PISTON & ROD GP 1928808 - Caterpillar

Removal Procedure
If reusing the exhaust elbow, and or the bellows, refer to Special Instruction, REHS5014, "Reuse Guideline for the Lines Group - Flexpipe on Tier 4 Engines".
Illustration 1 g02197073
Loosen clamp assemblies (1) , (3) and (5) .Note: Mark the orientation of clamp assembly (3) prior to removal.
Slide elbow (2) into bellows (4) in order to gain clearance. Remove the bellows assembly.Installation Procedure
If reusing the exhaust elbow, and or the bellows, refer to Special Instruction, REHS5014, "Reuse Guideline for the Lines Group - Flexpipe on Tier 4 Engines".
Illustration 2 g02095400
Illustration 3 g02092825
Alignment wrap (A) is not shown for photographic purposes. Typical ExampleNote: Alignment wrap (A) will be included with the new bellows assembly. The Tooling will be pre-installed on the bellows.Note: The alignment wrap (A) should not be removed until Step 11. Bellows (4) should never be flexed during installation.
Distance (X) is 40 mm (1.6 inch). Place Mark (B) onto elbow (2) . a Distance (X) from the end of elbow (2) .
Insert elbow (2) into the bellows. The elbow should be inserted as far as possible without using force. This action will minimize the overall length of the bellows assembly and will help with installation.
Illustration 4 g02197073
Alignment wrap (A) is not shown for photographic purposes.
Illustration 5 g02097701
The photo is a cutaway view of the ball clamp assembly which is located near the combustion head group.
Illustration 6 g02098533
The photo is a cutaway view of the ball clamp assembly.
Prior to installation, position both ball clamp assemblies (1) and (5) onto the bellows assembly.
Position the bellows assembly between the Clean Emissions Module and the turbocharger adapter. Adjust the length of elbow (2) in the slip joint at clamp assembly (3) in order to position the bellows assembly.
Verify that the cup of the ball joint (E) does not touch the radius of the ball (D) . Position ball clamp (1) and hand tighten ball clamp (1) . Measure Distance (Y) and Distance (Z) . The two measurements should be equal. Repeat the measurements every 90° around ball clamp (1) . If necessary, adjust ball clamp (1) .
Repeat Step 6 for ball clamp (5) which is located near the turbocharger.
Verify that Mark (B) is not visible at the slip joint that is positioned near clamp assembly (3) .Note: Do not use power tools in order to torque clamp assemblies (1) , (3) , and (5) .
Torque ball clamp (1) to a torque of 35 2 N m (26 1 lb ft).
Torque ball clamp (5) to a torque of 35 2 N m (26 1 lb ft).
Remove alignment wrap (A) from bellows (4) .
Torque clamp assembly (3) to a torque of 55 8 N m (41 6 lb ft).