793F Off-Highway Truck Engine Supplement Caterpillar

Removal Procedure

Show/hide table

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

Show/hide table

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

1. Refer to Operation and Maintenance Manual, "System Pressure Release".

2. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedure.
   Show/hide table

   NOTICE
   Do not reuse the exhaust bellows or the clamps for the bellows. The used parts will loosen and the joint will separate. Always install new bellows and clamps.

   Show/hide table

   Illustration 1	g03141396

3. Remove panels (1).
   Show/hide table

   Illustration 2	g03141416

   Show/hide table

   NOTICE
   Do not step on the turbochargers. Doing so can damage the turbocharger and shorten the turbocharger life.

   Show/hide table

   NOTICE
   Install caps and plugs on all openings to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component must be cleaned thoroughly to prevent dirt from entering the internal mechanism.

4. Loosen clamps (2) and remove elbow (3).
   Show/hide table

   Illustration 3	g03141460

5. Disconnect hose assemblies (4), hose assemblies (5), and hose assemblies (6).
   Show/hide table

   Illustration 4	g03141464

   Show/hide table

   Illustration 5	g03141736

6. Disconnect clamps (7) and bellows (8).
   Show/hide table

   Illustration 6	g03141760

7. Disconnect clamps (9) and bellows (10).
   Show/hide table

   Illustration 7	g03144577

8. Disconnect clamps (11) and bellows (12).
   Show/hide table

   Illustration 8	g03143516

   Show/hide table

   Illustration 9	g03143918

   Show/hide table

   NOTICE
   If the turbine housing or the compressor housing must be rotated to remove the turbocharger, loosen the V-band clamps only enough to allow for rotation (typically 7-10 turns). If the V-band clamps are loosened excessively, the housing may contact the turbine wheel or the compressor wheel and cause damage. Contact with the housing may cause rapid wear and shorten turbocharger life.

9. Attach Tooling (A) and a suitable lifting device onto turbocharger (13). The weight of turbocharger (13) is approximately 136 kg (300 lb).

10. Remove bolts (14). Mark the orientation of V-band clamp (15) and V-band clamp (16) for installation purposes. If necessary, loosen V-band clamp (15) and V-band clamp (16). Remove turbocharger (13).
    Show/hide table

    Illustration 10	g03153258

11. Remove screen assembly (17) and O-ring seal (18).

Installation Procedure

Show/hide table

NOTICE
Do not reuse the exhaust bellows or the clamps for the bellows. The used parts will loosen and the joint will separate. Always install new bellows and clamps.

Show/hide table

Illustration 11	g03153258

1. Install O-ring seal (18) and screen assembly (17).
   Show/hide table

   Illustration 12	g03153318

   Show/hide table

   Illustration 13	g03143516

   Show/hide table

   NOTICE
   Follow the procedure for bellows installation and tightening procedures. Tighten the V-band clamps on the turbine housing prior to the bellows V-band clamp to prevent any dragging or binding of the turbocharger rotating components. Contact may cause rapid wear and shorten turbocharger life.

2. Ensure turbocharger (13) is aligned with dowel (X) and oil drain fitting (Y). Use Tooling (A) and a suitable lifting device to install turbocharger (13). The weight of turbocharger (13) is approximately 136 kg (300 lb).

3. Install bolts (14). Tighten bolts (14) to a torque of 240 ± 40 N·m (177 ± 30 lb ft).

4. Do not tighten V-band clamp (16) or V-band clamp (15) at this time.
   Show/hide table

   Illustration 14	g03144577

5. Connect bellows (12) and clamps (11) loosely.
   Show/hide table

   Illustration 15	g03141760

6. Connect bellows (10) and clamps (9) loosely.
   Show/hide table

   Illustration 16	g03141464

   Show/hide table

   Illustration 17	g03141736

7. Connect bellows (8) and clamps (7) loosely.
   Show/hide table

   Illustration 18	g03143918

8. Apply Tooling (B) onto the stud of V-band clamp (16) and V-band clamp (15). Tighten V-band clamp (16) and V-band clamp (15) to a torque of 28 ± 2 N·m (248 ± 18 lb in). Loosen V-band clamp (16) and V-band clamp (15) by two to three turns. Tap lightly with a suitable hammer around the diameter of V-band clamp (16) and V-band clamp (15). Tighten V-band clamp (16) and V-band clamp (15) to a final torque of 26 to 30 N·m (19 to 22 lb ft).

9. Tighten clamps (11), clamps (9), and clamps (7) to a torque of 7.5 ± 1.0 N·m (66.4 ± 8.9 lb in).

10. Ensure that the compressor wheel spins freely without binding or dragging. Contact with the housing may cause rapid wear and shorten turbocharger life.
    Show/hide table

    Illustration 19	g03141460

11. Refill the oil inlet with clean oil. Connect hose assemblies (6), hose assemblies (5), and hose assemblies (4).
    Show/hide table

    Illustration 20	g03141416

    Show/hide table

    NOTICE
    Do not step on the turbochargers. Doing so can damage the turbocharger and shorten the turbocharger life.

12. Install elbow (3) and tighten clamps (2).
    Show/hide table

    Illustration 21	g03141396

13. Install panels (1).

14. Refer to Specifications, "Turbocharger".

15. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedure.