MUFFLER AS 4674842 - Caterpillar

Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-15000 hrs,
0-12 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
: Injury can occur to personnel if the rework is done improperly. Personal Protective Equipment (PPE) suitable to the work being performed must be worn when performing the rework.
: The power module must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energization or start up of the power module. Failure to follow these warnings could result in injury to personnel during service.
Ensure that the coolant has reduced to a safe temperature before removing the expansion tank.
Drain the coolant into a container.
Disconnect the hoses and lines to the expansion tank.
Image1.1.1
Remove the conduit from the mounting brackets.
Image1.2.1
Use a forklift truck to support the expansion tank with extended forks and blocks. Carefully lower the tank.
The following instruction outlines a alternative method for supporting the tank if a forklift truck is not available.
Secure two steel angles each around 800mm in length. Drill two holes in each angle at the locations specified in Image1.3.1
Mount 2 steel angles onto the flange of the exhaust silencer with screws to support the expansion tank once the mounting bolts are removed Place suitable blocks of wood (approximately 80x100x400mm) between the angle and the bottom of the expansion tank as shown in Image1.3.2.
Image1.3.1
Image1.3.2
Unscrew the 4 M10 bolts at each of the corners of the expansion tank. Remove the bolts, washers, and spacers. Retain the washers for reuse. Push the tank as far as possible to the side exposing the threaded holes overhead.
Image1.4.1
To prep for welding remove the paint around the holes to a diameter of around 40mm. Screw a 8T-4185 bolt into a 8Y-3925 threaded boss leaving approximately 5mm sticking out the other end to position the boss in the proper location for welding. Screw the assembly into the threaded hole overhead until the boss is secure and flush against the structural tube. Weld the boss in place. Remove the bolt, clean the weld, and paint all exposed metal.
Repeat the steps for the adjacent hole.
Push the tank to the other side and repeat for the remaining two holes.
Parts Required
4 8T4185 Bolt
4 8Y3925 Boss
Image1.5.1
Return the expansion tank to its original position, and install a washer and bolt in each mounting location.
Tighten the bolts with 55+-10 Nm of torque.
Image1.6.1
Reconnect the hoses, lines and clamps to the expansion tank. Reinstall the conduit into the mounting brackets. Fill the tank with coolant. Check the connections of the coolant system for leaks. The power module can now be returned to service.
Image1.7.1