242739 Volvo.Penta Relay

Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-6146 Load Leveling Beam 1
ZZ 179-4453 Cap 5
179-4454 Cap 2
9S-8927 Plug 2
5P-2909 Plug 11
9S-8895 Plug 2
8S-4950 Cap 2
8S-4951 Cap 11
9S-8896 Cap 2
5H-4019 Cover 1
2J-2668 Cover 5
2J-5608 Cover 2 Start By:
Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".
Release the pressure in the braking system. Refer to Disassembly and Assembly, "System Pressure - Release".
Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
Remove the exhaust purifier and muffler. Refer to Disassembly and Assembly, "Exhaust Purifier and Muffler - Remove".
Remove the upper drive shaft. Refer to Disassembly and Assembly, RENR8505, "Drive Shaft (Upper) - Remove and Install".
Remove the engine bottom guard. Refer to Disassembly and Assembly, " Bottom Guard (Engine) - Remove and Install".
Remove the transmission bottom guard. Refer to Disassembly and Assembly, RENR8505, "Bottom Guard (Transmission) - Remove and Install". Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.Note: Put identification marks on all hoses, on all hose assemblies, on all wires and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This will help to prevent fluid loss, and this will help to keep contaminants from entering the 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.
Hot oil and components can cause personal injury.Do not allow hot oil or components to contact skin.
Turn the battery disconnect switch to the OFF position.
Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the tools.
Drain the hydraulic tank into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Capacities (Refill)" for the capacity of the hydraulic tank for the machine that is being serviced. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the proper draining procedure.
Illustration 1 g01074378
Remove five bolts (2) and firewall (1).
Remove seven bolts (3) (not shown) and firewall (4).
Remove three bolts (6) (not shown) and firewall (5).
Illustration 2 g01074379
Disconnect hose assembly (7).
Remove clamps (10), (11), and (12).
Remove tube assemblies (8) and (9).
Illustration 3 g01074380
Disconnect hose assemblies (13), (14), and (15).
Illustration 4 g01074381
Disconnect hose assemblies (18) and (19).
Remove tube assemblies (16) and (17).