814422 Volvo.Penta Spacer washer

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     -     Guide Bolt(M16 x 2.0 by 240 mm)     2    
B     161-9203     Grease Cartridge     1    Start By:
Remove the pump drive. Refer to Disassembly and Assembly, "Pump Drive - Remove".
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g01018027
Position a suitable container below the torsional coupling in order to contain any lost oil. The torsional coupling holds approximately 2.0 L (2.11 qt) of oil. Remove two bolts (1) and the hard washers from the torsional coupling.
Illustration 2 g01017550
Illustration 3 g01012177
Install Tooling (A) through torsional coupling (3) into the flywheel. Remove the remaining ten bolts (1). Position a lifting strap around the torsional coupling, as shown. Remove torsional coupling (3) from the flywheel. The torsional coupling weighs approximately 131 kg (290 lb).Installation Procedure
The coupling is packaged with the following items: 2 L (2.11 qt) of 75W 90 oil, washer seals and O-ring seals. Seals may be damaged during the installation. As a result, a few extra seals should be ordered.Note: The coupling must be installed on the flywheel in order to check the pressure.Note: For proper installation, two guide rods are required in order to position the coupling in the correct orientation that is against the flywheel. Tooling (A) should be used.
Before the installation, ensure that the following items are accounted for: coupling, washer seals, O-ring seals, 2 L (2.11 qt) of 75W 90 oil, bolts and hard washers.
Clean the mounting surface of the flywheel and the surfaces of the coupling with a common noncorrosive cleaner.
Illustration 4 g01017551
Install Tooling (A) into the flywheel (2). Position the guide rods in the horizontal position with respect to the center of the flywheel. The correct positioning is shown in Illustration 4.
Liberally lubricate all O-ring seals and washer seals with 75W 90 oil.
Install one O-ring seal onto each guide rod and slide the O-ring seal against the flywheel.
Illustration 5 g01012177
Position a suitable lifting device on coupling (3). The proper positioning is shown in Illustration 5. Position the coupling on guide rods and position the coupling 50.8 mm (2.00 inch) from the flywheel.Note: Orient the oil fill tap on top when the coupling is lifted into position.
Install the following parts in the open holes: bolts, washers, washer seals and O-ring seals. Install the parts in the following orientation: bolt, washer, washer seal, coupling, O-ring seal and flywheel. Position the 12 O-ring seals in the O-ring grooves that are located on the flywheel side of the coupling.
Illustration 6 g01017550
Slowly slide the coupling toward the flywheel until the mounting bolts can be threaded into the flywheel. Thread all ten bolts (1) into the flywheel without positioning the coupling against the flywheel. Ensure that the O-ring seals are retained in position.
Once the ten bolts are threaded into the flywheel, slide the coupling against the flywheel. Hold the coupling in place against the flywheel and hand tighten the ten bolts.
Slowly remove Tooling (A). Look into the holes for Tooling (A). Verify that the O-ring seals are in the proper positions in the seal grooves. The use of a flashlight may be required.
Illustration 7 g01018027
Install the following parts in the holes for the guide rods: bolts, washers and washer seals. Install the parts in the following orientation: bolt, washer, washer seal and coupling. Install two bolts (1) slowly. Ensure that no tearing of the seals will occur.
Torque all bolts to a torque of 270 40 N m (200 30 lb ft).
Fill the coupling with 2 L (2.11 qt) of 75W 90 oil. Fill the coupling through the oil fill tap.
Check the pressure through the oil fill tap up to a pressure of 172.37 kPa (25 psi). No leak should be observed. A slow air leak that is no greater than 3.45 kPa (0.5 psi) is permissible.Note: If an air leak is observed, reinstall guide rods and slide the coupling away from the flywheel. Check for pinched O-ring seals. Replace O-ring seals if the O-ring seals are damaged. Repeat Step 7 to Step 14.
Apply thread sealant to the oil filler plug and install the oil filler plug.