0434063 JOHNSON GEAR & PINION ASSY.

Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.Safety Section
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.
When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.
Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.
Personal injury can result from improper handling of chemicals.Make sure you use all the necessary protective equipment required to do the job.Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.
Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.
Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.
Problem
There have been instances of coolant leaks from the 458-8496 Cooler. This condition may result in one of the following event codes:
Table 1
J1939 Code J1939 Description CDL Code CDL Description
110-0 Engine Coolant Temperature : High - most severe (3) E361 (3) High Engine Coolant Temperature
110-15 Engine Coolant Temperature : High - least severe (1) E361 (1) High Engine Coolant Temperature
110-16 Engine Coolant Temperature : High - moderate (2) E361 (2) High Engine Coolant Temperature
111-1 Engine Coolant Level : Low - most severe (3) E2143 (3) Low Engine Coolant Level
111-18 Engine Coolant Level : Low - moderate severity (2) E2143 (2) Low Engine Coolant Level Required Parts
Table 2
592-8999 Blanking Plate Group Part Numbers
Engine Type Coolant Inlet Coolant Outlet Gas Inlet Gas Outlet
C7.1, C6.6, C4.4 (TA) 592-8967 592-8966 592-8967 592-8966
C4.4 (TTA) 592-8981 Installation Procedure
A new air-pressure decay test has been created for the NRS cooler. The blanking plates listed in Table 2 are required to complete the test. The plates can be ordered or the drawings can be requested.592-8999 blanking plate group consists of three blanking plates that are used on the inlet and outlet ports of the NRS cooler. 592-8967 Blanking plate for hose fitting can be used for the gas inlet port or the coolant inlet port of the NRS cooler.592–8966 blanking plate can be used for the gas outlet port of the NRS cooler or the coolant outlet port of the NRS cooler (except on C4.4 TTA engines).592-8981 blanking plate to be used on the coolant outlet port of the NRS cooler on C4.4 TTA engines.Refer to Systems Operation, Testing and Adjusting, Exh