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797F Tier 4 Off-Highway Truck Field Assembly Caterpillar


Engine Aftertreatment System - Install

Usage:

797F LTZ
Reference: Special Instruction, "Visual Service Procedures - Colors and Symbols"M0066576

Parts and Specification Information

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NOTICE

This machine is equipped with a Tier 4 Certified Engine system that is configured to meet the emissions requirements mandated by the US Environmental Protection Agency (EPA). Care must be taken to comply with all instructions within this document to ensure that the engine as assembled (including the exhaust piping, DEF Fluid lines and controls) performs as designed in order to meet and maintain Tier 4 emissions requirements.

Note: Verify that all parts are shipped and undamaged for preparation of assembly. Missing or damaged parts can be ordered prior to assembly to avoid delays during assembly.

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Table 1
Item  Part Number  Part Description  Qty  Specification  Approximate Weight 
462-7605 Truck Installation Ar, 439-2114 Exhaust Pipe Gp 
1  490-0337  Clean Emissions Module Ar  1    884.5 kg (1950 lb) 
2  8T-0649  Bolt  32     
3  267-8821  Washer  32     
4  471-8191  Tube As  1     
5  471-8188  Tube As  1     
6  422-0218  Exhaust Gasket  2     
7  8T-4185  Bolt  24     
8  8T-4121  Hard Washer  48     
9  344-5675  Nut  24     
10  474-2504  Bracket As  2     
11  142-4229  Clamp  4     
12  8T-4184  Bolt  4     
13  5P-1076  Hard Washer  8     
14  329-3356  Nut  4     
15  8T-4224  Hard Washer  6     
16  7X-2539  Bolt  6     
17  479-2172  Bolt As  1     
18  8T-1899  Clip  1     
19  6V-7359  Grommet  1     
20  8T-1900  Clip  1     
21  504-6762  Elbow  1     
22  504-6761  Elbow  1     
23  134-5641  Gasket  2     
24  268-4770  Bolt  16     
25  149-4741  Washer  16     
26  149-0206  Hex Nut  16     
27  474-1056  Bracket As  2     
28  517-2006  Bracket  1     
28A  517-2005  Bracket  1     
29  517-2007  Clamp Bracket As  2     
30  457-6133  Clamp  4     
31  6V-7687  Locknut  4     
32  8T-4223  Hard Washer  8     
33  8T-4196  Bolt  32     
34  7X-7729  Washer  40     
35  359-9373  Spacer  4     
36  8T-4176  Bolt  4     
37  8T-4195  Bolt  8     
38  516-9917  Bracket As  1     
39  529-8617  Tube As  2     
40  517-4561  Ring As  8     
41  524-8983  Bellows As  4     
42  448-0509  Band Clamp  4  TIGHTEN TO 55 ± 5 N·m (41 ± 4 lb ft) TAP 3X AND TIGHTEN TO 55 ± 5 N·m (41 ± 4 lb ft)   
43  541-9385  Heat Shield As  1     
44  541-9387  Heat Shield As  1     
45  541-9384  Heat Shield As  1     
46  541-9386  Heat Shield As  1     
47  158-2317  Elbow  2     
47A  517-3642  Exhaust Pipe As  2     
48  267-8821  Washer  8     
49  7X-2553  Bolts  8     
50  198-4778  Hard Washer  8     
51  8T-4194  Bolt  8     
52  155-3567  Piston  2     
53  155-3569  Seal Ring  2     
54  155-3566  Elbow  2     
55  538-9577  Spring  2     
56           
57  6V-1820  Bolt  6     
58  6V-5839  Washer  6     
59  8X-3253  Lock  3     
60  -  -  -     
61  474-2507  Plate As  1    172 kg (379 lb) 
62  267-8821  Washer  16  Lubricate with Tooling (T2) prior to assembly   
63  8T-0649  Bolt  8  Lubricate with Tooling (T2) prior to assembly   
64  8T-4132  Nut  8     
65  350-1640  Plate  4     
66  350-3030  Plate  1     
67  9X-8257  Washer  2     
68  7X-2553  Bolt  2     
69  267-8821  Washer  11  Lubricate with Tooling (T2) prior to assembly   
70  8T-4193  Bolt  11  Lubricate with Tooling (T2) prior to assembly   
71  469-4243  Plate As  2     
72  474-6611  Plate As  1     
73  470-3105  Plate As  1     
74  488-3974  Bolt As  14     
75  468-9981  Support As  1     
76  470-3095  Plate As  1     
77  470-3093  Plate  1     
78  488-3974  Bolt As  22     
79  467-9960  Handrail As  1     
80  467-9959  Post As  1     
81  469-0361  Handrail As  1     
82  479-2171  Bolt As  10     
83  8T-4223  Hard Washer  4     
84  8T-4184  Bolt  4     
85  8T-4121  Hard Washer  2     
86  8T-4186  Bolt  2     
87  479-2172  Bolt As  2     
88  523-6520  Diesel Exhaust Fluid Module Ar  1    653 kg (1440 lb) 
89  511-0198  Bar  4     
90  267-3507  Hard Washer  4     
91  8T-6380  Bolt  4     
92  469-0423  Plate As  1     
93  135-8577  Bolt As  2     
94  479-2172  Bolt As  18     
95  438-1633  Plate As  3     
96  424-2323  Block  18     
97  424-2320  Block  3     
98  424-2315  Block  6     
99  424-2329  Block  3     
100  438-1631  Plate As  3     
101  424-2352  Plate  3     
102  6D-4247  Clip  2     
103  8T-4121  Hard Washer  2     
104  8T-4133  Nut  1     
105  5P-7467  Clip  1     
106  5P-7466  Clip  1     
107  5P-8112  Grommet  1     
108  507-3809  Plate  1     
109  2G-8767  Washer  2     
110  6G-2256  Clamp  1     
111  309-1905  Taperlock Stud  2     
112  344-5675  Nut  2     
113  204-8000  Cable Tie Mounting  2     
114  122-0450  Grommet  2     
115  204-2281  Cable Strap  2     
116  7K-1181  Cable Strap  8     
117  465-1734  Access Cover Gp  1     
118  8T-4223  Hard Washer  4     
119  8T-4179  Bolt  4     
120  459-9296  Receiver  1     
121  2P-1293  Locknut  1     
122  462-2891  Element  1     
123  4H-2558  Grommet  1     
124  465-9464  Engine Harness As  1     
125  204-8000  Cable Tie Mounting  10     
126  204-2281  Cable Strap  13     
127  479-2171  Bolt As  5     
128  475-9989  Hose As  1     
129  5P-7854  Clip  3     
130  8T-4121  Hard Washer  5     
131  8T-4185  Bolt  1     
132  133-6934  Spacer  1     
133  479-2172  Bolt As  2     
134  459-4032  Bracket  1     
135  8T-4136  Bolt  1     
136  344-5675  Nut  1     
137  483-4287  Plate  2     
138  8T-4137  Bolt  1     
139  8T-4196  Bolt  1     
140  7X-7729  Washer  2     
141  8T-6685  Bolt  2     
142  8P-0056  Sleeve  2     
143  475-9986  Cover  1     

Installation Procedure

Start By:

  1. Install the Right - Hand platform

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.

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------ WARNING! ------

Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

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------ WARNING! ------

Personal injury or death can occur from heavy components falling during removal or installation.

Properly support the component with a suitable lifting device during removal or installation.

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------ WARNING! ------

Personal injury or death can result from improper lifting or blocking.

When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.

Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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------ WARNING! ------

Do not attempt to assemble this machine until you read and you understand the assembly instructions.

Improper assembly procedures could result in injury or death.

Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting"
topic for safety information.

Note: Remove all protective shipping covers, flanges, plugs, caps, clamps, cable straps, and material.

Note: Clean mounting and contact surfaces for major component installation free of wax, dirt, debris, paint, and grease.

Note: If necessary, chase unprotected threaded holes with an appropriately sized tap to remove paint, rust, or other debris.

Note: Unless otherwise specified, all torque requirements are Standard Torque values. Refer to the "General Information" section in this document for the correct torque values.

Note: Before tightening the cable straps (mounting hardware), remove the slack from the harness assemblies and allow adequate strain relief.

Note: Any tooling that is used for lifting the machine or for securing the machine in the raised position should be used on a concrete surface capable of supporting the weight of the machine.

Clean Exhaust Module (CEM) Install

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    Illustration 1g06192063
    Band Joint Check
    Typical Example

  1. Prior to installing the clean exhaust module (CEM), check the bellows Band joints of the flex pipe sections for proper engagement and correct parts. Mark the corresponding parts for ease of installation. Measure the Band joint engagement and record the measurement as Dimension (X). Ensure that the outer Band joint profile engages the inner Band joint profile to Dimension (X), circumferentially, while installing the Band clamps.
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    Illustration 2g06335988
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    Illustration 3g06028462
    (1) 490-0337 Clean Emissions Module Ar
    (7) 8T-4185 Bolt
    (6) 422-0218 Gasket
    (5) 471-8188 Tube As
    (4) 471-8191 Tube As
    (9) 344-5675 Nut
    (8) 8T-4121 Hard Washer

    Note: Install all mounting hardware loosely (hand tight) until the flex pipe alignments are made.

  2. Install one gasket (6) onto one tube assembly (5). If necessary, use one or two of bolts (7) to keep gasket (6) in place and prevent tube assembly (5) from falling. Use two people to position one tube assembly (5) onto the forward leg of exhaust module (1) "Aftertreatment 1". The weight of tube assembly (5) is approximately 33 kg (73 lb). Position one gasket (6) while installing twenty-four hard washers (8), twelve bolts (7), and twelve nuts (9).

    Note: Use the locating dowel to index the exhaust elbows to the correct orientation.

    Note: Install the fastening hardware immediately so that tube assembly (5) cannot fall.

  3. Install one gasket (6) onto one tube assembly (4). If necessary, use one or two of bolts (7) to keep gasket (6) in place and prevent tube assembly (4) from falling. Use two people to position one tube assembly (4) onto the rear leg of exhaust module (1) "Aftertreatment 2". The weight of tube assembly (4) is approximately 33 kg (73 lb). Position one gasket (6) while installing twenty-four hard washers (8), twelve bolts (7), and twelve nuts (9).

    Note: Use the locating dowel to index the exhaust elbows to the correct orientation.

    Note: Install the fastening hardware immediately so that tube assembly (4) cannot fall.

