0302406 JOHNSON SLEEVE

Cleanliness
Whenever hydraulic, fuel, lubricating oil or air lines are disconnected, clean the point of disconnection and the adjacent area. As soon as the disconnection is made, cap, plug or tape the line or opening to prevent entry of foreign material. The same recommendations for cleaning and covering apply when access covers or inspection plates are removed.Clean and inspect all parts. Be sure all passages and holes are open. Cover all parts to keep them clean. Be sure parts are clean when installed. Leave new parts in their containers until ready for assembly.Removal And Installation
Unless otherwise specified, all removals should be accomplished using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other and as near perpendicular as possible to the top of the object being lifted. When it is necessary to remove a component on an angle, remember that the capacity of an eyebolt diminishes as the angle between the supporting members and the object becomes less than 90°. Eyebolts and brackets should never be bent and should only have stress in tension. A length of pipe and a washer can be used, as shown, to help relieve these stresses on eyebolts.Forged eyebolts are available. Each size eyebolt has a maximum load recommendation.Some removals require the use of lifting fixtures to obtain proper balance and to provide safe handling.If a part resists removal, check to be certain all nuts and bolts have been removed and that an adjacent part is not interfering. Disassembly And Assembly
When assembling an engine, complete each step in turn. Do not partially assemble one part and start assembling some other part. Make all adjustments as recommended. Always check the job after it is completed to see nothing has been overlooked.Lubrication For A Rebuilt Engine
It is very important for a rebuilt engine to have "adequate" (needed) lubrication during the first seconds of operation. A "dry start" (without needed lubrication) on a rebuilt engine can cause bearing damage.When an engine is rebuilt with new parts, oil is put on each part as it is installed. This is generally enough lubrication for engine start-up. However, this lubrication may not be enough or may be lost if the rebuilt engine is placed in storage for any length of time.To prevent the possibility of a "dry start" and bearing damage during the first seconds of running, use the 1P540 Flow Checking Tool Group and shop air pressure to pressure lubricate (fill the main oil passage with oil under pressure) all rebuilt engines.Procedure for Pressure Lubrication
1. Clean the tank of the 1P540 Flow Checking Tool Group thoroughly, and set the pressure regulator to 35 5 psi (240 35 kPa).
Air pressure should not be more than 50 psi (345 kPa) at any time.
2. Put engine oil in the tank.3. Connect the tooling to the main oil passage of the engine.4. Add air pressure to the tank, with the regulator set at 35 5 psi (240 35 kPa). Although the tank does have a hand pump, it is difficult to get enough air pressure to do the job with the hand pump. Therefore, use of shop air is recommended.5. Let the engine oil flow into the oil passage under pressure.Fill the crankcase with the correct oil. The amount of oil used in the pressure lubrication procedure must be subtracted from the recommended refill capacity in the Lubrication and Maintenance Guide. If the engine is not going to be used for a long time, do the above procedure again before the first starting.If shop air is not available for charging the tank, the hand pump may be used to get the minimum required pressure.
Do not use the same 1P540 Flow Checking Tool Group for both "pressure lubrication application" and for checking fuel flow. Incorrect cleaning is probable if the tool is used for both fuel and lube oil. Even a minute amount of dirt in the fuel system can cause fuel nozzle failure.
Initial Operation After Engine Reconditioning
The quality of oil control components used in Caterpillar engines is such that, following engine reconditioning (with Caterpillar Service Parts), only an initial operational check is necessary before continued operation in normal service.The purpose of this initial operational check is to: insure that the engine has been assembled properly; determine if proper pressures and temperatures are maintained in the lubrication, cooling and fuel systems; correct any leaks; perform necessary adjustments (such as valve clearance, governor high and low idle speeds, etc.); check the power setting of the engine.To provide a safe, uniform initial operational check, the following procedure is recommended: 1. Motor engine at cranking speed until oil pressure is observed.2. Operate engine for 10 minutes at low idle.3. Operate engine for 15 minutes at half-load and 3/4 rated speed.4. Operate engine for 30 minutes at rated load and speed.Service Tools
Puller Assembly (2 or 3 Arm)
Two or three arm puller assemblies can be used to remove gears, bearing cages, hubs, bearings, shafts, etc.
TYPICAL EXAMPLE
1. Puller.
TYPICAL EXAMPLE
1. Puller. 2. Step Plate.
TYPICAL EXAMPLE
1. Puller. 2. Step Plate.Push Pullers
Push Pullers can be used to remove pulleys, gears, shafts, etc., and can be used in a variety of pulling combinations.
TYPICAL EXAMPLE
*1. Adapters. 2. Ratchet Box Wrench. 3. Push Puller. 4. Step Plate. 5. Legs. *Use as required.
TYPICAL EXAMPLE
1. Push Puller. 2. Adapter. 3. Step Plate.
TYPICAL EXAMPLE
1. Ratchet Box Wrench. 2. Push Puller. 3. Reducing Adapter.
TYPICAL EXAMPLE
1. Push Puller. 2. Ratchet Box Wrench. 3. Step Plate. 4. Bearing Pulling Attachment.
TYPICAL EXAMPLE
1. Push Puller. 2. Bearing Cup Pulling Attachment. 3. Reducing Adapter.
TYPICAL EXAMPLE
1. Bearing Pulling Attachment. 2. Push Puller. 3. Reducing Adapter.Bearing Pulling Attachment
Bearing Pulling Attachments can be used with forcing bolts, to remove shafts, bearings, gears, etc. They can be used with Push Pullers to provide a variety of pulling combinations.
TYPICAL EXAMPLE
1. Bearing Pulling Attachment. 2. Forcing Bolts.Bearing Cup Pulling Attachment
Bearing Cup Pulling Attachments are used to remove bearing races or cups, sleeve-type bearings, bearings, seats, etc. and can be used with Push Pullers.
TYPICAL EXAMPLE
1. Screw. 2. Bearing Cup Pulling Attachment. 3.