5033941 JOHNSON VALVE, MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9U-6198 Crankshaft Turning Tool 1
Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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.
Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Fuel Injection Timing - Check". Note: The air compressor must be timed with the engine in order to minimize engine vibration.
Remove the air pressure from the air tank and drain the coolant from the cooling system.
Illustration 1 g00947002
Disconnect air lines from the air compressor. Disconnect coolant hose (1) and coolant hose (2) from the air compressor.
Disconnect oil supply tube assembly (3) from the air compressor.
Remove bolts (4). Remove bolt (5). Remove bracket (6) that supports the air compressor.
Illustration 2 g00947132
Remove nut (7) from the front side of the front housing. Remove nut (11). Carefully remove the air compressor from the front housing. Remove O-ring seal (10) from the air compressor.
If necessary, remove nut (8) from the air compressor crankshaft. Remove air compressor drive gear (9). Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 9U-6198 Crankshaft Turning Tool 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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.
Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Fuel Injection Timing - Check". Note: The air compressor must be timed with the engine in order to minimize engine vibration.
Illustration 3 g00947202
Position air compressor drive gear (9) on the air compressor crankshaft. Install nut (8). Tighten the nut to a torque of 120 N m (89 lb ft).
Remove bolts (14) and remove cover (12) from the mounting bracket.
Rotate the air compressor crankshaft until the Timing Mark (X) on the rear face of the air compressor crankshaft is aligned with the Timing Mark (A 6) of the mounting bracket for the air compressor.
Install O-ring seal (10) on the air compressor. Lubricate the O-ring seal with clean engine oil. Align the mounting studs with the air compressor and the front housing. Slide the air compressor into the front housing. Rotate the crankshaft of the air compressor in a clockwise direction in order to align the air compressor drive gear and the air compressor idler gear. Carefully push the air compressor against the front housing.
Ensure that Timing Mark (X) on the rear face of the air compressor crankshaft is aligned with the Timing Mark (A 6) of the mounting bracket for the air compressor. If the alignment is not correct, pull the air compressor away from the front housing. Rotate the air compressor crankshaft in the pertinent direction in order to allow the air compressor drive gear to mesh with the next tooth of the air compressor idler gear. Carefully push the air compressor against the front housing.
Install O-ring seal (13) and cover (12) on the air compressor. Install bolts (14).
Install nut (11) and nut (7) in order to secure the air compressor to the front housing. Tighten the nuts to a torque of 75 N m (55 lb ft).
Illustration 4 g00947002
Position bracket (6) and Install two bolts (4) in order to secure the bracket to the air compressor. Tighten the bolts to a torque of 22 N m (16 lb ft). Install bolt (5) in order to secure the bracket to the cylinder block. Tighten the bolt to a torque of 44 N m (32