0581631 JOHNSON PLATE ASSEMBLEY COMPLETE

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.
The bellows must be supported at all times when the bellows are not installed in the application. Failure to support the bellows adequately could result in the failure of the bellows. Do not use power tools in order to disassemble or assemble any part of the flexible exhaust system.The alignment of the bellows is important. Incorrect alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the uniformity of the spacing between the convolutions on the bellows.Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.
Use the correct personal protective equipment when removing the clamp.
Illustration 1 g03796494
Typical example
Use suitable material in order to encase bellows (5). Use cable straps in order to retain the suitable material. Encasing the flexible exhaust pipe will prevent damage of the bellows.
Make temporary marks in Position (A) and Position (B) for installation purposes.
Sufficiently loosen ball clamp (3) and V-band clamp (5) in order to allow the assembly of flexible exhaust pipe (4) to be removed.
Remove flexible exhaust pipe (4) from Selective Catalyst Reduction (SCR) (1) and Diesel Oxidation Catalyst (DOC) (8). Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress.
Remove gasket (2) (not shown) and gasket (7) (not shown). Disassembly Procedure
Use the correct personal protective equipment when removing the clamp.
Illustration 2 g03796524
If necessary, follow Step 2.f through Step 1.g in order to disassemble the assembly of flexible exhaust pipe (4).
Make temporary marks on the assembly of flexible exhaust pipe (4) for installation purposes.
Sufficiently loosen ball clamp (15) and remove elbow (17) from bellows (5).
Remove gasket (16).
Sufficiently loosen V-clamp (13) and remove bellows (5) from tube assembly (12). Note: Ensure that the bellows are not subjected to any undue stress.
Remove gasket (14).
Sufficiently loosen V-clamp (10) and remove tube assembly (12) from tube assembly (9).
Remove gasket (11). Assembly Procedure
Ensure that all components of the flexible exhaust pipe assembly are clean and free from wear and damage. If necessary, replace any components of the flexible exhaust pipe assembly that are worn or damaged. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information.
Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.
Illustration 3 g03796524
If necessary, follow Step 2.a through Step 2.g in order to assemble the flexible exhaust pipe (4).
Install a new gasket (11) onto tube assembly (9). Install V-clamp (10) onto the tube assembly.
Install tube assembly (9) onto tube assembly (12) and align with temporary marks. Tighten V-clamp (10) hand tight.
Install a new gasket (14) to tube assembly (12). Install V-clamp (13) onto the tube assembly.
Install bellows (5) to tube assembly (12) and align with temporary marks. Tighten V-clamp (13) hand tight. Note: Ensure that the bellows are not subjected to any undue stress.
Install a new gasket (16) to elbow (17). Install a new ball clamp (15) to the elbow.
Install elbow (17) to bellows (5) and align with temporary marks. Tighten ball clamp (15) hand tight.
Do not tighten ball clamp (15), V-clamp (13), or V-clamp (10) until the assembly of flexible exhaust pipe (4) has been installed to the SCR and the DOC. Installation Procedure
Ensure that all components of the flexible exhaust pipe assembly are clean and free from wear and damage. If necessary, replace any components of the flexible exhaust pipe assembly that are worn or damaged. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information.
Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.
Illustration 4 g03796930
Typical example
If the assembly of flexible exhaust pipe (4) as previously disassembled, ensure that the clamps are sufficiently loose in order to aid assembly.
Install a new gasket (2) (not shown) and a new gasket (7) (not shown) onto SCR (1) and DOC (8).
Install a new ball clamp (3) onto SCR (1).
Install V-band clamp (5) onto DOC (8)
Install the assembly of flexible exhaust pipe (4) onto SCR (1) and DOC (8) and align with temporary marks in Position (A) and Position (