0434396 JOHNSON HYDRAULIC ASSY.

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 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 the components are disconnected or removed as follows:a. Start the engine.b. Fully retract the stick cylinder rod.c. Adjust the position of the bucket so that it will be flat on the ground when the boom is lowered.d. Lower the boom until the bucket is flat on the ground.e. Shut off the engine, and place key in the "ON" position. Put the hydraulic activation control lever in the "UNLOCK" position.f. 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.g. Return the key to "OFF" position.h. Slowly loosen the fill plug on the hydraulic tank, and release the pressure.i. Tighten the fill plug on the hydraulic tank to as torque of 68 7 N m (50 5 lb ft).j. The pressure in the hydraulic system has been released and the lines and the components can be removed.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 130 liters (34 U.S. gal). 3. Remove four bolts (1), the washers and support assembly (2).
Do not damage the hydraulic oil cooler core when the refrigerant condenser is being removed.
4. Remove four bolts (3) that hold refrigerant condenser (4) to the hydraulic oil cooler. Lay the refrigerant condenser out of the way of the hydraulic oil cooler. 5. Place a drain pan under the hydraulic oil cooler. Oil will flow from the hose connections when they are disconnected.6. Loosen two clamps (5) on hose assembly (6). Loosen two clamps (10) on hose assembly (11).7. Remove two clamps (8) and four bolts (9).8. Remove tube assemblies (7) and (12) from the hydraulic oil cooler. 9. Fasten a hoist to hydraulic oil cooler (14) as shown. Remove four bolts (13) that hold the hydraulic oil cooler in position. Remove the hydraulic oil cooler from the machine. The weight of the hydraulic oil cooler is 79 kg (175 lb). The following steps are for the installation of the hydraulic oil cooler.10. Check the condition of the hydraulic oil cooler prior to the installation. Remove any dirt or debris that may restrict the flow of air through the core. If any of the cooling fins are bent, they should be straightened. 11. Fasten a hoist to hydraulic oil cooler (14) as shown. Carefully install the hydraulic oil cooler in the machine. Install four bolts (13) that hold it in position. 12. Install tube assemblies (7) and (12).13. Install two clamps (8) and four bolts (9).14. Tighten two clamps (10) on hose assembly (11).15. Tighten two clamps (5) on hose assembly (6). 16. Put refrigerant condenser (4) in position on the hydraulic oil cooler. Install four bolts (3) that hold it in position. 17. Install support assembly (2), the washers and four 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 hydraulic oil system.18. Fill the hydraulic oil tank with oil to the correct level.End By:a. install hood assembly