Installation Instructions for a Turbocharger With a Water Cooled Turbocharger Cartridge{1050, 1065} Caterpillar

Landfill Compactor:

836 (PIN: 7FR1-UP)

Introduction

This instruction is for machines that have experienced excessive activation of the aftermarket fire suppression system in certain applications of the 836 (PIN: 7FR1-UP) Landfill Compactor. The landfill compactor is equipped with the 3408E (S/N: 99C1-UP) Engine. Customers may have an aftermarket fire suppression system that is activated by excessive heat in the engine compartment of the machine. Many operators use shielding for the exhaust system of the engine in order to minimize the heat in the engine compartment. The shielding helps to contain most of the heat in the exhaust system of the engine. The excessive heat in the exhaust system has been known to cause failure of the bearing for the turbocharger. A new turbocharger cartridge that is water cooled is now available. The turbocharger cartridge that is water cooled helps to prevent overheating of the bearing.

This instruction outlines the recommended procedure to remove the existing turbocharger. The instruction also provides installation instructions for the new turbocharger cartridge.

Required Parts

Optional Parts

Removal Procedure

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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

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Illustration 1	g00639974

1. Open drain valve (1). Drain coolant from the engine until the coolant is at a level below the bottom of the radiator inlet tube. Make sure that the valve is fully closed after the required amount is drained from the cooling system.

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Illustration 2	g00639978

2. Remove two exhaust clamps (2) from elbow (3) for the exhaust tube. Remove the elbow for the exhaust tube from the engine.

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Illustration 3	g00639985

3. Remove turbocharger oil supply line (4) from the engine block and the turbocharger.

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Illustration 4	g00640154

4. Remove six bolts (5) from turbocharger outlet (6). Remove the turbocharger outlet from the engine. Remove all gasket material from the turbocharger outlet and from the aftercooler housing.

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Illustration 5	g00640172

5. Loosen the clamps that hold air inlet tube (7). Remove tube (7) .

6. Remove the bolts from the elbow for the turbocharger oil drain line. The oil drain line for the turbocharger is located on the bottom side of the turbocharger.

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Illustration 6	g00640178

7. Remove the clamp that holds turbocharger cartridge (8) to the turbine housing of the turbocharger. Remove the turbocharger cartridge and the compressor housing from the turbine housing of the turbocharger.

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Illustration 7	g00641738

8. Loosen clamp (9) on the turbocharger compressor housing. Remove turbocharger cartridge (8) from the compressor housing of the turbocharger.

9. Inspect the compressor housing of the turbocharger and the turbine housing of the turbocharger for any gouges or rubbing. If there is any damage, replace the necessary parts.

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Illustration 8	g00641756

10. Remove turbocharger oil drain line (10) from the engine.

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Illustration 9	g00641769

11. Loosen clamp (11) on the radiator inlet tube. Inspect condition of the rubber hose. If the rubber hose is worn or damaged, use new parts for replacement.

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Illustration 10	g00641780

12. Remove four bolts (12) from the radiator inlet tube. Remove the radiator inlet tube from the engine. Remove all gasket material from the radiator.

Installation Procedure

Note: Check the condition of all O-rings. If an O-ring is worn or damaged, use a new part for replacement.

Note: Do not reuse gaskets. Use new gaskets for all assembly.

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Illustration 11	g00641805

1. Install the new 179-1495 Radiator Inlet Tube on the engine. Install a new 4N-1418 Radiator Inlet Gasket on the tube. Install four bolts (12). Reuse the old bolts.

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Illustration 12	g00641769

2. Tighten clamp (11) on the radiator inlet tube.

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Illustration 13	g00641821

3. Install one 8M-0755 Connector (13) in the radiator inlet tube.

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Illustration 14	g00641841

4. Install one 114-2687 O-Ring Seal (16) on 176-3117 Oil Drain Tube (17).

   Two 1A-2029 Bolts (15) and one 7N-7559 Gasket (14) will be used for final assembly on the turbocharger.

