860921 Volvo.Penta Gasket

Walk-Around Inspection
Inspect Engine for Leaks and Loose Connections
A walk-around inspection should only take a few minutes of your time. By taking the time to make these checks, costly repairs and accidents can be avoided and your equipment will be ready to run should the need arise.For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil or coolant leaks, loose bolts, worn fan belts, loose connections and trash build-up. Remove trash build-up and have repairs made as needed.* All guards must be in place. Repair or replace missing or damaged guards.* Wipe all fittings, caps and plugs before servicing to reduce the chance of system contamination.
For any type of leak (coolant, lube, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted.
Accumulated grease and oil on an engine or deck is a fire hazard. Remove this debris with steam cleaning or high pressure water.
* Make sure cooling lines are properly clamped and tight. Check for loose fittings or leaks. Check the condition of all pipes and fittings.* Inspect the water pump for coolant leaks. The water pump seal is lubricated by coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and parts contract.Excessive coolant leakage may indicate the need to replace the water pump seal. For removal and installation of water pumps and/or seals, see the Service Manual for this engine or consult your Caterpillar dealer.* Inspect the lubrication system for leaks at the front and rear crankshaft seals, the oil pan, the oil filters, and the valve covers.
Fuel line clamps should not be over torqued. Over torqueing causes the clamps to butterfly, which results in low clamping force, fuel line vibration and eventual failure. Refer to the Torque Specifications in this manual.
* Inspect the fuel system for leaks. Look for loose fuel line clamps and fittings.* Inspect the air inlet system piping and elbows for cracks and loose clamps.* Inspect the alternator belt and the accessory drive belts for cracks, breaks or other damage.* Drain water and sediment from fuel tanks on a daily basis to ensure that only clean fuel enters the fuel system.* Inspect the wiring and the wiring harnesses for loose connections and worn or frayed wires.* Inspect the engine ground strap for good connection and condition.* Check the condition and the electrolyte level of batteries, unless equipped with a maintenance free battery.* Check the condition of the gauges. Replace any gauges which are cracked or cannot be calibrated.* Check the oil filter, fuel pressure, and water temperature gauge readings frequently during normal operation. Record the data in a log book. The data should be saved for future reference. Comparing the data over time will show normal gauge ranges for your engine. Readings outside of the normal ranges may indicate operation problems.Engine Crankcase
Check Oil Level
The preferred time to check the oil level is when the engine is stopped. This maintenance should be performed on as level a surface as possible.
Oil level gauge (dipstick) (1) and oil filler cap (2).1. Ensure that the dipstick is seated. Remove the dipstick and observe the oil level. Install the dipstick. 2. Maintain the oil level between the ADD and FULL marks on the ENGINE STOPPED side of the dipstick. Do not fill the crankcase above the FULL mark.
Operating your engine when the oil level is above the FULL mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into the oil reduce the oil's lubricating characteristics and could result in the loss of power.
3. Remove the oil filler cap and add oil if necessary. Clean the filler cap. Clean the cap receptacle. Install the cap. Some engine applications (for example, mountain snow groomers) operate at angles which can cause initial excessive oil consumption after the crankcase has been filled to the FULL mark. This is a normal result of the crankshaft counterweight dipping into the oil because of the non-level operation. The oil consumption will cease after the "excess" oil has blown off. It is recommended that the dipstick FULL mark and the oil fill quantity be adjusted if the engine will be operated at an extreme angle for an extended period of time.Cooling System
Check Coolant Level
Check the coolant level with the engine stopped and cool.
Radiator (cooling system) filler cap.1. Remove the cooling system filler cap slowly to relieve any pressure.2. Maintain the coolant level within 13 mm (1/2 inch) below the bottom of the fill pipe or to the proper level on the sight glass (if equipped).
Typical filler cap gaskets.3. Clean the filler cap. Inspect the filler cap gaskets. Replace the cap if the gaskets are damaged. Clean the filler cap receptacle. Install the cap.4. Inspect for leaks.Water Separator
Drain Water
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To prevent possible injury, turn the start switch OFF when changing fuel filters or water separator elements. Clean up fuel spills immediately.
The water separator is not a filter. The water separator separates water from the fuel. The engine should never be allowed to run with the water separator more than 1/2 full- engine damage may result.
Typical water separator vent valve (1) and drain valve (2).1. Close the fuel supply line.2. Open vent valve (1). Open drain valve (2). Catch the draining water in a suitable container and dispose of properly.3. Close drain valve (2). Close vent valve (1). Open the fuel supply line.