5030992 JOHNSON BOLT, Stop

Introduction
This publication describes the procedures that are necessary in order to install a 3516B high displacement engine in a 793B Off-Highway Truck. This publication only concerns items that are unique to the installation of the high displacement engine. Refer to the disassembly and assembly module for the procedures that are necessary in order to install the engine in the truck.
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3516B High Displacement EngineThe 3516B high displacement engine provides increased machine performance with less fuel consumption in certain applications. The 3516B high displacement engine uses four identical single stage turbochargers that eliminate the need for a wastegate. There are two pairs of turbochargers on the standard engine. Each pair of turbochargers has a low pressure turbocharger and a high pressure turbocharger. The low pressure turbocharger and the high pressure turbocharger are connected in series. The series arrangement turbochargers require a wastegate in order to regulate the boost pressure. The separate turbochargers of the 3516B high displacement engine do not require a wastegate. The installation of the 3516B high displacement engine requires changes to the parts groups that follow: air inlet tubes, coolant return lines for the turbochargers, tubes for the Separate Circuit Aftercooler (SCAC), air line for the wastegate and VIMS software.Note: If the truck is not equipped with the VIMS system, modifications are required. Refer to Special Instruction, SEHS9829, "Retrofitting a 793B Off Highway Truck with Vital Information Management System".ReferencesDisassembly and Assembly, SENR5676, "793B Truck Engine Supplement"Disassembly and Assembly, SENR5692, "793B Truck Machine Systems"Special Instruction, SEHS9829, "Retrofitting a 793B Off Highway Truck with Vital Information Management System"Read the entire special instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.
Personal injury or death can result from improper assembly procedures.Do not attempt any assembly until you have read and understand the assembly instructions.
The photos and illustrations are for illustrative purposes. The illustrations may not be drawn to scale. THE PHOTOS MAY NOT BE FROM AN ACTUAL INSTALLATION PROCEDURE.Important Safety Information
The following information is an explanation of various labels that are found in this document.WarningsThe warning label informs the technician that an injury or death can occur as a result of a condition that may exist.NoticesA notice informs the technician that component damage can occur as a result of a condition that exists.NotesA note contains general information for the technician about the operation that is being performed.Proper repair is important to the safe operation and the reliable operation of this machine. This document outlines basic recommended procedures. Some of the procedures require special tools, devices, or work methods.Before you perform any repairs or before you perform any maintenance, read all safety information. Understand all safety information before you perform any repairs or before you perform any maintenance.Safety information is provided in this document and on the machine. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.The Safety Alert Symbol that is followed by a Signal Word identifies a hazard. "DANGER", "", and "CAUTION" are "Signal Words". Illustration 2 shows the Safety Alert Symbol and the signal word "".
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The signal word "" has the following meanings:
Pay Attention !
Become Alert !
Your Safety Is Involved !The message that appears under the safety alert symbol explains the hazard.Operations or conditions that may cause product damage are identified by "" labels on the machine and in the service information.The person that services the machine may be unfamiliar with many of the systems on the machine. Use caution when you perform service work. Special knowledge of the systems and of the components is important. Before you remove any component or before you disassemble any component obtain knowledge of the system and knowledge of the component.Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. You must determine that the tools, procedures, work methods, and operating techniques are safe. You must determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.Basic Precautions
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.
Always observe the list of basic precautions that follows:Safety Signs
Safety signs include the items that follow: signs, information plates and decals. Read all "Safety" signs on the machine before operating, lubricating or repairing the machine. Understand all "Safety" signs on the machine before operating, lubricating or repairing the machine. Replace any safety signs that are in the conditions that f