7733670_080 Volvo.Penta oil cooler with installation comps

Parts Needed
(1) For the right side of the machine make two blocks (1) and one plate (2) to the dimensions shown. Make 16.75Ø (.66"Ø) hole (A) through blocks (1) at the location shown. Use a 21.0Ø (.82"Ø) drill bit to make holes (A) larger to the depth shown. Make threads in holes (A) with a 3/4" - 10 tap. Remove section (B) from plate (2) to the dimension shown. (2) Make two gussets (3) from 12.0 (.5") thick steel to the dimensions shown. Make a 5.0 (.19") × 45° chamfer along edges (C). Make one block (4) 25.0 (1.0") thick to the dimensions shown. Use a 16.75Ø (.66"Ø) drill bit to make two holes (D) through block (4) at the location shown. Make threads in holes (D) with a 3/4" - 10 tap. (3) Make one plate (5) from 18.0 (.71") thick steel to the dimensions shown. Make two 32.0Ø (1.25"Ø) holes (E) through plate (5) as shown. Make an 8.0 (.32") × 45° chamfer along side (F). For machines before 24W1520, 25W513, 26W391 and 27W667, make plate (6) from 10.0 (.38") thick steel to the dimensions shown. Make two 20.5Ø (.81"Ø) holes (G) at the locations shown.Installation Of Engine Support Assemblies
(1) Remove crankcase guards (1) and (2). Drain the oil from the hydraulic tank. Disconnect and remove transmission oil cooler hoses (3) and (4) from the machine. This drains the oil from the cooler (capacity approximately 8.0 liters (2 gallons). Disconnect elbow (5) and hose (6) from the flywheel housing. Fasten hose (6) back to get access to remove the driveshaft. Put marks on driveshaft (7), plate assemblies (8) and flanges (9). This permits installation of the driveshaft in the same position after the repair procedure is done. Remove the driveshaft and plate assemblies. (2) Disconnect and remove dust ejector tube (10), shield (11) and plate assemblies (12) and (13). (3) Disconnect hose assembly (14) from elbow (15). Loosen clamps (16). Disconnect elbows (15) and (17) from the hydraulic pump. This drains the hydraulic oil from pump inlet tube (18), approximately 20 liters (5.0 gallons). Disconnect clamps (19), loosen the clamps at the front end of tube (18) and remove the tube from the machine. (4) Disconnect hose (20) from tube (21). Disconnect tube (21) from the hydraulic tank. Slide the tube toward the rear of the machine beyond engine rear support bracket (22). It is not necessary to remove the tube from the machine. (5) Remove the caps from engine rear supports (22) and (23). Put a hydraulic jack under the engine flywheel housing. Put a block of mild steel or similar material between the jack and the flywheel housing. Lift the rear of the engine just enough to remove supports (22) and (23). (6) Install 5T2979 Support Assembly (24) and 5T2980 Support Assembly (25), with the original hardware, where the former supports were removed. If your machine is within the serial number ranges given in step 3, page 3, put plate (6) (step 3, page 3) under support (24) before the support is fastened to the frame rail. Tighten the bolts that hold the supports to the frame rails. (7) Fasten blocks (26) (item 1, step 1, page 2) to support (24) with two 1D4614 Bolts and 5P8248 Washers. Blocks (26) should be against the frame rail with little or no gap between them and the frame. If necessary, use shims behind the blocks to fill any gap. The end of blocks (26) with threads must be in the down position. Make 10.0 (.38") fillet welds along each side and across the bottom of each block. Tack weld plate (27) (item 2, step 2, page 2) to blocks (26) at the dimension shown. Make 10.0 (.38") fillet welds along the top, each side and along the bottom of plate (27). (8) Install block (28) (item 4, step 2, page 3) on support (25) with two 1D4614 Bolts and 5P8248 Washers. Put plate (29) (item 5, step 3, page 3) with the chamfer down, under block (28) and against former bracket (30). Tack weld block (28) to plate (29). Remove block (28) and plate (29). Make a 6.5 (.25") fillet weld along each end and along the side of block (28) toward the engine. Install block (28) on support (25) and tighten the bolts. Fasten plate (29) to bracket (30) with an 8.0 (.31") bevel groove weld. Tack weld gussets (31) (item 3, step 2, page 3) to former gussets (32) and to plate (29) as shown. Make a 5.0 (.19") bevel groove weld along each side of gussets (31). Make 6.5 (.25") fillet welds along each side at the top of gussets (31). Lower the engine and install the caps on the engine rear supports.Alignment Of Engine And Power Train
(1) Make plate (1) from mild steel to the dimension shown. Cut a piece of 9.5Ø (.38"Ø) rod (2), 255.0 (10.0") long. Weld rod (2) to plate (1) with a 3.0 (.12") fillet weld. Fasten plate (1) to drive shaft yoke (3) with a 1A1135 Bolt [5/8" - 11 × 51 (2.0") long] and a 1D4720 Nut. Use an 8S2328 Dial Indicator Group on rod (2) to check the F.I.M. (full indicator movement) around outer surface (A) of yoke (4) as shown. If the F.I.M. is more than 5.3 (.21"), the engine must be moved to get the F.I.M. below this specification. Move the engine from side to side as needed to get the F.I.M. to be as near 0.0 (0.0") as possible, to increase the service life of the drive shaft components. Tighten the engine rear support bolts to 435 20 (320 15 lb.ft.) torque. (2) Put the marks in alignment and install driveshaft (5) and plate assemblies (6) on yokes (3) and (4) as shown.Assembly Procedure
(1) Connect tube (1) to the hydraulic tank with the former hardware. Install clamp (2) on tube (1). Install plates (3) and (4). (2) Install shield (5) and dust ejector tube (6). Connect