3801218 Volvo.Penta Lower gear, exch, complete

Introduction
This Special Instruction is used in order to install the new 368-4968 Engine Support Gp on certain PM-200 Cold Planers.Do not perform any procedure in this Special Instruction until you read this information and you understand this information.Required Parts
Table 1
Part Number     Description     Quantity    
001-7043     Elbow     1    
0S-1594     Bolt     1    
132-5789     Clip     1    
146-0835     Stud     2    
174-4883     Stud     4    
190-3635     Pulley     1    
1B-7538     Bolt     6    
226-7683     Charging Alternator Gp     1    
232-6560     Adapter     1    
243-2310     Cover     1    
8M-0505     Connector     1    
238-5080     O-Ring Seal     1    
336-4436     Serpentine Belt     1    
345-8401     Pulley     1    
347-7963     Belt Tensioner     1    
279-2589     Idler Pulley     1    
357-6056     Bracket As     1    
368-4963     Plate     1    
368-4966     Support As     1    
368-4969     Special Spacer     2    
355-7402     Ground Cable As     1    
368-9152     Bracket As     1    
373-9419     Bracket     1    
375-8063     Hose As     1    
378-8299     Support Bracket     2    
3E-4352     Hard Washer     2    
3H-7654     Hard Washer     12    
3S-2093     Cable Strap     1    
4K-5175     Bolt     12    
5P-8245     Hard Washer     4    
5P-8247     Hard Washer     6    
5P-8347     Bolt     4    
5S-0003     Nut     2    
6V-5839     Washer     1    
8T-0643     Bolt     1    
8T-4121     Hard Washer     4    
8T-4198     Bolt     4    
8T-4223     Hard Washer     8    
8T-4224     Hard Washer     4    
9X-6458     Hard Washer     4    
9X-8873     Bolt     4    
9X-8877     Bolt     8    
379-9319     Guard As     1    
5V-1497     Retainers     2    
6P-6256     Spring Retainers     2    
8T-4121     Hard Washers     2    
8T-4185     Bolts     2    
8T-4223     Hard Washers     2    
8T-4835     Bolts     2    Removal Procedure
Drain the engine coolant.
Disconnect the alternator harness.
Remove the engine serpentine belt.
Remove the alternator.
Remove the four bolts from the center of the crankshaft adapter and remove the crankshaft pulley.
Remove the 12 bolts that secure the vibration damper and remove the damper.
Illustration 1 g02677237
(1) Alternator bracket bolts (2) Bolts that secure the crankshaft adapter
Remove bolts (1) in order to remove the alternator mounting bracket. Remove the bracket.
Remove bolts (2) from the crankshaft adapter and remove the crankshaft adapter.
Secure the engine using the front lifting plate.
Remove the two bolts that secure the 185-6278 Engine Support Gp to the machine frame.
Remove the 185-6278 Engine Support Gp .Installation Procedure
Illustration 2 g02684460
(3) 368-4966 Support As
Install the new 368-4966 Support As using the new 9X-8873 Bolts and 8T-4223 Hard Washers .
Illustration 3 g02684476
(4) Two 368-4969 Special Spacers (5) 368-4963 Plate (6) Four 5P-8347 Bolts (7) Four 8T-4224 Hard Washers (8) Two 378-8299 Support Brackets
Install plate (5) and spacers (4), using bolts (6), washers (7), and spacers (8). Refer to Illustration 3.
Illustration 4 g02684549
(9) 368-9152 Bracket As (10) Four 4K-5175 Bolts
Install bracket assembly (9) using bolts (10) .
Install the new 232-6560 Adapter using new 1B-7538 Bolts and 5P-8247 Hard Washers .
Reinstall the existing damper and the new 345-8401 Pulley using new 4K-5175 Bolts and new 3H-7654 Hard Washers .