20460204 Volvo.Penta Pulley

Start By:a. remove top cover assembly (radiator)Fluid 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 of fluids according to local regulations and mandates.
At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gage to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
Mark and identify hose assemblies for installation purposes. Cap and plug hose assemblies to avoid system contamination. 1. Position a suitable container under plug adapter (2) to contain the coolant for storage or disposal. Loosen drain plug (1) on plug adapter (2). Repeat procedure on remaining plug adapter. The capacity of the cooling system is 300 L (79 U.S. gal). 2. Remove the two tie straps holding wiring harness (4) to radiator (3). 3. Install Tool (A) on panel assembly (5). Position a lifting sling through Tool (A), as shown. Secure the lifting sling to a hoist. Remove bolt (6) and the washer from panel assembly (5). 4. Remove bolt (7) and the washer from panel assembly (5). Remove two bolts (8) and the washers from panel assembly (5). Remove panel assembly (5) from the enclosure assembly. The weight of panel assembly (5) is 34 Kg (75 lb). 5. Remove four bolts (10) from elbow (11). Remove elbow (11) and the gasket from the radiator. Disconnect wiring harness (9) from the liquid level sensor at the electrical connections. Remove tie straps (12) from wiring harness (9). Repeat for the remaining temperature sensor and elbow. Set wiring harness (9) out of the way. 6. Remove four bolts (13) from radiator elbow (14). Remove elbow (14) and the gasket from the radiator. Repeat for the remaining elbow. 7. Using two people, remove 11 bolts (15) and the washers from panel assembly (16). Remove panel assembly (16) from the enclosure assembly. The weight of panel assembly (16) is 27 Kg (59 lb). It is not necessary to purge the air conditioning system to remove the radiator. The refrigerant condenser can be set aside without having to purge the air conditioning system. 8. Remove two bolts (17), the nuts, the spacers, the mounts, and