3855518 Volvo.Penta Repair kit, 290 DP

Introduction
This service publication contains the information that is needed in order to install the 318-8496 Engine Kit for Power Optimization. A complete listing of the parts that are contained in this kit are listed in the Parts Manual, SEBC1501.This supplemental product support literature should be used with the appropriate Service Manual that is available for the standard machine.Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document.
Personal injury or death can result from improper assembly procedures.Do not attempt any assembly until you have read and understand the assembly instructions.
Personal injury or death can result from improper lifting or blocking.When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.
Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.
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 you open any compartment or disassemble 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.
Personal injury can result from hydraulic oil pressure and hot oil.Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.
Installation "A"
Note: Use the following instructions when installing the kit without new battery cables and a new oil pan.Installation of the 318-8496 Engine Kit (Power Optimization) without new Battery Cables or Oil Pan for the 980H Wheel Loader
Machine Preparation
Refer to Service Manual, RENR8667, "980H Wheel Loader-Power Train-D&A", "Crankcase Guard - Remove and Install" and remove the crankcase guard.
Refer to Service Manual, RENR8667, "980H Wheel Loader-Power Train-D&A", "Power Train Guard (transmission) - Remove and Install" and remove the power train guard.
Clean the machine completely. Pay special attention to the engine and transmission components.
Move the machine to a service bay. Raise the lift arms with the bucket in the full dump position. Allow the bucket to rest on the cutting edge.Note: Access to the main control valve is needed if the machine is not equipped with the payload control system or the aggregate autodig system in order to install the sensor.Release System Pressure
Personal injury or death can result from machine articulation or movement.Machine frames can move and a person can be crushed.Connect the steering frame lock link between the front and rear frames before working on machine. Secure clevis pin with locking pin.Before operating the machine, fasten the steering frame lock link into the stored position and secure the clevis pin with locking pin.Failure to lock into the stored position before operating can result in loss of steering.
Park the machine with the bucket in the full dump position and resting on the cutting edge.
Illustration 1 g00497283
The machine must be on a hard, level surface.