896775 Volvo.Penta Pipe

1. Disconnect wire (1) from water temperature sending unit.2. Remove cover (2) from water temperature contactor. 3. Disconnect wires (3) from terminals in water temperature contactor. 4. Identify and disconnect wires (4) from the oil pressure switch. 5. Disconnect wire (5) from the oil pressure sending unit. 6. Identify and disconnect wire (6) from the alternator.7. Identify and disconnect ground wire (7).8. Identify and disconnect wires (8) from solenoid.9. Identify and disconnect wire (9) from large terminal on solenoid. 10. Pull wiring harness (10) away from engine.11. Disconnect and remove governor control (11).12. Remove forged eyebolt (12) and bolt (13) from generator frame.13. Remove generator fan guards (14).14. Remove three bolts and nuts (15) and generator cover (16). The fan was set at the factory with clearance between the fan and baffle which would provide maximum efficiency of the fan. Before removing the fan, make a mark (17) for position of fan on shaft. Reinstall fan to marked position.15. Remove two bolts (18) from generator fan halves. 16. Remove fan (19) in two sections. 17. Install two 1/2"-13NC forged eyebolts (20) in generator frame and attach a suitable hoist.18. Support rear of engine with wooden blocks (21) before removing generator. 19. Install heavy gasket material (22) approximately .070 in. (1,78 mm) thick between rotor assembly and stator assembly to support rotor assembly after the generator has been removed. 20. Remove eight drive disk-to-flywheel bolts (23).21. Remove twelve generator adapter to flywheel housing mounting bolts (24). 22. Remove generator rear mounting bolts (25). 23. Remove generator and regulator as a unit. Weight approximately 900 lbs. (408 kg).Install Generator On Engine
Clean all accumulations of dirt or grease from mounting surfaces before checking dimensions or installing the generator on the engine. 1. Measure the distance from the engine flywheel housing mounting surface to the drive disk recess in flywheel. 2. Measure the distance from the generator end ring mounting surface to the outside surface of the drive disk. This distance should equal the distance in Step 1. If these two distances are not equal, spacers between the generator drive hub and the drive disks should be added or removed as required. The generator rotor shaft should be parallel with the generator frame when checking the distance in Step 2. 3. Install four 3/8"-16NC guide pins (1) in flywheel and housing. Pins should be at least 2 1/4 in. long (57,2 mm).4. Support the generator from an overhead hoist and move the generator horizontally into place. Make certain drive disks fit completely into the drive disk recess in the flywheel. The generator is connected to the engine by inserting bolts from the generator side and tightening them into the threaded holes in the engine flywheel and flywheel housing. 5. Install the flywheel bolts using the spacers and lockwashers provided. Tighten bolts alternately and evenly to a torque of 32 5 lb. ft. (4,4 0,7 mkg). Remove the two guide pins and install and tighten remaining two bolts.6. Install generator adapter to flywheel housing mounting bolts alternately and evenly to a torque of 32 5 lb. ft. (4,4 0,7 mkg). 7. Use a feeler gauge (2) to determine if there is a gap between the generator mounting feet and the generator mounting base. Add shims as necessary between the generator mounting feet and the base and then bolt the generator to the base. 8. When alignment procedures are satisfactory, install two fan halves (3). 9. Install and tighten two fan bolts (4). Install fan to its original position on the shaft. This should have been indicated by marking the shaft and fan (5) before moving or removing the fan. The fan should be between 1/4 to 1/2 in. from baffle when properly positioned. Before placing generator set in operation check clearance between the generator stationary and rotating parts. 10. After aligning and coupling generator to engine place generator cover (6) around frame and pull engine wiring harness (7) through cover.11. Install cover positioning bolts and 1/2"-13NC forged eyebolt (8).12. Install cover bolts (9).13. Install fan guards (10).14. Install governor control (11). 15. Connect wire (12) to large terminal on solenoid.16. Connect wires (13) to solenoid.17. Connect ground wire (14).18. Connect wire (15) to the alternator. 19. Connect wire (16) to the oil pressure sending unit. 20. Connect wires (17) to oil pressure switch. 21. Connect wires (18) to terminals in water temperature contactor. 22. Install cover (19) on water temperature contactor.23. Connect wire (20) to water temperature sending unit.