C175-16 and C175-20 Locomotive Engines Caterpillar

Removal Procedure

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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	g06306309

1. Disconnect spring assemblies (2) and (4).

2. Remove heat shields (1) and (3).
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   NOTICE
   Clamp assemblies MUST only be used once. Discard all clamp assemblies after use.

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   Illustration 2	g06196364

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   Illustration 3	g06207955

   Note: Ball clamps (7) and (10) are designed for one time use.

3. Use two people to remove exhaust line (8). The weight of exhaust line (8) is approximately 40 kg (89 lb).

4. Remove nuts (6) and brackets (9).

5. Remove ball clamps (7).

6. Remove exhaust line (8) with slip tube (12), clamp (11), clamp (10), and elbow (5) as a unit.
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   Illustration 4	g06196363

   Note: Ball clamps (17) and (18) are designed for one time use.

7. Use two people to remove exhaust line (13). The weight of exhaust line (13) is approximately 30 kg (67 lb).

8. Remove nuts (16) and brackets (15).

9. Remove ball clamps (17).

10. Remove exhaust line (13) with elbow (14) and clamp (18) as a unit.

Installation Procedure

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Illustration 5	g06194488

1. Install exhaust elbow (5), plates (9), and nuts (6). Loosely tighten nuts (6).

2. Install exhaust elbow (14), plates (15), and nuts (16). Loosely tighten nuts (16).
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   Illustration 6	g06193811

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   Illustration 7	g06195318

3. Pre assemble slip tube (12) to the bellows assembly of exhaust line (8).

4. The slip joint at clamp (11) and slip tube (12) should overlap by a minimum length of 40 mm (1.6 inch). The engagement is sufficient when the ink line on slip tube (12) is no longer visible.
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   Illustration 8	g06193699

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   Illustration 9	g06306314

   Note: Do not remove bellows alignment wrap (C) until Step 24 to avoid damage to the convolutes.

   Note: Do not reuse clamps (11), (10), and (7). Clamps (11), (10), and (7) is for one time use only.

5. Use Tooling (B) to orient exhaust elbow (5) to angle approximately 32.8 degrees as shown in Illustration 9. Tighten one nut (6) to keep exhaust elbow (5) orientation in place. Angle may need to be readjusted to optimize alignment later.

6. Apply Tooling (A) to the inner surface of ball clamps (7) and (10).

7. Place ball clamp (10) on exhaust elbow (5) and ball clamp (7) on the Clean Emission Module inlet.

8. Use the following steps to install the bellows assembly and slip tube (12).

   1. Install the bellows assembly and slip tube (12) as a unit between exhaust elbow (5) and the Clean Emission Module inlet. Align slip tube (12) to exhaust elbow (5) and then align the bellows assembly to the Clean Emission Module inlet.
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      Illustration 10	g06193695

   2. Verify that the cup of the ball joint (H) does not touch the radius of ball (G).

   3. Ball clamp (7) at the ball joint is to be positioned such that Dimension (Y) and (Z) are equal. Measure every 90° around clamp (7), if necessary adjust the ball clamp.

   4. Repeat Steps 8.b and 8.c for ball clamp (10).

9. Tighten all nuts (6) at exhaust elbow (5) to a torque of 34 N·m (25 lb ft).

10. Tighten ball clamp (7) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).

11. Tap ball clamp (7) with dead blow hammer. Retorque ball clamp (7) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).

12. Tighten ball clamp (10) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).

13. Tap ball clamp (10) with dead blow hammer. Retorque ball clamp (10) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).

14. Verify ink mark on slip tube (12) shown in Illustration 6 is not visible. Tighten clamp (11) to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

15. Tap clamp (11) with dead blow hammer. Retorque clamp (11) to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
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    Illustration 11	g06193697

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    Illustration 12	g06306316

16. Use Tooling (B) to orient exhaust elbow (14) to angle approximately 51.7 degrees as shown in Illustration 12. Tighten one nut (16) to keep exhaust elbow (14) orientation in place. Angle may need to be readjusted to optimize alignment later.

17. Apply Tooling (A) to the inner surface of ball clamps (17) and (18).

18. Place ball clamp (18) on exhaust elbow (14) and ball clamp (17) on the Clean Emission Module inlet.

19. Install the bellows assembly of exhaust line (13) between exhaust elbow (14) and the Clean Emission Module inlet.

20. Follow Steps 8.b through 8.d to position ball clamps (17) and (18) around the ball joints of exhaust line (13).

21. Tighten ball clamp (17) around exhaust line (13) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).

22. Tap ball clamp (17) with dead blow hammer. Retorque ball clamp (17) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).

23. Tighten ball clamp (18) around exhaust line (13) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).

24. Tap ball clamp (18) with dead blow hammer. Retorque ball clamp (18) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).

25. Remove bellows alignment wraps (C).

26. Inspect the flex pipe bellows for damage prior to installation of the heat shields.
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    Illustration 13	g06306309

27. Install heat shields (1) and (3).

28. Connect spring assemblies (2) and (4).