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    Illustration 4g06337897
    (7) 8T-4185 Bolt
    (9) 344-5675 Nut

  4. Tighten twenty-four bolts (7) and twenty-four nuts (9) to a final torque.
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    Illustration 5g06363679
    (A) 8T-4908 Bolt
    (B) 198-4776 Hard Washer
    (C) 483-7626 Plate As

  5. Remove sixteen bolts (A), sixteen washers (B), and four plate assemblies (C). Retain the hardware.
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    Illustration 6g06338342
    (10) 474-2504 Bracket As
    (11) 142-4229 Clamp
    (12) 8T-4184 Bolt
    (13) 5P-1076 Hard Washer
    (14) 329-3356 Nut

  6. Insert two bracket assemblies (10), four clamps (11), eight washers (13), four bolts (12), and four nuts (14), Tighten the hardware loosely.
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    Illustration 7g06339718

  7. Loosen bolts (D) and clips (E) for the DEF lines mounting hardware at ten locations.

    Note: The clips and injectors are identified with color coded cable straps which correspond to color coded tape on the def hoses. Do not remove the color coded cable straps until instructed.

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    Illustration 8g06339719

  8. Loosen bolts (F) and clips (G) for the DEF lines mounting hardware at five locations. Loosen nuts (H) and clips (J) for the DEF lines mounting hardware at two locations.

    Note: The clips and injectors are identified with color coded cable straps which correspond to color coded tape on the def hoses. Do not remove the color coded cable straps until instructed.

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    Illustration 9g06336019

  9. Loosen bolts (K), plate (L), blocks (M), clips (N), bolt (P), and clip (R) for the DEF lines mounting hardware.

    Note: The clips and injectors are identified with color coded cable straps which correspond to color coded tape on the def hoses. Do not remove the color coded cable straps until instructed.

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    Illustration 10g06192406
    Lifting Bracket Locations
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    Illustration 11g06336847
    (1) 490-0337 Clean Emissions Module Ar
    (2) 8T-0649 Bolt
    (3) 267-8821 Washer
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    Illustration 12g06192527
    Platform Mounting Locations
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    Illustration 13g06192480
    Platform and Mounting Bracket Alignment

  10. Use a suitable lifting device to position and lower clean emissions module (1) onto the right hand platform. The weight of emissions module (1) is approximately 884 kg (1950lb). Align thirtytwo mounting holes in the platform with thirtytwo mounting holes on the CEM unit mounting bracket. Install thirtytwo washers (3) and thirtytwo bolts (2).

    Note: For alignment purposes, it may be necessary to make adjustments to the exhaust module mounting brackets.

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    Illustration 14g06337271
    (S) 497-9308 Hose As
    (T) 497-9306 Hose As
    (V) 497-9307 Hose As
    (W) 497-9305 Hose As
    (15) 8T-4224 Hard Washer
    (16) 7X-2539 Bolt
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    Illustration 15g06337301
    Detail A
    (T) 497-9306 Hose As
    (W) 497-9305 Hose As
    (15) 8T-4224 Hard Washer
    (16) 7X-2538 Bolt
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    Illustration 16g06337303
    Detail B
    (S) 497-9308 Hose As
    (V) 497-9307 Hose As
    (15) 8T-4224 Hard Washer
    (16) 7X-2538 Bolt

  11. Position hose assembly (S), hose assembly (V), hose assembly (T), and hose assembly (W). Install six hard washers (15) and six bolts (16).
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    Illustration 17g06339741
    Injectors
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    Illustration 18g06339750
    Components removed for clarity
    (A1) Injector
    (B1) Injector
    (C1) Injector
    (D1) Injector
    (S) 497-9308 Hose As (RED)
    (T) 497-9306 Hose As (GREEN)

  12. Remove and discard the protective caps from the injectors. Remove and discard the protective plugs from the def hoses. Route hose assemblies (S) and hose assemblies (T) through clips (E) and clips (G). Connect hose assembly (S)"(RED)" to injector (A1) and Injector (B1) on the rear-leg of the exhaust module "Aftertreatment 2". Route and connect hose assembly (T)"(GREEN)" to injector (C1) and Injector (D1) on the front-leg of the exhaust module "Aftertreatment 1".

    Note: Remove and discard the color coded cable straps.

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    Illustration 19g06339754
    Injectors
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    Illustration 20g06339758
    Components removed for clarity
    (E1) Injector
    (F1) Injector
    (G1) Injector
    (H1) Injector
    (V) 497-9307 Hose As (YELLOW)
    (W) 497-9305 Hose As (BLUE)

  13. Remove and discard the protective caps from the injectors. Remove and discard the protective plugs from the def hoses. Route hose assemblies (V) and hose assemblies (W) through clips (E) and clips (G). Connect hose assembly (V)"(YELLOW)" to injector (E1) and Injector (F1) on the rear-leg of the exhaust module "Aftertreatment 2". Route and connect hose assembly (W)"(BLUE)" to injector (G1) and Injector (H1) on the front-leg of the exhaust module "Aftertreatment 1".

    Note: Remove and discard the color coded cable straps.

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    Illustration 21g06036548
    Components removed for clarity
    (4A) 365-0268 Bulk Insulation
    (AA) Insulation Section
    (BA) Insulation Section
    (CA) Insulation Section
    (DA) Insulation Section
    (EA) Insulation Section
    (FA) Insulation Section
    (GA) Insulation Section
    (HA) Insulation Section
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    Illustration 22g06339763
    Components removed for clarity
    (S) "RED" 497-9308 Hose As
    (T) "GREEN" 497-9306 Hose As
    (V) "YELLOW" 497-9307 Hose As
    (W) "BLUE" 497-9305 Hose As

  14. Cut eight sections of insulation (4A) to the following lengths.

    • (AA) 541 ± 3 mm (21 ± 0.1 inch)

    • (BA) 541 ± 3 mm (21 ± 0.1 inch)

    • (CA) 541 ± 3 mm (21 ± 0.1 inch)

    • (DA) 541 ± 3 mm (21 ± 0.1 inch)

    • (EA) 318 ± 3 mm (13 ± 0.1 inch)

    • (FA) 318 ± 3 mm (13 ± 0.1 inch)

    • (GA) 318 ± 3 mm (13 ± 0.1 inch)

    • (HA) 318 ± 3 mm (13 ± 0.1 inch)

    1. Assemble insulation sections (AA) and (BA) onto hose assembly (S).

    2. Assemble insulation sections (CA) and (DA) onto hose assembly (T).

    3. Assemble insulation sections (EA) and (FA) onto hose assembly (V).

    4. Assemble insulation sections (GA) and (HA) onto hose assembly (W).
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    Illustration 23g06339768

  15. Tighten ten bolts (D).
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    Illustration 24g06339774

  16. Tighten five bolts (F). Tighten two nuts (H).
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    Illustration 25g06336952

  17. Tighten four bolts (K). Tighten bolt (P).
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    Illustration 26g06339781
    (A) 8T-4908 Bolt
    (B) 198-4776 Hard Washer
    (C) 483-7626 Plate As

  18. Install four plate assemblies (C), sixteen washers (B), and sixteen bolts (A).
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    Illustration 27g06339783

  19. Loosen four bolts (X).
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    Illustration 28g06339787
    (J1) Coolant Port
    (K1) Coolant Port
    (Y) 559-9276 Hose As
    (Z) 507-3832 Hose As

  20. Route hose assembly (Y) and hose assembly (Z).

  21. Connect hose assembly (Y) to the coolant port indicated with an (J1). Connect hose assembly (Z) to the coolant port indicated with a (K1).

    Note: Ensure that the O-ring seals remain on the elbow connectors.

  22. Tighten four bolts (X).
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    Illustration 29g06336960
    (L1) 31 Pin
    (M1) 23 Pin
    (N1) 31 Pin
    (P1) 23 Pin
    (AA) 507-8585 Harness Assembly
    (AB) 511-9872 Harness Assembly
    (17) 479-2172 Bolt
    (18) 8T-1899 Clip
    (19) 6V-7359 Grommet
    (20) 8T-1900 Clip

  23. Route harness assembly (AB). Connect (L1) connector of harness assembly (AA) to (N1) connector of harness assembly (AB). Connect (P1) connector of harness assembly (AA) to (M1) connector of harness assembly (AB). Install grommet (19), clip (18), and clip (20), and bolt assembly (17).
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    Illustration 30g06337327
    (21) 504-6762 Elbow
    (22) 504-6761 Elbow
    (23) 134-5641 Gasket
    (24) 268-4770 Bolt
    (25) 149-4741 Hard Washer
    (26) 149-0206 Hex Nut

  24. Install two gaskets (23), elbow (21), elbow (22), sixteen hard washers (25), sixteen bolts (24), and sixteen nuts (26).

Flex Pipe Install

Note: Unless otherwise specified, assemble all components loosely (hand-tight) until the flex pipe alignments are made. Once the flex pipe alignments are made, tighten all hardware to standard torque values.

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    Illustration 31g06339849
    Bracket Sub-Assembly (AC)
    ( 27) 474-1056 Bracket As
    (28) 517-2006 Bracket Front Exhaust Leg
    (28A) 517-2005 Bracket Rear Exhaust Leg
    (29) 517-2007 Clamp Bracket As
    (30) 457-6133 Clamp
    (31) 6V-7687 Locknut
    (32) 8T-4223 Hard Washer
    (33) 8T-4196 Bolt
    (34) 7X-7729 Washer
    (35) 359-9373 Spacer
    (36) 8T-4176 Bolt
    (37) 8T-4195 Bolt

  1. Loosely assemble bracket assembly (AC). Repeat this step for the remaining bracket.
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    Illustration 32g06337325
    Bracket Sub-Assembly (AC)
    ( AC) Bracket Sub-Assembly
    (38) 516-9917 Bracket As
    (33) 8T-4196 Bolt
    (34) 7X-7729 Washer
    (38) 516-9917 Bracket As

  2. Install top bracket assembly (38), two bracket sub-assemblies (AC), twentyfour washers (34), and twentyfour bolts (33). Install the hardware loosely.
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    Illustration 33g06337836

  3. Position four clamps (30) out of the way.
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    Illustration 34g06337443
    (39) 529-8617 Tube As
    (1A) Band Clamp
    (41) 524-8983 Bellows As

  4. Insert tube assembly (39) into bellows assembly (41). Tighten band clamp (1A) loosely. Repeat this step for the remaining tube assembly (39) and bellows assembly (41).
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    Illustration 35g06337428
    Front Exhaust Leg
    (1A) Band Clamp
    (41) 524-8983 Bellows As
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    Illustration 36g06339991
    Slip Joint - Upper Front
    (R1) Ink Line
    (D1) 54.5 ± 15 mm (2.2 ± 0.6 inch)

  5. Insert bellows (41) to Dimension (D1).

    Note: Proper engagement of the slip joint is verified when the ink line (R1) on the slip joint inner tube is no longer visible.

