER |
29. | [1] | 146220-4620 | CAM PLATE |
30. | [1] | 146600-3000 | O-RING |
31. | [1] | 146300-1900 | PUMP PLUNGER |
32. | [1] | 146301-0200 | SLIDING PIECE |
33. | [1] | 146603-0700 | SHIM D17.5&7.5T0.60 |
34. | [1] | 146306-2200 | COMPRESSION SPRING |
35/1. | [0] | 146603-0700 | SHIM D17.5&7.5T0.60 |
35/1. | [0] | 146603-0800 | SHIM D17.5&7.5T0.70 |
35/1. | [0] | 146603-0900 | SHIM D17.5&7.5T0.90 |
35/1. | [0] | 146603-1000 | SHIM D17.5&7.5T1.00 |
35/1. | [0] | 146603-1100 | SHIM D17.5&7.5T1.20 |
35/1. | [0] | 146603-3600 | SHIM D17.5&7.5T2.40 |
36. | [1] | 146600-3000 | O-RING |
37. | [1] | 146310-0700 | COVER |
38. | [2] | 146620-5000 | BLEEDER SCREW |
39. | [1] | 146310-0100 | COVER |
40. | [2] | 146620-5000 | BLEEDER SCREW |
43. | [1] | 146230-0000 | SHIM |
44. | [1] | 146230-0100 | PLAIN WASHER |
45. | [1] | 146231-0001 | SLOTTED WASHER |
47. | [2] | 146233-0000 | SLOTTED WASHER |
48/1. | [1] | 146603-0000 | SHIM D17.0&5.2T0.50 |
48/1. | [1] | 146603-0100 | SHIM D17.0&5.2T0.80 |
48/1. | [1] | 146603-0200 | SHIM D17.0&5.2T1.00 |
48/1. | [1] | 146603-0300 | SHIM D17.0&5.2T1.20 |
48/1. | [1] | 146603-0400 | SHIM D17.0&5.2T1.50 |
48/1. | [1] | 146603-0500 | SHIM D17.0&5.2T1.80 |
48/1. | [1] | 146603-0600 | SHIM D17.0&5.2T2.00 |
48/1. | [1] | 146690-1400 | SHIM D17&5.2T0.9 |
48/1. | [1] | 146690-1500 | SHIM D17&5.2T1.1 |
48/1. | [1] | 146690-1600 | SHIM D17&5.2T1.3 |
48/1. | [1] | 146690-1700 | SHIM D17&5.2T1.4 |
48/1. | [1] | 146690-1800 | SHIM D17&5.2T1.6 |
48/1. | [1] | 146690-1900 | SHIM D17&5.2T1.7 |
48/1. | [1] | 146690-5800 | SHIM |
48/1. | [1] | 146690-5900 | SHIM |
48/1. | [1] | 146690-6000 | SHIM |
48/1. | [1] | 146690-6100 | SHIM |
48/1. | [1] | 146690-6200 | SHIM |
48/1. | [1] | 146690-6300 | SHIM |
48/1. | [1] | 146690-6400 | SHIM |
48/1. | [1] | 146690-6500 | SHIM |
48/1. | [1] | 146690-6600 | SHIM |
48/1. | [1] | 146690-6700 | SHIM |
48/1. | [1] | 146690-6800 | SHIM |
48/1. | [1] | 146690-6900 | SHIM |
48/1. | [1] | 146690-7000 | SHIM |
48/1. | [1] | 146690-7100 | SHIM |
48/1. | [1] | 146690-7200 | SHIM |
48/1. | [1] | 146690-7300 | SHIM |
48/1. | [1] | 146690-7400 | SHIM |
48/1. | [1] | 146690-7500 | SHIM |
48/1. | [1] | 146690-7800 | SHIM |
49. | [2] | 146234-0120 | GUIDE PIN |
50. | [1] | 146403-6520 | HYDRAULIC HEAD |
50. | [1] | 146403-6520 | HYDRAULIC HEAD |
50. | [1] | 146403-6520 | HYDRAULIC HEAD |
51. | [1] | 146600-0000 | O-RING |
52/1. | [1] | 146420-0000 | SHIM D9.5&3.0T1.90 |
52/1. | [1] | 146420-0100 | SHIM D9.5&3.0T1.92 |
52/1. | [1] | 146420-0200 | SHIM D9.5&3.0T1.94 |
52/1. | [1] | 146420-0300 | SHIM D9.5&3.0T1.96 |
52/1. | [1] | 146420-0400 | SHIM D9.5&3.0T1.98 |
52/1. | [1] | 146420-0500 | SHIM D9.5&3.0T2.00 |
52/1. | [1] | 146420-0600 | SHIM D9.5&3.0T2.02 |
52/1. | [1] | 146420-0700 | SHIM D9.5&3.0T2.04 |
