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 Products 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 clamp (1) and exhaust pipe (2). Remove three bolts (3) and elbow (4).
2. Loosen hose clamps (5) and (6) and remove air hose (7).
3. Disconnect oil supply tube assembly (8) from the turbocharger.
4. Disconnect oil drain tube assembly (10) from the turbocharger.
5. Remove four locknuts (9), the turbocharger and gasket from the exhaust manifold.
6. Remove the housings from the cartridge.
NOTE: Place alignment marks on the turbocharger cartridge and housings. Alignment marks will be used during assembly.
NOTE: Turbocharger is serviceable at cartridge level only, or replacement of the complete turbocharger. Internal parts are not serviceable.
NOTE: For waste-gate type turbochargers, the waste-gate mechanism is part of the turbine housing assembly and is pre-set at the factory. There are no adjustments or serviceable parts of the waste-gate mechanism.
NOTE: The following steps are for the installation of the turbocharger.
7. Check the condition of the gasket used between the turbocharger and the exhaust manifold. If the gasket is damaged, use a new part for replacement.
8. Install the end housings to the cartridge. Tighten the bolts that hold the compressor housing to the cartridge to a torque of 7.3 ± 0.5 N·m (65.00 ± 5.00 lb in). Apply 5P-3931 Anti-Seize Compound to the threads of the bolts that hold the turbine housing to the turbocharger. Tighten the bolts that hold the turbine housing to the cartridge to a torque of 15.8 ± 0.5 N·m (140.00 ± 5.00 lb in). The end play for the shaft is 0.051 to 0.083 mm (.0020 to .0033 in).
9. Apply 5P-3931 Anti-Seize Compound on the threads of the turbocharge mounting studs.
10. Put the gasket and turbocharger in position on the exhaust manifold. Install four locknuts (9) that hold it. Tighten the locknuts to a torque of 54 ± 5 N·m (40 ± 4 lb ft).
11. Tighten clamps (5).
12. Check the condition of the gaskets used between the turbocharger and the oil supply and drain tube assemblies. If the gaskets are damaged, use new parts for replacement.
13. Pre-lubricate the turbocharger with clean engine oil.
NOTE: Compressor housing orientation of replacement turbochargers may need to be changed for some applications.
14. Connect oil drain tube assembly (10) and oil supply tube assembly (8) to the turbocharger.
15. Install air hose (7) and install clamp (6). Tighten to a torque of 14 ± 1 N·m (10 ± 1 lb ft).
16. Install elbow (4) and bolts (3).
Install exhaust pipe (2) and clamp (1).