7738870_009 Volvo.Penta Gear

Introduction
These checks are required for component removal and installation. Initial check after completion.Note: Service literature procedures, specific to the model and serial number, must be used in this process. The checklist does not substitute procedures for the procedures given in the service literature.
Table 1
Customer Name/ Location     Machine Unit Number     Machine Serial Number     Machine Service Meter Hours     Work Order Number    
/                    
Table 2
Tracking Data     Engine Removed     Engine Installed    
Serial Number            
CID Number (1)            
Source/Rebuilder (2)            
( 1 ) CID (Component Identification) is the number assigned to the component by the user/dealer.
( 2 ) Suorce/Rebuilder is either NEW, REMAN, DLR (Dealer Rebuilt), or CUST (Customer Rebuilt).Checklist
Table 3
   
    1.         Record Complaint:            
                   
           
    2.         Pre-repair contamination control.        
            A.     High-pressure wash the rear half of the motor grader to remove all dirt/debris.        
            B.     Keep the work area clean and the floor dry – contain all fluid spills.        
            C.     Cover components with plastic or keep in containers until installation to keep clean.        
            D.     Verify new parts cleanliness. Assure they are cleaned & capped/protected against dirt.        
           
    3.         Investigate engine history or failure cause, if appropriate.        
            A.     Question the operator on application, operating conditions, and history. Review SOS history.        
            B.     Review engine ECM for detected fault information – record in work order folder.        
            C.     Take SOS Sample refer to: Contamination Control Guidelines, SEBF8482, "Obtaining Oil Sample for Analysis". Drain the engine and related power train oil reservoirs and visually check oil for water, coolant, or debris contaminants.        
            D.     Remove/inspect system filters/screens and save any contamination evidence.        
           
    4.         High-pressure wash the machine area around the engine, before and after removal.        
           
    5.         Cover and cap all cleaned and reused components/lines until installed to prevent dirt entry.
Cover all removed component cores with plastic sheets until shipping covers are available.        
           
    6.         Inspect engine mounts and machine frame for stripped threads, cracks or deformation.
Repair/replace and paint as needed.        
           
    7.         Inspect and clean or replace system hoses/tubes. Clean with CAT hose cleaner group. Refer to Tool Operating Manual, NEHS0643, "Using the 233-7191, 233-7192, 233-7193 and 265-4959 hose cleaning groups" and Contamination Control Guidelines, SEBF8485, "Cleaning Fluid-Carrying Hose and Tube Assemblies In Shop and Field Applications". Use new clamps (torque to spec), o-ring seals, and gaskets.        
           
    8.         Inspect/replace electrical connectors and harnesses for loose pins, brittleness, and fatigue.
Replace the engine/torque converter wire harness every rebuild life cycle.        
           
    9.       &nbs