0314090 JOHNSON RETAINER

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 bad bend.3. Install a new fuel filter. Clean the fuel screen located in the inlet valve of the fuel transfer pump.4. Remove any air that may be in the fuel system. Open the drain valve on the fuel injection pump housing. Operate the fuel priming pump until fuel without air comes from the drain lines. Close the drain valve.To remove air from the fuel injection lines, loosen the fuel line nuts 1/2 turn. Move the governor lever to the low idle position. Crank engine with the starter motor until fuel without air comes from the fuel line connections. Tighten the fuel line nuts.Check Engine Cylinders Separately
An easy check can be made to find the cylinder that runs rough (misfires) and causes black smoke to come out of the exhaust pipe.Run the engine at the speed that is the roughest. Loosen the fuel line nut at a fuel injection pump. This will stop the flow of fuel to that cylinder. Do this for each cylinder until a loosened fuel line is found that makes no difference in engine performance. Be sure to tighten each fuel line nut after the test before the next fuel line nut is loosened. Check each cylinder by this method. When a cylinder is found where the loosened fuel line nut does not make a difference in engine performance, test the injection pump and fuel injection nozzle for that cylinder.Temperature of an exhaust manifold port, when the engine runs at low idle speed, can also be an indication of the condition of a fuel injection nozzle. Low temperature at an exhaust manifold port is an indication of no fuel to the cylinder. This can possibly be an indication of a nozzle with a defect. Extra high temperature at an exhaust manifold port can be an indication of too much fuel to the cylinder, also caused by a nozzle with a defect.The most common defects found with the fuel injection valves are:1. Carbon on tip of the nozzle or in the nozzle orifice.2. Orifice wear.
Do not test or disassemble nozzles unless you have the correct service tools.
Testing 7000 Series Fuel Injection Nozzles
*5P4150 Nozzle Testing Group.5P4244 Adapter.8S2270 Fuel Collector.FT1384 Extension.8S2245 Cleaning Tool Group.8S2258 Brass Wire Brush.6V4979 Carbon Seal Installation Tool.1F1153 Needle Nose Pliers.5P4721 Tube Assembly.7/64" Hex Wrench.*Special Instruction Form No. SEHS7292.
5P4150 NOZZLE TESTING GROUP
1. Nozzle Assembly. A. 5P4244 Adapter. B. 5P4146 Gauge, 0 to 1000 psi (0 to 6900 kPa). C. 5P4271 Tube Assembly. D. 2P2324 Gauge, 0 to 5000 psi (0 to 34 500 kPa). E. Gauge protector valve for 2P2324 Gauge. F. FT1384 Extension. G. Gauge protector valve for 5P4146 Gauge. H. On-off valve. J. 8S2270 Fuel Collector. K. Pump isolator valve.
EXTRA VALVE
L. Gauge protector valve (must be in open position at all times).
Be sure to use clean SAE J967 Calibration Fluid when tests are made. Dirty test fluid will damage components of fuel injection nozzles. The temperature of the test fluid must be 65 to 75°F (18 to 24°C) for good test results.
Order calibration fluid by part number, in the quantities needed, according to the information that follows: 6V6068 Calibration Fluid, 5 U.S. gal. (18.9 liter).6V6067 Calibration Fluid, 55 U.S. gal. (208.2 liter).The Fuel Injection Nozzle can not be disassembled for cleaning or adjustment. Do the tests that follow to determine if the nozzle performance is acceptable.I. Valve Opening Pressure Test.II. Flush the Nozzle.III. Tip Leakage Test.IV. Orifice Restriction Test.V. Bleedscrew Leakage Test.Nozzle Preparation for Test
Before fuel injection nozzle (1) can be tested, all loose carbon around the tip of the nozzle must be removed with the 8S2258 Brass Wire Brush (M).
REMOVING CARBON DAM
1. Fuel injection nozzle. 2. Carbon dam. 3. Seal. Remove carbon dam (2) with needle nose pliers and remove seal (3) from the nozzle.
Do not use a steel brush or a wire wheel to clean the nozzle body or the nozzle tip. Use of these tools can cause a small reduction of orifice size, and this will cause a large reduction in engine horsepower. Too much use of the 8S2258 Brass Wire Brush will also remove the coating that is on the nozzle for protection.
8S2245 CLEANING KIT
M. 8S2258 Brass Wire Brush. N. 6V4979 Carbon Seal Tool. P. 8S2250 Nozzle Holding Tool.Clean the groove for carbon seal dam (2) and the body of the nozzle below the groove with the 8S2258 Brass Wire Brush (M). Remove the carbon, but be sure not to use the brush enough to cause damage to the body of the nozzle. A change in color in the area below the groove is normal and does not effect the body of the nozzle.
FUEL INJECTION NOZZLE
4. Bleed screw and seal.Remove bleed screw and seal (4) from the nozzle. The bleed screw and seal must be removed for all tests except test V; Bleed Screw Leakage Test.I. Valve Opening Pressure Test (VOP)
1. Install 5P4721 Tube Assembly (C) to the tester.2. Install the fuel injection nozzle with 5P4244 Adapter (A) on tube assembly (C). Be sure the nozzle tip is down and extends into FT1384 Extension (F) and 8S2270 Fuel Collector (J).
When fuel injection nozzles are tested, be sure to wear eye protection. Fuel comes from the orifices in the nozzle tip with high pressure. The fuel can pierce (go thru) the skin and cause serious injury to the operator. Keep the tip of the nozzle pointed away from the operator and into the 8S2270 Fuel Collector and FT1384 Extension.
Put a shop towel around the upper part of the nozzle to take in any fuel leakage.
3. Close on-off valve (H). Open pump isolator valve (K).