0438904 JOHNSON POWERHEAD GASKET SET

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     138-7575     Link Bracket     4    
B     138-7573     Link Bracket     1    
C     6V-3145     Load Leveling Beam     1    
D     138-7575     Link Bracket     1    Start By:
Remove the cab. Refer to Disassembly and Assembly, SENR6693, "Cab - Remove" for the machine that is being serviced.
Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove" for the machine that is being serviced.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. 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 on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. 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 cooling system pressure cap is cool enough to touch with your bare hand.Remove the cooling system pressure cap slowly to relieve pressure.Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
Drain the coolant from the cooling system. Refer to the Operation and Maintenance Manual, SEBU6471, "Cooling System Coolant (DEAC) - Change" for the correct procedure. The capacity of the cooling system is 36 L (9.5 US gal).
Drain the hydraulic tank into a suitable container for storage or disposal. The capacity of the hydraulic tank is 49.2 L (13 US gal).
Illustration 1 g00681364
Disconnect three wire connectors (1) .
Disconnect wiring harness (2) .
Illustration 2 g00681372
Disconnect two wire connectors (3) .
Illustration 3 g00681374
Disconnect wire (4) from the hydraulic tank.
Disconnect hose (5) .
Disconnect wire connector (6) to the ether starting aid.
Illustration 4 g00681380
Loosen the two hose clamps and remove hose (7) .
Disconnect two hoses (8) .
Disconnect two hoses (9) from the hydraulic control valve.
Disconnect hose (10) .
Illustration 5 g00681381
Disconnect three hoses (11) from the hydraulic control valve.