826K Landfill Compactor, 825K Soil Compactor and 824K Wheel Dozer Engine Supplement Caterpillar

Removal Procedure

1. 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".
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   Illustration 1	g03648876

2. Open door (1).
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   Illustration 2	g03648883

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   Illustration 3	g03648918

3. Mark the orientation of clamp (3) prior to loosening.

4. Loosen clamps (3), (4), and (7).

5. Disconnect nitrogen oxide sensor (5).

6. Slide elbow (6) into bellows assembly (2) in order to gain clearance.

7. Remove the flexible exhaust pipe assembly.

Installation Procedure

1. 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".
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   Illustration 4	g03649140
   Typical example of the alignment wrap.

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   Illustration 5	g03648883

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   Illustration 6	g03648918

   Note: The alignment wrap will be included with the new bellows assembly (2). Bellows assembly (2) should never be flexed during installation.

2. Do not remove the alignment wrap until Step 10.

3. Pre-assemble elbow (6) and bellows assembly (2) to the turbo inlet and the after treatment outlet in a loose condition.
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   Illustration 7	g03649231

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   Illustration 8	g03649263

4. Assemble the turbo end ball joint, as shown in Illustration 7. Be sure that clamp (4) is between Ink/Bump Marks (Y). Loosely tighten clamp (4).

5. Use the turbo end ball joint and the slip adjustability in order to align and assemble the after treatment end ball joint, as shown in Illustration 5. Be sure that clamp (7) is between Ink/Bump Marks (Z). Loosely tighten clamp (7).
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   Illustration 9	g03649156
   The alignment wrap is not shown for photographic purposes.

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   Illustration 10	g03648883

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   Illustration 11	g03648918

6. The slip joint for bellows assembly (2) should slide smoothly with a minimum engagement to Mark (X). Mark (X) is equal to 40.0 mm (1.57 inch). Total engagement will be verified when Mark (X) is no longer visible on elbow (6).

   Note: Do not use power tools in order to torque clamps (3), (4), and (7).

7. Tighten clamp (4) to a torque of 35 ± 2 N·m (26 ± 1 lb ft).

8. Tighten clamp (7) to a torque of 35 ± 2 N·m (26 ± 1 lb ft).

9. Verify that Mark (X) is not visible at the slip joint of elbow (6) and bellows assembly (2).

10. Remove the alignment wrap from bellows assembly (2).

11. Tighten clamp (3) to a torque of 55 ± 8 N·m (41 ± 6 lb ft).

    Note: New nitrogen oxide sensors (5) are pre-lubricated. Do not apply Tooling (A) to the threads of new nitrogen oxide sensor (5). When installing an existing nitrogen oxide sensor (5) install Tooling (A) on the threads only.

12. Apply Tooling (A) to the threads only of nitrogen oxide sensor (5). Install nitrogen oxide sensor (5). Tighten nitrogen oxide sensor (5) to a torque of 50 ± 10 N·m (37 ± 7 lb ft).
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    Illustration 12	g03648876

13. Close door (1).