0378944 JOHNSON GEARCASE ASSY., Less driveshaft and pump

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) - 1/2 Inch Drive T50 Torx Bit 1
- 1/2 Inch Drive x 8 mm Hex Drive 1
B - Guide Studs
M10 by 80 mm 2
C - Guide Studs
M10 by 130 mm 2
(1) Either tool may be necessary in order to install the alternator pulley.
If necessary, follow Step 1.a through Step 1.k in order to install the alternator bracket to the cylinder block of the hydraulic excavator.
Ensure that all of the components of the alternator bracket are clean and free from wear and damage. Replace all components that are worn or damaged.
Illustration 1 g02095234
Position bracket (22) onto the cylinder block. Ensure that the bracket is correctly oriented.
Install bolts (23) and tighten the bolts to a torque of 44 N m (32 lb ft).
Illustration 2 g02165614
Illustration 3 g02352949
Install Tooling (B) to the cylinder block.
Position alternator bracket (17) onto Tooling (B). Install bolts (18) to the alternator bracket and hand tighten the bolts. Note: Support the alternator bracket as the bolts are installed. The weight of the bracket is approximately 19 kg (42 lb).
Remove Tooling (B) and install the remaining bolts (18) to the alternator bracket and hand tighten the bolts.
Ensure that spacers (20) are correctly installed to alternator bracket (17).
Install bolts (19) to alternator bracket (17) and hand tighten the bolts.
Illustration 4 g02165494
Tighten bolts (18) to a torque of 44 N m (32 lb ft).
Tighten bolts (19) to a torque of 44 N m (32 lb ft). Note: Ensure that Position (X) on alternator bracket (17) does not move in either direction.
Install the refrigerant compressor. Refer to Disassembly and Assembly , "Refrigerant Compressor - Remove and Install" for the correct procedure. Installation Procedure
Illustration 5 g02022404
Illustration 6 g02165615
Illustration 7 g02352950
If necessary, follow Step 1.a through Step 1.h in order to install alternator bracket (11) onto the cylinder block.
Ensure that alternator bracket (11) is clean and free from wear and damage. If necessary, replace the alternator bracket.
Ensure that dowels (16) are free from wear and damage. If necessary, replace the dowels.
Install Tooling (B) to the cylinder block.
Position alternator bracket (11) onto Tooling (B). Install bolts (12) hand tight.
Remove Tooling (B) and install remaining bolts (12) hand tight.
Tighten bolts (12) to a torque of 44 N m (32 lb ft).
If necessary, install belt tensioner (14) onto alternator bracket (11) and tighten bolt (15). Refer to Disassembly and Assembly, "Belt Tensioner - Install" for the correct procedure.
If necessary, install flat idler pulley (13) onto alternator bracket (11). Refer to Disassembly and Assembly, "Idler Pulley (Flat Idler Pulley) - Remove and Install" for the correct procedure.
Illustration 8 g02019754
Typical example
If necessary, follow Step 2.a through Step 2.d in order to install pulley (8) to alternator (2). Note: Either of Tooling (A) may be required in order to carry out the installation of the alternator pulley.
Place alternator (2) in a suitable support.
Ensure that pulley (8) is correctly oriented.
Install pulley (8) and a new nut (9) to alternator shaft (10).
Position a cranked ring spanner onto nut (9) and use a suitable tool in order to prevent the cranked ring spanner from turning. Use Tooling (A) in order to turn the shaft of the alternator in a counterclockwise direction. Tighten the nut to the correct torque. Refer to Specifications, "Alternator" for the correct torque.
Illustration 9