Usage:
3408 (48W) Machine Engines In The Machines That Follow: D9N (1JD, 6XJ),
768C (02X) Tractors;
769C (01X) Trucks;
771C (3BJ) Quarry Trucks;
589 (31Z) Pipe Layers;
PR-45C (7PJ),
PM-565 (3TK) Cold Planners;
631E (1AB, 1NB),
637E (1FB, 1JB) Tractors;
657E (6MB, 86Z, 87Z) Scrapers;
834B (92Z) Wheel Tractors;
836 (3RL) Compactors;
988B (50W),
988F (8YG) Wheel Loaders;
3412 (73W) Machine Engines In The Machines That Follow: D10N (2YD, 3SK),
772B (64W) Tractors;
773B (63W) Trucks;
775B (7XJ) Quarry Trucks;
RR-750C (7CK),
PR-1000 (5XC) Cold Planners;
651E (89Z),
657E (90Z, 91Z) Tractors;
990 (7HK),
992C (49Z),
992D (7MJ) Wheel Loaders
Reference: Service Magazine; December 24, 1990; Page 9; "Update Information For Exhaust Manifolds".
Description of Change: New exhaust manifold end sections and center sections and longer spacers are used in the exhaust manifold groups on the engines in these machines. In conjunction with this change, longer exhaust manifold mounting studs are used in the cylinder heads on these engines. The new exhaust manifold sections incorporate the following improvements:
- * A 10.5 mm (.41 in) diameter slotted hole 15.0 mm (.59 in) wide alternating from the top to bottom at each mounting flange. This provides increased mounting stud clearance with manifold thermal expansion. It also provides for improved horizontal alignment of the manifold slip joints.
- * A 15.0 mm (.59 in) diameter hole at each flange (adjacent to the slotted holes) for increased mounting stud clearance.
NOTE: Only one slotted hole at each flange is needed for alignment of the slip joint.
The longer exhaust manifold mounting studs and spacers provide increased durability and are more resistant to bending fatigue.
Adaptable To: The illustrations identify the new and former exhaust manifold sections. The former 4S-6137 Stud has been replaced by the new 100.0 mm (3.94 in) long 106-1792 Stud. The former 2S-3770 Spacer has been replaced by the new 53.0 mm (2.09 in) long 108-3612 Spacer. The chart identifies the effectivity of the new components.
Since one new manifold section replaces two former sections, some components are not direct repalcements. Using the Illustration 1 as an example: If a 9Y-1229 Manifold (1) needs to be replaced, then a 107-8106 Manifold (4) needs to be used. This would require the elimination of one of the 9Y-1230 Manifolds (2). If a 9Y-1230 Manifold (2) needs to be replaced, then a 107-8106 Manifold (4) or 107-8112 Manifold (5) needs to be used. This would require the elimination of either a 9Y-1229 Manifold (1) or 9Y-1231 Manifold.
NOTE: The following illustrations refer to left and right manifold components. The left and right sides are in regards to the engine when viewed from the flywheel housing end.
Illustration 1. (Both Left And Right Side) (A) Former Exhaust Manifold Components For 3408 (48W) Machine Engine. 8N-0990 or 9Y-1229 Manifold (1). 8N-0989 or 9Y1230 Manifold (2). 8N-0991 or 9Y-1231 Manifold (3). (B) Current Exhaust Manifold Components For 3408 (48W) Machine Engine. 107-8106 Manifold (4). 107-8112 Manifold (5).
Illustration 2. (Both Left And Right Side) (A) Former Exhaust Manifold Components For 3412 (73W) Machine Engines. 8N-0990 or 9Y-1229 Manifold (1). 8N-0989 or 9Y-1230 Manifold (2). 8N-0991 or 9Y-1231 Manifold (3). (B) Current Exhaust Manifold Components For 3412 (73W) Machine Engines. 107-8106 Manifold (4). 107-8107 Manifold (10). 107-8112 Manifold (5).