52/1. | [1] | 146420-0800 | SHIM D9.5&3.0T2.06 |
52/1. | [1] | 146420-0900 | SHIM D9.5&3.0T2.08 |
52/1. | [1] | 146420-1000 | SHIM D9.5&3.0T2.10 |
52/1. | [1] | 146420-1100 | SHIM D9.5&3.0T2.12 |
52/1. | [1] | 146420-1200 | SHIM D9.5&3.0T2.14 |
52/1. | [1] | 146420-1300 | SHIM D9.5&3.0T2.16 |
52/1. | [1] | 146420-1400 | SHIM D9.5&3.0T2.18 |
52/1. | [1] | 146420-1500 | SHIM D9.5&3.0T2.20 |
52/1. | [1] | 146420-1600 | SHIM D9.5&3.0T2.22 |
52/1. | [1] | 146420-1700 | SHIM D9.5&3.0T2.24 |
52/1. | [1] | 146420-1800 | SHIM D9.5&3.0T2.26 |
52/1. | [1] | 146420-1900 | SHIM D9.5&3.0T2.28 |
52/1. | [1] | 146420-2000 | SHIM D9.5&3.0T2.30 |
52/1. | [1] | 146420-2100 | SHIM D9.5&3.0T2.32 |
52/1. | [1] | 146420-2200 | SHIM D9.5&3.0T2.34 |
52/1. | [1] | 146420-2300 | SHIM D9.5&3.0T2.36 |
52/1. | [1] | 146420-2400 | SHIM D9.5&3.0T2.38 |
52/1. | [1] | 146420-2500 | SHIM D9.5&3.0T2.40 |
52/1. | [1] | 146420-2600 | SHIM D9.5&3.0T2.42 |
52/1. | [1] | 146420-2700 | SHIM D9.5&3.0T2.44 |
52/1. | [1] | 146420-2800 | SHIM D9.5&3.0T2.46 |
52/1. | [1] | 146420-2900 | SHIM D9.5&3.0T2.48 |
52/1. | [1] | 146420-3000 | SHIM D9.5&3.0T2.50 |
52/1. | [1] | 146420-3100 | SHIM D9.5&3.0T2.52 |
52/1. | [1] | 146420-3200 | SHIM D9.5&3.0T2.54 |
52/1. | [1] | 146420-3300 | SHIM D9.5&3.0T2.56 |
52/1. | [1] | 146420-3400 | SHIM D9.5&3.0T2.58 |
52/1. | [1] | 146420-3500 | SHIM D9.5&3.0T2.60 |
52/1. | [1] | 146420-3600 | SHIM D9.5&3.0T2.62 |
52/1. | [1] | 146420-3700 | SHIM D9.5&3.0T2.64 |
52/1. | [1] | 146420-3800 | SHIM D9.5&3.0T2.66 |
52/1. | [1] | 146420-3900 | SHIM D9.5&3.0T2.68 |
52/1. | [1] | 146420-4000 | SHIM D9.5&3.0T2.70 |
52/1. | [1] | 146420-4100 | SHIM D9.5&3.0T2.72 |
52/1. | [1] | 146420-4200 | SHIM D9.5&3.0T2.74 |
52/1. | [1] | 146420-4300 | SHIM D9.5&3.0T2.76 |
52/1. | [1] | 146420-4400 | SHIM D9.5&3.0T2.78 |
52/1. | [1] | 146420-4500 | SHIM D9.5&3.0T2.80 |
52/1. | [1] | 146420-4600 | SHIM D9.5&3.0T2.82 |
52/1. | [1] | 146420-4700 | SHIM D9.5&3.0T2.84 |
52/1. | [1] | 146420-4800 | SHIM D9.5&3.0T2.86 |
52/1. | [1] | 146420-4900 | SHIM D9.5&3.0T2.88 |
52/1. | [1] | 146420-5000 | SHIM D9.5&3.0T2.90 |
52/1. | [1] | 146420-5100 | SHIM D9.5&3.0T1.74 |
52/1. | [1] | 146420-5200 | SHIM D9.5&3.0T1.76 |
52/1. | [1] | 146420-5300 | SHIM D9.5&3.0T1.78 |
52/1. | [1] | 146420-5400 | SHIM D9.5&3.0T1.80 |
52/1. | [1] | 146420-5500 | SHIM D9.5&3.0T1.82 |
52/1. | [1] | 146420-5600 | SHIM D9.5&3.0T1.84 |
52/1. | [1] | 146420-5700 | SHIM D9.5&3.0T1.86 |
52/1. | [1] | 146420-5800 | SHIM D9.5&3.0T1.88 |
54. | [4] | 146433-0100 | GASKET D12&6.4T1.00 |
55. | [4] | 146430-0320 | DELIVERY-VALVE ASSEMBLY |
56. | [4] | 146432-0700 | COMPRESSION SPRING |
58. | [4] | 146440-0220 | FITTING |
60. | [3] | 139106-0100 | FLAT-HEAD SCREW |
