2001/09/24 Caterpillar

Articulated Truck:

D350E (S/N: 9LR1-UP)

D400E (S/N: 2YR1-UP)

Reference: Manual, SEBD0512, "Service Welding Guide".

Description of Change: An additional joint can be installed to the flexible pipe assembly on the exhaust heated body arrangement in order to reduce torsional stresses. This will offer an increase in the service life of the tube.

Adaptable To: The additional joint is adaptable to D400E (S/N: 2YR1-UP) and D350E (S/N: 9LR1-UP).

Some of the existing components of the exhaust heated body arrangement must be modified in order to install the additional joint.

The following parts are required in order to complete the modification:

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Illustration 1	g00717481
Lug for the Exhaust Heated Body Arrangement Elbow.

1. Two lugs (4) must be manufactured locally. Use mild steel. The lugs must have a thickness of 5 mm ( 3/16 inch). Refer to Illustration 1 and Table 2.
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   Table 2

   Dimension	Measurement
   A	30 mm (1.18 inch)
   B	40 mm (1.58 inch)
   C	20 mm (0.79 inch)
   D	10 mm (0.39 inch)
   E	10 mm (0.39 inch)
   F	5 mm (0.20 inch)
   G	20 mm (0.79 inch)
   H	63.5 mm (2.50 inch) Radius
   J	8.5 mm (0.33 inch) Radius
   K	6 mm (0.24 inch) Radius
   L	6 mm (0.24 inch) Diameter
   M	45 Degrees

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Illustration 2	g00721005
110-7590 Flexible Pipe Assembly

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Illustration 3	g00717409
Shorten 110-7590 Flexible Pipe Assembly (5) .

2. The flexible pipe assembly (5) must be shortened at end (X). Refer to Illustration 2, Illustration 3 and Table 3.

   Note: This is the end of the flexible pipe assembly which connects to 7U-7416 Elbow (6).

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   Table 3

   Dimension	Measurement
   N	60 mm (2.36 inch)
   P	200 mm (7.87 inch)

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Illustration 4	g00717427
Modification for 7U-7416 Elbow

3. Shorten 7U-7416 Elbow (6) by the amount (T). Refer to Illustration 4 and Table 4. The two lugs (4) that are detailed in Step 1 must be welded into position. Refer to Manual, SEBD0512, "Service Welding Guide". Provide a 3 mm (0.12 inch) fillet weld around lugs (4). Use electrodes to "AWS E7018" or an equivalent specification.
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   Table 4

   Dimension	Measurement
   Q	63.5 mm (2.50 inch)
   R	65.88 mm (2.59 inch)
   S	167 mm (6.58 inch)
   T	55 mm (2.17 inch)

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Illustration 5	g00717882
Holes For the Extension Springs

4. Drill two holes with 6 mm (0.24 inch) diameters (7) in the mounting assembly. Refer to Illustration 5 and Table 5.
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   Table 5

   Dimension	Measurement
   U	190 ± 3 mm (7.48 ± 0.12 inch)
   V	95 mm (3.74 inch)
   W	15 mm (0.59 inch)
   X	6 mm (0.24 inch) Diameter

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Illustration 6	g00717881
Exhaust Heated Body Arrangement

5. Put clamps (2) over the ends of joint (3) .

6. Coat the inside of the ends of joint (3) with 5P-3931 Anti-Seize Compound and insert elbow (6) 35 mm (1.38 inch) into joint (3) .

7. Insert flexible pipe assembly (5) 50 mm (1.97 inch) into joint (3) .

8. Tighten the two clamps (2) to a torque of 48 ± 10 N·m (35 ± 7.5 lb ft).

9. Attach the two extension springs (1) between the two holes (7) on either side of the mounting assembly and the two lugs (4) on elbow (6) .