3860249 Volvo.Penta Hose, engine cooler to thermostat

Personal injury or death may result from failure to adhere to the following procedures.Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system.Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.
Personal injury can result from hydraulic oil pressure and hot oil.Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.
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 cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.
Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Recover the refrigerant. Refer to Service Manual, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines" for the recovery and charging procedure. Refer to Special Publication, NENG2500, "Air Conditioning Tools" for the correct tools.
Illustration 1 g06510668
Loosen clamp (1) and disconnect hose (2).
Loosen clamp (3) and disconnect hose (4).
Illustration 2 g06510669
Loosen clamp (5) and disconnect hose (6).
Illustration 3 g06510670
Loosen clamp (8) and disconnect hose (7).
Illustration 4 g06510671Note: Refer to Special Instruction, REHS8231, "Removal Procedures for Diesel Exhaust Fluid (DEF) Connectors" for the correct removal procedure of the hoses.Note: Plug the DEF Injector nozzles with protective caps to maintain cleanliness.
Disconnect hoses (9), the hose assembly, and harness assembly (10).
Illustration 5 g06510672
Remove cable strap (11).
Illustration 6