123. | [1] | 146620-8800 | FLAT-HEAD SCREW |
130. | [1] | 146421-1020 | CAPSULE |
130/2. | [1] | 139508-0200 | GASKET D11.4&8.2T1 |
130/3. | [1] | 146422-0300 | BLEEDER SCREW |
130/4. | [1] | 146600-0500 | O-RING |
133. | [1] | 146600-0600 | O-RING |
134. | [1] | 146600-0700 | O-RING |
135. | [1] | 146110-3220 | CONTROL VALVE |
135/5. | [1] | 146114-0000 | SPRING WASHER |
136. | [1] | 148120-0020 | OVER FLOW VALVE |
137. | [3] | 139512-0200 | GASKET D18.5&12.2T1.00 |
138. | [1] | 146667-0320 | INLET UNION |
158. | [1] | 146614-6900 | SPACER BUSHING |
200. | [1] | 146206-0100 | COILED SPRING |
230. | [1] | 148613-1020 | BRACKET |
236. | [1] | 146620-2700 | HEX-SOCKET-HEAD CAP SCREW |
237. | [1] | 146620-0200 | HEX-SOCKET-HEAD CAP SCREW |
240. | [1] | 146688-0120 | PULLING ELECTROMAGNET |
240/8. | [1] | 146600-1700 | O-RING |
243. | [1] | 146621-1000 | UNION NUT |
245. | [3] | 139512-0200 | GASKET D18.5&12.2T1.00 |
246. | [1] | 139812-0500 | EYE BOLT |
247. | [1] | 146665-4120 | INLET UNION |
248. | [1] | 146614-0200 | SPACER BUSHING |
275. | [1] | 148612-0800 | BRACKET |
276. | [2] | 010010-2840 | BLEEDER SCREW |
278. | [2] | 146616-8500 | SPACER BUSHING |
282. | [1] | 139006-4400 | BLEEDER SCREW |
298. | [3] | 146659-8000 | CLAMPING BAND |
504/1. | [1] | 146649-4500 | RESISTER |
504/1. | [1] | 146649-4600 | RESISTER |
504/1. | [1] | 146649-4700 | RESISTER |
504/1. | [1] | 146649-4800 | RESISTER |
504/1. | [1] | 146649-4900 | RESISTER |
504/1. | [1] | 146649-5000 | RESISTER |
504/1. | [1] | 146649-5100 | RESISTER |
504/1. | [1] | 146649-5200 | RESISTER |
504/1. | [1] | 146649-5300 | RESISTER |
504/1. | [1] | 146649-5400 | RESISTER |
504/1. | [1] | 146649-5500 | RESISTER |
504/1. | [1] | 146649-5600 | RESISTER |
504/1. | [1] | 146649-5700 | RESISTER |
505. | [1] | 148530-0720 | GOVERNOR;ELECTRIC |
506. | [3] | 146620-8900 | FLAT-HEAD SCREW |
515. | [1] | 106144-1051 | TIMING CONTROL VALVE |
515/12. | [1] | 161440-3800 | O-RING |
515/13. | [1] | 161440-3700 | O-RING |
516. | [2] | 010206-1440 | HEX-SOCKET-HEAD CAP SCREW M6P1L14 |
531. | [1] | 479773-4521 | PULSE GENERATOR |
531/6. | [1] | 479773-6500 | O-RING |
800S. | [1] | 148009-0420 | PUMP HOUSING |
800S/1/6. | [1] | 146601-0900 | PACKING RING |
804S. | [1] | 146232-0720 | COMPRESSION SPRING |
878S. | [1] | 148600-1300 | SEAL RING |
906. | [1] | 148633-1100 | NAMEPLATE |
Include in #2:
104700-2002
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 460 611 906
9460611906
ZEXEL
104700-2002
1047002002
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
1404 Test oil ISO4113orSAEJ967d
Test oil temperature
degC
45
45
50
Nozzle
105780-0060
Bosch type code
NP-DN0SD1510
Nozzle holder
105780-2150
Opening pressure
MPa
13
13
13.3
Opening pressure
kgf/cm2
133
133
136
Injection pipe
157805-7320
Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450
Inside diameter - outside diameter - length (mm) mm 2-6-450
Joint assembly
157641-4720
Tube assembly
157641-4020
Transfer pump pressure
kPa
20
20
20
Transfer pump pressure
kgf/cm2
0.2
0.2
0.2
Direction of rotation (viewed from drive side)
Left L
Left L
Governor adjustment
Pump speed
r/min
1000
1000
1000
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.7
2.7
2.7
Pump chamber pressure
kPa
568.5
539
598
Pump chamber pressure
kgf/cm2
5.8
5.5
6.1
Basic
*
Governor adjustment_02
Pump speed
r/min
100
100
100
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.7
2.7
2.7
Pump chamber pressure
kPa
294
294
Pump chamber pressure
kgf/cm2
3
3
Governor adjustment_03
Pump speed
r/min
1000
1000
1000
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.7
2.7
2.7
Pump chamber pressure
kPa
569
530
608
Pump chamber pressure
kgf/cm2
5.8
5.4
6.2
Governor adjustment_04
Pump speed
r/min
2500
2500
2500
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.7
2.7
2.7
Pump chamber pressure
kPa
745
696
794
Pump chamber pressure
kgf/cm2
7.6
7.1
8.1
Boost compensator adjustment
Pump speed
r/min
1000
1000
1000
TCV duty (%) F TCV 60Hz
%
70
70
70
U alpha soll
V
2.7
2.7
2.7
Timer stroke
mm
4.5
4.3
4.7
Basic
*
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.7
2.7
2.7
Timer stroke
mm
7.1
5.1
9.1
Boost compensator adjustment_03
Pump speed
r/min
1000
1000
1000
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.7
2.7
2.7
Timer stroke
mm
7.8
5.8
9.8
Boost compensator adjustment_04
Pump speed
r/min
1000
1000
1000
TCV duty (%) F TCV 60Hz
%
70
70
70
U alpha soll
V
2.7
2.7
2.7
Timer stroke
mm
4.5
4.2
4.8
Boost compensator adjustment_05
Pump speed
r/min
1000
1000
1000
TCV duty (%) F TCV 60Hz
%
0
0
0
U alpha soll
V
2.7
2.7
2.7
Timer stroke
mm
0
0
0
Boost compensator adjustment_06
Pump speed
r/min
1500
1500
1500
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.7
2.7
2.7
Timer stroke
mm
9.75
9.3
10.2
Speed control lever angle
Pump speed
r/min
1000
1000
1000
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.7
2.7
2.7
Overflow quantity
cm3/min
530
400
660
0000000901
Pump speed
r/min
1200
1200
1200
U alpha soll + dU alpha soll
V
2.73
2.73
2.73
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
55.9
55.4
56.4
Difference in delivery
mm3/st.
3
Basic
*
_02
Pump speed
r/min
400
400
400
U alpha soll + dU alpha soll
V
2.09
2.09
2.09
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
12.4
9.4
15.4
Difference in delivery
mm3/st.
2
Basic
*
Remarks
Confirmation of difference in delivery
Confirmation of difference in delivery
_03
Pump speed
r/min
2700
2700
2700
U alpha soll + dU alpha soll
V
1.93
1.93
1.93
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
19.5
17
22
Difference in delivery
mm3/st.
