961794 Volvo.Penta Electric cable, cable

1. Remove guard (1) below the engine. Remove the 1/2 in. bolts from guard (2) below the pumps and move the guard out of the way.2. Drain enough oil from the hydraulic tank to put the oil level below the add mark.3. Remove the valve from the hydraulic tank and put tooling (B) in its place. 4. Install tooling (A) on the tank. Connect an air hose to tooling (A) to put the tank under a vacuum. Tooling (A) will prevent the loss of oil when the lines are removed from the hydraulic oil cooler. 5. Remove oil lines (3). Put plugs in the openings. 6. Remove baffle (4). 7. Disconnect everything from cross support (6). Remove twelve bolts (5) and remove cross support (6). 8. Disconnect halon line (7) from the elbow on the back of the heat shield. Remove both heat shields (8). 9. Remove bracket (9) on the right side of the engine.10. Remove the muffler. See MUFFLER REMOVAL AND INSTALLATION. 11. Remove lock (10) and disconnect the wire harness. 12. Disconnect governor control cable (12) from the governor. Remove the two nuts that hold bracket (11) to the pipe and move the bracket and governor control cable out of the way. 13. Disconnect wires (15) from the air conditioning compressor. Loosen the belt adjuster and remove the drive belt from the air conditioner compressor. Remove the two bolts from the mounting bracket and the bolt, washer and spacer from the belt adjuster and move air conditioner compressor (13) out of the way.14. Remove one of the bolts from radiator brace (14) and move the brace out of the way. Close the water valves at the engine and disconnect the heater hoses from the engine. 15. Remove alternator bracket (16). 16. Put identification on the wires connected to starter (17) and disconnect the wires from the starter.17. Disconnect oil line (18) for the oil pressure gauge.18. Cut cable ties (19) that hold the thermocouple wire to the oil line. Remove the thermocouple from the front of the timing gear cover and move the thermocouple and wire clear of the engine.19. Close the fuel shutoff valve on the back of the water separator. The water separator is fastened to the hydraulic tank. 20. Put identification on fuel lines (20) and disconnect them from the fuel lines from the tank and water separator. 21. Remove bolts (21) and move electrical panel (22) away from the hydraulic oil cooler. 22. Remove the bolts that hold brackets (23) and (24) to the corner support and loosen the bolts that hold the brackets to the rear door and support. Do the same thing on the other side of the machine. 23. Disconnect wire harness (26) from the solenoid on the ether starting aid. Remove the bolts that hold bracket (25) for the ether starting aid to the support. Remove bracket (25) and the ether line from the support so they will not be damaged when the support is removed. 25. Remove oil level gauge (29) from the engine.25. Fasten tooling (C) and a hoist to support (27). Remove bolts (28) from both ends of support (27) and remove the support. Weight of the support is approximately 214 kg (475 lb.). 26. Remove bolts (30) and the spacers from both sides of the engine. 27. Fasten two bracket-links (31) from tooling (D) to the timing gear cover as shown. 28. Fasten one bracket-link (32) from tooling (D) to the cylinder block as shown. 29. Fasten the remainder of tooling (D) and a hoist to the engine as shown. 30. Put a hydraulic jack and wood blocks in position under axial piston pumps (33) to give support to the pumps when the engine is removed.31. Remove bolts (35) that hold the flywheel housing to the pump drive housing and remove bracket (34).32. Move the engine away from the pump drive. Tilt the engine with tooling (D) and remove the engine and radiator from the chassis. The weight of the engine and radiator is approximately 826 kg (1825 lb.).Install Engine And Radiator
1. Fasten tooling (D) and a hoist to the engine. Put the engine and radiator in position in the chassis. Use tooling (D) to put the engine in a level position. 2. Put clean oil on O-ring seal (1). Move the engine and put it in position on the pump drive housing. 3. Put bracket (2) in position and install bolts (3) that hold the pump drive housing to the flywheel housing.4. Remove the hydraulic jack and wood blocks from under axial piston pumps (4). 5. Install bolts (5), two washers and spacers on both sides of the engine and tighten bolts (5) to a torque of 122 20 N m (91 15 lb.ft.). 6. Fasten tooling (C) and a hoist to support (6) and put the support in position on the machine. Install the six bolts at the top of the support. 7. Install the bolts in brackets (7) and (8) at both ends of the support and tighten all the bolts that hold the support in place. 8. Put bracket (9) for the ether starting aid and the ether line in position on the support and install the bolts that hold the bracket and ether line in place. Connect wire harness (10) to the solenoid on the ether starting aid. 9. Install oil level gauge (11). 10. Put electrical panel (12) in position in front of the hydraulic oil cooler and install bolts (13) to hold it in place. 11. Connect fuel lines (14) to the fuel line from the tank and water separator. Open the fuel shutoff valve on the back of the water separator. 12. Connect the wires to starter (15).13. Connect oil line (16) from the oil pressure gauge to the oil line from the engine.14. Install the thermocouple for the water temperature gauge in the front of the timing gear cover. Install cable ties (17) to hold the extra thermocouple wire to the oil