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    Illustration 37g06337439
    Front Exhaust Leg
    (1A) Band Clamp
    (42) 448-0509 Band Clamp

  6. Install two band clamps (42) and tube and bellows sub-assembly (AD) onto the manifold. Hold tube assembly and bellows sub-assembly (AD) in position. The slip joint should slide smoothly with a minimum engagement of 40 mm (1.6 inch).

  7. Proper engagement of the slip joint is verified when the ink line on the slip joint inner tube is no longer visible.

    Note: 3 degree spherical rotation capable.

  8. Tighten two band clamps (42) to a torque of 55 ± 5 N·m (41 ± 4 lb ft) with a maximum wrench speed of 75 RPM. Strike the Band clamp at the fastener three times with a soft faced mallet to seat the clamp. The strike direction should be radial to the tube. If a hard faced mallet is used, strike a piece of wood instead of directly on the Band clamp. The force of each strike is approximately the same as the force required to drive a nail into soft wood. Tighten four band clamps, again, to a torque of 55 ± 5 N·m (41 ± 4 lb ft) with a maximum wrench speed of 75 RPM.
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    Illustration 38g06339972
    Band Clamp Installation - Typical Example
    (S1) Indicator Feature
    (T1) Indicator Feature
    (42) 448-0509 Band Clamp (Ball)
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    Illustration 39g06339980
    Band Clamp Installation - Typical Example
    (D4) Dimension
    (D5) Dimension
    (V1) Cup
    (W1) Radius
    (42) 448-0509 Clamp (Band)

  9. Verify that the cup of the Ball joint (V1) does not touch the radius of the Ball (W1). Refer to Step 1 for the correct Band joint engagement.

  10. Band clamps (42) are to be located between the indicator features (S1) and (T1) after final assembly. Position Band clamp (42) and loosely tighten Band clamp (42). Verify that the Band clamp is centered between the indicator features. Measure from the edge of the Band clamp to the indicator feature on each side. Record the measurements as Dimension (D4) and Dimension (D5). The difference between Dimension (D4) and Dimension (D5) cannot exceed 2 mm (0.08 inch).

  11. Reverify the engagement of the slip joint. Ensure that the ink line on the slip joint inner tube is not visible and the band clamps cover the slots completely.

  12. Tighten band clamp (1A) to a torque of 45 ± 5 N·m (33 ± 4 lb ft) with a maximum wrench speed of 75 RPM.

  13. Tighten the front clamp bracket to the front bracket. Tighten the front bracket to the top bracket.

    Note: The top bracket will remain loose at this time.

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    Illustration 40g06337722
    Rear Exhaust Leg
    (1A) Band Clamp
    (41) 524-8983 Bellows As
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    Illustration 41g06338146
    Slip Joint - Upper Rear
    (R1) Ink Line
    (D2) 57 ± 5 mm (2.2 ± 0.2 inch)

  14. Insert bellows (41) to Dimension (D2).

    Note: Proper engagement of the slip joint is verified when the ink line (R1) on the slip joint inner tube is no longer visible.

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    Illustration 42g06337728
    Rear Exhaust Leg
    (1A) Band Clamp
    (42) 448-0509 Band Clamp

  15. Install two band clamps (42) and tube and bellows sub-assembly (AD) onto the manifold. Hold tube assembly and bellows sub-assembly (AD) in position. The slip joint should slide smoothly with a minimum engagement of 40 mm (1.6 inch).

    Note: Proper engagement of the slip joint is verified when the ink line on the slip joint inner tube is no longer visible.

    Note: 3 degree spherical rotation capable.

  16. Tighten two band clamps (42) to a torque of 55 ± 5 N·m (41 ± 4 lb ft) with a maximum wrench speed of 75 RPM. Strike the Band clamp at the fastener three times with a soft faced mallet to seat the clamp. The strike direction should be radial to the tube. If a hard faced mallet is used, strike a piece of wood instead of directly on the Band clamp. The force of each strike is approximately the same as the force required to drive a nail into soft wood. Tighten four band clamps, again, to a torque of 55 ± 5 N·m (41 ± 4 lb ft) with a maximum wrench speed of 75 RPM.
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    Illustration 43g06339972
    Band Clamp Installation - Typical Example
    (S1) Indicator Feature
    (T1) Indicator Feature
    (42) 448-0509 Band Clamp (Ball)
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    Illustration 44g06339980
    Band Clamp Installation - Typical Example
    (D4) Dimension
    (D5) Dimension
    (V1) Cup
    (W1) Radius
    (42) 448-0509 Clamp (Band)

  17. Verify that the cup of the ball joint (V1) does not touch the radius of the ball (W1). Refer to Step 1 for the correct Band joint engagement.

  18. Band clamps (42) are to be located between the indicator features (S1) and (T1) after final assembly. Position Band clamp (42) and loosely tighten band clamp (42). Verify that the Band clamp is centered between the indicator features. Measure from the edge of the Band clamp to the indicator feature on each side. Record the measurements as Dimension (D4) and Dimension (D5). The difference between Dimension (D4) and Dimension (D5) cannot exceed 2 mm (0.08 inch).

  19. Reverify the engagement of the slip joint. Ensure that the ink line on the slip joint inner tube is not visible and the band clamps cover the slots completely.

  20. Tighten band clamp (1A) to a torque of 45 ± 5 N·m (33 ± 4 lb ft) with a maximum wrench speed of 75 RPM.
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    Illustration 45g06337853

  21. Position four clamps (30) and tighten the hardware.

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    NOTICE

    Do not step or stand on the assembled flex pipe.

