785967 Volvo.Penta Gear

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     138-7575     Link Bracket     2    Start By:
Remove the radiator cowling. Refer to Disassembly and Assembly, "Cowling (Radiator) - Remove and Install".
Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.
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.
Note: Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will prevent dirt from entering the internal mechanism.
Position a suitable container below the radiator in order to contain the coolant for storage or for disposal. Drain the coolant from the radiator. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change". The capacity of the radiator is 268 L (71 US gal).
Illustration 1 g00652862
Note: It is not necessary to evacuate the air conditioning system during the removal of refrigerant condenser (1) .
Remove four bolts (2), the nuts, and the hard washers that hold refrigerant condenser (1) in position. Move refrigerant condenser (1) away from the radiator and fasten the refrigerant condenser to the front of the machine.
Illustration 2 g00652863
Remove nut (3), the hard washers, and the clips that hold two hose assemblies (4) to the radiator.
Illustration 3 g00652864
Remove four bolts (6) from elbow (5). Remove four bolts (10) from elbow (9). Disconnect elbow (5) and elbow (9) from the top of the radiator. Remove the gasket from each elbow.
Remove four tie straps (7) that hold wire harness (8) to the radiator. Position the wire harness away from the radiator.
Illustration 4 g00652889
Attach Tooling (A) to radiator top tank assembly (11). Position a suitable lifting device on Tooling (A). Secure the lifting device to a suitable hoist. Remove 20 bolts (13) and the washers that hold five tube assemblies (14) to the radiator.Note: Four tube assemblies (14) are located in front of the radiator. The remaining tube assembly (not shown) is located behind the radiator.
Remove 20 bolts (12) and the hard washers that hold radiator top tank assembly (11) to the channel assemblies. Remove radiator top tank assembly (11) from the radiator core assemblies. The weight of the radiator top tank assembly is 95 kg (209 lb).
Remove the 23 seals (not shown) from the bottom of radiator top tank assembly (11) .Note: Some of the seals may stick to the radiator core assemblies.
Illustration 5 g00711179
Remove two bolts (16) and the hard washers that hold radiator core assembly (15) in position. Remove radiator core assembly (15) and seal (17) from the radiator bottom tank assembly.
Repeat Step 9 for each of the radiator core assemblies (15) that need to be removed.