861060T Mercruiser BRACKET, Shift/Electrical Mounting

Start By:a. remove radiator guard (cowling group)b. remove crankcase guards Fluid Spillage ContainmentCare must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Product Guide, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
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 filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
1. Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator into a suitable container for storage or disposal. The capacity of the cooling system is 106 liters (28 U.S. gal). 2. Disconnect air hose assembly (5) from air horn (4).3. Mark and identify the number of shims (1) (not shown) located on each side of tube assembly (3) for installation purposes. Remove eight bolts (2) and the washers that hold tube assembly (3) to the frame assembly. Using two people remove tube assembly (3) with air horn (4) attached, from the machine. The weight of tube assembly (3) with air horn (4) is 27 kg (60 lb). 4. Remove the two right hand side head lamps (6) from the front fender as shown. Mark and identify the four wires from wire harness (7) for installation purposes. Disconnect the four wires from the electrical connections on the backs of head lamps (6). 5. Pull wire harness (7) through the fender, and remove all tie straps (8) that hold wire harness (7) to the inside of the fender and the radiator. Set wire harness (7) out of the way. 6. Remove clip (10) that holds two air conditioning condenser hose assemblies (9) and (11) to the radiator. Disconnect air conditioning condenser hose assembly (11) from air conditioning dryer (12).7. Remove clip (14) that holds two air conditioning evaporator tubes (13) to the radiator. 8. Disconnect air conditioning tube assembly (16) from air conditioning dryer (12). Remove bolt (15) and the washer that holds air conditioning condenser hose assembly (9) and air conditioning dryer (12) to the radiator. Remove air conditioning dryer (12) from the machine. 9. Remove bolt (17) and the washer that hold air conditioner accumulator bracket (18) to the radiator. Set air conditioner accumulator bracket (18) with the accumulator attached out of the way. It is not necessary to purge the air conditioning system during the removal of the air conditioning condenser from the radiator. The air conditioning condenser, with one hose assembly still attached, can be removed from the radiator and secured to the front of the cab.10. Remove four nuts and bolts (19) and the washers that hold air conditioning condenser (20) to the radiator. Position air conditioning condenser (20) on the front of the cab, out of the way of the radiator. 11. Remove three bolts (21) and the washers that hold lower baffle assembly (22) to the frame assembly. Remove lower baffle assembly (22). 12. Mark and identify four bolts (23) for installation purposes. Remove four bolts (23). Remove gasket (24) and set outlet tube assembly (25) out of the way. 13. Remove two bolts (26) and the washers that hold fan guard (27) to the radiator. Remove bolt (29) and the washer that holds two heater hoses (28) to the radiator. 14. Remove two bolts (30) and the washers that hold fan guard (27) to the radiator. Remove two bolts (31) and the washers that hold two heater hoses (28) to the radiator. 15. Remove three bolts (32) and the washers that hold the top of fan guard (27) to the radiator. Remove five bolts (33) and the washers and plate (34). Set battery cable (36) and wire harness (35) out of the way. 16. Disconnect ether starting aid tube assembly (37) from the ether starting aid. Remove tie strap (38) and disconnect wire harness (39) at the electrical connection. 17. Loosen the hose clamps on two hose couplings (41). Slide each hose couplings (41) off both inlet tube assemblies (40). 18. Install Tooling (A) on the radiator as shown. Fasten a suitable lifting device to Tooling (A). 19. Remove four nuts and bolts (42) and the washers that hold radiator (43) to the frame assembly. 20. Carefully remove radiator (43) off the frame assembly. The weight of radiator (43) is 400 kg (880 lb). The following steps are for the installation of the radiator.
Check the condition of the radiator prior to installation. Remove any dirt or debris that may restrict the flow of air through the cores. If any of the cooling fins are bent, they should be straightened. Failure to remove the dirt or debris could cause the engine to overheat.
21. Fasten Tooling (A) and a hoist to the radiator. Carefully install radiator (43) on the frame assembly. The weight of radiator (43) is 400 kg (880 lb). 22. Install four nuts and bolts (42) and the washers that hold radiator (43) to the frame assembly. 23. Remove Tooling (A) from the radiator. 24. Slide each hose couplings (41) on both inlet tube assemblies (40). Tighten the hose clamps on two hose couplings (41). 25. Connect ether starting aid tube assembly (37) to the ether starting aid. Connect wire harness (39) at the electrical connection, and install a new tie strap (38). 26. Install three bolts (32) and the washers that hold the top of fan guard (27) to the radiator. Put plate (34), battery cable (36) and wire harness (35) in position on radiator guard (27). Install five bolts (33) and the washers