829746 Volvo.Penta Flange

Introduction
This Special Instruction details the fabrication of parts, rework of the engine hood, and installation of parts to equip the listed machines with a precleaner for air going to the engine air filters.Do not perform the procedures that are outlined in this Special Instruction until you understand the information that is contained in this document.Safety
Dust generated when grinding or cutting nonmetallic materials may be very fine, abrasive, flammable, and/or explosive. Material being removed may contain crystalline silica, quartz, glass fibers, and other fine materials. Prolonged breathing of the dust may cause cancer and irreversible lung damage. Wear goggles, gloves, and a dust respirator certified by the National Institute for Occupational Safety and Health (NIOSH) and by the Mine Safety and Health Administration (MSHA).In the event of contact with the skin, flush the skin with plenty of water. If dust material gets into the eyes, flush the eyes with an approved flushing system and seek medical attention. Before smoking or eating, clean hands thoroughly. Keep the work site clean and dispose of all dust and particles in containers approved for flammable materials.Refer to the dust handling instructions in this publication for correct disposal of the dust.
Paint and products used in painting may be flammable and hazardous. Read, understand, and follow instructions for use on the container. Wear NIOSH/MSHA certified respiratory protection.
Reference
Special Instruction, REHS1841, "General Welding Procedures"Operation and Maintenance Manual, "Hood Control"Operation and Maintenance Manual, "Engine Air Filter Primary Element - Clean/Replace"Required Parts
Table 1
Required Parts    
Item    Qty    Description    
1     1     Air Intake Cover    
2     1     Guard and Tube (External)    
3     1     Flange    Table 1 lists the parts that must be fabricated before a precleaner can be installed. Refer to ""Fabrication of Parts for the Precleaner"".
Table 2
Required Parts    
Item    Qty    Part Number    Description    
4     1     130-3281     Precleaner As    
5     8     6V-7357     Bolt    
6     8     9X-6165     Washer    
7     1     8T-4990     Hose Clamp    
8     1     124-2456     Film    
9     2     9U-7073     Tapered Cap/Plug    
10     4     9U-7069     Tapered Cap/Plug    Table 2 lists the standard parts that must be obtained before a precleaner can be installed.
Table 3
Consumables    
CAT Paint Primer    
CAT Black Paint    
CAT Yellow Paint    
Sealant    
Teroson PU 92 (Terostat 92) (Polyurethane-based adhesive sealant)    
Thread Lock (Loctite 242)    Table 3 lists the consumables that must be obtained before a precleaner can be installed.Fabrication of Parts for the Precleaner
Air Intake Cover
Illustration 1 g03777624
Air Intake Cover (1) (A) 170.5 mm (6.72 inch) (B) 170.5 mm (6.72 inch) (C) 2700 mm (106.30 inch) radius (D) 1.2 mm (0.05 inch) (E) 32 mm (1.26 inch) (F) 38 mm (1.50 inch) (G) 2800 mm (110.24 inch) radius (H) 151.5 mm (5.96 inch) (J) 151.5 mm (5.96 inch) (K) 38 mm (1.50 inch) (L) 32 mm (1.26 inch) (M) 18 mm (0.71 inch) radius (x4)
Fabricate Air Intake Cover (1) from 1.2 mm (0.05 inch) thick steel plate. Refer to Illustration 1
Paint the air intake cover with CAT primer and CAT yellow paint.Guard and Tube External
Fabrication of Plate 1 (F1)
Illustration 2 g03857168
Fabrication of Plate (carbon steel) 3 mm (0.12 inch) thick (C1) Diameter 206 mm (8.11inch) (C2) Diameter 6.5 mm (0.26 inch) times eight (D1) 45.2 mm (1.78 inch) times four (D2) 109 mm (4.30 inch) times four (D3) 62.3 mm (2.453 inch) (D4) 45.2 mm (1.78 inch) times four (D5) 11.1 mm (0.44 inch) (D6) 3 mm (0.12 inch) (R1) Radius 220 mm (8.66 inch) (R2) Radius 208.3 mm (8.2 inch) (R3) Radius 134 mm (5.28 inch) (R4) Radius 5 1 mm (0.20 0.04 inch) times twoFollow the information in Illustration 2 to fabricate plate 1 (F1) .