RADIATOR GP 10R1038 - Caterpillar

This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
1. Remove the existing following components from the engine:
2396659/">239-6659 Muffler (Qty 1)
5I-7848 U-Bolt (Qty 2) (retain for re-use)
5I-7639 Clamp As. (Qty 1)
196-8013 Pipe (Qty 1)
196-8014 Bracket (Qty 1) (retain for re-use)
196-8012 Bracket (Qty 1) (retain for re-use)
5I-7937 Gasket (Qty 1)
196-8015 Stud (Qty 3)
Refer to Image1.1.1.
Image1.1.1
2. Modify the new 5I-7639 Clamp Assembly (refer to Image1.2.1) and the new 2396659/">239-6659 Muffler (refer to Image1.2.2).
Image1.2.1
Image1.2.2
3. Assemble the 196-8014 Bracket and the 196-8012 Bracket which was removed in Step 1. The alignment for both brackets for the muffler will need to be adjusted. Assemble the right and left bracket to the flywheel housing. The dimension of A and B (both to the center of U-bolt hole) must be 253mm and parallel to each other. Tighten the four bolts to a specified torque of 43 +/-5 N.m. Refer to Image1.3.1.
Image1.3.1
4. Assemble the new 196-8015 Stud and set the new 5I-7937 Gasket to the turbocharger. Tighten the stud to a specified torque of 23 +/-2 N.m.
5. Assemble the new 501-2401 Bellows Assembly to the new muffler which was modified in Step 2. Insert the 501-2401 Bellows Assembly to the new 5I-7639 Clamp Assembly which was modified in Step 2, and join them with the muffler.
6. Place the muffler, that was assembled in Step 5, in the proper position. Tighten the nuts (double nuts) in the turbocharger side, avoiding any overload to the bellows, to a specified torque of 36 +/- 6 N.m. Fix the U-bolt to the bracket ensuring that there is no inclination in the muffler. Tighten the upper nuts to a specified torque of 35 +/- 6 N.m and the bottom nuts to a specified torque of 10 +/- 2 N.m, avoiding any overload to the muffler. Refer to Image1.6.1, 1.6.2, and 1.6.3.
Image1.6.1
Image1.6.2
Image1.6.3
7. Fix the clamp that connects the muffler and the bellows assembly. Tighten the two bolts to a specified torque of 64 +/- 10 N.m.