D350E Series II and D400E Series II Articulated Trucks 3406E Engine Supplement Caterpillar

Removal Procedure

Start By:

1. Remove the air cleaner and the bracket. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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Illustration 1	g00560955

1. Remove six bolts (1) and the washers. Remove turbocharger guard (2).
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   Illustration 2	g00559884

2. Remove four bolts (3) and the nuts from exhaust pipe (4). Remove the gasket from the exhaust pipe.
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   Illustration 3	g00560424

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   Illustration 4	g00560404

3. Remove two bolts (5) that secure exhaust pipe (4) to plate (6). If necessary, remove three U-clamps (7), the washers, and the nuts that secure exhaust shield (8) to exhaust pipe (4).

4. Remove clamp (9) that secures exhaust pipe (4) to turbocharger (10). Remove the exhaust pipe from the machine.
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   Illustration 5	g00560954

5. Remove two bolts (11) and the nuts that secure exhaust pipe support (12) to the exhaust manifold.
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   Illustration 6	g00560406

6. Remove four clamps (13). Position hose (14) onto tube (15).

7. Remove two bolts (16), the washers, two plates (17), and elbow (18). Remove the two O-rings from the elbow.
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   Illustration 7	g00560407
   The fuel tank has been removed for photographic clarity.

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   Illustration 8	g00560408
   The fuel tank has been removed for photographic clarity.

8. Disconnect fitting (19) and remove two bolts (20). Remove the seal and tube assembly (21).

9. If necessary, remove connector (22) and the seal.

10. Remove two bolts (25) and the washers that secure tube assembly (26) to turbocharger (10). Remove the seal.

11. If necessary, remove two bolts (23), elbow (24), and tube assembly (26). Remove the lower seal on the tube assembly. Remove the seal between the elbow and the engine.
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    Illustration 9	g00560409
    The fuel tank has been removed for photographic clarity.

12. Install Tooling (A), an appropriate lifting strap, and a hoist to turbocharger (10).
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    Illustration 10	g00560410

13. Remove four bolts (27) and the nuts that secure turbocharger (10) to the exhaust manifold. Remove the turbocharger from the machine. The weight of the turbocharger is 32 kg (70 lb). Remove the turbocharger gasket.

Installation Procedure

1. Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.

2. Lubricate O-rings with an appropriate lubricant.
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   Illustration 11	g00560409
   The fuel tank has been removed for photographic clarity.

3. Install Tooling (A), an appropriate lifting strap, and a hoist to turbocharger (10).

4. Place the turbocharger and a new gasket into position. The weight of the turbocharger is 32 kg (70 lb).
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   Illustration 12	g00560410

5. Install four bolts (27) and the nuts that secure turbocharger (10) to the exhaust manifold. Remove Tooling (A) from the turbocharger.

   Note: Lubricate bolts with 4C-5599 Anti-Seize Compound.

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   Illustration 13	g00560407
   The fuel tank has been removed for photographic clarity.

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   Illustration 14	g00560408
   The fuel tank has been removed for photographic clarity.

6. If necessary, install the lower seal to tube assembly (26). Install the seal to elbow (24). Place elbow (24) and tube assembly (26) into position. Install two bolts (23) that secure the elbow and the tube assembly to the engine.

7. Install the seal that seals tube assembly (26) to turbocharger (10). Position the tube assembly. Install two bolts (25) and the washers that secure tube assembly (26) to turbocharger (10).

8. If necessary, install connector (22) and the seal.

9. Place tube assembly (21) and the seal into position. Connect fitting (19) and install two bolts (20).
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   Illustration 15	g00560406

10. Install elbow (18), two plates (17), the washers, and two bolts (16).

11. Position hose (14) between elbow (18) and tube (13). Install four clamps (13). Tighten the clamps to a torque of 11 ± 1 N·m (8 ± 1 lb ft).
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    Illustration 16	g00560954

12. Position exhaust pipe support (12) to the exhaust manifold. Install two bolts (11) and the nuts.

    Note: Lubricate bolts with 4C-5599 Anti-Seize Compound.

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    Illustration 17	g00561174

13. Position exhaust pipe (4) to plate (6). Install two bolts (5) that secure the exhaust pipe to the plate. If necessary, install exhaust shield (8), three U-clamps (7), the washers, and the nuts that secure the exhaust shield to exhaust pipe (4). Tighten the nuts to a torque of 25 ± 6 N·m (18± 4 lb ft).
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    Illustration 18	g00559884

14. Place the gasket and exhaust pipe (4) into position. Install four bolts (3) and the nuts to exhaust pipe (4).
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    Illustration 19	g00561173

15. Install clamp (9) that secures exhaust pipe (4) to turbocharger (10).
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    Illustration 20	g00560955

16. Place turbocharger guard (2) into position. Install six bolts (1) and the washers. Tighten the bolts to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

End By:

1. Install the air cleaner and the bracket. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".