0335894 JOHNSON EXHAUST HOUSING ASSY.

At operating temperature, the engine cooling system is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the machine has stopped and the fill cap and radiator are cool enough to touch with the 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. Release the pressure in the cooling system by slowly loosening the fill cap on the radiator.2. Open drain valve (1), and drain the coolant from the cooling system into a suitable container. The capacity of the cooling system is 16 liters (4.2 U.S. gal).
At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the fill cap on the hydraulic oil tank only when the engine is stopped and the fill cap is cool enough to touch with your bare hand.
3. Release the pressure in the hydraulic system by slowly loosening the fill cap located on top of the hydraulic oil tank.4. Remove drain cap (2), and drain the hydraulic oil into a suitable container. The capacity of the hydraulic oil tank is 56.8 liters (15 U.S. gal). Clean and install the drain cap. 5. Remove the two nuts and bolts that fasten clamp (3) to the brace.6. Mark or identify the cable assemblies for installation purposes. Disconnect cable assemblies (4) from the quick start post.7. Remove the bolt and clamp that fasten two hose assemblies (5) to the brace. 8. Mark or identify the cable assemblies for installation purposes. Disconnect two cable assemblies (6) from the disconnect switch. 9. Remove bolt (8) that fastens the hose clamp and hose assembly (7) to the brace assembly.10. Disconnect hose assembly (7) from the hydraulic oil tank. Cap and plug immediately. 11. Attach lifting straps and a hoist to brace assembly (9) as shown. Remove eight bolts (10), and remove the brace assembly from the machine. The weight of the brace assembly is 40 kg (88 lb). 12. Put identification marks on the two wires connected to the fuel level sending switch. Disconnect the two wires from the fuel level sending switch.13. Remove the cable ties that fasten wiring harness (11) to the fuel/hydraulic oil tank. 14. Close fuel return valve (12) and fuel supply valve (14). Disconnect fuel lines (13) and (15) from the valves. Cap and plug immediately. 15. Remove bolt (16) that fastens the cable assembly and clamp to the door catch.16. Disconnect hose assembly (17) from the brake/shift valve. Cap and plug immediately.17. Loosen the two bolts, and remove hose clamp (18) from the bracket.18. Disconnect hose assembly (19) from the propel pump. Cap and plug immediately. 19. Disconnect hose assemblies (20) and (21) from the vibratory pump. Cap and plug immediately. 20. Disconnect hose assemblies (22) and (23) from the propel pump. Cap and plug immediately. 21. Disconnect hose assemblies (24) from the propel pump. Cap and plug immediately.22. Disconnect hose assembly (25) from the vibratory pump. Cap and plug immediately. 23. Disconnect hose assembly (26) from the propel pump. Cap and plug immediately. 24. Disconnect hose assemblies (27) from the propel pump. Cap and plug immediately. 25. Disconnect hose assemblies (28) and (29) from the vibratory cooling/control valve. Cap and plug immediately. 26. Disconnect hose assemblies (30) from the vibratory cooling/control valve. Cap and plug immediately. 27. Disconnect hose assembly (31) from the vibratory cooling/control valve. Cap and plug immediately. 28. Disconnect hose assemblies (32) and (33) from the fuel/hydraulic oil tank. Cap and plug immediately. 29. Put identification marks on the two wires connected to hydraulic oil temperature switch (34). Disconnect the two wires from hydraulic oil temperature switch (34).30. Remove the two bolts that fasten starter relay switch (35) to the frame. Move the wiring harness out of the way. 31. Disconnect hose assembly (36) from the brake valve. Cap and plug immediately. 32. Disconnect hose assembly (33) from the steering pump. Cap and plug immediately. Remove hose assembly (33) from the machine.33. Disconnect two hose assemblies (37) from the steering pump. Cap and plug immediately. 34. Disconnect electrical connectors (38), (40) and (41). Remove the two screws that fasten electrical connector (39) to the frame.35. Remove nut (39), the ground cable and the two ground wires from the stud. 36. Disconnect electrical connector (42) from the brake valve. 37. Remove nut (43), and remove the ground wire from the stud.38. Disconnect electrical connector (44) for the water spray system. Remove the nut, and remove the ground wire from the stud. Remove all cable ties that fasten the wiring harness to the frame. Move the wiring harness out of the way. 39. Remove the bolt that fastens ground cable (45) to the flywheel housing.40. Remove the two bolts and muffler bracket (46) from the flywheel housing. 41. Remove two nuts and bolts (48) that fasten hose bracket (47) to the flywheel housing. Move and hold the hose assemblies and bracket out of the way. 42. Loosen the two hose clamps, and remove hose (49) from the engine and air cleaner housing. 43. Attach a hoist to the lifting brackets on engine (50) as shown.44. Remove four nuts and bolts (51) that hold the engine to the frame of the machine.45. Remove four bolts (52) and support (53).46. Make sure all necessary hose assemblies and electrical wires have been disconnected. Carefully remove the engine, radiator and pumps as a unit from the machine. The weight of the engine, radiator and pumps as a unit is 726 kg (1600 lb). For installation of the engine, reverse the removal steps. After the engine has been installed, fill the cooling system with coolant to the correct level. Fill the hydraulic oil tank to the courect level. See the Operation & Maintenance Manual for the correct filling procedures.End By:a. * lower operators platformb. install muffler*This procedure is in the CB-434C Machine Systems Disassembly & Assembly module, Form No. KENR2833.