870980 Volvo.Penta Main switch

Bleed the high pressure air system before disconnecting air compressor lines. Personnel could be injured.
1. Disconnect five lines (2) from compressor (4).2. Disconnect two lines (3) from compressor governor (1).3. Loosen three bolts. One comes from other side of front engine cover. (Do not attempt to remove all the bolts till lifting strap is attached from a hoist.) 4. Attach lifting strap from hoist to compressor (4).5. Remove the three bolts.6. Remove the compressor. The weight of the compressor is 34 kg (75 lb). For installation of the air compressor, reverse the removal steps.End By:a. install side panelsb. install top hoodDisassemble Air Compressor
Start By:a. remove air compressor
Typical Example1. Remove elbow (1) and adapter. Remove the gasket, screen and gasket from behind the flange.2. Remove air compressor governor (2).3. Put a mark on the head assembly and block for correct assembly.
Typical Example4. Remove six bolts (3). Remove head assembly (4).
Typical Example5. Remove inlet valve springs (5) from the head assembly.6. Remove discharge valve seats (6).
Typical Example7. Remove discharge valves (7). Remove springs from behind the valves. Check the discharge valve stops for wear or damage. If the discharge valve travel exceeds 1.45 mm (.057 in), make a replacement of the head assembly.
Typical Example8. Remove inlet valves (8) from guides. Remove guides (9) from around the inlet valve seats.
Typical Example9. Remove unloader spring (10), spring seat and spring saddle (12).10. Remove unloader plungers (11) and guides.
Typical Example11. To remove unloader pistons (13) from the bore, put a cover over the inlet port, then blow air pressure in the governor mounting pad unloader port (14).
Typical Example12. Check inlet valve seats (15) and unloader bore bushings (16) for wear or damage. If necessary, make a replacement.
Typical Example13. Remove bolts (17). Remove cover (18) and gasket from the crankcase assembly.14. Put marks on the rod bearing caps and rods for correct assembly.
Typical Example15. Remove bolts (19) and locks. Remove rod bearing caps (20). Push the pistons and rods through the top of the crankcase assembly.
Typical Example16. Remove rod pin (21) from the piston. Remove rod (23).17. Remove bearings (22) from the rod and caps.
Typical Example18. Use tooling (A) to remove bushing (24) from the rod.
Typical Example19. Remove buttons (25) from each end of the rod pins.
Typical Example20. Remove piston rings (26) from piston (27) with an approved ring expander.
Typical Example21. Remove O-ring seal (29) from the crankshaft.22. Remove bolts (28). Remove adapter (30) from the crankcase assembly.
Typical Example23. Remove three O-ring seals (32) from the adapter.24. Remove thrust bearing (31).
Typical Example25. Use tooling (A) and a press to remove the bearing from the adapter.
Do not cause damage to the bearing surfaces of the crankshaft when it is removed from the crankcase assembly.
Typical Example26. Remove crankshaft (33) from the crankcase assembly.
Typical Example27. Remove bolts (34). Remove cover (35). Remove two O-rings seals from the crankcase assembly.
Typical Example28. Remove O-ring seal (37) from the cover.29. Remove thrust bearing (36).
Typical Example30. Remove bearing (38) from the cover.Assemble Air Compressor
1. Check all parts for wear or damage. If necessary, make a replacement with a new part.2. Make sure all parts are clean and free of dirt and foreign material.
Typical Example3. Use tool (A) and a press to install the bearing in cover (1).
Typical Example4. Install O-ring seal (3) on the cover.5. Install thrust bearing (2).
Typical Example6. Install O-ring seals (4) in the crankcase assembly.7. Put a small amount of SAE 30 Oil on the O-ring seal. Install the cover on the crankcase assembly (5). Tighten the bolts to a torque of 35 to 46 N m (25 to 35 lb ft).
Typical Example8. Put crankshaft (6) in position in the crankcase assembly.
Typical Example9. Use tool (A) and a press to install the bearings in adapter (7).
Typical Example10. Install O-ring seal (9) on the adapter.11. Install thrust bearing (8).
Typical Example12. Install O-ring seals (10) in the crankcase assembly.13. Put adapter (7) in position on the crankcase assembly. Install the bolts that hold it. Tighten the bolts to a torque of 49 to 60 N m (38 to 45 lb ft).
Typical Example14. Use tooling (A) to install the bushings in the rods. Make sure the oil hole in the bushing is in alignment with the oil hole in the rod. The bushing inside diameter must be 13.498 to 13.505 mm (.5314 to .5317 in).
Typical Example15. Install buttons (14) in each end of the rod pins.16. Put rod (13) in position in piston (11). Install rod pin (12) in the piston.
Typical Example17. Install piston rings (15) and oil ring (16) on the pistons. Check all groove and ring clearance. The correct groove clearance for the piston rings is 0.05 to 0.10 mm (.002 to .004 in). The correct groove clearance for the oil ring is 0.03 to 0.08 mm (.001 to .003 in). The correct ring gap clearance is 0.05 to 0.25 mm (.002 to .010