864115 Volvo.Penta Smoke limiter

Necessary Parts
All reinforcement plates must be fabricated as shown. Fabricate two sets of plates, one set for each support rail using high strength type steel (minimum yield 435 MPa [63,000 psi]), except where indicated. 1. Fabricate plate (1). 2. Fabricate plate (2). 3. Fabricate plate (3). 4. Fabricate plate (4). 5. Fabricate plate (5). 6. Fabricate plate (6). 7. Fabricate plate (7). 8. Fabricate bars (8) and (9) at the dimensions shown using mild type structural steel (minimum yield strength 207 MPa (30,000 psi) [two each]. 9. Fabricate block (10) [L.H.]. 10. Fabricate block (11) [R.H.]. 11. Fabricate plate (12) [two each]. 12. Fabricate plate (13) [two each].Also needed:1-5T2980 Engine Mount (L.H.)1-8W4933 Engine Mount (R.H.)4-1D4614 Bolt4-1D4610 Bolt8-6V2360 Washer1-4D0672 DowelWelding Procedure
1. The following weld procedure is for one engine support rail only; repeat the procedure for the other rail. 2. With a air carbon arc torch or similar tool, remove plate (14) from the inboard side of the rail assembly. Grind the area smooth. On the support rail on the left side of the engine, remove two lugs (4T0681) and (6M4016). The 4T0681 Lug will be needed again, but the 6M4016 Lug will not. 3. Put plate (3) in position on the support rail at the dimension shown and make 6 mm (.24") fillet welds along both sides. 4. Put plate (9) in position on the support rail as shown and make 10 mm (.39") bevel groove flush welds at location (A), and a 10 mm (.39") bevel groove weld at location (B).5. Make a 6 mm (.24") fillet weld at location (C). 6. Locate bar (8) with engine mount (15), two 1D4610 Bolts (16), 6V2360 Washers and a C-clamp as shown.7. Make one weld pass at location (D).8. Remove the C-clamp, bolts, washers and engine mount.9. Make one weld pass at location (E).10. Complete welding at locations (D) and (E) with a 10 mm (.39") bevel groove flush weld.11. Check to make sure the plate is flat. Grind the surface flush. 12. Install plate (1) and make 10 mm (.39") fillet welds at locations (F) and (G).13. Make a 10 mm (.39") fillet weld all around at three locations (H) as shown. 14. Install plate (2) and make 6 mm (.24") fillet welds at locations (J) and a 6 mm (.24") square groove weld at location (K). 15. Install plate (4) and make a 6 mm (.24") fillet weld all around at locations (L). 16. Install plate (5) and make a 6 mm (.24") fillet weld all around at location (M). 17. Install plate (6) and make a 6 mm (.24") fillet weld all around at location (N). Make a 6 mm (.24") flare bevel groove weld at location (O).18. Make 6 mm (.24") square groove welds at locations (P). 19. Grind the surface smooth. 20. Install plate (7) and make 6 mm (.24") fillet welds all around the plate at location (Q). 21. Make 10 mm (.39") fillet welds at locations (R). 22. Install plates (12) and (13) in position and make the following welds as specified.S - 6 mm (.24") fillet weldT - 10 mm (.40") flare bevel groove weldV - 6 mm (.24") flare bevel groove weldW - 8 mm (.31") bevel groove weldX - 6 mm (.24") flare bevel groove weldY - 10 mm (.40") bevel groove weldZ - 6 mm (.24") fillet weld (must be made after blocks (10) and (11) have been installed.AA - 8 mm (.31") bevel groove weldBB - No weldCC - No weld 23. Install blocks (10) [L.H.] and (11) [R.H.] in position and make the following welds as specified. If this reinforcement procedure was done earlier using only plates (1) through (9), then cut the end of plate (9) to allow blocks (10) and (11) to fit in position on the rails.DD - 18 mm (.70") bevel groove flush weld (grind smooth)EE - 6 mm (.24") fillet weldFF - 6 mm (.24") Fillet weld 24. Using the engine mount as a guide, mark location of holes (GG).25. Drill holes (GG) with a 16.75 mm (.66") Ø drill and tap with a 3/4"-10 tap.26. Install a 4S0672 Dowel at location (HH). 27. Install 4T0681 Lug (17) (removed earlier) at the dimensions shown with a 6 mm (.24") fillet weld on both sides at location (JJ). 28. Install the support rails on the engine with new engine mounts (15) [both sides]. Tighten bolts (18) to a torque of 205 13 N m (185 10 lb ft).29. Tighten bolts (19) to standard torque. 30. Make sure the distance between the support rails is approximately at the dimension shown.Power Pack Installation
Installation procedure of the power pack unit in the scraper is the same as given in the Service Manual, except the power train lines, breather tube and support bracket must be repositioned to allow for more clearance between the engine support rail and the lines. 1. Remove power train oil lines (1), breather tube (2) and bracket (3) from their existing positions in the chassis.2. Turn bracket (3) around 180° as shown and again install the lines, tube and clips as shown. If necessary, tube (2) and bracket (3) may be bent to allow for more clearance when installing the power pack unit. 3. Be careful when lowering the power pack unit into position in the chassis. Make sure clip (4) [on the retarder oil cooler line] does not make contact with ejector cylinder hose (5), or damage to the hose could result.