0284645 JOHNSON ENGINE COVER ASSY.

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     138-7575     Link Bracket     1    Start By:
Remove the battery and battery cable. Refer to Disassembly and Assembly, "Battery and Battery Cable - Remove and Install ".
Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install".
Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
Remove the fan guard. Refer to Disassembly and Assembly, "Fan Guard - Remove and Install".
Remove the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install".
Remove the counterweight. Refer to Disassembly and Assembly, "Counterweight - Remove and Install ".
Keep all parts clean from contaminants.Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components.To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly.Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination.
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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
At operating temperature, the hydraulic oil is hot and under pressure. Hot oils can cause burns.To prevent possible personal injury, release the pressure in the implement hydraulic circuit (boom, stick, bucket, and swing), travel circuits, and the hydraulic oil tank at the filler cap before any hydraulic lines or components are disconnected or removed.Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, all hoses and all tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.Note: Side covers, panels and shields were removed for photographic purposes. The engine can be removed with the covers, panels and shields in place.
Illustration 1 g00942330
Drain coolant from the radiator into a suitable container for storage or disposal. Use drain valve (1). The radiator contains 5.7 L (1.5 US gal).
Illustration 2 g00945224
Remove muffler clamp (2) and the bolt (3). Remove exhaust elbow (4) .
Illustration 3 g00945370
Install a nylon strap to hydraulic pump (5) .
Remove bolts (6) that secure the hydraulic pump to the pump drive. Separate the hydraulic pump from the pump drive. Set the hydraulic pump aside.
Illustration 4 g00945376
Remove cable straps (7). Disconnect governor cable (8) .
Illustration 5 g00945397
. Disconnect fuel hoses (9). Remove hose clamp (12) .
Loosen hose clamp (10). Disconnect lower radiator hose (11) .
Illustration 6 g00945530
Remove hose (13). Remove tank assembly (14) .
Remove clip (18) .
Remove clip (15). Remove hose clamp (17). Remove fuel line (16) .
Illustration 7 g00945635
Loosen hose clamp (20). Disconnect upper radiator hose (19) .