0340772 JOHNSON EXHAUST HOUSING, Outer

FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
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 shin and eyes to prevent personal injury.
Check the fill cap on the radiator to see if the cap is cool enough to touch with the bare hand. Remove the cap slowly to release pressure.
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin. Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work.
Drain all fluids in a suitable container for storage or disposal.1. Drain the coolant from the cooling system. The capacity of the cooling system is 76 Liters (20 U.S. gal). 2. Remove two bolts (1) and quick connector (2). 3. Remove bolt (3), the washer and the clip.4. Disconnect electrical wires (4).5. Disconnect electrical wiring harness (5), and position out of the way. 6. Remove the two bolts and washers (6), and set the electrical wiring harness out of the way. 7. Attach a lifting sling and a hoist to the top cover, as shown. 8. Remove three bolts (8) and the washers on each side.9. Remove two bolts (9) and the washers on each side. Remove top cover (7) with ladders attached as a unit. The weight of cover (7), with ladders, as a unit is 83 kg (182 lb). 10. Remove the handle and nut (11). Remove retaining nut (10), and push the control assembly thru the hole. Position out of the way. 11. Remove the handle and nut (12). Remove retaining nut (13). Push the control assembly thru the hole, and position out of the way. 12. Remove bolt (17) and the washer, and position control assembly (15) out of the way.13. Disconnect electrical wire (19).14. Loosen clamps (14) on the top hose, and slide the hose back off the radiator.15. Remove bolts (16) and the washers holding fan guards (18) in place. Remove two bolts (20) and the washers. Remove fan guards (18). 16. Loosen two clamps (21), and slide the bottom hose down and off the water pump inlet. 17. Attach Tool (A) and a lifting device to the radiator, as shown. 18. Remove two bolts (22) and the washers from radiator brace (23) on each side. 19. Loosen two bolts (24), and move brace (23) towards the engine for clearance. 20. Remove bolt (26) and the washers, and position cable assembly (25) out of the way.21. Remove two bolts (27), the washers and the spacers from each side.22. Remove the radiator and radiator guard assembly. The weight of the radiator and radiator guard assembly is 295 kg (650 lb) The following steps are for the installation of the radiator guard and radiator.23. Position the radiator and radiator guard assembly. The weight of the radiator and radiator guard assembly is 295 kg (650 lb). 24. Install two bolts (27), the washers and the spacers from each side.25. Position cable assembly (25), and install bolt (26) and the washers. 26. Put brace (23) in position, and install two bolts (24). 27. Install two bolts (22) and the washers to radiator brace (23) on each side. 28. Slide the bottom hose in position, and tighten two clamps (21). 29. Install fan guard (18).30. Install bolts (16) and the washers holding fan guards (18) in place. Install two bolts (20) and the washers.31. Slide the top hose on the radiator, and tighten clamps (14).32. Connect electrical wire (19).33. Position control assembly (15), and install bolt (17) and the washer. 34. Position control assembly thru the hole, and install retaining nut (10). Install the handle and nut (11). 35. Position control assembly thru the hole, and install retaining nut (13). Install the handle and nut (12). 36. Install top cover (7) with ladders attached as a unit. The weight of cover (7) with ladders as a unit is 83 kg (182 lb)37. Install three bolts (8) and the washers on each side.38. Install two bolts (9) and the washers on each side. 39. Position the electrical wiring harness, and install two bolts (6) and the washers. 40. Connect electrical wiring harness (5).41. Connect electrical wires (4).42. Install bolt (3), the washer and the clip. 43. Put quick connector (2) in position, and install two bolts (1). Refer to the Topic "Lubricant Viscosities and Refill Capacities" in the "Operation and Maintenance Manual" for the proper filling procedure and the proper levels for the engine.