960632 Volvo.Penta Plug

At operating temperature, the hydraulic oil is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuits (boom, stick and bucket) before any hydraulic lines or components are disconnected or removed.
2. Release the pressure in the hydraulic system as follows: a. Lower the blade to the ground if so equipped.b. Fully retract the rod in the stick cylinder.c. Adjust the position of the bucket so it will be flat on the ground when the boom is lowered.d. Lower the boom until the bucket is flat on the ground.e. Shut off the engine, and put the hydraulic activation control lever in the "Lock" position.f. Move the control levers for the boom, bucket, stick and swing through their full travel strokes. This will relieve any pressure that may be present in the pilot system.g. Slowly loosen the Fill/Vent plug on the hydraulic oil tank to release the pressure.h. Tighten the Fill/vent plug on the hydraulic oil tank.i. The pressure in the hydraulic system has now been released. Lines and components can now be removed.3. Remove the plug from the bottom of the hydraulic oil tank. Install the ecology drain valve to drain the oil from the hydraulic oil tank. Drain the oil into a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 57 liters (14.8 U.S. 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 fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure in the cooling system. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
4. Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 14.6 liters (3.8 U.S. gal). 5. Open right rear access door (1) to the engine/main hydraulic pump compartment. 6. Remove the bolts and washers that hold sheet assembly (2) in position above the main hydraulic pump. Remove the sheet assembly. 7. Remove all bolts (3) and the washers that hold sheet assemblies (4) and (5) in position. Remove the sheet assemblies from between the engine and main hydraulic pump.8. Put identification marks on all hose assemblies (6) and tube assemblies that are connected to the main hydraulic pump. Disconnect the hose assemblies and tube assemblies. Put plugs in the lines to prevent oil loss and to keep dirt out of the hydraulic system.
View From Under Machine9. Remove sheets (7) and (8) from under the engine.
View From Under Machine10. Remove clips (9). Disconnect wiring harness (10), and move it away from the engine. 11. Remove spring (11). Loosen nut (12). Disconnect cable assembly (13) from the fuel system. Move the cable assembly away from the engine. 12. Put identification marks on all wires (14) that are connected to the electric starting motor and the alternator. Disconnect all wires from the electric starting motor and alternator. 13. Disconnect wires (15) for the energized-to-run solenoid. 14. Disconnect wires (16) from the water temperature sending unit. 15. Loosen two clamps (17). Disconnect two heater hose assemblies (18). 16. Loosen two clamps (19), and remove upper radiator hose (20). 17. Loosen clamp (21).18. Disconnect hose (22) from the water temperature regulator housing.19. Loosen clamp (23).20. Disconnect hose (24) at the water pump. 21. Remove the two clamps and lower radiator hose (25). 22. Loosen two clamp (26), and disconnect air inlet hose (27). 23. Remove bolts (28) and the washers that hold the upper and lower fan guards (29) in position. Remove the fan guards. 24. Remove four bolts (30) and fan assembly (31) from the engine.
The front and rear upper and lower rubber engine mounts have different part numbers. The rubber mounts must not be mixed. After removal of the engine and main hydraulic pump, put identification marks on the rubber mounts as to their location.
25. Remove four bolts (32), the washers and upper front and rear rubber mounts (33) and (34) from the engine. 26. Fasten a hoist to engine lifting brackets (35).
There is limited space in the engine compartment. Prior to removing the engine and main hydraulic pump, be sure all hose assemblies, tube assemblies, electrical connections, nylon ties, clips and clamps have been removed. Do not damage the radiator core during removal of the engine. The engine must be held level during removal to prevent possible interference between components.
27. Carefully lift engine and main hydraulic pump (36) out of the machine. The combined weight of the engine and main hydraulic pump is approximately 544 kg (1200 lb).28. Remove the lower front and rear rubber mounts from the engine mounting brackets or from the frame of the machine. Remove the washer located at each engine support assembly.29. If necessary, remove the two front and rear engine mounting brackets from the engine. The following steps are for the installation of the engine and main hydraulic pump.30. Be sure the mating surfaces on the cylinder block and the four engine mounting brackets are clean.31. Apply 7M-7456 Bearing Mount on the bolts that hold the engine mounting brackets to the cylinder block. Install the four engine mounting brackets and the 16 mounting bolts. Tighten the mounting bolts to a torque of 105 20 N m (75 15 lb ft).32. Be sure the mating surfaces of the main frame and the engine mounting bracket are thoroughly clean.
Visually check the condition of the upper rubber mounts and the lower rubber mounts. If the rubber mounts are worn or damaged or appear to be compressed, use new parts for replacement. To ensure correct engine operation, be sure the rubber mounts are installed in their original locations in the front and rear engine mounting brackets.
33. Put the lower rubber mounts in their original locations on the front and rear engine mounting brackets. Put