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Illustration 15	g00641877

5. Lightly lubricate the O-ring seal on tube assembly (17) with clean engine oil. Install the tube assembly in the elbow on the cylinder block. Make sure that the tube is fully seated.

   Note: A new 4N-6672 Gasket must be used, if the elbow on the cylinder block has been removed.

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Illustration 16	g00641972

6. Remove plug (18) from the inlet of the aftercooler.

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Illustration 17	g00641994

7. Install one 7L-7262 Flared Elbow (19) in the aftercooler.

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Illustration 18	g00641889

8. Install new 7N-8187 Turbocharger Cartridge (20) in the compressor housing of the turbocharger. Install clamp (9). Do not tighten the clamp completely. The turbocharger cartridge must be free to rotate in order to install the turbocharger on the engine.

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Illustration 19	g00641929

9. Install two 7N-7878 Cover Plates (21) and two 8N-0788 Covers (22) on the turbocharger cartridge. Use the new hardware and the new gaskets that are provided in order to attach the plates.

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Illustration 20	g00641952

10. Install two 8M-0755 Connectors (23) .

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Illustration 21	g00641958

11. Install turbocharger cartridge (20) in the turbine housing of the turbocharger. Install the clamp that holds turbocharger cartridge (20) to the turbine housing of the turbocharger. Do not tighten the clamp completely.

12. Position the turbocharger cartridge so that tube assembly (17) can be attached to the turbocharger cartridge. Install the 7N-7559 Gasket and two 1A-2029 Bolts on tube assembly (17) .

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Illustration 22	g00642012

13. Install 176-3120 Coolant Supply Hose (24) for the coolant supply to the turbocharger from the inlet of the aftercooler.

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Illustration 23	g00642013

14. Install 176-3118 Oil Supply Tube (25). The following new parts must be used for installation of the oil supply tube: 7N-8875 Gasket , two 1A-2029 Bolts and two 9X-6458 Hard Washers .

    Note: A new 114-4427 O-Ring Seal must be installed on the elbow for the oil supply tube on the side of the cylinder block, if the elbow has been removed.

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Illustration 24	g00639978

15. Install elbow (3) for the exhaust tube on the engine. Install two 8N-0879 Clamps (Exhaust) (2). Tighten the clamps to a torque of 7.5 ± 1.0 N·m (66 ± 9 lb in).

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Illustration 25	g00642014

16. Reuse the clamp that previously held the turbocharger oil supply line. Install clamp (26) .

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Illustration 26	g00640154

17. Install a new 4N-6296 Gasket on the aftercooler housing. Install turbocharger outlet (6) on the engine. Lightly lubricate O-rings with clean engine oil before assembly. Install six bolts (5) in the turbocharger outlet.

18. Use the following procedure in order to tighten the clamps on the turbocharger.

    1. Tighten the clamps to a torque of 14 ± 1 N·m (10 ± 1 lb ft).

    2. Lightly tap around the diameter of the clamps with a soft hammer.

    3. Tighten the clamps again to a torque of 14 ± 1 N·m (10 ± 1 lb ft).

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Illustration 27	g00640172

19. Install inlet tube (7). Tighten the clamps that hold inlet tube (7) .

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Illustration 28	g00642021

20. Install 176-3121 Coolant Return Line (27) from the turbocharger to the fitting that is on the radiator inlet tube.

    Note: Make sure that the coolant return line has a consistent upward slope from the turbocharger to the radiator inlet at all locations. Make sure that the line does not have any dips. The cooling system for the turbocharger will not operate correctly if the return line is not installed exactly in this manner.

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Illustration 29	g00667388

21. Install the 6K-2198 Boss and the clamp for holding coolant return line (27) with the hardware provided. The boss should be installed in area (28) on the inside of the shielding on the vertical support. The boss should be positioned so that the coolant return line is held in place with a consistent upward slope.

22. Refill the cooling system to the correct level.

23. Run the engine and check for leaks.