0100 YRM 1243
Assembly 1. Wipe off anti-seize or lubricating compound from threads of temperature sensors and pressure tube fittings. 2. Apply new anti-seize or lubricating compound to threaded ends of temperature sensors and pressure tube fittings. 3. Assemble DPF Outlet, with new gasket, onto DPF filter compartment with new or cleaned filter using eight capscrews and eight nuts. See Figure 60. DO NOT tighten capscrews and nuts. 4. Assemble DPF filter compartment, with new gasket, onto DPF collar. See Figure 60.
Exhaust System Repair 1. If studs in exhaust manifold were removed, install all studs with end stamp ISOM or M away from engine. Use new studs if studs were removed.
WARNING The DPF is heavy. Make sure lifting device has enough capacity to lift DPF. The DPF weighs approximately 25 kg (55 lb). Make sure not to damage the DPF muffler assembly by falling or impact as it contains a ceramic filter. Even if there is no apparent damage, a dropped or shocked DPF will need to be replaced with a new one. 2. Attach lifting device to DPF and install DPF into lift truck.
5. Assemble DPF collar, with new gasket, onto DOC using eight capscrews and eight nuts. See Figure 60. DO NOT tighten capscrews and nuts.
3. Install four DPF support bracket capscrews and nuts into DPF and DPF support bracket. See Figure 60. Tighten capscrews and nuts to 49 to 55 N•m (37 to 41 lbf ft).
6. In a star pattern begin tightening sixteen capscrews and nut to 49 to 55 N•m (37 to 41 lbf ft).
4. Remove lifting device and caps on ends of DPF.
7. Install mounting bracket using four mounting capscrews and four mounting nuts. See Figure 60. DO NOT tighten capscrews and nuts. 8. Install (3) temperature sensors in their designated fittings on DPF as indicated during removal. Tighten 25 to 34 N•m (18 to 25 lbf ft). See Figure 60. 9. Install hose clamps on pressure tubes. See Figure 60. 10. Install pressure tubes into hose ends at pressure sensor and tighten threaded end of pressure tube at fitting indicated during removal. See Figure 60. Tighten pressure tube fittings to 16 to 22 N•m (12 to 16 lbf ft). 11. Pinch hose clamps and slide into position sealing pressure tubes and pressure hose together. 12. Tighten four mounting capscrews and mounting nuts securing DPF on mounting bracket to 49 to 55 N•m (37 to 41 lbf ft).
Install NOTE: DO NOT tighten exhaust clamps until exhaust system has been completely installed in lift truck.
5. Install new gasket on exhaust manifold. See Figure 59. 6. Install new gasket on DPF in. See Figure 59. 7. Install exhaust pipe into lift truck. NOTE: Exhaust pipes to be installed so flex joint is in a straight line with no preload. 8. Install four locknuts securing exhaust manifold to exhaust pipe. See Figure 59. Tighten locknuts finger tight. 9. Install four locknuts securing exhaust pipe to DPF in. See Figure 59. Tighten locknuts finger tight. NOTE: Perform Step 10 and Step 11 on long wheel base lift trucks. 10. Install four capscrews and foldover nuts in clamp bracket. See Figure 56. 11. Install u-bolt onto exhaust pipe and into clamp bracket. Install two nuts and two washers onto ubolt. See Figure 56. Tighten nuts finger tight. 12. Install u-bolt onto exhaust pipe and into frame bracket. Install two nuts and two washers onto ubolt. See Figure 56. Tighten nuts finger tight.
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