478416 Volvo.Penta Spacer

Start By:a. remove radiatorb. remove air cleanerc. remove mufflerd. remove front and rear guards (belly guards)e. remove batteriesf. remove floor plates If vehicle is equipped with a cab and air conditioning the cab and compressor will need to be removed. Fluid Spillage ContainmentCare 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.
At operating temperature, the implement hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic system before hydraulic lines or components are disconnected or removed.
Put identification on all lines, hoses, wires and tubes for installation purposes. Cap and plug all lines, hoses and tubes to prevent fluid loss and contaminants from entering the system.1. Drain the idyllic tank. The capacity is approximately 83 liters (22 gal U.S.) 2. Remove eight nuts (1), washers, and exhaust elbow (2).3. Remove three bolts (3), washers, and spacers. 4. Remove bolt (4), washers, nut, and support assembly (5).5. Remove strap (6).6. Remove bolt (7), washers, spacers and support assembly (8). 7. Remove five straps (9).8. Remove bolt (10), and washer.9. Disconnect terminal (11), (12), and (13). 10. Remove strap (14) disconnect connector (15), (16), and terminal (17). 11. Close valve assemblies (18), and (19). 12. Disconnect connector (20), and remove three straps (21).13. Remove bolt (22), and washer. Remove harness assemblies (23), and (24) from the engine and position out of the way. 14. Remove strap (25), bolt (26), and washer. 15. Remove strap (27). Disconnect terminals (28), and (29). 16. Remove cotter, and pin (31), and disconnect rod end (32) from lever (30).17. Loosen nut (34), and reposition cable group (33) to the side. 18. Loosen clamp (36), and disconnect hose (37). Remove bolt (35), washer and reposition hose (37) to the side.19. Loosen clamp (38), disconnect hose (39), and reposition to the side. 20. Loosen clamp (41), and disconnect hose (42). 21. Remove four bolts (43), washers, spacer, and half flange. Reposition hose assembly (44) to the side. 22. Remove four bolts (45), washers, half flange, and reposition hose assembly (46) to the side. Remove strap (47). 23. Remove two strap's (48). Disconnect hose assembly (49).24. Remove four bolts (50), washers, half flange, and reposition hose assembly (51) to the side. 25. Disconnect hose assemblies (52), and (53). 26. Remove bolt (54), and washer.27. Repeat step 26 for the opposite side. 28. Disconnect hose assemblies (55), and (56). Remove two strap's (57). 29. Remove four bolts (58), washers, half flange, and reposition hose assembly (59) to the side. 30. Remove four bolts (60), washers, half flange, and reposition hose assembly (61) to the side. 31. Disconnect hose assemblies (62), (63), and (64). 32. Disconnect hose assemblies (65), and (66). 33. Disconnect hose assemblies (67), and (68). 34. Disconnect hose assembly (69). 35. Attach tooling (A) as shown. 36. Remove bolt (71), washer, sleeve, mount assembly, and plate assembly. 37. Remove bolt (71), washer, sleeve, mount assembly, and plate assembly. 38. Remove two bolts (72), nuts, washers, sleeves, and mount assemblies. 39. Using a suitable lifting device, remove the engine and pumps from the machine onto tooling (B) as shown. The weight of the engine and pumps is 590 Kg (1300 lb) 40. Remove four bolts (73), washers, half flange, and reposition hose assembly (74) to the side.41. Remove two bolts (75), washers and hydraulic travel pump (76). 42. Remove tube assemblies (77), and (78). 43. Remove tube assembly (79). 44. Remove hose assembly (80).45. Remove cotter and pin (81). Reposition cable assembly (82) to the side. 46. Attach a suitable lifting device as shown. Remove two bolts (83), washers, and hydraulic travel pump (84). The weight of the hydraulic travel pump is 64 Kg (140 lb). 47. Attach a suitable lifting device as shown. Remove two bolts (85), washers. Remove four nuts (86), washers, and hydraulic travel pump (87). The weight of the hydraulic travel pump is 64 Kg (140 lb). 48. Loosen screw (88), and remove coupling (89). Install in reverse order.49. Tighten the hydraulic travel pump mounting nuts to 65 10 N m (48 7 lb ft).End By:a. install mufflerb. install air cleanerc. install radiatord. install floor platese. install front and rear guards (belly guards)f. install batteries If vehicle is equipped with a cab and air conditioning the cab and compressor will need to be installed. Fill the hydraulic tank to the proper level. See the Operation And Maintenance Manual for proper level. Fill the radiator to the proper level. See the Operation And Maintenance Manual for proper level.