0382575 JOHNSON GEARCASE ASSEMBLY,Less driveshaft & pump

Each time any significant quantity of oil (or other fluid) is spilled on or near the engine it should be cleaned up. Accumulated grease and oil on an engine is a fire hazard. Remove this debris with steam cleaning or high pressure water at PM Level 2 or every 6000 hours.Wipe clean all fittings, caps and plugs before servicing.
Starting the Engine
Do not store starting fluid containers in the cab. Failure to do so, could result in an explosion and/or fire and possible personal injury.If equipped with an electrically or fuel ignited manifold heater, DO NOT use ether.If equipped with Flammstart, DO NOT use ether.
Startability will be improved at temperatures below +32°F (0°C) by the use of a starting aid (ether) or use of a cylinder block coolant heater or other means to heat the crankcase oil. This will help alleviate white smoke and misfire during cold weather start-up.Use ether when temperatures are below 32°F (0°C) for cold weather starting purposes only.
When using starting fluid, follow the manufacturer's instructions carefully, use it sparingly and spray it ONLY WHILE CRANKING THE ENGINE. Excessive ether can cause piston and ring damage.Use ether for cold starting purposes only.
If the engine fails to start within 30 seconds, release the starter switch and wait two minutes to allow the starter motor to cool before using it again.Start the engine using the following procedure:1. Place the transmission in NEUTRAL and disengage the flywheel clutch (if equipped) to remove the transmission drag and prevent movement of the truck.Depressing the clutch in cold weather can mean the difference between starting and not starting. Depressing the clutch in warm weather produces faster starts and reduces battery drain.2. Turn the ignition switch to the ON position and push the crank button or turn the ignition switch to the START position.It may be necessary to push down on the throttle to get the fuel rack to move to the "fuel on" position for mechanical fuel system engines.
DO NOT PUSH DOWN OR HOLD THE THROTTLE DOWN while cranking the Electronic engine. The system will automatically provide the correct amount of fuel to start the engine.
3. Crank the engine. If the engine fails to start in 30 seconds, release the starting (ignition) switch and wait two minutes to allow the starter motor to cool before using it again. The Electronic engine may need to crank slightly longer than a mechanically governed engine, because some oil pressure is required for the electronic actuator to move the rack. The CHECK ENGINE/DIAGNOSTIC lamp should be ON while the engine is cranking, but should go OFF after engine oil pressure is achieved.
Do not increase engine speed until the oil pressure gauge indicates normal. Oil pressure should raise within 15 seconds after the engine starts.If oil pressure is not indicated on gauge within 15 seconds, do not drive the truck. Stop the engine, investigate and correct the cause.
4. Allow the engine to idle three to five minutes, or until the water temperature gauge has begun to rise. Check all gauges during the warm-up period.5. Check fuel level gauge. Do not fill fuel tank to top. Fuel expands as it gets warm and may overflow.Starting With Jumper Cables
When boost starting an engine, follow the instructions to properly start the engine. This engine may be equipped with a 12 or 24 volt starting system. Use only equal voltage for boost starting. The use of higher voltage will damage the electrical system.
Improper jumper cable connections can cause an explosion resulting in personal injury.Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jumper cable ends to contact each other or the engine.
When using jumper cables always connect POSITIVE (+) cable to POSITIVE (+) terminal of battery which is connected to starter solenoid and NEGATIVE (-) cable from external source to starter NEGATIVE (-) terminal. If not equipped with a starter NEGATIVE terminal, connect to the engine block.Do not reverse the battery cables. The alternator can be damaged. Attach ground cable last and remove first.
1. When using an external electrical source to start your truck engine, turn the START switch off and remove the key and turn off all electrical accessories before attaching cables.2. Connect one end of the cable to the POSITIVE (+) terminal of the battery being started. Connect the other end to the POSITIVE (+) terminal of the power source.3. Connect one end of the other cable to the NEGATIVE (-) terminal of the power source. Connect the other end to the starter NEGATIVE (-) terminal or to the engine block. This prevents potential sparks from igniting combustible gases produced by some batteries.4. Start the engine. After the engine starts, disconnect the cable from the starter NEGATIVE (-) terminal or engine block. Disconnect the other end from the NEGATIVE (-) terminal of the power source.5. Disconnect the cable from the POSITIVE (+) terminal of the battery on the engine being started. Disconnect the cable from the POSITIVE (+) terminal of the power source.Emergency Starting
If the truck engine stops and/or will not start because of a wiring harness problem or a failed solenoid, use the following procedure to start the engine so the truck can be moved to a repair shop.1. Remove the solenoid. Disconnect the wires from the solenoid and insulate them with tape.2. Remove or depress the solenoid plunger. A. If the truck is equipped with a type A solenoid: remove the solenoid, depress the plunger and crimp the brass sleeve with a pair of pliers. This will hold the plunger in the run position so it can be reinstalled without causing a shutdown.B. If the truck is equipped with type B solenoid: remove the solenoid and straighten the crimp in the steel sleeve and remove the plunger. Reinstall the solenoid after removing the plunger.3. Start the engine and proceed to the nearest Caterpillar engine servicing dealer.