5
Basic
*
Remarks
Confirmation of difference in delivery
Confirmation of difference in delivery
_04
Pump speed
r/min
100
100
100
U alpha soll + dU alpha soll
V
3.5
3.5
3.5
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
59.9
49.9
69.9
_05
Pump speed
r/min
400
400
400
U alpha soll + dU alpha soll
V
2.09
2.09
2.09
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
12.4
9.4
15.4
_06
Pump speed
r/min
600
600
600
U alpha soll + dU alpha soll
V
2.41
2.41
2.41
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
36.3
34.3
38.3
_07
Pump speed
r/min
800
800
800
U alpha soll + dU alpha soll
V
2.05
2.05
2.05
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
17.8
15.8
19.8
_08
Pump speed
r/min
1200
1200
1200
U alpha soll + dU alpha soll
V
2.11
2.11
2.11
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
24.8
22.8
26.8
_09
Pump speed
r/min
1200
1200
1200
U alpha soll + dU alpha soll
V
2.73
2.73
2.73
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
55.9
54.9
56.9
_10
Pump speed
r/min
1600
1600
1600
U alpha soll + dU alpha soll
V
2.35
2.35
2.35
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
38.4
36.4
40.4
_11
Pump speed
r/min
2000
2000
2000
U alpha soll + dU alpha soll
V
2.64
2.64
2.64
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
52.7
50.7
54.7
_12
Pump speed
r/min
2400
2400
2400
U alpha soll + dU alpha soll
V
2.39
2.39
2.39
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
41.1
38.6
43.6
_13
Pump speed
r/min
2700
2700
2700
U alpha soll + dU alpha soll
V
1.93
1.93
1.93
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
19.5
17
22
_14
Pump speed
r/min
2700
2700
2700
U alpha soll + dU alpha soll
V
1
1
1
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
3
Stop lever angle
Pump speed
r/min
400
400
400
U alpha soll + dU alpha soll
V
2.09
2.09
2.09
TCV duty (%) F TCV 60Hz
%
0
0
0
Average injection quantity
cm3/min
0
0
0
Stop lever angle_02
Pump speed
r/min
2400
2400
2400
U alpha soll + dU alpha soll
V
2.39
2.39
2.39
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
cm3/min
0
0
0
0000001101
Pump speed
r/min
200
200
200
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.7
2.7
2.7
Speed output
N=Measure the actual speed. r/min N+-8
N=Measure the actual speed. r/min N+-8
0000001201
Pump speed
r/min
1200
1200
1200
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.73
2.73
2.73
Temperature output
Measure T = actual output temperature degC T+-5
Measure T = actual output temperature degC T+-5
0000001301
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001401
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.8
5.7
5.9
Pre-stroke
mm
0.1
0.08
0.12
Test data Ex:
Injection timing adjustment Comp. resistor/voltage

Compensation resistance/compensation voltage comparison
A = Compensation resistor number
B= Compensation resistance
C = Compensation voltage delta U alpha soll
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0000001601 HARNESS & CONNECTOR

TCV connector assembly specification
(1)Ensure the GE harness is not twisted at section A.
(2)Refer to diagram for direction of binder B.
(3)Route the TCV harness in the direction indicated by the arrows in the figure and install the connector C.
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0000001701 HARNESS & CONNECTOR

Connector and binder assembly specification
(1)Install the connector in the position shown in the figure.
(2)At the clip position at J (bracket's groove position), clip the F.C.V. harness and the G.E. harness together horizontally.
(3)After clipping, the GE harness and the FCV harness must be within L1 from the pump flange face.
A:P/U Connector
B:F.C.V., Q adjustment connector
C:Q adjustment resistor
D:G.E. Connector
E:T.C.V. Connector
F:G.E. harness, F.C.V. Harness
G:Bracket groove
H:Clip position
I:Binder
J:Push type clip
K:Pump flange face
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L1=Max.207mm
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L1=Max.207mm
Information:
Problem 4
The starting motor remains engaged or the starting motor continues to run after the engine is running.
Check the components of the starting circuit.
Measure the voltages at terminal (TS-26) of the junction box while the engine is running.Result
The voltage at the terminal is zero volts.The problem is in the starting motor (SM), the pinion solenoid (PS), or the magnetic switch (MS). Repair the faulty component. STOP.
The voltage at the terminal is between 15 volts and 32 volts.The START terminals of the start/stop switch are normally closed. This is normal for an automatic start system. In a manual start system, the switches should be normally open. The switch is on terminals (SSS-1) and (SSS-2) for a normal start/stop switch. Repair the faulty switch. STOP.Problem 5
The engine shutdown occurs after the engine runs for more than 3 minutes.
Check the protection switches.
Remove the jumper that is between terminals (TS-9) and (TS-10) of the junction box.
If the engine is equipped with a low oil pressure indicator, disconnect the diode that is between terminals (TS-8) and (TS-10). The cathode lead of the diode should be connected to terminal (TS-10).
If the engine is equipped with a low oil pressure indicator, ensure that a jumper is not installed between terminals (TS-8) and (TS-9).
Start the engine.
