0383716 JOHNSON GEARCASE AND BUSHING ASSEMBLY

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 given 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 service personnel must find the problem and its source, then make the necessary repairs.1. Engine Will Not Start.2. Misfiring Or Running Rough.3. Stall At Low rpm.4. Sudden Changes In Engine rpm.5. Not Enough Power.6. Too Much Vibration.7. Loud Combustion Noise.8. Loud Noise (Clicking) From Valve Compartment.9. Oil In Cooling System.10. Mechanical Noise (Knock) In Engine.11. Fuel Consumption Too High.12. Loud Noise From Valves Or Valve Drive Components.13. Little Movement Of Rocker Arm And Too Much Valve Lash.14. Valve Spring Lock Is Free.15. Oil At The Exhaust.16. Little Or No Valve Lash.17. Engine Has Early Wear.18. Coolant In Lubrication Oil.19. Too Much Black Or Gray Smoke.20. Too Much White Or Blue Smoke.21. Engine Has Low Oil Pressure.22. Engine Uses Too Much Lubrication Oil.23. Engine Coolant Is Too Hot.24. Starting Motor Does Not Turn.25. Alternator Gives No Charge.26. Alternator Charge Rate Is Low Or Not Regular.27. Alternator Charge Is Too High.28. Alternator Has Noise.29. Exhaust Temperature Is Too High. Problem 1. Engine Will Not Start Probable Cause:1. Empty Fuel Tank Put fuel in fuel tank and prime fuel system.2. Poor Quality Fuel Remove the fuel from the fuel tank. Install a new fuel filter element. Put a good grade of clean fuel in the fuel tank.3. Dirty Fuel Filter Install new fuel filter.4. Dirty Or Broken Fuel Lines Clean or install new fuel lines as necessary.5. Linkage To Sleeve Control Shaft Is Held In Shutoff Position Check the operation of the shutoff solenoid and the shutoff linkage. Solenoid must pull up to compress spring for fuel turn on. Check governor linkage for free movement. Sleeves must turn freely on pump plungers in all positions of sleeve control shaft. The thrust collar must turn freely on the governor shaft at all positions between shutoff and full load. If linkage does not move freely under these conditions, clean all parts thoroughly. Inspect all parts for wear and make replacement where needed.6. Fuel Pressure Is Too Low Replace the fuel filter. Inspect the bypass valve for free movement. Install a new bypass valve if necessary.7. Air In The Fuel System Find the air leak in the fuel system and correct it. Remove air from the fuel system. See Fuel System Inspection in Testing & Adjusting.8. Fuel System Not Timed Correctly To Engine Make adjustment to timing if necessary.9. Constant Bleed Valve Stays Open (not enough fuel pressure for starting) Replace constant bleed valve.10. No Over Fueling Spring Install an over fueling spring.11. Fuel Ratio Control Has A Defect Check fuel ratio control setting. Adjust if necessary. Check operation of solenoid. Problem 2. Misfiring Or Running Rough Probable Cause:1. Fuel Pressure Is Low Make sure there is enough fuel in the fuel tank. Look for leaks or defective bends in the fuel line between fuel tank and fuel transfer pump. Look for air in the fuel system. Check fuel pressure. The outlet pressure of the fuel transfer pump at full load speed is 205 35 kPa (30 5 psi). If fuel pressure is lower than above pressure, install a new fuel filter element. Inspect the fuel bypass valve for free movement. Install a new fuel bypass valve if necessary.2. Air In The Fuel System Find the air leak in the fuel system and correct it. Remove air from the fuel system. See Fuel System Inspection in Testing & Adjusting.3. Leak Or Break In Fuel Line Between Injection Pump And Injection Valve Install a new fuel line.4. Wrong Valve Lash Make adjustment according to Testing & Adjusting.5. Defect In Fuel Injection Nozzle Run engine at rpm that gives maximum misfiring or rough running. Then loosen a fuel line nut on the injection line for each cylinder, one at a time. Find the cylinder where loosening the fuel line nut does not change the way the engine runs. Test the fuel injection nozzle for that cylinder. Install new parts where needed.6. Wrong Fuel Injection Timing Make adjustment to timing. Problem 3. Stall At Low rpm Probable Cause:1. Fuel Pressure Is Low Make sure there is enough fuel in the fuel tank. Look for leaks or defective bends in the fuel line between fuel tank and fuel transfer pump. Look for air in the fuel system. Check fuel pressure. The outlet pressure of the fuel transfer pump at full load speed is 205 35 kPa (30 5 psi). If fuel pressure is lower than above pressure, install a new fuel filter element. Inspect the bypass valve for free movement. Install a new bypass valve if necessary.2. Idle rpm Too Low Make adjustment to governor so idle rpm is the same as given in the TMI (Technical Marketing Information) or Fuel Setting And Related Information Fiche.3. Defect In Fuel Injection Nozzle Install a new fuel injection nozzle.4. Wrong Valve Lash Make adjustment according to Testing & Adjusting.5. Spring