0394621 JOHNSON LOW COMPRESSION CYLINDER HEAD KIT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 439-3938 Link Bracket 2
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, PERJ1017, "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.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
Illustration 1 g02254793
Remove the clamps and hose assembly (2).
Remove the bolts, elbow (1), and the O-ring seals.
Remove the bolts, air inlet elbow (3), and the O-ring seal.
Repeat for all of the air inlet elbows.
Illustration 2 g02254854
Attach Tooling (A) and a suitable lifting device to air inlet cover (4). The weight of air inlet cover (4) is approximately 41 kg (90 lb).
Remove bolts (5), air inlet cover (4), and the seal.
Remove the bolts, elbow (6), elbow (7), elbow (8), and the O-ring seals.
Illustration 3 g02254873
Remove the bolts, elbow (9), and the O-ring seals.
If necessary, remove tube assembly (10).
Attach Tooling (A) and a suitable lifting device onto aftercooler core (11). The weight of aftercooler core (11) is approximately 180 kg (400 lb).
Remove bolts (14), aftercooler core (11), and the seal.
If necessary, remove bolts (13) and tanks (12) from the ends of aftercooler core (11).Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 439-3938 Link Bracket 2
B - P80 Rubber Lubricant -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 4 g02254873
If necessary, install tanks (12) and bolts (13) on the ends of aftercooler core (11). Tighten bolts (13) to a torque of 20 5 N m (15 4 lb ft).
Install the seal on the air inlet manifold.
Attach Tooling (A) and a suitable lifting device onto aftercooler core (11). The weight of aftercooler core (11) is approximately 180 kg (400 lb). Position aftercooler core (11) onto the air inlet manifold. Ensure that the bottom seal is properly seated. Install bolts (14).
If necessary, install tube assembly (10).
Apply Tooling (B) to the O-ring seals. Install the O-ring seals, elbow (9), and the bolts.
Illustration 5 g02254854
Apply Tooling (B) to the O-ring seals. Install the O-ring seals, elbow (8), elbow (7), elbow (6), and the bolts.
Attach Tooling (A) and a suitable lifting device to air inlet cover (4). The weight of air inlet cover (4) is approximately 41 kg (90 lb).
Install the seal on the aftercooler core. Position air inlet cover (4) onto the aftercooler core. Ensure that the seal is seated between air inlet cover (4) and the aftercooler core. Install bolts (5).
Illustration 6 g02254793
Install the O-ring seal, air inlet elbow (3), and the bolts.
Apply Tooling (B) to the O-ring seals. Install the O-ring seals, elbow (1), and the bolts.
Install hose assembly (2) and the clamps. Install the clamps according to the following procedure.
Align the clamps with the marks on the hose assembly.
Orient the clamps so that the T-bolts are a minimum of 90 degrees from each other.
Tighten the clamps to a torque of 9 2 N m (80 18 lb in).
Repeat for the other air inlet elbows.
Fill the cooling system with coolant. Refer to Operation and Maintenance Manu