  22. Once the flex pipe adjustment and alignment is made, tighten all mounting hardware to the final torque values.

  23. Tighten the rear clamp bracket to the rear side bracket. Tighten the rear side bracket to the rear bracket. Tighten the rear bracket to the top bracket. Tighten the top bracket to the frame.

  24. Remove the bellows alignment and protective packaging form both exhaust lags by cutting the straps.
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    Illustration 46g06337890
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    Illustration 47g06337901
    (40) 517-4561 Ring As
    (43) 541-9385 Heat Shield As
    (44) 541-9387 Heat Shield As
    (45) 541-9384 Heat Shield As
    (46) 541-9386 Heat Shield As

  25. Install eight ring assemblies (40) on each side of the bellows assemblies. Install heat shield (43), (44), (45), and (46).

    Note: Orientate the seams to the inside bracket.

Exhaust Install - 439-2114 Heated Truck Body

  1. The following procedure should be performed with the truck body installed.
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    Illustration 48g06338359
    (47) 158-2317 Elbow
    (48) 267-8821 Washer
    (49) 7X-2553 Bolt
    (50) 198-4778 Hard Washer
    (51) 8T-4194 Bolt
    (12) 8T-4184 Bolt
    (14) 329-3356 Nut

  2. Install two elbows (47), eight washers (48), and eight bolts (49). Install eight washers (50) and eight bolts (51). Tighten four bolts (12) and four nuts (14).
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    Illustration 49g06340237
    (52) 155-3567 Piston
    (53) 155-3569 Seal Ring

  3. Install ring (53) onto piston (52).
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    Illustration 50g06340239
    (54) 155-3566 Elbow
    (55) 538-9577 Spring
    (56) Piston Assembly

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    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.

  4. Install spring (55) and elbow (54) onto piston assembly (56).
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    Illustration 51g06359045
    Exhaust Elbow Sub-Assembly (AE)
    ( 57) 6V-1820 Bolt
    (58) 6V-5839 Washer
    (59) 8X-3253 Lock

  5. Install three locks (59), six washers (58), and six bolts (57). Repeat Step 3 through Step 5 for the remaining piston and elbow.

    Note: Position lock (59) to the outside of the piston.

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    Illustration 52g06338388
    (AE) Exhaust Elbow Sub-Assembly
    (61) 474-2507 Plate As
    (62) 267-8821 Washer
    (63) 8T-0649 Bolt
    (64) 8T-4132 Nut
    (65) 350-1640 Plate

  6. Lubricate with Tooling (T2) the face of hard washers (69) and the threads of bolts (70) prior to assembly. Install two exhaust elbow sub-assemblies (AE), four plates (65), plate assembly (61), sixteen washers (62), eight bolts (63), eight nuts (64).

  7. Clean the contact surfaces free of wax, dirt, debris, paint, and grease.
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    Illustration 53g06338405
    Truck Body
    (66) 350-3030 Plate
    (67) 9X-8257 Washer
    (68) 7X-2553 Bolt
    (69) 267-8821 Washer
    (70) 8T-4193 Bolt
    (AF) Exhaust Elbow Sub-Assembly

  8. Lubricate with Tooling (T2) the face of hard washers (69) and the threads of bolts (70) prior to assembly. Install plate (66), two washers (67) , and two bolts (68). Use Tooling (T1) and a suitable lifting device to install exhaust elbow subassembly (AF).The weight of exhaust elbow subassembly (AF) is approximately 328 kg (723 lb). Install eleven washers (69) and eleven bolts (70).

Adjustment Procedure

Note: The truck body and canopy must be installed to adjust the compression of the piston spring on the exhaust elbows. Refer to the truck body and canopy installation procedure in this document.

  1. Perform the following step after the truck body and canopy has been installed.
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      Illustration 54g06338422
      Body Down Position

    1. With the truck body in the DOWN position, install or remove plates (65) as needed to achieve an 150 ± 10 mm (6 ± 0.4 inch) Dimension (D3) compressed length of the piston spring (55).

Exhaust Install - 439-2113 Extension

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    Illustration 55g06358150
    (47A) 517-3642 Exhaust Pipe As
    (48) 267-8821 Washer
    (49) 7X-2553 Bolt
    (50) 198-4778 Hard Washer
    (51) 8T-4194 Bolt
    (12) 8T-4184 Bolt
    (14) 329-3356 Nut

  1. Install two exhaust pipe assemblies (47A), eight washers (48), and eight bolts (49). Install eight washers (50) and eight bolts (51). Tighten four bolts (12) and four nuts (14).

Handrail Install

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    Illustration 56g06339110
    (71) 469-4243 Plate As
    (72) 474-6611 Plate As
    (73) 470-3105 Plate As
    (74) 488-3974 Bolt As

  1. Install two plate assemblies (71), plate assembly (72), plate assembly (73), and fourteen bolt assemblies (74).
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    Illustration 57g06339193
    (75) 468-9981 Support As
    (76) 470-3095 Plate As
    (77) 470-3093 Plate
    (78) 488-3974 Bolt As

  2. Install support assembly (75), plate assembly (76), plate (77), and twentytwo bolt assemblies (78).
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    Illustration 58g06339219
    (79) 467-9960 Handrail As
    (80) 467-9959 Post As
    (81) 469-0361 Handrail As
    (82) 479-2171 Bolt As
    (83) 8T-4223 Hard Washer
    (84) 8T-4184 Bolt
    (85) 8T-4121 Hard Washer
    (86) 8T-4186 Bolt
    (87) 479-2172 Bolt As

  3. Install handrail assembly (79), post assembly (80), handrail assembly (81), ten bolt assemblies (82), four washers (83), four bolt (84), two washer (85), two bolts (86), and two bolt assemblies (87).

