850071 Volvo.Penta Countershaft

Introduction
This Special Instruction will provide the information required to update the prelube wiring group on certain 789D Off-Highway Trucks. The procedure contains required parts, fabrication details, and installation instructions.ReferenceRefer to Special Instruction, REHS1841, "General Welding Procedures" for additional welding information.Safety
Shock/Electrocution Hazard – Do not operate this equipment or work on this equipment unless you have read and understand the instructions and warnings in the Service Manual. Failure to follow the instructions or heed the warnings will result in serious injury or death.
Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.
Personal injury or death can result from fumes, gases, and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin, and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both to keep fumes and gases from your breathing area. Wear eye, ear, and body protection before working. Protect yourself and others by reading and understanding this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death.Read and understand the instructions of the manufacturer and the safety practices of your employer. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" which is published by the American Welding Society.American Welding Society
8669 NW 36 Street #130
Miami, Florida 33166-6672
1-800-443-9353See "OSHA Safety and Health Standards, 29 CFR 1910" which is available from the U.S. Department of Labor.U.S. Department of Labor
Washington, D.C. 20210
See applicable requirements for your local area.
Required Parts
Table 1
Required Parts    
Item     Qty     Part Number     Description    
1     1     4E-7829     Block    
2     1     446-9281     Bracket As    
3     1     8X-7517     Bracket As    
4     3     243-5821     Bracket As    
5     11     8T-4121     Hard Washer    
6     4     8T-4182     Bolt    
7     1     267-2746     Cover As    
8     6     9X-8256     Washer    
9     2     5C-9553     Bolt    
10     1     326-8116     Fuse    
11     2     449-3238     Cable As    
12     2     264-3617     Lockwasher    
13     2     7X-0608     Hard Washer    
14     2     5C-7261     Nut    
15     6     7K-1181     Cable Strap    
16     1     204-2281     Cable Strap    
17     1     091-9035     Spacer    
18     5     177-4562     Grommet    
19     5     8T-1890     Clip    
20     5     8T-1889     Clip    
21     6     8T-4136     Bolt    
22     1     337-9078     Magnetic Switch Gp    
23     4     8T-4171     Bolt    
24     1     354-7480     Cable As    
25     1     140-0860     Ground Strap    
26     1     8T-4223     Hard Washer    
27     1     8T-4179     Bolt    Prepare the Machine
Note: Permit only one person on the machine. Either keep others away from the machine, or keep other personnel in the sight of the operator.
Move the machine to a smooth horizontal location. Move away from any machines that are working and any personnel.
Move the transmission control to the PARK position.
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