0383626 CARBURETOR ASSEMBLY, Complete, upper & lower JOHNSON
55ES69A
CARBURETOR
Price: query
Rating:
Number on catalog scheme: 38362
Compatible models:
55ES69A
JOHNSON
BRP JOHNSON entire parts catalog list:
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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 of 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.Troubleshooting Index
1. Contactor Switch For Water Temperature Fails To Activate Shutoff.2. Contactor Switch For Water Temperature Activates Shutoff At Wrong Temperature.3. Switch For Oil Pressure Fails To Activate Shutoff.4. Engine Protection Panel Will Not Activate Engine Shutoff.5. Engine Protection Panel Stops Engine When Reset Button Is Released.6. Electrical Gauges Give Wrong Readings. Problem 1: Contactor Switch For Water Temperature Fails To Activate Shutoff Probable Cause:1. Wrong Connections: Connect battery to C and fuel shutoff solenoid to NO connections. Check connections to other components or make installation of new wiring.2. Low Water Level In Cooling System: Fill the cooling system.3. Wrong Setting Of Switch: Make a test of temperature setting and, if necessary, install new contactor switch with correct setting. See Specifications. Problem 2: Contactor Switch For Water Temperature Activates Shutoff At Wrong Temperature Probable Cause:1. Wrong Setting Of Switch: Make a test of temperature setting and, if necessary, install new contactor switch with correct setting. See Specifications. Problem 3: Switch For Oil Pressure Fails To Activate Shutoff Probable Cause:1. Wrong Connections: Check and make connections as shown in wiring diagrams.2. Wrong Setting Of Switch: Test and adjust switch. If necessary, install new switch. Problem 4: Engine Protection Panel Will Not Activate Engine Shutoff Probable Cause:1. Fuse Burnt: Find and correct cause for burnt fuse. Install new fuse.2. Grounded Or Loose Wiring: Check and repair any worn or loose wiring.3. Components In System Not Functioning Correctly: Check components and install new ones as needed. Problem 5: Engine Protection Panel Stops Engine When Reset Button Is Released Probable Cause:1. Grounded Wiring Between "S" Terminal And Switches: Install new wiring.2. Broken Water Temperature Or Oil Pressure Switches: Check the switches and install new ones as needed. Problem 6: Electrical Gauges Give Wrong Readings Probable Cause:1. Wrong Connections: Check wiring connections to be sure they are tight. Check to see that the gauges are correctly connected as shown in the wiring diagrams.2. Sending Units Fail To Operate: Check the sending units and install a new one if necessary.3. Wrong Sending Unit In System: Install correct sending unit.Electrical System
Contactor Switch For Water Temperature
First Method Of Checking
1. Make a heat sink as shown. Material can be brass, steel or cast iron. Drill a 17.8 mm (.70 in.) hole through the plate and use a tap to make 1/2 in. NPT threads.2. Put marks on wire connections to contactor terminals and disconnect the wire.
Heat Sink [Dimensions in mm (in.)]
Test Of Contactor Switch
(1) 2F7112 Thermometer. (2) Fabricated heat sink.3. Remove the contactor and install a 3J5389 Plug. Install the contactor switch in the heat sink.4. Connect the wires to the contactor switch to check all of the system; contactor switch, wires, etc. If the wires cannot be disconnected, use the second method of testing.5. When the contactor switch is connected again, start the engine and run it at low idle rpm. The pressure switch will complete the circuit when the engine is running. When applying heat to the water in Step 6, be sure to stir (keep water moving) while heating.6. Put the heat sink and contactor element in water. Use blocks to support the heat sink at surface level. Use a torch to make the water hot and read the temperature on thermometer (1) at which the engine stops (switch is closed). For the 5L6435 Contactor, the temperature should be 98 0.6°C (209 1°F). Let the water temperature go down. The contactor switch will open when the temperature is 8°C (12°F) lower than the temperature at which the contactor closes.7. Install new contactor switch if necessary.To check other components in the system, put a jumper wire between C and NO terminals of the contactor switch for water temperature.Second Method Of Checking
1. Remove the wires from the contactor switch.2. Connect the 8T500 Circuit Tester between the C and NO terminals.3. Start the engine and get it hot by making a reduction in coolant flow or air flow through the radiator. Temperature must not go more than approximately 3° above the maximum.
If the engine cannot be run safely at these high temperatures, the contactor must be checked off the engine.
