0586065 JOHNSON SWITCH, Safety

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     385-1861     Connector Plug     2    
B     352-5891     Lifting Strap     2    
C     -     Loctite 771     -    Start By:
Connect the engine to Caterpillar Electronic Technician (Cat ET) before the DPF is removed from the engine. Once the engine is connected to Cat ET, then perform an ash service test. This test is a manual regeneration. Allow the DPF to cool before proceeding.
Remove the soot antenna.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
Illustration 1 g03458476
Put Identification Marks (X) on both sides of clamp assemblies (6) and (7) for installation purposes.
Put Identification Mark (Y) on the diesel particulate filter (4) for installation purposes. Identification Mark (Y) is showing the flow of exhaust gases through the diesel particulate filter.
Disconnect harness assembly (1) .
Disconnect hose assemblies (2) and cap with Tooling (A) .
Loosen clamp assembly (3) .
Disconnect temperature sensor (8). Disconnect tube assemblies (9) from both ends of diesel particulate filter (4) .
Loosen clamp assemblies (5) and (6) .
Use Tooling (B) and a suitable lifting device to remove diesel particulate filter (4). The weight of diesel particulate filter (4) is approximately 57 kg (126 lb).
Remove clamp assemblies (7) and diesel particulate filter (4) .
Discard clamp assemblies (3) and (5) .Installation Procedure
Note: When installing a new diesel particulate filter or a cleaned diesel particulate filter, an Ash Model reset must be performed. Refer to Special Instruction, REHS8180, "Aftertreatment Filter Maintenance on Tier 4 Final Products Equipped with a Diesel Particulate Filter (DPF), Diesel Oxidation Catalyst (DOC), and a Selective Catalyst Reduction (SCR) Filter" for the correct procedure.
Install diesel particulate filter (4) in the reverse order of removal.
Illustration 2 g02798280
Note: Do not use power tools in order to torque clamp assemblies (5) .
Apply Tooling (C) to the threads of clamp assemblies (5) along Distance (Z). Distance (Z) is 25 mm (1.0 inch) above the trunnion. Tighten clamp assemblies (5) to a torque of 16.5 1.5 N m (146 13 lb in).
Illustration 3 g02798274
Cutaway view of clamp assembly (3) in position on the assembly.Note: Do not use power tools in order to torque clamp assembly (3) .
Verify that the cup of the Ball Joint (G) does not touch the radius of the Ball (F). Position ball clamp assembly (3) and hand tighten clamp assembly (3). Clamp assembly (3) should be in the center of the joint.
Dimension (D) and Dimension (E) should be equal within 2.0 mm (0.08 inch). Repeat the measurements every 90° around clamp assembly (3). If necessary, adjust clamp assembly (3) .
Torque clamp assembly (3) to a torque of 35 2 N m (26 1 lb ft).
Tighten temperature sensor (8) to a torque of 45 5 N m (33 4 lb ft).