78361 Volvo.Penta Spring

Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.
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.
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.
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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Put identification marks on all hose assemblies, on all tube assemblies and on all wire harnesses for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss and contaminants from entering the system.
Drain the engine coolant into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct procedure.
Recover the refrigerant. Refer to Service Manual, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines" for the recovery and the charging procedure. Refer to Special Publication, NEDG2500, "Air Conditioning Tools" for the correct tools.
Turn the battery disconnect switch to the OFF position.
Turn the fuel supply to the OFF position.
Illustration 1 g06439509
Remove the cable straps. Disconnect harness assembly (1). Reposition harness assembly (2) out of the way.
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Remove clips (4) and (5). Disconnect hose assembly (3).
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Disconnect hose assembly (6).
Remove the strap. Loosen clamp (7) and disconnect hose (8).
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Loosen clamps (9) and disconnect tube assembly (10).
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Loosen clamps (11). Remove tube assembly (10).
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Disconnect hose assemblies (12) and (13).
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Objects are made opaque for clari