960630 Volvo.Penta Plug

1. Release the pressure in the hydraulic system by slowly loosening the fill plug located on top of the hydraulic oil tank.2. Remove the hood from the machine. The weight of the hood is 68 kg (150 lb). Open the right rear access door.3. Remove the cover from under the hydraulic oil tank to gain access to the drain plug; then drain the hydraulic oil tank. The capacity of the hydraulic oil tank is 300 liters (80 U.S. gal). Steps 4 through 6 are only for machines equipped with air conditioning.
Do not damage the hydraulic oil cooler core when the air conditioner condenser and receiver are being moved.
4. Remove four bolts (1) that hold the left side mounting bracket for the air conditioner condenser and receiver to the front mounting bracket.5. While holding air conditioner condenser and receiver (3) in position, remove three bolts (4). Lower the air conditioner condenser, receiver and front mounting bracket down onto the access covers as a unit.6. Remove the three bolts that hold left side mounting bracket (2) in position. Remove the bracket. 7. Disconnect pipes (5) and (6) from the hydraulic oil cooler.8. Fasten a hoist to the lifting eyes on the hydraulic oil cooler. Remove the two remaining bolts that are holding hydraulic oil cooler (7) to the mounting frame.
During removal and installation, guide the hydraulic oil cooler straight up and out of the mounting bracket to prevent possible damage to the core.
9. Remove hydraulic oil cooler (7). The weight of the hydraulic oil cooler is 79 kg (175 lb). 10. Remove two wing nuts (8) and protector (9) from the front of the hydraulic oil cooler. The following steps are for the installation of the hydraulic oil cooler.11. Check the condition of the hydraulic oil cooler prior to installation. Remove any dirt or debris that may restrict the flow of air through the core. If any of the cooling fins are bent, they should be straightened prior to installation. Be sure the protector for the hydraulic oil cooler is clean and free of dirt and debris.12. Install protector (9) and two wing nuts (8) on the front of the hydraulic oil cooler.13. Fasten a hoist to hydraulic oil cooler (7), and put it in position on the mounting frame. Install the two lower mounting bolts that hold it.14. Connect pipes (5) and (6) to the hydraulic oil cooler.15. Reinstall left side mounting bracket (2) and the three bolts that hold it.16. Put the air conditioner condenser, receiver and front mounting bracket in position in front of the hydraulic oil cooler. Install the three bolts that hold the unit on the right side. Install four bolts (1) that hold left side mounting bracket (2) to the front mounting bracket.17. Be sure the drain plug for the hydraulic oil tank is tight. Reinstall the cover under the hydraulic oil tank.18. Reinstall the hood on the machine.19. Fill the hydraulic oil tank with oil to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.