Usage:
FLUID SPILLAGE CONTAINMENT
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Product Guide", NENG2500, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
1. Remove oil supply tube (1) from the turbocharger and the oil filter base.
2. Remove four bolts (3), and remove oil drain tube (2) and elbow (4) from the turbocharger. Separate the elbow from the drain tube. Remove the O-ring seal from the tube.
3. Remove four nuts and bolts (6). Remove bolt (5) and remove tube (7).
4. Remove the O-ring seal from tube (7).
5. Remove bolts (9), elbow (8) and pipe (10).
6. The weight of the turbocharger is approximately 24 kg (53 lb). Fasten a nylon strap and a hoist to the turbocharger, and remove four bolts (12) and nuts that hold it to the exhaust manifold. Remove turbocharger (11).
NOTE: The following steps are for the installation of the turbocharger.
7. Inspect all gaskets and O-ring seals for damage, and make a replacement if needed.
8. Install a gasket between the turbocharger and exhaust manifold. Put 5P-3931 Anti-Seize Compound on the threads of bolts (12). Put turbocharger (11) in position and install bolts and nuts (12). Tighten the bolts to a torque of 55 ± 5 N·m (41 ± 4 lb ft).
9. Apply 5P-3931 Anti-Seize Compound to the male ends of pipe (10) and bolts (9). Install pipe (10) and elbow (8). Tighten bolts (9) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).
10. Lubricate the O-ring seals with clean oil and install tube (7). Install bolts (5) and (6).
11. Install the O-ring seal on tube (2). Lubricate the O-ring seal with clean oil and install tube (2) in elbow (4). Put the gaskets in position on the block and on the turbocharger, and install tube (2) with bolts (3).
12. Put a gasket in position between oil supply tube (1) and the turbocharger. Install oil supply tube (1).
Disassemble Turbocharger
Start By:
a. remove turbocharger
FLUID SPILLAGE CONTAINMENT
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Product Guide", NENG2500, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
1. Put identification marks on the two housings and the cartridge assembly for use at assembly.
2. Remove two clamps (3) and make a separation of compressor housing (1) and turbine housing (2) from the cartridge assembly.
| NOTICE |
|---|
When the nut is loosened, do not put a side force on the shaft. |
3. Put cartridge assembly (4) in position on Tooling (A). Remove the nut from the shaft.
4. Use a press to push the shaft assembly out of the cartridge assembly. Remove compressor wheel (5).
5. Remove seal ring (8) and shroud (7) from shaft assembly (6).
6. Remove snap ring (9) with Tool (B).
7. Use two screwdrivers to remove insert (10) from the cartridge housing.
8. Remove O-ring seal (12) from the insert.
9. Remove sleeve (11) from the insert. Remove the seal ring from the sleeve.
10. Remove deflector (13) from the housing.
11. Remove ring (14) from the cartridge housing.
12. Remove sleeve (15) and bearing (16) from the cartridge housing.
13. Remove ring (17).
14. Use Tool (C) to remove snap ring (19), bearing (18) and snap ring (20) from the cartridge housing.
15. Turn the cartridge housing over. Use Tool (C) to remove snap ring (22), bearing (21) and snap ring (23) from the housing.
Assemble Turbocharger
1. Make sure all oil passages are open and clean. Put clean engine oil on all parts before assembly.
2. Use Tool (A) to install snap ring (23), bearing (21) and snap ring (22) in the housing.
NOTE: Install the snap rings with the round side toward the bearing.
3. Turn the housing over. Use Tool (A) to install snap ring (20), bearing (18) and snap ring (19).
NOTE: Install the snap rings with the round side toward the bearing.
4. Put ring (17) in position in the housing.
5. Put bearing (16) in position. Make an alignment of the holes in the bearing with the dowels in the housing. Grooved side of the bearing must be up.
6. Put sleeve (15) in position in the housing.
7. Put ring (14) in position on top of the bearing.
8. Install deflector (13) as shown.
9. Put seal ring (24) in position on sleeve (11). Install the sleeve in insert (10).
10. Put O-ring seal (12) in position on the insert.
11. Put insert assembly (10) in position in the housing.
12. Use Tool (B) to install snap ring (9) in the housing.
13. Put shaft assembly (6) in position on Tooling (C).
14. Put 6V-2055 High Vacuum Grease in the seal ring groove on the shaft assembly.
15. Install seal ring (8) on shaft assembly (6).
16. Put shroud (7) in position on the shaft assembly.
17. Put cartridge assembly (4) and compressor wheel (5) in position on the shaft assembly.
| NOTICE |
|---|
Do not put a side force on the shaft when the nut is tightened. |
18. Put a small amount of oil on the face of the compressor wheel that will be under the nut. Install the nut and tighten it to a torque of 60 ± 3 N·m (44 ± 2 lb ft).
19. Remove the nut and put 4C-9507 Retaining Compound on the threads of the shaft. Install the nut and tighten to a torque of 60 ± 3 N·m (44 ± 2 lb ft).
20. Put the cartridge housing assembly in position in a vise with soft jaws.
21. Put Tooling (D) in position and check the end play. The end play must be between 0.08 - 0.20 mm (.003 - .008 in).
22. Put compressor housing (1) and turbine housing (2) in position and install clamps (3).
23. Tighten the clamps to a torque of 14 ± 1 N·m (10 ± 1 lb ft).
End By:
a. install turbocharger