863820T 1 Mercruiser COOLER, Power Steering

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     138-7575     Link Bracket     1    
B     6V-6146     Load Leveling Beam     1    
C     FT-1114     Vacuum Cap     1    
ZZ     9U-7075     Cap     2    
9U-7077 Cap     2    
9U-7069 Cap     2    
9U-7073 Cap     2    
9U-7072 Cap     2    
6V-9511 Face Seal Plug     2    
6V-9512 Face Seal Plug     2    
9U-7091 Protective Cap     2    
6V-9508 Face Seal Plug     2    
6V-9829 Cap As     2    
6V-9832 Cap As     2    
6V-9833 Cap As     2    
5H-4019 Cover     2    Start By:
Remove the rear chassis support. Refer to Disassembly and Assembly, "Rear Chassis Support - Remove".
Remove the pump drive shaft. Refer to Disassembly and Assembly, "Pump Drive Shaft - Remove and Install".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.Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
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.
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.
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.Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
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.
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.
Illustration 1 g00918914
Attach Tooling (C) to the hydraulic tank. Tooling (A) will contain the hydraulic oil.
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 correct procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools.
Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 38 L (10 US gal). Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".