0315774 JOHNSON PAD,Bracket

BrakeSaver Troubleshooting
There are two operation checks that are fast and need no special equipment. One check is the Pull-Down RPM Check to see if the BrakeSaver can give full braking force. The other check is the Klunk Check to see if the valve spool in the BrakeSaver control valve has free movement. These two checks give an approximate indication that the BrakeSaver has the correct operation.Pull-Down RPM Check
The engine must give rated horsepower for this test to have accuracy.1. Actuate the brakes, put the transmission in NEUTRAL and operate the engine at high idle rpm (accelerator pedal all the way down).2. Make a record of the engine rpm.3. Put the BrakeSaver control to the full ON position.4. Make a record of the engine rpm with the BrakeSaver full on.5. The engine rpm with the BrakeSaver full on must be 150 25 rpm less than the engine rpm with the BrakeSaver off. If the difference in rpm is less than 125 rpm, the BrakeSaver is not giving full braking force. If the difference in rpm is more than 175 rpm, check the air pressure to the BrakeSaver control valve. The air pressure must not be more than 345 kPa (50 psi).
Do not run the engine at high idle rpm with the BrakeSaver ON for more than 15 seconds at a time. Let the engine run a low idle with the BrakeSaver off for five minutes to keep from getting the engine cooling system too hot.
Klunk Check (check for free movement of the valve spool)
1. Run the engine until the truck air system is at its maximum pressure and then stop the engine.2. Put the BrakeSaver in the full ON position before the air pressure in the truck air system gets below 480 kPa (70 psi).3. Put the BrakeSaver in the OFF position. A noise ("klunk") must be heard at the BrakeSaver control valve as the valve spool hits the cover at the air inlet end of the control valve.4. If the noise is not heard at the BrakeSaver control valve, remove and disassemble the control valve. Inspect the valve for: * A damaged valve body.* Damaged or worn springs in the valve spool.* Damaged or worn valve spool.* Damaged or worn O-ring seals or diaphragm in the control valve.* Closed holes (small holes to feel pressure) in the side of the valve spool.For specific problems, make reference to the BrakeSaver Troubleshooting Problem List.BrakeSaver Troubleshooting Problem List
1. BrakeSaver Does Not Give Full Braking Force With The Selector Switch In The MANUAL Position.2. BrakeSaver Does Not Give Full Braking Force With The Selector Switch In The AUTOMATIC-MANUAL Position.3. BrakeSaver Oil Temperature Is Too High.4. BrakeSaver Does Not Turn OFF Or Become Empty.5. Oil Leakage From The Flywheel Housing.6. Oil Leakage From The Clutch Housing Or Transmission.
Indicator Holes For Troubleshooting
(1) Oil pressure from the BrakeSaver. (2) Oil pressure from the engine. (3) Oil pressure to the BrakeSaver. (4) Test point for BrakeSaver oil temperature. (5) Oil pressure to the engine. (6) Air pressure hole from the control valve. (7) Oil pressure to the cooler. (8) Oil pressure from the cooler. Fuel System
Either too much fuel or not enough fuel for combustion can be the cause of a problem in the fuel system. Many times work is done on the fuel system when the problem is really with some other part of the engine. The source of the problem is difficult to find, especially when smoke comes from the exhaust. Smoke that comes from the exhaust can be caused by a defective fuel injection nozzle, but it can also be caused by one or more of the reasons that follow:* Not enough air for good combustion.* An overload at high altitude.* Oil leakage into combustion chamber.* Not enough compression.* Fuel injection timing retarded.Fuel System Inspection
A problem with the components that send fuel to the engine can cause low fuel pressure. This can decrease engine performance.1. Check the fuel level in the fuel tank. Look at the cap for the fuel tank to make sure the vent is not filled with dirt.2. Check the fuel lines for fuel leakage. Be sure the fuel supply line does not have a restriction or a defective bend.3. Install a new fuel filter. Clean the primary fuel filter.4. Remove any air that may be in the fuel system. Use the fuel priming pump to move fuel through low pressure part of the system. Fuel with air will return to the tank through the fuel return line.To remove air from the fuel injection lines, loosen the fuel line nuts at the through the head adapter nozzles 1/2 turn. Crank engine with the starting motor until fuel without air comes from the fuel line connections. Tighten the fuel line nuts. The fuel priming pump will not give enough pressure to push fuel through the orifice reverse flow check valves in the fuel injection pumps.Fuel Transfer Pump
Fuel Lines
(1) Fuel inlet.With the engine operating at full load speed, the fuel transfer pump moves fuel through the secondary filter and the fuel injection pump housing at approximately 240 kPa (35 psi).To check the fuel transfer pump pressure, disconnect the fuel line (from the filter) at the fuel injection pump housing inlet (1). Install a tee at inlet (1) and connect the fuel line to the tee. Connect a pressure indicator to the tee and start the engine.Minimum fuel pressures must be 70 kPa (10 psi) at low idle and 170 kPa (25 psi) at full load speed (and engine under full load).If the fuel pressure is not above the minimum specifications, stop the engine. Make a replacement of the primary and secondary fuel filters and check to make sure the fuel lines and hoses are not plugged or damaged.Start the engine and again check the fuel pressure. If the fuel pressure is not above the minimum specification, a repair or replacement of the fuel transfer pump is needed.Checking Engine Cylinders Separately
An easy check can be made to find the cylinder