Illustration 3. (Left side manifold components are on the left side of the illustration and right side manifold components are on the right side of the illustration.) (A) Former Exhaust Manifold Components For 3408 (48W) Machine Engine. 8N-0990 or 9Y-1229 Manifold (1). 8N-0989 or 9Y-1230 Manifold (2). 8N-5108 or 7E-3204 Manifold (6). 8N-5109 or 7E-3203 Manifold (7). (B) Current Exhaust Manifold Components For 3408 (48W) Machine Engine. 107-8106 Manifold (4). 107-8108 Manifold (8). (107-8109 Manifold (9).
Illustration 4. (Left side manifold components are on the left side of the illustration and right side manifold components are on the right side of the illustration.) (A) Former Exhaust Manifold Components For 3412 (73W) Machine Engine. 8N-0990 or 9Y-1229 Manifold (1). 8N-0989 or 9Y-1230 Manifold (2). 8N-5108 or 7E-3204 Manifold (6). 8N-5109 or 7E-3203 Manifold (7). (B) Current Exhaust Manifold Components For 3412 (73W) Machine Engine. 107-8106 Manifold (4). 107-8108 Manifold (8). (107-8109 Manifold (9). 107-8107 Manifold (10).
Illustration 5. (Left side manifold components are on the left side of the illustration and right side manifold components are on the right side of the illustration.) (A) Former Exhaust Manifold Components For 3412 (73W) Machine Engine. 8N-0990 or 9Y-1229 Manifold (1). 8N-0989 or 9Y-1230 Manifold (2). 1N-3175 or 7W-8792 Manifold (11). 1N-3176 or 7W-8791 Manifold (12). (B) Current (Left Side) Exhaust Manifold Components For 3412 (73W) Machine Engine. 107-8106 Manifold (4). 7W-8792 Manifold (11). 7W-8791 Manifold (12).
Illuatration 6. 7E-9719 Exhaust Manifold used on 768C, 769C, 771C Trucks. There is no change to the manifold. Due to now using the longer 106-1792 Studs, a new 114-9223 Spacer has be added for each stud. This change is effective with 3408 Machine Engine 48W37173.
Illuatration 7. 4P-7847, 4P-7848 Exhaust Manifold used on 772B, 773B, 775B Trucks. There is no change to the manifold. Due to now using the longer 106-1792 Studs, a new 114-9223 Spacer has be added for each stud. This change is effective with 3412 Machine Engine 73W15505.
NOTE: Put 5P-3931 Anti-Seize Compound on the studs. New 2N-2766 Lock Nuts should always be used. Do NOT use an impact wrench to run the nuts down; the threads could become galled. This can result in false torque readings when the nuts are tightened.
A 9U-7224 Manifold Installation Guide is available to align the manifold studs in the center of the slotted and oversize holes during installation of the exhaust manifold group. Since each flange has slotted and oversize holes, a 9U-7224 Installation Guide is required for each manifold section. The installation guide is slid over a stud and into the upper 15.0 mm (.59 in) oversize holes in each manifold section. The spacers, washers and nuts can then be installed on the other studs and pre-torqued to 14 N·m (10 lb ft) to hold the manifold group in place. The installation guides can then be removed and the remainder of the spacers, washers and nuts installed.
When assembling the manifold sections, make sure the male end of the manifold end sections is clean, dry, and free of grease or oil. Apply a thin uniform coat of 2P-2333 Manifold Sealer to the male end sections. Apply a thin coat of engine oil to the female end of the manifold section. After installing the assembled exhaust manifold group on the engine, allow the manifold sealer to cure thoroughly (overnight if possible) before starting the engine.
If a previous end or center section is damaged beyond repair, the new manifold sections are interchangeable. When replacing a previous manifold section make sure to use the equivalent new parts as indicated in the illustrations.
A new nut tightening sequence and lower torque are required with the new exhaust manifolds. Tighten the exhaust manifold retaining nuts in the sequence shown in Illustration 8. Tighten the nuts to a torque of 38 ± 5 N·m (28 ± 4 lb ft).
Illustration 8. Tightening sequence for exhaust manifold retaining nuts.