Reconnect the jumper that is between terminals (TS-9) and (TS-10) of the junction box after the test is completed.Result
The engine starts and the engine runs.The problem is in the oil pressure switch or the water temperature contactor switch. Go to Step 5 of "Problem 1".
The engine starts but engine shutdown occurs immediately.Go to Step 1 of "Problem 3".
The engine starts and the engine runs but engine shutdown occurs after the engine runs for more than 3 minutes.Go to Step 2.
The engine cranks but the engine does not start.Go to Step 1 of "Problem 1".
Check the start/stop switch and slave relay (SR1).
Disconnect the wire in the junction box that connects terminal (SR1-85) of the slave relay (SR1) to terminal (TD-7) of the time delay relay (TD).
Crank the engine. Activate the emergency stop switch, if necessary.Result
The engine starts and the engine runs.The start/stop switch has a short circuit or a wiring problem is causing a voltage at terminal (TD-7). Reconnect the wire to the terminal. STOP.
Engine shutdown still occurs after several minutes.The contacts of (SR1) periodically close. The problem may also be with the governor or the fuel supply to the engine. Refer to the Engine Service Manual. If a 2301A Electric Governor is used, the SR1 contacts may be opening. Refer to 2301A Electric Governor Service Manual, SENR3585. Test SR1. Refer to Testing and Adjusting, "Slave Relay Test".Problem 6
Engine shutdown does not occur when a fault is detected.
Check the protection switches and the crank terminate switch of the electronic speed switch.
Reset circuit breaker (CB7).
Start the engine and run the engine at low idle.
Contact with electrical components can cause injury or death.Remove all jewelry and avoid contact with electrical components. Use properly insulated tools when working on the junction box of an
The starting motor remains engaged or the starting motor continues to run after the engine is running.
Check the components of the starting circuit.
Measure the voltages at terminal (TS-26) of the junction box while the engine is running.Result
The voltage at the terminal is zero volts.The problem is in the starting motor (SM), the pinion solenoid (PS), or the magnetic switch (MS). Repair the faulty component. STOP.
The voltage at the terminal is between 15 volts and 32 volts.The START terminals of the start/stop switch are normally closed. This is normal for an automatic start system. In a manual start system, the switches should be normally open. The switch is on terminals (SSS-1) and (SSS-2) for a normal start/stop switch. Repair the faulty switch. STOP.Problem 5
The engine shutdown occurs after the engine runs for more than 3 minutes.
Check the protection switches.
Remove the jumper that is between terminals (TS-9) and (TS-10) of the junction box.
If the engine is equipped with a low oil pressure indicator, disconnect the diode that is between terminals (TS-8) and (TS-10). The cathode lead of the diode should be connected to terminal (TS-10).
If the engine is equipped with a low oil pressure indicator, ensure that a jumper is not installed between terminals (TS-8) and (TS-9).
Start the engine.
Reconnect the jumper that is between terminals (TS-9) and (TS-10) of the junction box after the test is completed.Result
The engine starts and the engine runs.The problem is in the oil pressure switch or the water temperature contactor switch. Go to Step 5 of "Problem 1".
The engine starts but engine shutdown occurs immediately.Go to Step 1 of "Problem 3".
The engine starts and the engine runs but engine shutdown occurs after the engine runs for more than 3 minutes.Go to Step 2.
The engine cranks but the engine does not start.Go to Step 1 of "Problem 1".
Check the start/stop switch and slave relay (SR1).
Disconnect the wire in the junction box that connects terminal (SR1-85) of the slave relay (SR1) to terminal (TD-7) of the time delay relay (TD).
Crank the engine. Activate the emergency stop switch, if necessary.Result
The engine starts and the engine runs.The start/stop switch has a short circuit or a wiring problem is causing a voltage at terminal (TD-7). Reconnect the wire to the terminal. STOP.
Engine shutdown still occurs after several minutes.The contacts of (SR1) periodically close. The problem may also be with the governor or the fuel supply to the engine. Refer to the Engine Service Manual. If a 2301A Electric Governor is used, the SR1 contacts may be opening. Refer to 2301A Electric Governor Service Manual, SENR3585. Test SR1. Refer to Testing and Adjusting, "Slave Relay Test".Problem 6
Engine shutdown does not occur when a fault is detected.
Check the protection switches and the crank terminate switch of the electronic speed switch.
Reset circuit breaker (CB7).
Start the engine and run the engine at low idle.
Contact with electrical components can cause injury or death.Remove all jewelry and avoid contact with electrical components. Use properly insulated tools when working on the junction box of an