860793 Volvo.Penta Injection pump

Start By:a. remove hood assembly Fluid Spillage ContainmentCare must be taken to ensure that the fluids are contained during performance of the inspection, the maintenance, the testing, the adjusting and the repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling of the any components containing fluids. Refer to the "Tools And Shop Products Guide", NENG2500 for the tools and the supplies suitable to collect and contain any of the fluids in Caterpillar machines. Dispose of the fluids according to local regulations and mandates.
At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuits (the boom, the stick and the bucket) before any of the hydraulic lines or any of the components are disconnected or removed.
1. Release the pressure in the implement hydraulic circuits (the boom, the stick and the bucket) before any of the hydraulic lines or any of the components are disconnected or removed. Release the pressure as follows:a. Shut off the engine and place key in the "ON" position. Put the hydraulic activation control lever in the "UNLOCK" position.b. Move the control levers for the boom, the stick and the swing to all full stroke positions. This will release any pressure that might be present in the pilot system.c. Return the key to "OFF" position.d. Slowly loosen the fill plug on the hydraulic tank, and release the pressure.e. Tighten the fill plug on the hydraulic tank.f. The pressure in the hydraulic system has been released, the lines and the components can be removed. Drain the hydraulic tank oil in a suitable container for storage or disposal.2. Drain the oil from the hydraulic oil tank into a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 99 liters (26 U.S. gal). 3. Open the access door to the left side of the engine compartment. 4. Remove two bolts (1), four bolts (2) and the washers to disconnect refrigerant condenser (3) from the hydraulic oil cooler. Do Notdisconnect the refrigerant lines. Position the refrigerant condenser for ease in removing the hydraulic oil cooler.
The refrigerant has NOT been evacuated for the air conditioning system, the air conditioning system is under pressure and can cause personal injury.
5. Remove four mounting bolts (4) from the hydraulic oil cooler. 6. Removing bracket (6) from the radiator to allow for the removal of the hydraulic oil cooler.7. Attach Tooling (A) and lifting slings to the hydraulic oil cooler as shown.8. Using a hoist raise the hydraulic oil cooler approximately 15 cm (6 in)to access hoses (5) and (7).9. Place a drain pan under the hydraulic oil cooler before disconnecting hose (7).10. Disconnect hose (5).11. Remove the hydraulic oil cooler. The weight of the hydraulic oil cooler is 68 kg (150 lb). For the installation of the hydraulic oil cooler reverse the removal steps. Refer to the Topic "Lubricant Viscosities and Refill Capacities" in the "Operation and Maintenance Manual" for the proper filling procedure and the proper levels for the hydraulic system.12. Fill the hydraulic oil tank with oil to the correct levels.End By:a. install hood assembly