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Volute and Wear Ring
1.
Press new wear ring into the volute carefully so that it
seats squarely in the bottom of the bore.
2.
Place the volute over the lubricated O-ring of the gear
case cover and replace the fasteners to secure.
3.
Complete reassembly of the pump and any fittings
previously removed.
Testing
1. Before testing the pump, rotate the engine crankshaft
as outlined in the “Preparation Before Operation” sec-
tion. Be sure there are no abnormal rubbing noises.
2. The mechanical seal may leak when the pump is first
run after it has been repaired. This leakage should
stop after the seal faces run-in.
3. With the pump running, check for unusual noises or
leaks at volute joints, pump adapter/gear case engine
screws, or gear case / engine adapter interface.
These should be corrected before the pump is re-
turned to service.
Controller and Engine Troubleshooting Guide
Problem
Fix
Controller Won’t Power Up
Check battery voltage.
Check 20A fuse near starter on engine harness (WH00046) and 2A
fuse in main controller harness (WH00023).
Make sure the 3-pin MPU connector is properly connected and the
3/8” ring from the 2-pin MPU connector is grounded to the block.
This connector provides ground to the controller
Check for backed out terminals in 12-pin Deutsch connectors. Look
closely at pin #1 (ground) and pin #3 (b). If equipped with
auxiliary controller, check for backed out pins in WH00024 auxiliary
controller harness.
Check continuity of battery wire (pin #3 on 12-pin Deutsch
connector) from engine to ignition switch connector.
Controller Powers Up, Engine Won’t Crank:
Check for backed out terminals in 12-pin Deutsch connectors. Look
closely at pin #2 (crank) terminal.
Check for bad relays at the engine and in the main control harness
(WH00023).
Check functionality of starter solenoid.
Engine Cranks, But Won’t Start
Make sure fuel system is primed.
Check functionality of glow plugs.
Check for clogged fuel filter.
Check for proper cranking speed (generally above 250rpm).
Check quality of fuel.
Engine Shutdown, Oil Lamp Displayed
Check oil level.
Check fuel level/fuel supply. An engine that runs out of fuel due to
the fuel starvation will display a low oil pressure fault.
Verify actual oil pressure and compare to oil pressure displayed.
Summary of Contents for E500 Series
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