0435263 JOHNSON PISTON ASSY.

Start By:a. remove hood assembly Fluid Spillage ContainmentCare must be taken to ensure that the fluids are contained during performance of the inspection, the maintenance, the testing, the adjusting and the repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any of the components containing fluids. Refer to the "Tools And Shop Products Guide", NENG2500 for the tools and the supplies suitable to collect and contain any of the fluids in Caterpillar machines. Dispose of the fluids according to local regulations and mandates. In the following procedure, the counterweight has been removed for better photo illustration.
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 the fan assembly from the engine. Refer to the topic "Remove & Install Fan Assembly" in this module.
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 fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure in the cooling system. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
4. Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 25 liters (6.6 U.S. gal).
View From Under Machine5. Remove bolts (1), the washers and sheet assembly (2) from under the radiator.
View From Under Machine6. Loosen clamp (3), and disconnect lower radiator hose assembly (4) from under the radiator.
View From Under Machine7. Remove five bolts (5), the washers and cover assembly (6).8. Remove three bolts (7), the washers and cover assembly (8). 9. Remove bolt (12), the washer and nut from the end of the governor control cable assembly.10. Loosen nut (10) that holds the governor control cable assembly to bracket (13).11. Place a