240602 Volvo.Penta Bushing

Start By:a. drain radiatorb. remove dust ejectorc. remove exhaust extensionFluid Spillage Containment
Care 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 Products 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. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury.
1. Position a suitable container under the radiator. Loosen the radiator cap from the tank assembly. Remove the drain plug from the plug adapter, and drain the radiator below the level of the expansion tank assembly. The capacity of the cooling system is 142 L (37 U.S. gal). For more information, refer to the topic "Drain And Refill Radiator" in this manual. 2. Mark and identify two wire harnesses (1) and (3) for installation purposes. Disconnect two wire harness (1) and (3) from relay panel (2). 3. Mark and identify two hoses (7) and (8) for installation purposes. Put a suitable container under two hoses (7) and (8) to contain the coolant for storage or disposal. Loosen two clamps (5) and (6). Disconnect two hoses (7) and (8) from tank assembly (4). 4. Loosen clamp (9) and disconnect hose (10) from tank assembly (4). 5. Remove two bolts (11) and the washers from grate assembly (12). 6. Remove 20 bolts (13) and the washers that holds the front hood assembly to engine enclosure tube assemblies (14). 7. Remove bolt (16) and the washer from front hood assembly (15). 8. Position a suitable lifting device on front hood assembly (15) and grate assembly (12) as shown. Secure the lifting device to a hoist. Remove front hood assembly (15) and grate assembly (12) as a unit, from the engine enclosure. The weight of front hood assembly (12) and grate assembly (15) as a unit, is 204 Kg (450 lb). 9. Remove right hand door assembly (17) from right hand door assembly (18). 10. Remove bolt (20), the washer, and right hand door assembly (19) from the engine enclosure. 11. Remove four bolts (21), the washers, and plate (22) from the engine enclosure tube assembly.12. Remove step sheet assembly (23) from the engine enclosure tube assembly. 13. Position a suitable lifting device on right hand door assembly (24) as shown. Secure the lifting device to a hoist. 14. Remove two bolts (25), the washers, and right hand door assembly (24) from rear frame assembly (26). The weight of right hand door assembly (24) is 34 Kg (75 lb). Repeat Steps 9, 10, 13 and 14 for the remaining left side. For the removal and installation of the fan, the air conditioning system does not need to be evacuated. The air conditioning condenser can be removed without disconnecting the hose assemblies. 15. Loosen, but do not remove two bolts (27) on each side of air conditioning condenser (29), that hold brackets (30) to the radiator guard and support.16. Using two people, remove four bolts (28) and the washers from each side of air conditioning condenser (29). Remove air conditioning condenser (29) from the radiator. Set air conditioning condenser (29) outside of rear frame assembly (26) as shown. Position wood blocks (not shown) under air conditioning condenser (29). 17. Remove bolt (33), and the washer that holds bracket (32) to each side of radiator guard and support (31). Remove two bolts (35), the hard washers, and the two nuts from each side of top fan guard assembly (34). Remove top fan guard assembly (34) from bottom fan guard assembly (36).
Care must be taken when removing spider assembly. Avoid making contact with any of the radiator cores during the spider assembly removal. Contact made on the radiator cores with the spider assembly may cause component damage.
18. Position a suitable lifting device on spider assembly (37) as shown. Secure the lifting device to a hoist. 19. Remove eight bolts (38), and the washers that hold fan adapter (40) to fan pulley hub (39). Carefully position spider assembly (37) and fan adapter (40) as a unit, in the radiator guard and support. The weight of spider assembly (37) and fan adapter (40) as a unit, is 57 Kg (125 lb). 20. Mark and identify wire harness (43) for installation purposes. Loosen two screws (42) and disconnect wire harness (43) from flood lamp (44). Pull wire harness (43) through grommet (41). 21. Remove two bolts (45), and the washers from radiator (47). Set wire harness (46) aside.22. Repeat Steps 20 and 21 for the remaining side. 23. Mark and identify wire harness (48) for installation purposes. Disconnect wire harness (48) at the electrical connection. 24. Mark and identify wire harness (49) for installation purposes. Disconnect wire harness (49) at the electrical connection. 25. Remove two bolts (51), two bolts (53), elbow (52), and gasket (50) from radiator (47). 26. Loosen two hose clamps (55), and slide hose (54) from radiator (47). 27. Put Tooling (A) in position on radiator guard and support (31) as shown. Put a suitable lifting device on Tooling (A). Secure the lifting device to a hoist. 28. Remove four bolts (56) and the washers from each side of rear frame assembly (26). Remove radiator guard and support (31) from rear frame assembly (26). The weight of radiator guard and support (31) is 640 Kg (1410 lb). The following steps are for the installation of the radiator guard and support.29. Make sure all components of the radiator guard and support are clean of dirt and foreign material prior to