823595 Volvo.Penta Pulley

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 fluids according to local regulations and mandates.
At operating temperature, the hydraulic oil is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuits (boom, stick, implement and swing), the travel circuits and the hydraulic oil tank at the breather cap before any hydraulic lines or components are disconnected or removed. Remove the filler plug only when the engine is stopped and the filler plug is cool enough to touch.
1. Release the pressure in the hydraulic system as follows: a. Start the machine. Fully retract the stick cylinder rod.b. Adjust the position of the implement so that it will be flat on the ground when the boom is lowered.c. Lower the implement until it is flat on the ground.d. Shut off the engine.e. Place the engine start switch in the ON position without starting the engine.f. Move the control levers for the boom, stick and the implement to all full stroke positions. This will release any pressure that may be present in the pilot system.g. Slowly move the travel pilot control pedal to FORWARD and REVERSE travel positions. This will release any pressure in the travel circuit.h. Slowly loosen and remove the pressure cap on the hydraulic oil tank to release the pressure.i. Reinstall and tighten the pressure cap on the hydraulic oil tank.j. The pressure in the hydraulic system has been released and implement/travel lines and components can be removed.
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 fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure in the cooling system. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
2. Release the pressure in the cooling system by slowly loosening the fill cap on the radiator.3. Remove the fan assembly from the engine. See the topic "Remove & Install Fan Assembly" in this module.
View From Under Machine4. Remove four bolts (2) and cover (1) from under the engine.
View From Under Machine5. Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 35 liters (9.1 U.S. gal).6. Loosen the clamp, and disconnect lower radiator hose (3) from the bottom of the radiator.
View From Under Machine7. Remove bolt (4), the washer and nut that hold the radiator enclosure to the right hand rear corner of the frame assembly.
View From Above Engine8. Remove two bolts (5), the washers and nuts that hold the left hand side of the radiator enclosure in position. 9. Open access door (6) on the radiator enclosure, and fasten it in the OPEN position. 10. Remove two sound suppression mounting bolts (7) from the plate assemblies. Carefully remove the sound suppression liner group from the radiator enclosure. 11. Disconnect two wires (8) from the horn.12. Remove four mounting bolts (9) and horn (10) from the radiator enclosure. 13. Fasten Tool (A) and a hoist to radiator enclosure (11) as shown. Carefully remove the radiator enclosure from the machine. The weight of the radiator enclosure is 27 kg (60 lb). 14. Disconnect hose assemblies (12) and (13) from the bottom of the hydraulic oil cooler. Put plugs in the hose assemblies to prevent oil loss and to keep dirt and debris out of the hydraulic system. 15. Remove two nuts (14), washers and bolts that hold the radiator group to the frame of the machine. 16. Fasten Tool (A) and a hoist to radiator group (15) as shown. Carefully remove the radiator group from the machine. The weight of the radiator group is 82 kg (180 lb). 17. Put a drain pan in position under the radiator group. Remove two caps (16) from the bottom of the hydraulic oil cooler. Oil will drain out of the cooler. 18. Remove four bolts (17) and the washers that hold reservoir (18) in position. 19. Disconnect hose assemblies (19) and (20) from reservoir (18). Remove the reservoir from the radiator. 20. Loosen clamp (21), and remove hose assembly (19) from the radiator. 21. Remove eight bolts (22) and top support (23). 22. Remove eight bolts (24) from side support (25). 23. Remove drain valve assembly (26) from the bottom of the radiator. 24. Remove connector (27) from drain valve assembly (26). 25. Position the radiator with the front side facing up as shown. Remove five bolts (28) and