0308077 JOHNSON SCREW

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 assembly must be supported at all times when the bellows assembly is not installed in the application. Failure to support the bellows assembly adequately could result in the failure of the bellows assembly. Do not use power tools to disassemble or assemble any part of the flexible exhaust system.The alignment of the bellows assembly is important. Incorrect alignment may lead to premature failure of the bellows assembly. Misalignment can be identified by visually inspecting the uniformity of the spacing between the convolutions on the bellows assembly.Inspect the bellows assembly for damage prior to installation. If there is any damage to the convolutions, discard the bellows assembly. If there is any difficulty in installation after the repair, discard the bellows assembly.
Illustration 1 g06039737
Illustration 2 g06040018
Take note of the lateral alignment of the bellows assembly for assembly purposes. The lateral alignment of the bellows assembly is critical. All the components must be assembled in the same alignment as prior to disassembly.Note: Flexible exhaust pipe (6) will be removed as an assembly.
Use suitable material to encase bellows (1) to prevent damage to bellows (1). Encase bellows (1) of flexible exhaust pipe (6) between Position (E) and Position (F). Install suitable cable straps to secure the suitable material over bellows (1).Note: Make sure that flexible exhaust pipe (6) is supported at all times.
Loosen clamp (2) on flexible exhaust pipe (6).Note: If V-band clamp (3) remains tight on the flanges, apply releasing fluid on V-band clamp (3). Lightly tap the bolt on V-band clamp (3) with a suitable soft faced hammer to assist removal.Note: Do not use a prybar to remove V-band clamp (3).
Loosen the bolt for V-band clamp (3).Note: Make sure that the assembly of flexible exhaust pipe (6) is supported as the clamps are removed.
Remove the complete assembly of flexible exhaust pipe (6) from the CEM (4) and exhaust back pressure valve (5).Disassembly Procedure for the Flexible Exhaust Pipe Assembly
If any part of the flexible exhaust pipe assembly is damaged, refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information.
Illustration 3 g06040029
Typical example
Note: Make sure that bellows (1) is not subjected to any undue stress that can damage bellows (1).
If necessary, loosen ball clamp (8). Remove bellows (1) from adapter (7). Remove ball clamp (8).Assembly Procedure for the Flexible Exhaust Pipe Assembly
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Drill Bit
3 mm (0.118 inch) Ø 1
B - Drill Bit
6.5 mm (0.256 inch) Ø 1
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.
Illustration 4 g06040084
Typical example
Use the correct personal protective equipment when removing the clamp.
Note: Do not center punch the spot weld on clamp (2).
If you need to reinstall original bellows (1), place the internal area in Position (G) (not shown) of bellows (1) on a suitable support. Use Tooling (A) to drill a pilot hole through the spot weld in Position (H) on clamp (2).
Use Tooling (B) to drill out the spot weld in Position (H) on clamp (2). Remove clamp (2) from bellows (1).
Remove all burrs from the internal and external areas of clamp (2). Ensure that debris does not enter bellows (1).
Illustration 5 g06040094
Illustration 6 g06040223Note: Make sure that bellows (1) is not subjected to any undue stress.Note: If you install a new bellows (1), clamp (2) will be pre-installed to bellows (1).
Position a new clamp (2) onto bellows (1). Hand tighten new clamp (2). Make sure that the center of new clamp (2) is central to Slots (J) on bellows (1). New clamp (2) must be flush with the end of bellow