Inspection and Installation Procedure for C175 Exhaust Bellows {1059, 1061} Caterpillar

Locomotive Engine

C175-16 (S/N: 3A91-UP; Y3A1-UP; KWT1-UP; R1X1-UP)

Off Highway Truck

793F (S/N: SND1-UP; SSP1-UP; RBT1-UP)

793F AC (S/N: EMD1-UP)

794 AC (S/N: MN51-UP; MT51-UP)

795F (S/N: SNT1-UP)

795F AC (S/N: ERM1-UP)

797F (S/N: LAJ1-UP; WSP1-UP)

Introduction

The following Special Instruction covers the inspection and installation of 437-3038 Exhaust Log Bellows, 466-4983 Bellows As, 485-3800 Bellows As, and 443-5940 Turbine Inlet Bellows on C175 Engines.

Do not perform any procedures listed in this Special Instruction until you have read and understood the information.

Required Tooling

Pre-Installation Inspection

Show/hide table

Illustration 1	g03701901

1. Inspect for a minimum of 2.5 mm (0.10 inch) ribbon of bellows material concentric around the flange.
   Show/hide table

   Illustration 2	g03701966
   (1) Measurement Locations

   Show/hide table

   Illustration 3	g03703303
   (2) Liner is Not Seated Properly

2. Measure four locations around the flange of the bellow (no more than 1 mm (0.040 inch) delta between measurements allowed) to verify correct liner seating. If the liner is not straight or if the liner is loose, the bellows should be discarded.

Bellows Installation

Use only 437-3038 Log Bellows, 466-4983 Bellows As, 485-3800 Bellows As, 442-5766 V Band Clamps, and 467-4241 Band Clamp with 463-4043 Compression Tool.

Use only 443-5940 Turbine Inlet Bellows and 446-1290 V Band Clamps with 452-6804 Compression Tool.

Show/hide table

Illustration 4	g03360580

Show/hide table

Illustration 5	g03360680

Show/hide table

Illustration 6	g03703335
Incorrect Condition - Liners touching during compression. If this occurs, discard the bellows.

Show/hide table

Illustration 7	g03703531

1. Use compression tools as mentioned above to compress bellows for install. If there is a popping noise during compression or if the liners contact each other, discard the bellow.
   Show/hide table

   Illustration 8	g03703696

2. Install bellows onto the engine ensuring proper seating of shim rings under the clamps. Proper installation is critical to prevent premature bellows failure.
   Show/hide table

   Illustration 9	g03703573
   Incorrect Shim Ring and Clamp Installation.

   Show/hide table

   Illustration 10	g03703645
   Incorrect Clamp Installation.

3. If the clamp is not properly seated and you cannot start the nut, refer to the following suggestions:

   • Check the shim alignment (Is there a gap? Are shims outside the clamp?).

   • Check legs of the clamp (are legs of the clamp on top of a shim ring).

   • Check if the clamp is fully seated on the manifold and on shim rings.
   Show/hide table

   Illustration 11	g03703672

   Show/hide table

   Illustration 12	g03703674

4. If the clamp is properly seated, the threads of the t-bolt are available to start the nut. Torque the nut to 17 N·m (12.5 lb ft), tap around clamp, torque nut again to 17 N·m (12.5 lb ft), tap around clamp, and torque nut to 17 N·m (12.5 lb ft).

Post Installation Inspection

1. Inspect again all clamps to ensure proper seating of shim rings and uniform tightening.