0433930 JOHNSON CYLINDER & C'CASE ASSY., 8 models

Removing The Engine
HOT ENGINE COMPONENTS CAN CAUSE SERIOUS BURNS. SHUT THE ENGINE DOWN AND ALLOW IT TO COOL BEFORE WORKING IN THE ENGINE COMPARTMENT.
MAIN BATTERY DISCONNECT SWITCH
FUEL SHUTOFF VALVES1. Turn the main battery disconnect switch to "Off".2. Close the fuel shutoff valves located under the fuel tank.
PUMP SUCTION SHUTOFF VALVES3. Close the two pump suction shutoff valves. 4. Remove the coolant drain plug from the elbow and allow the coolant to drain. After the coolant has drained, install the plug and disconnect the coolant hoses from the engine.5. Remove the muffler guards and exhaust guard. Attach a lifting device to the muffler, disconnect the exhaust elbow from the engine and the muffler from the muffler support, then lift the muffler and exhaust ducting away. Cover the engine opening. 6. Attach a lifting device to the air cleaner. Disconnect the hump hose from the engine and the air cleaner from the air cleaner support, then lift the air cleaner and intake ducting away. Cover all openings.7. Remove the muffler support, air cleaner support and guard rail.8. Disconnect the guard rail from the engine. 9. Remove the drive line guard, then disconnect the drive line from the crankshaft pulley adapter.
COMPRESSED AIR ESCAPING FROM THE SYSTEM CAN CAUSE SERIOUS INJURIES. STAY CLEAR OF ANY ESCAPING COMPRESSED AIR.
10. Open the ball valve on the air tank to relieve the air pressure. Mark for identification the hoses running from the tank to the compressor, then disconnect the hoses from the compressor. 11. Remove the cover from the water spray system pump. Loosen the jam nut, turn the adjusting nut to relieve belt tension, then remove the belt. 12. Loosen the jam nut and turn the adjusting nut to relieve the compressor belt tension, then remove the belt. 13. Disconnect the following from the engine: Fuel supply and return hoses - cap or plug all openings.Tachometer cable. Electrical wires and cables. 14. Mark all the hoses connected to the pumps for identification when installing the engine, thoroughly clean around the connections, then disconnect the hoses from the pumps. Cap or plug all openings immediately.15. Check the engine over and disconnect any remaining wires or hoses that might interfere with engine removal. 16. Attach a lifting beam and device to the engine, remove the engine mounting bolts, then lift the engine away. The total weight of the engine, gearbox and pumps is approximately 1650 pounds.Building The Engine Up
The simplest way to build up a new engine is to position the new engine beside the old one and properly support both so they can safely be worked on. Then remove one component at a time from the old engine and install it on the new engine until all required components have been transferred to the new engine. Components that may have to be transferred include: 1. Alternator and drive belt.2. Crankshaft pulley adapter.3. Compressor, compressor coolant hoses and compressor lubricant hose.4. Compressor idler pulley assembly, throttle cable bracket and governor control lever.5. Oil pressure switch, oil pressure sender, hoses and bracket.6. Water temperature sender.7. Tachometer drive.8. Hour meter.9. Pump drive gearbox (see page 4.0-3), drive plate (see page 4.0-3) and hydraulic pumps.Installing The Engine
1. Install the drive plate and pump drive gearbox on the engine (see page 4.0-8).2. Check that the mounting area on the machine is clear of all hoses, wires, control cables, etc. 3. Attach a lifting beam and lifting device to the lifting lugs on the engine and move the engine into position. The approximate total weight of the engine, pump drive gearbox and pumps is 1650 pounds. 4. Thoroughly clean around the pump fittings and hose ends, then connect the hydraulic hoses to the pumps. 5. Connect the following to the engine:Electrical wires and cables Fuel supply and return lines 6. If the alternator drive belt has not been installed, install it and adjust the belt tension (see page 2.0-20), then install the spray system pump drive belt and adjust the belt tension (see page 2.0-19). 7. Install the compressor drive belt and adjust the tension. 8. Connect to the compressor the air hoses from the air tank. Close the ball valve on the tank. 9. Connect the drive line to the crankshaft pulley adapter, then install the drive line guard. 10. Connect the coolant hoses to the engine.11. Install the muffler support, then connect the muffler to the support and the exhaust elbow to the engine. 12. Install the air cleaner support. Connect the air cleaner to the support and engine. Install the guard rail.13. Connect the throttle cable and brackets to the engine.14. Fill the engine cooling system with a mixture of 50% water and 50% ethylene glycol antifreeze.15. Check the oil levels in the engine and pump drive gearbox and add oil as necessary. Be sure the correct oil is used in each place. See General 2.0-1 for oil specifications.
FUEL SHUTOFF VALVES16. Open the fuel shutoff valves.
PUMP SUCTION SHUTOFF VALVES17. Open the two pump suction shutoff valves.
IF A NEW HYDRAULIC PUMP HAS BEEN INSTALLED, FOLLOW THE STARTUP PROCEDURE GIVEN IN THE APPROPRIATE SECTION FOR THE PUMP.
18. Loosen the suction line on the track pump until air-free hydraulic oil flows from the connection. Repeat the procedure for the control (auxiliary) pump and both conveyor pump sections.19. Fill the track pump and control pump to the uppermost case drain ports with filtered hydraulic oil.
MAIN BATTERY DISCONNECT SWITCH20. Turn the main battery disconnect switch to "O