0435140 EVINRUDE ENGINE COVER, Jo., 5DR

Troubleshooting
Troubleshooting can be difficult. On the following pages there is a list of possible problems. To make a repair to a problem, make reference to the cause and correction.This list of problems, causes and corrections will only give an indication of where a possible problem can be, and what repairs are needed. Normally, more or other repair work is needed beyond the recommendations in the list. Remember that a problem is not normally caused only by one part, but by the relation of one part with other parts. This list can not give all possible problems and corrections. The serviceman must find the problem and its source, then make the necessary repairs.1. Contactor Switch for Water Temperature Does Not Activate Shutoff Solenoid.2. Contactor Switch for Water Temperature Activates Shutoff Solenoid at Wrong Temperature.3. Contactor Switch for Oil Pressure Fails to Activate Shutoff Solenoid.4. Shutoff Solenoid Fails to Stop Engine.5. Shutoff Solenoid Prevents Engine Start.6. Clutch Will Not Engage (Slips), Heats or Lever Moves to Released Position.7. Clutch Shaft Has Too Much End Play.8. Clutch Bearings Have Short Service Life.9. Mechanical Shutoff Fails To Stop Engine Because Of Low Oil Pressure.10. Mechanical Shutoff Does Not Stop Engine When Coolant Temperature Is Too High.11. Mechanical Shutoff Will Not Let Engine Start.12. Electrical Gauges Give Wrong Readings.13. Contactor Switch for Overspeed Fails to Activate Shutoff Solenoid.14. Contactor Switch for Overspeed Activates Shutoff Solenoid at Wrong Speed.15. PSG Governors. a. Engine Speed Does Not Have Stability.b. Vibration At Governor Output Shaft.c. Fuel Control Response When The Engine Is Started Is Not Acceptable.d. Engine Has Slow Response To A Change In Speed Setting Or Load.e. No Output From Governor.f. Engine Will Not Drive Full Rated Load.g. Load Sharing Between Paralleled Units Is Not Correct (One unit on zero droop all others on droop).h. Load Sharing Between Paralleled Units Is Not Correct (all units on droop).16. Automatic Start/Stop Systems.CONTACTOR SWITCH FOR WATER TEMPERATURE DOES NOT ACTIVATE SHUTOFF SOLENOID CONTACTOR SWITCH FOR WATER TEMPERATURE ACTIVATES SHUTOFF SOLENOID AT WRONG TEMPERATURE CONTACTOR SWITCH FOR OIL PRESSURE FAILS TO ACTIVATE SHUTOFF SOLENOID SHUTOFF SOLENOID FAILS TO STOP ENGINE SHUTOFF SOLENOID PREVENTS ENGINE START CLUTCH WILL NOT ENGAGE (SLIPS), HEATS OR LEVER MOVES TO RELEASED POSITION CLUTCH SHAFT HAS TOO MUCH END PLAY CLUTCH BEARINGS HAVE SHORT SERVICE LIFE MECHANICAL SHUTOFF FAILS TO STOP ENGINE BECAUSE OF LOW OIL PRESSURE MECHANICAL SHUTOFF DOES NOT STOP ENGINE WHEN COOLANT TEMPERATURE IS TOO HIGH MECHANICAL SHUTOFF WILL NOT LET ENGINE START ELECTRICAL GAUGES GIVE WRONG READINGS CONTACTOR SWITCH FOR OVERSPEED FAILS TO ACTIVATE SHUTOFF SOLENOID CONTACTOR SWITCH FOR OVERSPEED ACTIVATES SHUTOFF SOLENOID AT WRONG SPEED ENGINE SPEED DOES NOT HAVE STABILITY VIBRATION AT GOVERNOR OUTPUT SHAFT FUEL CONTROL RESPONSE WHEN THE ENGINE IS STARTED IS NOT ACCEPTABLE ENGINE HAS SLOW RESPONSE TO A CHANGE IN SPEED SETTING OR LOAD No Output From Governor Engine Will Not Drive Full Rated Load Load Sharing Between Paralleled Units Is Not Correct (one unit on zero droop all the others on droop) Load Sharing Between Paralleled Units Is Not Correct (all units on droop) Automatic Start/Stop System Governor Air Actuator
Air Pressure Adjustment
ACTUATOR LINKAGE
1. Linkage.1. Remove linkage (1) between the actuator and the governor.2. Start the engine. Let the engine run until it gets to normal operation temperature.3. Make sure the high and low idle speeds are correct. If necessary, make adjustments to the governor high and low idle screws to get the correct rpm.4. Stop the engine.5. Install an air gauge (2) in the line between the actuator air control lever (3) and the actuator (4).
ADJUSTMENT OF ACTUATOR AIR PRESSURE
2. Air gauge. 3. Actuator air control lever. 4. Actuator. 5. Nut. 6. Plunger. 7. Screw.6. Start the engine.7. Check the air pressure to the actuator. Minimum air pressure at high idle must be 450 kPa (65 psi). Maximum air pressure must not be more than 550 kPa (80 psi).8. Put the governor hand control lever in the low idle position.9. Look at plunger (6). Move actuator air control lever (3) slowly to the high idle position. The plunger must start to move at 45 kPa (10 psi) air pressure. If the plunger moves at less than 45 kPa (10 psi) make the preload higher. If more than 45 kPa (10 psi) is needed to move the plunger, make the preload lower.10. Return air actuator control lever (3)