865560 Volvo.Penta Injection pump

Start By:a. remove radiator, oil cooler and condenserb. remove muffler assemblyc. remove front drive shaftd. remove main drive shaftFluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publication SENR5664 and NEDG5065 for the proper procedure, equipment and tools to reclaim refrigerant from any Caterpillar machine.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping refrigerant R-134A can cause freezing of human flesh.Do not smoke while working on air conditioning systems. INHALING REFRIGERANT 134A THROUGH ANY SMOKING MATERIAL, ALTHOUGH NOT TOXIC OR FLAMMABLE, CAN GENERATE LETHAL PHOSGENE GAS AND CAUSE VIOLENT ILLNESS OR DEATH. ALSO, HEAT MUST NEVER BE APPLIED TO A CHARGED SYSTEM. See Air Conditioning And Heating Service Manual, Form number SENR5664, for more information on removal and installation of lines and refrigerant from the system.
For purging and charging the air conditioning system, refer to the Air Conditioning And Heating Service Manual SENR5664. Loader lift arms have been removed for photographic purposes. Put identification on all lines, hoses, wires and tubes for installation purposes. Cap and plug all lines, hoses and tubes to prevent foreign material from entering the system. Drain all fluids in a suitable container for storage or disposal. 1. Disconnect cable assembly (1) from the hood assembly. 2. Remove two bolts (2) from the hood assembly and remove the hood assembly. 3. Remove oil filter (3) and fuel water separator (4). 4. Remove bolt (5) from the frame. 5. Remove bolt (6) from the bell housing. 6. Disconnect hose assembly (7) from the transmission. 7. Remove bolt (8) from the transmission. 8. Disconnect hose assembly (9) from the transmission. 9. Remove two bolts (10) and remove the valve and the hose assemblies. 10. Disconnect three wires (11) from the starter. 11. Disconnect wire (12) and plug (13) from the alternator. 12. Disconnect wire (14) from the water temperature regulator.13. Remove the tie wraps and disconnect the wire from the engine. 14. Remove bolt (15) from the frame. 15. Disconnect hose assemblies (16) and (17). 16. Disconnect hose assembly (18). 17. Disconnect hose assemblies (19) and (20) and disconnect throttle linkage (21). 18. Disconnect wiring harness (21). 19. Disconnect wiring harnesses (22) and (23).20. Disconnect wires (24), (25) and (26). 21. Disconnect two wires (27). 22. Purge refrigerant from the system. Disconnect air conditioning hose assembly (28). 23. Disconnect hose assembly (29). 24. Disconnect the wiring harnesses. 25. Disconnect wiring harness (30). 26. Disconnect hose assemblies (31) and (32). 27. Disconnect and remove bracket assembly (33). 28. Disconnect hose assembly (34). 29. Disconnect and remove hose assembly (35). 30. Remove six bolts and remove plate assembly (36). 31. Attach a suitable lifting device as shown to the hydraulic tank so that it does not fall during removal of engine, torque converter, transmission and implement pump. 32. Remove the four bolts on two hydraulic tank mounting brackets (37). 33. Attach tooling (A) and a suitable lifting device to the engine as shown. 34. Remove four mounting bolts (38).35. Remove the engine, torque converter, transmission and implement pump from the machine as a unit. The weight of the unit is 704 kg (1550 lbs). Install the engine, torque converter, transmission and implement pump in the reverse order of removal.End By:a. install main drive shaftb. install front drive shaftc. install muffler assemblyd. install radiator, oil cooler and condenser Refer to the Topic "Lubricant Viscosities and Refill Capacities" in the Operation and Maintenance Manual, publication number SEBU6873 for the proper filling procedure and the proper levels for the hydraulic system and the cooling system.