20460195 Volvo.Penta Vibration damper, (2&4)

Start By:a. remove top cover assembly (radiator)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 of fluids according to local regulations and mandates.
At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
Mark and identify hose assemblies for installation purposes. Cap and plug hose assemblies to avoid system contamination. 1. Position a suitable container under plug adapter (2) to contain the coolant for storage or disposal. Loosen drain plug (1) on plug adapter (2). Repeat procedure on remaining plug adapter. The capacity of the cooling system is 300 L (79 U.S. gal). 2. Remove the two tie straps holding wiring harness assembly (4) to top tank assembly (3). 3. Install Tool (A) on panel assembly (5). Position a lifting sling through Tool (A), as shown. Secure the lifting sling to a hoist. Remove bolt (6) and the washer from panel assembly (5). 4. Remove bolt (7) and the washer from panel assembly (5). Remove two bolts (8) and the washers from panel assembly (5). Remove panel assembly (5) from the enclosure assembly. The weight of panel assembly (5) is 34 Kg (75 lb). 5. Remove four bolts (10) from elbow (11). Disconnect elbow (11) and the gasket from the radiator. Disconnect wiring harness (9), from the liquid level sensor, at the electrical connections. Remove the straps (12) from wiring harness (9). Repeat for the remaining temperature sensor and elbow. Set wiring harness (9) out of the way. 6. Remove five bolts (13) and the washers from top tank assembly (3). Repeat this procedure on the other side of top tank assembly (3). 7. Install Tooling (B) to top tank assembly (3), as shown. Position two lifting slings through Tooling (B), as shown. Secure the lifting slings to a hoist. Remove 14 bolts (14) and the washers from top tank assembly (3). Remove top tank assembly (3) from the radiator core assembly. The weight of top tank assembly (8) is 96 Kg (211 lb). 8. Remove two bolts (15) and the washers from radiator core assembly (16). Using two people, carefully remove radiator core assembly (16). The weight of radiator core assembly (16) is 23 Kg (50 lb). 9. Remove end tank seal (17) from each end of radiator core assembly (16). The following steps are for the installation of the radiator core. 10. Apply 5P-3975 Rubber Lubricant on each end tank seal (17). Install end tank seal (17) on each end of radiator core assembly (16). 11. Using two people, carefully put radiator core assembly (16) in position in the radiator. Install two bolts (15) and the washers that secure radiator core assembly (16) to the radiator. The weight of radiator core assembly (16) is 23 Kg (50 lb). 12. Install Tooling (B) to top tank assembly (3), as shown. Position two lifting slings through Tooling (B), as shown. Secure the lifting slings to a hoist. Put top tank assembly (3) in position on the radiator. Install 14 bolts (11) and the washers. The weight of top tank assembly (3) is 96 Kg (211 lb). 13. Install five bolts (13) and the washers in top tank assembly (3). Repeat this procedure on the other side of top tank assembly (3). 14. Clean all gasket material on all mating surfaces of elbow (11). Put elbow (11) and the gasket in position on the radiator. Install four bolts (10). Put wiring harness (9) in position and install new tie straps (12). Connect wiring harness (9), to the liquid level sensor, at the electrical connection. Repeat for the remaining temperature sensor and elbow. 15. Install Tool (A) to panel assembly (5). Position a lifting sling through Tool (A). Secure the lifting sling to a hoist. Put panel assembly (5) in position on the enclosure. Install two bolts (8) and the washers. Install bolt (7) and the washer. The weight of upper panel (1) is 34 Kg (75 lb).16. Install bolt (6) and the washer. Remove Tool (A) from panel assembly (5). 17. Put wiring harness (4) in position on top tank assembly (3) and install the two new tie straps. 18. Tighten drain plug (1) on plug adapter (2). Refill the cooling system. The capacity of the cooling system is 300 L (79 U.S. gal). Refer to the Operations & Maintenance Manual for correct procedure.End By:a. install top cover assembly (radiator)