880095A03 Mercury TILLER HANDLE KIT

Inspect Tubes, Hoses, Bellows, and Clamps
Inspect all tubes and hoses for leaks that are caused by the following conditions. Replace any tube or hose which exhibits any of the following conditions. Failure to replace a tube or hose which exhibits any of the following conditions may result in a hazardous situation.
Hoses which are cracked
Hoses which are soft
Outer covering that is chafed or cut
Exposed wire that is used for reinforcement
Outer covering that is ballooning locally
Flexible part of the hose that is kinked or crushed
Armoring that is embedded in the outer covering
Exhaust bellows for leaks or damage
Hoses which exhibit signs of leakage which are not the result of loose couplings or clampsInspect all clamps for the following conditions. Replace any clamp which exhibits signs of any of the following conditions.
Cracking
Looseness
DamageInspect all couplings for leaks. Replace any coupling which exhibits signs of leaks.Each installation application can be different. The differences depend on the following factors:
Type of hose
Type of fitting material
Anticipated expansion and contraction of the hose
Anticipated expansion and contraction of the fittingsDue to extreme temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen which can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps.Replace hoses that are cracked or soft. Replace hoses that show signs of leakage. Replace hoses that show signs of damage. Replace hose clamps that are cracked or damaged. Tighten or replace hose clamps which are loose.Replace the Hoses and the Clamps
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, "Cat Dealer Service Tool Catalog" or refer to Special Publication, PECJ0003, "Cat Shop Supplies and Tools Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Cooling System
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
Personal injury can result from removing hoses or fittings in a pressure system.Failure to relieve pressure can cause personal injury.Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
Stop the engine.
Allow the engine to cool.
Before servicing a coolant hose, slowly loosen the filler cap for the cooling system to relieve any pressure.
Remove the filler cap for the cooling system.
Drain the coolant from the cooling system to a level that is below the hose that is being replaced. Drain the coolant into a suitable clean container. The coolant can be reused.
Remove the hose clamps.
Disconnect the old hose.
Replace the old hose with a new hose.
Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, "Torque Specifications", "Hose Clamps" for information about selecting and installing the proper hose clamps.
Refill the cooling system.
Clean the coolant filler cap. Inspect the gaskets on the filler cap. Inspect the gasket seat. Inspect the vacuum valve and seat for debris or damage. Replace the filler cap if the gaskets are damaged. Install the filler cap.
Start the engine. Inspect the cooling system for leaks.Lubrication System
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Drain the oil from the lubrication system to a level that is below the hose that is being replaced.
Remove the hose clamps.
Disconnect the old hose.
Replace the old hose with a new hose.
Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, "Torque Specifications", "Hose Clamps" for information about selecting and installing the proper hose clamps.
Refill the lubrication system. Refer to this Operation and Maintenance Manual, "Engine Oil Level - Check" to ensure that the lubrication system is filled with the proper amount of engine oil.
Start the engine. Inspect the lubrication system for leaks.Air System
Remove the hose clamps.
Disconnect the old hose.
Replace the old hose with a new hose.
Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, "Torque Specifications", "Hose Clamps" for information about selecting and installing the proper hose clamps.Note: The bellows and the V-clamps that are used on the exhaust bellows should never be reused.
Start the engine. Inspect the air lines for leaks.