21136325 Volvo.Penta Tube

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 Product Guide, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.Start By:a. remove fan & adapterb. remove crankcase guardsc. remove air lines group
At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the breather filter cap only when the engine is stopped and the breather filter cap is cool enough to touch. Slowly loosen the breather filter cap to release any pressure in the hydraulic tank. Be cautious of hot hydraulic oil when any lines are disconnected in the transmission system.
1. Drain the following fluids into a suitable container for storage or disposal:a. Drain the oil from the engine (only if equipped with the engine prelube arrangement). The capacity of the engine with filter is approximately 45.5 L (12 gal U.S.).b. Drain the oil from the transmission tank. The capacity of the transmission tank is approximately 81.5 L (21.5 gal U.S.).c. Drain the oil from the hoist, torque converter and brake tank. The capacity of the hoist, torque converter and brake tank is approximately 220 L (58 gal U.S.).d. Drain the oil from the steering tank. The capacity of the steering tank is approximately 55 L (14.5 gal U.S.).
With the body of the truck in the "Up" position, and the engine out of the machine, the weight of the machine may lift the front of the machine off the ground. Blocking or lift stands must be in position before the engine is removed. Failure to do so may result in personal bodily injury.
2. Lift and secure the truck bed using the body retaining pins. Refer to the topic, "Body Retaining Pins", in this manual.
At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
3. Loosen the clamps and disconnect and plug heater hoses (1) from the water pump cover.4. Disconnect and plug fuel lines (2). 5. Disconnect and plug hose assembly (3) from the elbow.6. Disconnect elbows (4) and (5) (not shown) from the brake and torque converter oil cooler. 7. Disconnect hose assemblies (6) from the air conditioning compressor.8. Disconnect the positive battery cable from the battery. Place identification marks on the electrical wires from the Truck Production Management System (TPMS) lights on the right fender. Disconnect and place the wires away from the engine. 9. Disconnect wire (7) from the TPMS sensor. 10. Disconnect wires (8) from the electric starting motor. Disconnect wires (9) from the solenoid. 11. Disconnect and plug hose assemblies (10) from the fitting. Disconnect clip (11) from the guard assembly and pull the hose assembly clear.12. Disconnect and plug hose assembly (12) from the pump drive group.
Before any lines are disconnected from the air compressor, make sure the air pressure is zero.
13. Release the air pressure at the valve on top of the transmission and hydraulic tank. 14. Disconnect air lines (13) and (14) from the air compressor. 15. Fasten a hoist and Tool (A) to the guard assembly. Remove bolts (15) and remove the guard assemblies from each end of the pump drive shaft. The weight of the guard assemblies is approximately 4.5 kg (10.00 lb). 16. Remove bolts (16) that secure the spider to the yoke on each end of the pump drive shaft. Remove pump drive shaft (17). 17. Fasten a hoist and Tool (A) to the main drive shaft guard assembly. Remove the bolts and remove the guard assemblies from each end of the main drive shaft. The weight of one guard assembly is approximately 29 kg (65 lb).18. Fasten a hoist to the main drive shaft (18). Remove bolts (19) that secure the spider assembly to the yoke. Pull drive shaft (18) clear of the torque converter. Use the hoist to lower the weight of the drive shaft onto the frame of the machine. 19. Disconnect hose assemblies (20), (21) and (22) from the transmission and torque converter scavenge pump. Disconnect hose assemblies (31) and (32) from the torque converter scavenge pump. 20. Disconnect hose assemblies (23), (24) and (25) from the torque converter inlet relief valve.21. Disconnect wire (26) from the torque converter oil temperature switch. 22. Disconnect hose assemblies (27) and (28) from the torque converter outlet relief valve. 23. Disconnect clip (29) from the torque converter. Place identification on wires for installation purposes.24. Disconnect wiring harness assembly (30). Disconnect wires from switch (31). 25. Disconnect hose assembly (32) from the lockup clutch and solenoid valve group. 26. Fasten Tool (B) and a hoist to the engine. Remove bolts (33) and the nuts. Remove caps (34) from each side of the flywheel housing. 27. Remove bolts (35) that secure the front support assembly to the frame. Remove engine (36) and torque converter as a unit. The combined weight of the engine and torque converter is approximately 3292 kg (7250 lb).Install Engine And Torque Converter
1. Fasten Tool (B) and a hoist to the engine. Place engine and torque converter (36) in position in the machine. Install bolts (35) that secure the front support to the frame. Tighten the bolts to