PISTON 1882080 - Caterpillar

Group 2
73D (05A11481), (1GW118-121)
773D (7ER1-99999, 7CS73, 7CS75, 7FZ73-227)
775D (6KR1-99999, 8AS75-77, 8AS79)
Parts Needed
Group 1
(69D, 769D, 771D, AD/AE40)
2 - 7L8055 BELLOWS16 - 5M2894 WASHER-HARD20 - 2N2766 LOCKNUT4 - 2N6319 BOLT-HIGH TE4 - 2W9779 CLAMP-BAND16 - 1061792 STUD-TAPERLO16 - 1083612 SPACER8 - 1299452 GASKET-EXH M2 - 1691918 SLEEVE2 - 1768219 SLEEVEGroup 2
(73D, 773D, 775D)
4 - 6B2882 SPACER4 - 3E7428 PLUG-PIPE4 - 7L8055 BELLOWS24 - 5M2894 WASHER-HARD32 - 2N2766 LOCKNUT8 - 2N6319 BOLT-HIGH TE2 - 1S4295 GASKET-TURBO8 - 2W9779 CLAMP-BAND 20 - 1083612 SPACER4 - 1149223 SPACER12 - 1299452 GASKET-EXH M4 - 1691918 SLEEVE1 - 1634167 MANIFOLD (RIGHT SIDE)1 - 1635514 MANIFOLD (LEFT SIDE)24 - 1061792 STUD TAPERLOCKAction Required
See the attached Rework Procedure.
Service Claim Allowances
Group 1
This is a 10-hour job.
Group 2
This is a 14-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
Remove existing manifolds from cylinder head.
Remove all manifold studs.
Machine existing manifolds as per Machining Work Instructions.
References:Diagram A -for machining part number 107-8106.Diagram B -for machining part number 107-8112.Diagram C -for assembly of right side manifold 773D/775D.Diagram D -for assembly of left side manifold 773D/775D.Diagram E -for assembly of both side manifolds 769D/771D.Diagram F -for the tightening procedure for 8 And 12 cylinder engines.
3408HEUI
Machining Work Instructions
107-8106 Manifold-Exhaust (End)
1. Cut end of manifold to dimension shown.2. Add 45 degree chamfer to edge.107-8112 Manifold-Exhaust (Rear)
1. Rough cut end of manifold to dimension shown.2. Turn manifold end to diameter shown.3. Face manifold end to finish dimension shown.4. Add 45 degree chamfer to edge.Installation Instructions
1. Press P/N 169-1918 Sleeve onto 107-8106 Manifold flush with end.2. Press P/N 176-8219 Sleeve onto 107-8112 Manifold flush with end.3. Sub-assemble bellow and clamps on manifolds (do not tighten locknuts) prior to installing on engine.4. Install all new studs, tighten to 30 5 N m.5. Install new exhaust gaskets.6. Install pre-assembled manifolds to cylinder head using 165-4638 centering tools (use one centering tool per manifold section).7. Install spacers, washers, and stud locknuts.8. Tighten all locknuts to a pre-torque of 20 3N m according to sequence shown, removing