0396010 JOHNSON CYLINDER & C'CASE ASSY.

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Personal injury can result from hot oil or hot components.At operating temperature, oil is hot and under pressure. Hot oil can cause burns.Remove the fill cap only when the engine is stopped, and the fill cap is cool enough to touch with your bare hand.Do not allow hot oil or components to contact skin.
Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal components.
Drain the engine oil from the engine. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct procedure.
Illustration 1 g00619649
Remove two bolts (2) and the washers that hold clamp assembly (3) to adapter (1).
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Remove two bolts (5), the nuts, the washers, the spacers, and the clips that hold tube (4) to oil pan (6).
Illustration 3 g00619659
Remove two bolts (9) and the washers that hold clamp assembly (8) to base adapter (7). Place tube (4) aside.
Illustration 4 g00619662
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Put identification marks on nine bolts (10) that hold oil pan (6) to oil pan (12). Put identification marks on nine bolts (15), and 28 bolts (13) that hold oil pan (6) to the engine.
Remove nine bolts (10) and the washers that hold oil pan (6) to oil pan (12). Remove nine bolts (15) and the washers that hold oil pan (6) to the engine.
Use two people in order to support oil pan (6). Remove 28 bolts (13) and the washers that hold oil pan (6) to the engine. Remove oil pan (6) and five gaskets (14) from the engine. Remove integral seal (11) (not shown) from oil pan (12). The weight of oil pan (6) is 23 kg (51 lb). Installation Procedure
Verify that all of the components are clean and free of foreign material prior to installation. Check all of the O-ring seals and the components for wear. Replace the O-ring seals and the components, if necessary.
Lubricate all O-ring seals with the lubricant that is being sealed.
Illustration 6 g00619692Note: Ensure that the mating surface of the oil pan is clean and free of foreign material prior to installing the gasket.
Install five gaskets (14) to oil pan (6), as shown. Apply Loctite 595 or 138-8436 Liquid Gasket to oil pan (6) as it is necessary.
Apply Loctite 595 or 138-8436 Liquid Gasket to all the joints of five gaskets (14).
Illustration 7 g00619662
Illustration 8 g00619664Note: Ensure that the mating surface of the engine is clean and free of foreign material prior to installing the oil pan.
Install integral seal (11) (not shown) to oil pan (12).
Use two people in order to position oil pan (6) and five gaskets (14) to the engine, as shown. Install 28 bolts (13) and the washers that hold oil pan (6) to the engine. Apply 4C-9508 Wicking Sealant to 28 bolts (13) after installation, as required. The weight of oil pan (6) is 23 kg (51 lb).
Install nine bolts (15) and the washers that hold oil pan (6) to oil pan (12). Install nine bolts (14) and the washers that hold oil pan (6) to the engine.
Illustration 9 g00619659
Position tube (4), as shown. Install two bolts (9) and the washers that hold clamp assembly (8) to base adapter (1).