20460473 Volvo.Penta Gear

At operating temperature, the hydraulic oil is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuits (boom, stick and bucket) before any hydraulic lines or components are disconnected or removed.
1. Release the pressure in the hydraulic system as follows:a. Fully retract the stick cylinder rod.b. Adjust the position of the bucket so it will be flat on the ground when the boom is lowered.c. Lower the boom until the bucket is flat on the ground.d. Stop the engine.e. Place the engine start switch in the "ON" position without starting the engine.f. Move the control levers for the boom, stick, bucket and swing to all full stroke positions. This will release any pressure that might be present in the pilot system.g. Slowly move the travel pilot control pedal to "FORWARD" and "REVERSE" travel positions. This will release any pressure in the travel circuit.h. Slowly loosen and remove the pressure cap on the hydraulic tank to release the hydraulic pressure.i. Reinstall and tighten the pressure cap on the hydraulic tank.j. The pressure in the hydraulic system has been released and implement/travel lines and components can be removed. 2. Remove two bolts (2) and the washers from firewall (1) located over the main hydraulic pump. 3. Remove three bolts (3) and the washers from firewall (1). 4. Remove one bolt (4) and the washer from firewall (1). 5. Remove two bolts (5) and plate (6) from the spray shield. 6. Remove three bolts (7) and the washers from spray shield (8). Remove the firewall from the machine. 7. Put identification marks on two hose assemblies (9) that are connected to the hydraulic oil filter group for installation purposes. Disconnect the two hose assemblies from the hydraulic oil filter group. Put plugs in the ends of the hose assemblies to prevent oil loss and to keep contaminants out of the hydraulic system. 8. For installation purposes, put identification marks on two hose assemblies (10) that are connected to the oil level gauge group for the hydraulic oil tank. Disconnect the two hose assemblies from the oil level gauge group. Put plugs in the ends of the hose assemblies to prevent oil loss and to keep contaminants out of the hydraulic system. 9. Remove bolt (11) and the washer that hold the engine enclosure to the radiator shroud. 10. Fasten lifting slings and a hoist to engine enclosure group (12) as shown. Put slight lifting tension on the engine enclosure group. 11. Remove two bolts (13) and the washers that hold tube assembly (14) to the frame of the machine. 12. Remove two bolts (15) and the washers that hold the tube assembly (not shown) to the frame of machine. 13. Remove two bolts (18) and two plates (17) that hold rear support assembly (16) to the frame of the machine. 14. Remove the two nuts, socket head bolts (20) and the two plates that hold front support assembly (19) to the frame of machine.15. Carefully remove engine enclosure group (12) from the machine. The weight of the engine enclosure group is 102 kg (225 lb). The following steps are for the installation of the engine enclosure group. 16. Fasten a lifting sling and a hoist to engine enclosure (12) as shown. Carefully put the engine enclosure in position on the machine. Do not remove the hoist from the engine enclosure at this time. 17. Install the two plates, two socket head bolts (20) and the nuts that hold front support assembly (19) to the frame of the machine. 18. Install two plates (17) and two bolts (18) that hold rear support assembly (16) to the frame of the machine. 19. Install two bolts (15) and the washers that hold the tube assembly (not shown) to the frame of the machine. 20. Install two bolts (13) and the washers that hold tube assembly (14) to the frame of the machine. 21. Install bolt (11) and the washer that hold the engine enclosure to the radiator shroud.22. Remove the hoist from the engine enclosure. 23. Connect two hose assemblies (10) to the oil level gauge group in their original locations. 24. Connect two hose assemblies (9) to the hydraulic oil filter group in their original locations. 25. Install the firewall in the machine. Install three bolts (7) and the washers in spray shield (8). 26. Install plate (6) and two bolts (5) in the spray shield. 27. Install bolt (4) and the washer in firewall (1). 28. Install three bolts (3) and the washers in firewall (1). 29. Install two bolts (2) and the washers in firewall (1). These bolts are located over the main hydraulic pump.30. Fill the hydraulic oil tank with oil to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.End By:a. install fan guardsb. install air cleaner groupc. install muffler group