21011809 Volvo.Penta Plug

Start By:
Remove the hood from the machine.
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.
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 Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines.Dispose of all fluids according to local regulations and mandates.
Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release" in this manual.
Drain the oil from the hydraulic tank into a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 98 L (25.8 US gal) .
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 filler cap is cool enough to touch with the bare hand.Remove the filler cap slowly to relieve pressure.Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 19 L (5 US gal) .
Illustration 1 g00416978
This view is under the machine.
Loosen two bolts (1) . Remove four bolts (2) . Slide plate (3) off two bolts (1) . Remove plate (3) from the machine.
Disconnect the ground wire from the engine.
Illustration 2 g00417199
Typical Example
Remove bolts (5) and the washers. Remove sheet (4) .
Illustration 3 g00417231
Remove the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install" in this manual.
Loosen five hose clamps (7) .
Disconnect hose (6) to the turbocharger.
Disconnect hose (8) to the crankcase breather.
Disconnect radiator top hose (9) .
Put identification marks on hose (11) and on hose (13) . Identification marks are for installation purposes. Disconnect hose (11) . Disconnect hose (13) .
Remove fan shroud (12) from the machine.
Loosen the hose clamp on the radiator bottom hose. Disconnect the radiator bottom hose.
Disconnect spring (10) on the governor control cable.
Illustration 4 g00417378
The counterweight is removed for photographic purposes.
Remove nut (14) and the washer from governor control cable (16) . Disconnect the governor control cable.
Loosen nuts (15) that secure governor control cable (16) to the bracket assembly.
Remove clip (19) . Reposition governor control cable (16) away from the engine.
Disconnect hose assembly (17) . Put a plug in hose assembly (17) . Put a cap on the pump. Plugs and caps prevent oil loss. Plugs and caps prevent contaminating the hydraulic system.
Disconnect hose assembly (18) . Put a plug in hose assembly (18) . Put a cap on the pump. Plugs and caps prevent oil loss. Plugs and caps prevent contaminating the hydraulic system.
Feed hose (18) through the hole in the sheet.
Put identification marks on all electrical connectors. Identification marks are for installation purposes. Disconnect all electrical connectors. Remove all electrical harness from the engine. Reposition all electrical harness away from the engine.
Illustration 5 g00417456
Illustration 6 g00417446
Put identification marks on all hose assemblies that are connected to the pilot pump and to the main hydraulic pump. Identification marks are for installation purposes. Remove hose assemblies (20) . Put plugs in the hose assemblies. Put caps on the pumps. Plugs and caps prevent oil loss. Plugs and caps prevent contaminating the hydraulic system.
Disconnect electrical connector (21) .
Remove bolts (22) and the washers that secure sheet (23) to the machine. Remove sheet (23) from the machine.
Remove the bolts from the support that hold sheet (23) and sheet (4) to the machine. Remove the support from the machine.
Loosen four hose clamps (24) .
Disconnect hose (25) .