0340777 JOHNSON COVER, Housing, rear

At operating temperature, the engine cooling system is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap on the radiator is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
1. Drain the coolant from the cooling system.
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publication SENR3334-01, SENR5664 and NEDG5065-01 for the proper procedure, equipment and tools to reclaim refrigerant from any Caterpillar machine.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping refrigerant R-12 (C C12F2 Dichloro Difluoro Methane) and refrigerant R-134A can cause freezing of human flesh. Do not smoke while working on air conditioning. Inhaling Refrigerant R-12 or R-134A through any smoking material, although not toxic or flammable, can cause violent illness. Also heat must never be applied to a charged system. See Air Conditioning And Heating Service Manual Form No. SENR3334-01 and SENR5664, for more information on removal and installation of lines and refrigerant from the system.
2. Evacuate the air conditioning system. 3. Remove eight bolts (1) and grille (2). 4. Remove two bolts and washers (3) and position air horn (4) out of the way. 5. Remove handle and nut (5). Remove retaining nut (6) and position control cable (7) out of the way. 6. Remove six bolts and washers (8) and hood door (9). 7. Attach a lifting strap to the hood to hold it in an upright position.8. Disconnect the hood support rod (12) at the hood.9. Remove seven bolts and washers (10) and hood assembly (11). The weight of the hood assembly is 27 kg (60 lb). 10. Remove two bolts and washers (14) from brace (13).11. Loosen two clamps (15) and slide the top hose towards the radiator.12. Disconnect two lines (18) from the air dryer.13. Attach Tooling (A) as shown.14. Remove three bolts and washers (17) from each side and remove top cover (16). The weight of the top cover is 22 kg (50 lb). 15. Remove bolt and washer (19) and disconnect hose assembly (20).16. Remove bolt and washer (21) and the bracket holding the hose assemblies to the radiator (three places). 17. Remove one bolt (22), loosen the other and swing brace (13) out of the way. 18. Remove four bolts and washers (23) holding the air dryer to the radiator guard. Remove two bolts and washers (26) and disconnect hose (25).19. Remove bolts and washers (28) and fan guards (27). 20. Remove five bolts and washers (29) from side panel (30). 21. Remove bolt and washer (33) holding control cable (34) to the radiator (two places).22. Remove four bolts (31) and housing (32). 23. Disconnect line (35). Remove nut, washers and bolt (36) holding the bracket to the bottom of the radiator. 24. Remove bolts, washers (37) and (38). 25. Disconnect two hose assemblies (39) at the solenoid valve.26. Disconnect two wiring harnesses (40). 27. Remove two bolts and washers (41). Disconnect hose assembly (42) from the condenser. 28. Attach Tooling (A) and lifting straps as shown. 29. Remove two bolts and washers (43) and (45) from the right side of the radiator.30. Remove all the bolts and washers and brackets (44) and (46) on the left side. Bracket removal on left side necessary to clear the bail cylinder.31. Slide the radiator forward to clear the fan. Remove the radiator and guard. Be careful not to damage the fan and the radiator core during removal. The following steps are for the installation of the radiator and guard. Be careful not to damage the fan and the radiator core during installation. 32. Install two bolts and washers (43) and (45) on the right side of the radiator.33. Install all the bolts and washers and brackets (44) and (46) on the left side.34. Install the radiator and guard. 35. Attach Tooling (A) and lifting straps as shown. 36. Install two bolts and washers (41). Connect hose assembly (42) to the condenser. 37. Connect two hose assemblies (39) at the solenoid valve.38. Connect two wiring harnesses (40). 39. Install bolts, washers (37) and (38). 40. Connect line (35). Install bracket to the bottom of the radiator and install nut, washers and bolt (36). 41. Install bolt and washer (33) holding control cable (34) to the radiator (two places).42. Install four bolts (31) and housing (32). 43. Install five bolts and washers (29) on side panel (30). 44. Install the air dryer to the radiator guard and install four bolts and washers (23). Install two bolts and washers (26) and connect hose (25).45. Install bolts and washers (28) and fan guards (27). 46. Install one bolt (22), reposition brace (13) and tighten the other bolt. 47. Install bolt and washer (21) and the bracket holding the hose assemblies to the radiator (three places).48. Install bolt and washer (19) and connect hose assembly (20). 49. Attach Tooling (A) as shown.50. Install three bolts and washers (17) on each side and install top cover (16). The weight of the top cover is 22 kg (50 lb).51. Connect two lines (18) on the air dryer.52. Install two bolts and washers (14) on brace (13).53. Reposition top hose and tighten two clamps (15). 54. Attach a lifting strap to the hood to hold it in an upright position.55. Install seven bolts and washers (10) and hood assembly (11). The weight of the hood assembly is 27 kg (60 lb).56. Connect the hood support rod (12) at the hood. 57. Install six bolts and washers (8