3803788 Volvo.Penta Injection pump, components not spec.

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     6V-3145     Load Leveler     1    
B     126-7914     Swivel hose     1    Start By:
Prepare the machine for disassembly. Refer to Disassembly and Assembly, "Preparation for Disassembly".
Remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".
Remove the radiator. Refer to Disassembly and Assembly, "Radiator - Remove".
Remove the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install".
Remove the machine preheater. Refer to Disassembly and Assembly, "Machine Preheater - Remove and Install".
At operating temperature, the hydraulic oil is hot and under pressure. Hot oils can cause burns.To prevent possible personal injury, release the pressure in the implement hydraulic circuit (boom, stick, bucket, and swing), travel circuits, and the hydraulic oil tank at the filler cap before any hydraulic lines or components are disconnected or removed.Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch.
At operating temperature, the engine coolant is hot and under pressure.Steam can cause personal injury.Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand.Remove the fill cap slowly to relieve pressure.Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
Hot oil and components can cause personal injury.Do not allow hot oil or components to contact the skin.Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work.
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.
Note: Put identification on all lines, hoses, wires, and tubes for installation purposes. Use caps and plugs on all lines, hoses, and tubes in order to prevent fluid loss or contamination of the systems.
Lower the bottom guard.Reference: Operation and Maintenance Manual, SEBU7196, "Lowering the Bottom Guard".
Illustration 1 g00472258
Perform the following steps in order to drain the hydraulic tank. The tank assembly for hydraulic oil is located behind the cab. The hydraulic oil tank is protected by two guards. These guards must be removed in order to access the drain plug on the hydraulic oil tank.
Lift the cover in order to access the hydraulic oil tank.
Illustration 2 g00599367
Remove five bolts (1) that hold the guard. Remove front guard (2) .
Illustration 3 g00599372
Remove bolts (3). Remove side guard (4) .
Illustration 4 g00472263
The drain valve is located on the lower left front corner of the tank. The drain valve is an ecology drain valve. Remove the plug at the bottom of the drain valve. Use Tooling (B) with an appropriate length of 25 mm (1 inch) hose to drain the oil. Screw the swivel into the drain valve. Drain the oil into a suitable container. The capacity of the hydraulic oil tank is 130 L (34 US gal).
Remove Tooling (B). Install the plug in the drain valve.
Illustration 5 g00623800
Disconnect two fuel lines (5). Move two fuel lines (5) away