7746400_163 Volvo.Penta electrical materials

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.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g00608602
Open drain plug (7) in the bottom of the water separator and drain the fuel into a suitable container.Note: Not all water separators will have a drain plug in the bottom of the water separator. Water separators that do not have a drain plug should be removed. The fuel should be poured out of the water separator. The fuel should be disposed of in a proper manner.Note: Properly dispose of this old fuel. Do not attempt to reuse the old fuel in the new water separator.
Turn retaining ring (5) above the water separator. Remove water separator (6). Properly dispose of any remaining fuel in the water separator.
Identify fuel lines (2) and (4) prior to removal from the water separator.Note: The engine will not operate if the fuel lines are improperly connected.
Remove hose clamp (1) and hose clamp (3) from the water separator.
Remove fuel line (2) and (4) from water separator base (11). Install plugs in fuel lines (2) and (4) .Note: Installation of plugs will prevent contamination from entering the fuel system.
Illustration 2 g00608628
Remove two bolts (13). Remove the washers and the nuts. Remove the water separator base from plate (8) .
Illustration 3 g00618766
Release two hose clamps (14) that are secured by bolts (13). Release cable clamp (15) that is secured by bolt (13) .Note: It is not necessary to remove hose clamps (14) or cable clamp (15) .
Remove two connectors (10) from water separator base (11). Remove two O-ring seals (9) .
Remove two plugs (12) from water separator base (11). Remove two O-ring seals (9) .Installation Procedure
Illustration 4 g00608628
Install two O-ring seals (9) on plugs (12). Install plugs (12) into water separator base (11) .
Install two O-ring seals (9) on connectors (10). Install connectors (10) into water separator base (11) .
Align and install water separator base (11) on plate (8) .
Secure water separator (11) to plate (8) with two bolts (13) and the washers and the nuts.
Illustration 5 g00618766
Install two hose clamps (14) on the back of plate (8). Install the cable clamp (15). Secure hose clamps (14) and cable clamp (15) by the use of bolts (13) .
Illustration 6 g00608602
Remove the cap and install fuel line (4). Remove the cap and install fuel line (2) .
Install fuel line clamps (3) and (1). Tighten fuel line clamps (3) and (1) .
Pour a small amount of new clean fuel into the new water separator.
Place water separator (6) in position on water separator base (11) .
Rotate ring (5) and tighten.
Move the battery disconnect switch to the ON position.
Start the machine and check for leaks.