0394500 JOHNSON REWIND STARTER ASSY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-6146 Load Leveling Beam 1
B 439-3938 Link Bracket 2 Start By:
Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".
Release the hydraulic system pressure. Refer to Disassembly and Assembly, "System Pressure - Release".
Remove the engine bottom guards. Refer to Disassembly and Assembly, "Bottom Guard (Engine) - Remove and Install".
Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove".
Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
Remove the radiator header tank. Refer to Disassembly and Assembly, "Radiator Tank (Header) - Remove".
Remove radiator. Refer to Disassembly and Assembly, "Radiator - Remove".
Remove turbocharger . Refer to Disassembly and Assembly, "Turbocharger - Remove".
Remove upper drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Upper) - Remove and Install".Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be cleaned thoroughly to prevent dirt from entering the internal mechanism.Note: Put identification marks on all lines, on all hoses, on all wires and on all tubes for installation purposes. Plug all lines, all hoses, and all tubes to prevent fluid loss and keep contaminants from entering the system.
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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
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 work tools 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.
Personal injury can result from contact with refrigerant.This system is under pressure at all times, even if the engine is not running. Heat should never be applied to a charged system.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 caution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, evacuate the system recovering the refrigerant before removing the fitting.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.Before any checks of the air conditioning and heating system are made, move the machine to a smooth horizontal surface. Lower all implements to the ground. Make sure the transmission is in NEUTRAL or PARK and that the parking brake is engaged. Keep all other personnel away from the machine or where they can be seen.
Drain the hydraulic tank into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Capacities (Refill)" for the capacity of the hydraulic tank. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the proper draining procedure.
Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the tools.
Illustration 1 g06472038
Illustration 2 g06472040
Remove clamp assembly (2) from firewall plate (1).
Illustration 3 g06472046
Remove seven plate mounting bolts (3) from firewall plate (1).
Illustration 4 g06472050
Remove electrical bulkhead connectors (4), (5), and (6).