4. Look at the circuit tester to see when the contactor switch closes. The light will be activated. The temperature must be 98 0.6°C (209 1°F) for the standard sea level contactor.5. Let the engine run to slow cooling and then stop the engine.6. Install new contactor switch if needed and connect wires to the contactor switch.Electrical Gauges And Sending Units
Remember that the electrical gauges and sending units are to operate in electrical balance. For this reason, the voltage and resistance ratings are important to get the correct indications on the gauges.Sending Units For Oil Pressure
Sending Unit For Oil Pressure
(1) Terminal. (2) Fitting.The sending unit for engine oil pressure can be checked for resistance to find if it is operating correctly. Connect the sending unit to a pressure source that can be measured with accuracy. Connect the ohmmeter between fitting (2) and terminal (1). Take resistance readings at the pressures given in the Attachment Specifications section.If the test performance is correct for the sending unit for the oil pressure, install a new gauge.Sending Unit For Water Temperature
A resistance check can be made to find if the sending unit is operating correctly. Connect an ohmmeter between nut (2) and terminal (1). Put bulb (3)
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 of 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.Troubleshooting Index
1. Contactor Switch For Water Temperature Fails To Activate Shutoff.2. Contactor Switch For Water Temperature Activates Shutoff At Wrong Temperature.3. Switch For Oil Pressure Fails To Activate Shutoff.4. Engine Protection Panel Will Not Activate Engine Shutoff.5. Engine Protection Panel Stops Engine When Reset Button Is Released.6. Electrical Gauges Give Wrong Readings. Problem 1: Contactor Switch For Water Temperature Fails To Activate Shutoff Probable Cause:1. Wrong Connections: Connect battery to C and fuel shutoff solenoid to NO connections. Check connections to other components or make installation of new wiring.2. Low Water Level In Cooling System: Fill the cooling system.3. Wrong Setting Of Switch: Make a test of temperature setting and, if necessary, install new contactor switch with correct setting. See Specifications. Problem 2: Contactor Switch For Water Temperature Activates Shutoff At Wrong Temperature Probable Cause:1. Wrong Setting Of Switch: Make a test of temperature setting and, if necessary, install new contactor switch with correct setting. See Specifications. Problem 3: Switch For Oil Pressure Fails To Activate Shutoff Probable Cause:1. Wrong Connections: Check and make connections as shown in wiring diagrams.2. Wrong Setting Of Switch: Test and adjust switch. If necessary, install new switch. Problem 4: Engine Protection Panel Will Not Activate Engine Shutoff Probable Cause:1. Fuse Burnt: Find and correct cause for burnt fuse. Install new fuse.2. Grounded Or Loose Wiring: Check and repair any worn or loose wiring.3. Components In System Not Functioning Correctly: Check components and install new ones as needed. Problem 5: Engine Protection Panel Stops Engine When Reset Button Is Released Probable Cause:1. Grounded Wiring Between "S" Terminal And Switches: Install new wiring.2. Broken Water Temperature Or Oil Pressure Switches: Check the switches and install new ones as needed. Problem 6: Electrical Gauges Give Wrong Readings Probable Cause:1. Wrong Connections: Check wiring connections to be sure they are tight. Check to see that the gauges are correctly connected as shown in the wiring diagrams.2. Sending Units Fail To Operate: Check the sending units and install a new one if necessary.3. Wrong Sending Unit In System: Install correct sending unit.Electrical System
Contactor Switch For Water Temperature
First Method Of Checking
1. Make a heat sink as shown. Material can be brass, steel or cast iron. Drill a 17.8 mm (.70 in.) hole through the plate and use a tap to make 1/2 in. NPT threads.2. Put marks on wire connections to contactor terminals and disconnect the wire.
Heat Sink [Dimensions in mm (in.)]
Test Of Contactor Switch
(1) 2F7112 Thermometer. (2) Fabricated heat sink.3. Remove the contactor and install a 3J5389 Plug. Install the contactor switch in the heat sink.4. Connect the wires to the contactor switch to check all of the system; contactor switch, wires, etc. If the wires cannot be disconnected, use the second method of testing.5. When the contactor switch is connected again, start the engine and run it at low idle rpm. The pressure switch will complete the circuit when the engine is running. When applying heat to the water in Step 6, be sure to stir (keep water moving) while heating.6. Put the heat sink and contactor element in water. Use blocks to support the heat sink at surface level. Use a torch to make the water hot and read the temperature on thermometer (1) at which the engine stops (switch is closed). For the 5L6435 Contactor, the temperature should be 98 0.6°C (209 1°F). Let the water temperature go down. The contactor switch will open when the temperature is 8°C (12°F) lower than the temperature at which the contactor closes.7. Install new contactor switch if necessary.To check other components in the system, put a jumper wire between C and NO terminals of the contactor switch for water temperature.Second Method Of Checking
1. Remove the wires from the contactor switch.2. Connect the 8T500 Circuit Tester between the C and NO terminals.3. Start the engine and get it hot by making a reduction in coolant flow or air flow through the radiator. Temperature must not go more than approximately 3° above the maximum.
If the engine cannot be run safely at these high temperatures, the contactor must be checked off the engine.
4. Look at the circuit tester to see when the contactor switch closes. The light will be activated. The temperature must be 98 0.6°C (209 1°F) for the standard sea level contactor.5. Let the engine run to slow cooling and then stop the engine.6. Install new contactor switch if needed and connect wires to the contactor switch.Electrical Gauges And Sending Units
Remember that the electrical gauges and sending units are to operate in electrical balance. For this reason, the voltage and resistance ratings are important to get the correct indications on the gauges.Sending Units For Oil Pressure
Sending Unit For Oil Pressure
(1) Terminal. (2) Fitting.The sending unit for engine oil pressure can be checked for resistance to find if it is operating correctly. Connect the sending unit to a pressure source that can be measured with accuracy. Connect the ohmmeter between fitting (2) and terminal (1). Take resistance readings at the pressures given in the Attachment Specifications section.If the test performance is correct for the sending unit for the oil pressure, install a new gauge.Sending Unit For Water Temperature
A resistance check can be made to find if the sending unit is operating correctly. Connect an ohmmeter between nut (2) and terminal (1). Put bulb (3)
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