861083 Volvo.Penta Suction pipe

Start By:
Remove the window guard. Refer to Disassembly and Assembly, RENR5140, "Window Guard - Remove".
Remove the left side and the right side radiator guards. Refer to Disassembly and Assembly, "Radiator Guard - Remove".
Tilt the cab. Refer to Operation and Maintenance Manual, "Cab - Tilt".
Drain the coolant from the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
Personal injury or death can result from improper lifting or blocking.When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.
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.
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publications Service Manuals, SENR3334, SENR5664, and NEDG5065 for the proper procedure, the proper equipment, and the proper tools needed in order to reclaim refrigerant from any Caterpillar equipment.
Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, all hoses, and all tubes. This helps to prevent fluid loss and this will help keep contaminants from entering the system.
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 correct procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools.
Illustration 1 g00798286
Loosen two retaining nuts (1) in order to disconnect two hoses (2) from air conditioner condenser (3).
Illustration 2 g00798292
Remove two bolts (4), four washers (5) and two nuts (6) in order to remove the five hose clips. Carefully feed two hoses (2) through the two rubber bushings to the area on the underside of the cab.
Illustration 3 g00798349
Loosen retaining nut (7) in order to disconnect hose (8) from bypass valve (9) .
Illustration 4 g00798350
Loosen two retaining nuts (10) in order to disconnect two hoses (11) from oil cooler (12) for the output transfer gears. Lay the hoses aside.Note: Only the 735 Articulated Truck is equipped with an oil cooler for the output transfer gears.
Illustration 5 g00798579
Remove three bolts (13), three washers (14), and top plate (15) that retains bracket (16) to radiator duct (17). Lower bracket (16) onto the chassis.
Illustration 6 g00798580
This is a view of the coolant tube for the top of the radiator.
Loosen two hose clamps (18) in order to slide hose (19) off tube (20).