INSTALLER 1U5228 - Caterpillar

Illustration 3 g02478996
Typical example
If necessary, follow Step 2.a through Step 2.b in order to disassemble the flexible exhaust pipe assembly.
Loosen ball clamp (6) and remove the ball clamp.
Remove the assembly of bellows (2) from the adapter (7). Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress.Assembly Procedure for the Flexible Exhaust Pipe Assembly
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Drill Bit
3 mm (0.118 inch) Ø 1
B - Drill Bit
6.5 mm (0.256 inch) Ø 1
Ensure that all components of the flexible exhaust pipe assembly are clean and free from wear and damage. If necessary, replace any components of the flexible exhaust pipe assembly that are worn or damaged. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information.
Illustration 4 g02478998
Typical example
If the flexible exhaust pipe assembly was previously disassembled. Follow Step 2.a through Step 2.h in order to assemble the flexible exhaust pipe assembly.
Use the correct personal protective equipment when removing the clamp.
If original bellows are to be reinstalled, place the internal area in Position (G) (not shown) of the bellows on a suitable support. Use Tooling (A) in order to drill a pilot hole through the spot weld in Position (H) on clamp (3). Note: Do not center punch the spot weld on clamp (7).
Use Tooling (B) in order to drill out spot weld in Position (H) on clamp (3). Remove clamp (3) from the bellows.
Remove all burrs from the internal and external areas of bellows (3). Ensure that debris does not enter bellows.
Illustration 5 g02479478
Illustration 6 g02478996
Typical example
Position a new clamp (3) onto bellows (2). Hand tighten clamp (3). Ensure that the center of the clamp is central to Slots (J) on the bellows. The clamp must be flush with the end of the bellows (2). Note: Ensure that the bellows are not subjected to any undue stress.
If new bellows (2) are installed, clamp (3) will be pre-installed to the bellows. Note: Ensure that the bellows are not subjected to any undue stress.
Position a new ball clamp (6) onto adapter (7).
Position bellow (2) onto adapter (7).
Tighten ball clamp (6) hand tight. Note: Ensure that the bellows are not subjected to any undue stress.Installation Procedure for the Flexible Exhaust Pipe as an Assembly
Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.
Check the flexible exhaust pipe assembly for damage. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information.
Illustration 7 g02479539
Typical example
Illustration 8 g02479541
Typical example
Install V-band clamp (1) onto exhaust back pressure valve (5).
Install assembly of the flexible exhaust pipe onto CEM (4) and exhaust back pressure valve (5). Note: Ensure that the assembly of the flexible exhaust pipe is supported at all times.
Position V-band clamp (1) onto adapter.
Tighten V-band clamp (1) hand tight.
Failure to reinstall the bellows into the original position