0435194 JOHNSON GEARCASE., Complete

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Remove the hood.
Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     138-7574     Link Bracket     2    
At operating temperature, the hydraulic oil is hot and under pressure. Hot oils can cause burns.To prevent possible personal injury, release the pressure in the implement hydraulic circuit (boom, stick, bucket, and swing), travel circuits, and the hydraulic oil tank at the filler cap before any hydraulic lines or components are disconnected or removed.Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch.
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 Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines.Dispose of all fluids according to local regulations and mandates.
Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release" in this manual.
Remove the drain plug from the hydraulic oil tank. Install the ecology drain valve in order to drain the oil from the hydraulic oil tank. Drain the oil into a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 98 L (25.8 US gal) .
At operating temperature, the engine coolant is hot and under pressure.Steam can cause personal injury.Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with the bare hand.Remove the filler cap slowly to relieve pressure.Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 19 L (5 US gal) .
Illustration 1 g00403454
Illustration 2 g00403456
Loosen clamp (2) . Disconnect radiator top hose (3) .
Loosen the clamp on the radiator bottom hose. Disconnect the radiator bottom hose.
Oil will drain from two hose assemblies (4) . Position a pan under the hydraulic oil cooler before disconnecting hose assemblies (4) . Collect the oil in the pan.
Disconnect two hose assemblies (4) . Put plugs in the ends of the hose assemblies. Put caps on the hydraulic oil cooler. Plugs and caps prevent hydraulic oil loss. Plugs and caps prevent contaminating the hydraulic system.
Remove the fan guards. Refer to Disassembly and Assembly, "Fan Guard - Remove and Install" in this manual.
Disconnect hose (1) to the expansion tank. Reposition the hose away from the radiator and hydraulic oil cooler.
Fasten Tooling (A) to radiator and hydraulic oil cooler (5) . Fasten a suitable lifting device to Tooling (A) .
Put slight lifting tension on the radiator and hydraulic oil cooler.
Remove bolts (6) and the washers that hold the radiator and hydraulic oil cooler to the support assembly.Note: Do not damage the radiator core or the hydraulic oil cooler core when the radiator and hydraulic oil cooler is removed from the machine.
Carefully remove radiator and hydraulic oil cooler (5) from the machine. The weight of the radiator and hydraulic oil cooler is 70 kg (155 lb) .