Module Arrangement (DEF) Install

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    Illustration 59g06340417
    (88) 523-6520 Diesel Exhaust Fluid Module Ar
    (AG) 497-9315 Cover
    (AH) 497-9313 Cover
    (AJ) 497-9311 Front Cover As
    (AK) 8T-4136 Bolt
    (AL) 7X-7729 Washer

  1. Remove and keep fortyeight bolts (AK) fortyeight washers (AL), front cover assembly (AJ), top cover assembly (AH), and cover (AG) from diesel exhaust fluid module arrangement (88).
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    Illustration 60g06340463
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    Illustration 61g06340483
    (88) 523-6520 Diesel Exhaust Fluid Module Ar
    (89) 511-0198 Bar
    (90) 267-3507 Hard Washer
    (91) 8T-6380 Bolt

  2. Use a suitable lifting device to position module arrangement (88) onto the fuel tank. The weight of module arrangement (88) is approximately 653 kg (1440 lb). Install four bars (89), four washers (90), and four bolts (91).
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    Illustration 62g06339365
    (92) 469-0423 Plate As
    (93) 135-8577 Bolt As

  3. Install plate assembly (92) and two bolts (93).
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    Illustration 63g06339381
    (94) 479-2172 Bolt As
    (95) 438-1633 Plate As
    (96) 424-2323 Block
    (97) 424-2320 Block
    (98) 424-2315 Block
    (99) 424-2329 Block
    (100) 438-1631 Plate As

  4. Assemble block (99), two blocks (98), two blocks (96), and block (97) onto plate assembly (100). Install plate assembly (95), and two bolts (94). Install the hardware loosely.
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    Illustration 64g06339383
    (AM) Bracket Sub-Assembly
    (94) 479-2172 Bolt As
    (96) 424-2323 Block
    (101) 424-2352 Plate

  5. Install four blocks (96) onto bracket sub-assembly (AM). Install plate (101) and two bolts (94). Install the hardware loosely.
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    Illustration 65g06339389
    (94) 479-2172 Bolt As
    (AM) Bracket Sub-Assembly

  6. Install three bracket sub-assemblies (AM) and twelve bolts (94).
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    Illustration 66g06339669
    Components removed for clarity
    (S) "RED" 497-9308 Hose As
    (T) "GREEN" 497-9306 Hose As
    (V) "YELLOW" 497-9307 Hose As
    (W) "BLUE" 497-9305 Hose As
    (AV) 508-8582 Clean Emissions Module Harness As
    (AN) 508-8583 Cable As
    (AP) 508-8584 Cable As
    (AR) 470-1680 Hose As
    (AS) 470-1679 Hose As
    (AT) 166-6127 Hydraulic Hose

  7. Route harness assembly (AV), cable assembly (AN), cable assembly (AP), hose assembly (AR), hose assembly (AS), and hose (AT) through three mounting bracket sub-assemblies (AM) and tighten the hardware.
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    Illustration 67g06340592
    (94) 479-2172 Bolt As
    (102) 6D-4247 Clip
    (103) 8T-4121 Hard Washer
    (104) 8T-4133 Nut
    (105) 5P-7467 Clip
    (106) 5P-7466 Clip
    (107) 5P-8112 Grommet
    (108) 507-3809 Plate
    (109) 2G-8767 Washer
    (110) 6G-2256 Clamp
    (111) 309-1905 Taperlock Stud
    (112) 344-5675 Nuts

  8. Install taperlock stud (111), two washers (109), clamp (110), clip (105), clip (106), grommet (107), plate (108), nut (112), two clips (102), bolt assembly (94), washer (103), and nut (104).
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    Illustration 68g06340628
    (AN) 508-8583 Cable As
    (AP) 508-8584 Cable As
    (103) 8T-4121 Hard Washer
    (111) 309-1905 Taperlock Stud
    (112) 344-5675 Nuts
    (113) 204-8000 Cable Tie Mounting
    (109) 2G-8767 Washer
    (110) 6G-2256 Clamp

  9. Install taperlock stud (111), two washers (109), clamp (110), two cable tie mounts (113), washer (103), and nut (112). Connect cable assembly (AN) and cable assembly (AP).
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    Illustration 69g06340658
    (AV) 508-8582 Clean Emissions Module Harness As
    (114) 122-0450 Grommet
    (115) 204-2281 Cable Strap

  10. connect harness assembly (AV). Install two grommets (114) and two cable straps (115).
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    Illustration 70g06339699
    (AR) 470-1680 Hose As
    (AS) 470-1679 Hose As
    (AT) 166-6127 Hydraulic Hose

  11. Connect hose assembly (AR), hose assembly (AS), and hose (AT).
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    Illustration 71g06340667
    (S) "RED" 497-9308 Hose As
    (T) "GREEN" 497-9306 Hose As
    (V) "YELLOW" 497-9307 Hose As
    (W) "BLUE" 497-9305 Hose As
    (116) 7K-1181 Cable Strap
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    Illustration 72g06045637
    Pump Outlet Port
    Typical Example
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    Illustration 73g06340670
    Detail C
    (X) Pump Outlet Port
    (AW) 509-1330 Harness As
    (116) 7K-1181 Cable Strap
    (S) "RED" 475-3231 Hose As
    (T) "GREEN" 475-3233 Hose As
    (V) "YELLOW" 475-3232 Hose As
    (W) "BLUE" 475-3234 Hose As

  12. Route and connect hose assembly (S), hose assembly (T), hose assembly (V), hose assembly (W) to outlet port (X) and harness assembly (AW) at four locations.

