793F Off-Highway Truck Engine Supplement Caterpillar


Turbocharger - Remove and Install

Usage:

793F D3T

Removal Procedure

------ WARNING! ------

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


------ WARNING! ------

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.



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.



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.


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

  2. Drain the coolant into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".


    Illustration 1g03141396

  3. Remove panels (1).


    Illustration 2g03381845

  4. Disconnect hose (2), V-band clamps (3), and bellows (4).


    Illustration 3g03381841

  5. Disconnect hose assemblies (5), hose assemblies (6), clamps (7), and bellows (8).


    Illustration 4g03381838

  6. Disconnect V-band clamps (9) and bellows (10).


    Illustration 5g03381843


    Illustration 6g03381840


    NOTICE

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



    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.


  7. Attach a suitable lifting device to turbocharger (11). The weight of turbocharger (11) is approximately 79 kg (175 lb).

  8. Remove bolts (12). Mark the orientation of V-band clamp (13). If necessary, loosen V-band clamp (13). Remove turbocharger (11).


    Illustration 7g03381842

  9. Remove screen assembly (14) and O-ring seal (15).

Installation Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
Loctite C5A Copper Anti-Seize 


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.




    Illustration 8g03381842

  1. Install O-ring seal (15) and screen assembly (14).


    Illustration 9g03381839


    Illustration 10g03381843


    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 (11) is aligned with dowel (X) and oil drain fitting (Y). Use a suitable lifting device to install turbocharger (11). The weight of turbocharger (11) is approximately 136 kg (300 lb).

  3. Install bolts (12).

  4. Do not tighten V-band clamp (13) at this time.


    Illustration 11g03381838

  5. Connect bellows (10) and V-band clamps (9).


    Illustration 12g03381841

  6. Refill the oil inlet with clean oil. Connect bellows (8), clamps (7), hose assemblies (6), and hose assemblies (5).


    Illustration 13g03381845

  7. Connect bellows (4), V-band clamps (3), and hose (2).


    Illustration 14g03381840

  8. Apply Tooling (A) onto the stud of V-band clamp (13). Tighten V-band clamp (13) to a torque of 20 N·m (177 lb in). Loosen V-band clamp (13) by two to three turns. Tap lightly with a suitable hammer around the diameter of V-band clamp (13). Tighten V-band clamp (13) to a final torque of 30 ± 2 N·m (266 ± 18 lb in).

  9. Tighten V-band clamps (9) and V-band clamps (7) to a torque of 6.5 ± 2 N·m (58 ± 18 lb in). Tighten V-band clamps (3) to a torque of 8.5 ± 2 N·m (75 ± 18 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.


    Illustration 15g03141396

  11. Install panels (1).

  12. Refer to Specifications, "Turbocharger".

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

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