C7.1 Industrial Engine Flexible Exhaust Pipe - Remove and Install Caterpillar

Removal Procedure for the Flexible Exhaust Pipe as an Assembly

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The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

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Illustration 1	g02354623

1. The lateral alignment of the bellows is critical. All the components must be assembled in the same alignment as prior to disassembly. The components that require correct lateral alignment are shown at Positions (A, B, and C).
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   Illustration 2	g02354616

2. Follow Steps 2.a through Step 2.d in order to remove the flexible exhaust as an assembly from the Clean Emission Module (CEM) and the turbocharger.

   1. Use suitable material in order to encase flexible exhaust pipe (3). Encasing the flexible exhaust pipe will prevent damage of the bellows. Encase bellows for the flexible exhaust pipe (3) between Position (D) and Position (E). Use cable straps in order to retain the suitable material.

      Note: Ensure that the flexible exhaust pipe is supported at all times.

   2. Loosen ball clamp (2) from the flexible exhaust pipe assembly.

   3. Loosen the bolt for V-band clamp (4).

      Note: If V-band clamp (4) remain tight on the flanges, apply releasing fluid on the V-band clamp. Lightly tap the bolt on the V-band clamp with a soft faced hammer in order to assist removal. Do not use a prybar in order to remove V-band clamp.

   4. Remove the assembly of the flexible exhaust pipe from the CEM (1) and the turbocharger (5).

      Note: Ensure that the assembly of the flexible exhaust pipe is supported as the clamps are removed.

Disassembly Procedure for the Flexible Exhaust Pipe Assembly

1. If any part of the flexible exhaust pipe assembly is damaged. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information.
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   Illustration 3	g02354617

2. If necessary, follow Step 2.a through Step 2.d in order to disassemble the flexible exhaust pipe assembly.

   1. Make temporary marks in Position (F) on all components of the bellows (3) and tube assembly (6) in order to show correct orientation and alignment.

      Note: Do not scribe the components in order to mark the position of the flexible exhaust pipe assembly.

   2. Loosen clamp (7) and remove tube assembly (6) from bellows (3).

   3. Loosen ball clamp (8) and remove the ball clamp. Discard the ball clamp.

   4. Remove bellows (3) from the elbow (9).

      Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress.

Assembly Procedure for the Flexible Exhaust Pipe Assembly

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.
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   Illustration 4	g02354618

2. If the flexible exhaust pipe assembly was previously disassembled. Follow Step 2.a through Step 2.i in order to assemble the flexible exhaust pipe assembly.

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   NOTICE
   Use the correct personal protective equipment when removing the clamp.

   1. If original bellows are to be reinstalled, place the internal area in Position (G) of the bellows on a suitable support. Use a 3 mm (0.118 inch) in order to drill a pilot hole through the spot weld in Position (H) on clamp (7).

      Note: Do not center punch the spot weld on clamp (7).

   2. Use a 6.5 mm (0.256 inch) in order to drill out spot weld in Position (H) on clamp (7). Remove clamp (7) from the bellows.

   3. Remove all burrs from the internal and external areas of bellows (3). Ensure that debris does not enter bellows.
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      Illustration 5	g02354619

   4. Position a new clamp (7) onto bellows (3). Hand tighten clamp (7). 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 (3).

      Note: Ensure that the bellows are not subjected to any undue stress.

   5. If new bellows (3) are installed, clamp (7) will be pre-installed to the bellows.

      Note: Ensure that the bellows are not subjected to any undue stress.

   6. Position a new ball clamp (8) onto elbow (9).

   7. Position bellows (3) onto elbow (9). Align the bellows and the elbow with temporary marks.

   8. Tighten ball clamp (8) hand tight.

      Note: Ensure that the bellows are not subjected to any undue stress.

   9. Install tube assembly (6), align the tube assembly with the temporary marks on the bellows. Tighten clamp (7) hand tight.

Installation Procedure for the Flexible Exhaust Pipe as an Assembly

1. 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.
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   Illustration 6	g02354616

2. Position a new ball clamp (2) onto the flexible exhaust pipe assembly.

3. Install V-band clamp (4) onto turbocharger (5).

4. Install assembly of the flexible exhaust pipe onto CEM (1) and turbocharger (5).

   Note: Ensure that the assembly of the flexible exhaust pipe is supported at all times.

5. Tighten V-band clamp (4) hand tight.

6. Tighten ball clamp (2) hand tight.
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   NOTICE
   Failure to reinstall the bellows into the original position will result in a failure of the bellows and possible emissions failure.

7. Align the assembly of the flexible exhaust pipe with the temporary marks. Ensure that bellows (3) are not subjected to any undue stress.
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   Illustration 7	g02250353

8. If a new bellows assembly has been installed, ensure that all components of the flexible exhaust pipe are not subjected to any undue stress and are correctly aligned.

9. Tighten ball clamp (2) to a torque of 35 N·m (26 lb ft).

10. Tighten clamp (7) to a torque of 55 N·m (40 lb ft).

11. Tighten ball clamp (8) to a torque of 35 N·m (26 lb ft).

12. Tighten V-band clamp (4) to a torque of 12 N·m (106 lb in).

13. Cut cable straps from the suitable material that was encasing the bellows (3) between Position (A) and Position (B). Remove the suitable material from bellows (3).