0434429 JOHNSON GEARCASE ASSY., Complete

At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuits (the boom, the stick and the bucket) before any of the hydraulic lines or any of the components are disconnected or removed.
1. Release the pressure in the implement hydraulic circuits (the boom, the stick and the bucket) before any of the hydraulic lines or any of the components are disconnected or removed. Release the pressure as follows:a. Shut off the engine and place key in the "ON" position. Put the hydraulic activation control lever in the "UNLOCK" position.b. Move the control levers for the boom, the stick and the swing to all full stroke positions. This will release any pressure that might be present in the pilot system.c. Return the key to "OFF" position.d. Slowly loosen the fill plug on the hydraulic tank, and release the pressure.e. Tighten the fill plug on the hydraulic tank.f. The pressure in the hydraulic system has been released, the lines and the components can be removed. Drain the hydraulic tank oil in a suitable container for storage or disposal.2. Drain the oil from the hydraulic oil tank into a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 99 liters (26 U.S. gal).
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury.
3. Drain the coolant in a suitable container for disposal or storage. The capacity of the coolant system is 15.5 liters (4.0 U. S. gal). 4. Remove two bolts (1) and the washers that secure plate (2). Remove plate (2) from the machine. 5. Remove five bolts (3) and the washers that secure plate (4). Remove plate (4) from the machine. 6. Remove four bolts (5) and the washers that secure plate (6). Remove plate (6) from the machine. 7. Disconnect electrical connector (7) from the governor motor control. 8. Remove two bolts (8) and the washers that secures the governor cable clamp. 9. Remove two bolts (9) and the washers that secures the governor cable clamp. 10. Remove three bolts (12) and the washers that secure the governor motor control (10) to support (11).11. Remove three bolts (13) and the washers that secure support (11) to the machine. 12. Remove the final two bolts (14) and the washers that secure support (11) the machine. Remove support (11) from the machine. 13. Remove four bolts (15) that secure guard (16).14. Remove bolts (17) that secures the wire clamp to guard (16). Remove guard (16). 15. Remove two hose assemblies (19) and (20) from pilot pump (18). 16. Remove five hose assemblies (21), (22), (23), (25), and (26) from the main hydraulic pump (24). 17. Disconnect electrical connector (27) from the main hydraulic pump (24).18. Remove bolt (28) and the washer that secures the wire clamp. 19. Remove hose assembly (29) from the main hydraulic pump (24).20. Remove four bolts (30) and the washers that secure the suction line to main hydraulic pump (24). 21. Slide rubber boot (34) away from the starter motor to expose nut (32).22. Remove nut (32) and the washer that secures two wires (31). Remove wires (31) washer (not shown) and rubber boot (33). 23. Remove bolt (36) that secures wire (35) to the electric starting motor. 24. Disconnect two electrical connectors (40) and electrical connector (37).25. Remove bolt (38) and the washers that secure wire clamp (39). 26. Remove bolt (41) and the washer that secures the wire clip. 27. Disconnect electrical connector (42) from the alternator. Disconnect electrical connector (43). 28. Slide rubber boot (44) away from the alternator to expose nut (45).29. Remove nut (45) and the washer that secures wire (46) to the alternator.30. Remove bolt (47) that secures two grounding wires (49).31. Remove bolt (48) that secures the p-clamp. 32. Disconnect electrical connection (50). Remove the connector from the wire clamp (51). 33. Remove four bolts (52) and the washers that secure the refrigerant compressor to the engine. Place the compressor on the frame of the machine. It is not necessary to remove the suction and the discharge lines from the compressor. 34. Disconnect electrical connector (53).35. Remove two wire ties (54) from the alternator mounting bracket. 36. Disconnect two electrical connections (55). 37. Remove bolt (56) and the washer that secure the hose clamp.38. Loosen hose clamp (58), and remove hose (57).39. Remove two bolts (59) that secure hose assembly (60). 40. Loosen hose clamp (62), and remove hose (61). 41. Loosen hose clamp (63), and remove fuel hose (64).42. Loosen hose clamp (65), and remove fuel hose (66).43. Loosen two hose clamps (67) and (69) that secure air inlet hose (68) to the engine. Remove air inlet hose (68). 44. Remove two nuts (70) that secure governor control linkage (72) to the fuel pump.45. Loosen two nuts (70) that secure governor control linkage (72) to the engine. 46. Loosen hose clamp (73) and remove air inlet hose (76).47. Remove four bolts (74) and the washers that secure air inlet pipe (75). Remove air inlet pipe (75).