5031483 JOHNSON RELAY, TNT

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     138-7575     Link Bracket     2    
B     6V-3145     Load Leveling Beam     1    
C     1U-9199     Lever Puller Hoist     1    
138-7574 Link Bracket     2    
ZZ     6V-9507     Face Seal Plug (9/16 - 18 THD)     1    
6V-9828 Cap As (9/16 - 18 THD)     1    
6V-9508 Face Seal Plug (11/16 - 16 THD)     2    
6V-9829 Cap As (11/16 - 16 THD)     2    
6V-9509 Face Seal Plug (13/16 - 16 THD)     2    
6V-9830 Cap As (13/16 - 16 THD)     2    
6V-9513 Face Seal Plug (1 11/16 - 12 THD)     1    
6V-9834 Cap As (1 11/16 - 12 THD)     1    Start By:
Remove the engine enclosure (hood). Refer to Disassembly and Assembly, "Engine Enclosure (Hood) - Remove and Install".
Remove the radiator, the hydraulic oil cooler, the air cooler and the fuel cooler. Refer to Disassembly and Assembly, "Radiator, Air Cooler, Hydraulic Oil Cooler and Fuel Cooler - Remove".
Tilt the cab, if equipped. Refer to Disassembly and Assembly, "Cab - Tilt".
Tilt the operator platform, if equipped. Refer to Disassembly and Assembly, "Operator Platform - Tilt".Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Personal injury can result from hydraulic oil pressure and hot oil.Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.Make sure all of the attachments have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.
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.
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.
Illustration 1 g00944732
Remove the cable straps that fasten hose (2) and the breather on support assembly (1) .
Illustration 2 g00944733
Remove panel (4) from both sides of the machine.
Attach Tooling (A) and a suitable lifting device to support assembly (1). Remove bolts (3) from both sides of the engine and remove support assembly (1). The weight of the support assembly is approximately 28 kg (62 lb).
Illustration 3 g00944735
Loosen screw (5) and separate harness assembly (6) .
Illustration 4 g00944736
Remove the cable straps that fasten harness assembly (7) to the flywheel housing.