  13. Install eight cable straps (116).
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    Illustration 74g06340671
    (AX) 8T-4189 Bolt

  14. Tighten nine bolts (AX).
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    Illustration 75g06340672
    (BA) 8T-4195 Bolt

  15. Tighten bolt (BA).
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    Illustration 76g06340673
    (BB)

  16. Tighten nut (BB).

  17. Adjust the slack of the hose assemblies, harness assemblies, and cable assemblies to provide adequate strain relief then tighten the mounting hardware in Step 7 through Step 16 to a final torque value.
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    Illustration 77g06341031
    (117) 465-1734 Access Cover Gp
    (BC) 8T-4137 Bolt
    (BD) 8T-4121 Hard Washer
    (BE) 487-6632 Plate As

  18. Remove three bolts (BC), three washers (BD), and plate assembly (BE) from access cover group (117). Retain the hardware.
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    Illustration 78g06341043
    (119) 8T-4179 Bolt
    (118) 8T-4223 Hard Washer
    (117) 465-1734 Access Cover Gp

  19. Install access cover group (117), four hard washers (118), and four bolts (119).
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    Illustration 79g06341048
    (120) 459-9296 Receiver
    (121) 2P-1293 Locknut

  20. Install receiver (120) and nut (121).
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    Illustration 80g06341066
    (127) 479-2171 Bolt As
    (126) 204-2281 Cable Strap
    (125) 204-8000 Cable Tie Mounting
    (123) 4H-2558 Grommet
    (122) 462-2891 Element DEF Line Heater 1
    (124) 465-9464 Power Harness As DEF Line Heater 1

  21. Install grommet (123). Route and connect element assembly (122) to the receiver . Route and connect harness assembly (124) onto element assembly (122). Install cable tie mount (125), botl assembly (127), and cable strap (126).
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    Illustration 81g06341083
    (128) 475-9989 Hose As

  22. Install hose assembly (128) onto the receiver .
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    Illustration 82g06341084
    (BC) 8T-4137 Bolt
    (BD) 8T-4121 Hard Washer
    (BE) 487-6632 Plate As

  23. Install cover assembly (BE), three washers (BD), and three bolts (BC).
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    Illustration 83g06341098
    (128) 475-9989 Hose As
    (127) 479-2171 Bolt As
    (126) 204-2281 Cable Strap
    (125) 204-8000 Cable Tie Mounting
    (129) 5P-7854 Clip
    (130) 8T-4121 Hard Washer
    (131) 8T-4185 Bolt
    (132) 133-6934 Spacer

  24. Route harness assembly (124) and hose assembly (128). Install two cable tie mounts (125), two bolt assemblies (127), and two cable straps (126).

  25. Install spacer (132), cable tie mount (125), clip (129), washer (130), bolt (131), and cable strap (126).
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    Illustration 84g06341106
    (127) 479-2171 Bolt As
    (126) 204-2281 Cable Strap
    (125) 204-8000 Cable Tie Mounting
    (129) 5P-7854 Clip
    (130) 8T-4121 Hard Washer
    (133) 479-2172 Bolt As
    (134) 459-4032 Bracket
    (135) 8T-4136 Bolt
    (136) 344-5675 Nut

  26. Install cable tie mount (125), bolt assembly (127), and cable strap (126).

  27. Install cable tie mount (125), clip (129), bolt assembly (133), and cable strap (126).

  28. Install cable tie mount (125), bracket (134), bolt assembly (133), and cable strap (126).

  29. Install clip (129), two washers (130), bolt (135), and nut (136).
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    Illustration 85g06341126
    (BF) Aftertreatment Interface
    (BG) DEF Line Heater 3
    (BH) DEF Line Heater 2
    (124) 465-9464 Power Harness As
    (125) 204-8000 Cable Tie Mounting
    (126) 204-2281 Cable Strap
    (127) 479-2171 Bolt As
    (128) 475-9989 Hose As

  30. Connect harness assembly (124) and hose assembly (128). connect (BF), (BG), and (BH). Install cable tie mount (125), bolt assembly (127), and cable strap (126).
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    Illustration 86g06341132
    (126) 204-2281 Cable Strap
    (125) 204-8000 Cable Tie Mounting
    (130) 8T-4121 Hard Washer
    (137) 483-4287 Plate
    (138) 8T-4137 Bolt
    (139) 8T-4196 Bolt

  31. Install plate (137), cable strap (126), two cable tie mounts (125), two cable straps (126), washer (130), and bolt (139). Install cable strap (126). Install plate (137), washer (130), bolt (138), and cable strap (126).
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    Illustration 87g06341145
    (140) 7X-7729 Washer
    (141) 8T-6685 Bolt
    (142) 8P-0056 Sleeve
    (143) 475-9986 Cover

  32. Install two sleeves (142), cover (143), two washers (140), and two bolts (141).

Caterpillar Information System:

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