240972 Volvo.Penta Washer

Personal injury can result from hot coolant, steam, and alkali.At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove filler cap from the radiator slowly to relieve pressure only when the engine is stopped and radiator cap is cool enough to touch with your bare hands.Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.
2. Drain the radiator. The capacity of the cooling system is 30.0 liters (8 U. S. gallons). Refer to the Operation and Maintenance Manual, Form No. KEBU7506, for the correct procedure.
Personal injury can result from hydraulic oil pressure and hot oil.Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.
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.
Identify all hydraulic lines as they are removed for reinstallation purposes. Cap and plug all lines and fittings to prevent any contaminants from entering the system.3. Release the pressure in the hydraulic system by slowly loosening the fill cap located on the top of the hydraulic oil tank.4. Drain the hydraulic oil from the hydraulic oil tank. The capacity of the hydraulic oil tank is 80 liters (21.1 U. S. gallons). Refer to the Operation and Maintenance Manual, Form No. KEBU7506, for the correct procedure. Steps 5 through 10 are for machines equipped with a hood. 5. Attach Tool (A) to left side panel (2). Remove four bolts (1)_and remove the left side panel. The weight of the left side panel is 29 kg (64 lb). Note: During installation, shim the left side panel to 5 mm (0.197 inch). 6. Repeat Step 5 for the right side panel. The wheel assembly has been removed for photographic purposes only.7. Remove bolts (4) from left side panel (3).8. Loosen bolts (5) and remove left side panel (3).9. Repeat steps 7 and 8 for the right side panel. 10. Attach Tooling (B) and a suitable hoist to support assembly (6). Loosen six bolts (7) and remove the support assembly from the machine. The weight of the support assembly is 26 kg (58 lb). Use steps 11 through 19 only if the machine is equipped with air conditioning. 11. Disconnect two electrical connectors (9).12. Remove the bolt from air conditioner compressor strap (8).13. Remove bolt (10) and remove air conditioning unit. Move the air conditioning unit out of the way. 14. Remove three clamps (11) from two hose assemblies (12). 15. Turn shut off valves (15) off.16. Disconnect two hose assemblies (14) from shut off valves (15). Plug hose assemblies immediately.17. Remove clamp (13) from two hose assemblies (14). 18. Remove clamps (16) from two hose assemblies (12) and (14). 19. Remove clamps (17) from two hose assemblies (12) and (14). 20. Disconnect air indicator tube (18) from the hydraulic oil tank frame.21. Loosen the clamp and remove coolant hose (19) from the top of the hydraulic oil tank frame.22. Disconnect fuel lines (20) from the engine. Cap and plug immediately. 23. Disconnect three electrical connectors (21).24. Disconnect three wires (22) from the fuel shutoff solenoid.25. Remove the cable ties that fasten wiring harness (23) to the engine. Move the wiring harness out of the way.26. Disconnect four hose assemblies (24) from the steering pump. Cap and plug immediately. 27. Disconnect wire (25) from the engine heater.28. Disconnect electrical connector (26).29. Disconnect two wires (27) from the alternator.30. Remove the cable ties that fasten wiring harness (28) to the engine. Move the wiring harness out of the way.31. Loosen the clamp, and remove coolant hose (29) from the engine. 32. Remove five wires (30) from the starter.33. Remove the nut and cover (31) from the starter.34. Remove the remaining two wires from the starter. 35. Disconnect hose assemblies (32) from the vibratory pump. Cap and plug immediately. 36. Disconnect electrical connection (33).37. Disconnect hose (34) from the vibratory pump. Cap and plug immediately. 38. Disconnect two electrical connectors (35).39. Disconnect hoses (36) from the propel pump. Cap and plug immediately.40. Remove the cotter pin and pin that fastens control cable (37) to the propel pump. Loosen the jam nut and remove control cable (37) from the bracket. Move the control cable out of the way. 41. Remove the cable ties that fasten wiring harness (38) to the propel pump. Move the wiring harness out of the way.42. Disconnect hoses (39) from the propel pump. Cap and plug immediately. 43. Attach Tooling (C) and a hoist to the engine (40) as shown. Remove four mounting bolts (41), and remove engine (40) and the pumps as a unit from the machine. The weight of the engine and pumps as a unit is approximately 726 kg (1600 lb). For the installation of the engine, reverse the removal steps. After the engine has been installed, fill the cooling system with coolant to the correct level. Fill the hydraulic oil system with hydraulic oil to the correct level. Refer to the Operation & Maintenance Manual, Form No. KEBU7506, for the correct procedures.End By:a. close engine enclosure or install hoodb. *lower