7744100_019 Volvo.Penta Pulley, (TD/TAD420)

Start By:
Refer to the Service Manual module Disassembly and Assembly, "System Pressure - Release".
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure.Steam can cause personal injury.Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand.Remove the cooling system pressure cap slowly to relieve pressure.Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
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, 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: The hood group was removed in order to photograph the removal of the refrigerant condenser.Note: Identify all hoses, wires, and tubes for installation purposes. Use caps and plugs on all lines, hoses and tubes in order to prevent fluid loss or contamination of the system.
Illustration 1 g00761581
Open doors (1) in order to access the refrigerant compressor. Open the left side engine compartment door in order to access the air conditioning condenser.
Illustration 2 g00761703
Evacuate the air conditioning system at service ports (2) .Reference: Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134A Refrigerant"and Special Publication, NEDG7006, "Air Conditioning Tools". The publications will provide the proper procedure, equipment and tools in order to evacuate the air conditioning system in any Caterpillar machine.
Close the engine doors (1) .
Drain about 40 L (10 US gal) from the radiator.Reference: For information about draining the radiator, refer to the Operation and Maintenance Manual, "Maintenance Section".
Illustration 3 g00761453
Open door (3) on each side of the machine.
Illustration 4 g00761452
Attach a suitable lifting device (4) and a hoist to the panel assembly. Remove three bolts (5) on both sides of the panel assembly.
Remove the panel assembly. The approximate weight of the panel assembly is 45 kg (100 lb).
Illustration 5 g00761476
Illustration 6 g00761461
Remove bolt (6) and clip for tube assembly (15) .
Loosen hose clamp (9). Remove four bolts (7) and remove tube assembly (8) .
Loosen hose clamp (10) and hose clamp (12). Remove tube assembly (11) .
Loosen hose clamp (14). Loosen the O-ring face seal nut and remove tube assembly (13). Move tube assembly (15) out of the way of the air conditioner condenser.
Illustration 7 g00761731
Remove two bolts (17) on each end of plate (16). Remove plate (16) .Show/hide tab